Note: Descriptions are shown in the official language in which they were submitted.
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CARTRIDGE FOR A VAPORIZER DEVICE
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The
present application claims priority to U.S. Provisional Application No.
62/915,005, filed on October 14, 2019, and titled "CARTRIDGE FOR A VAPORIZER
DEVICE," U.S. Provisional Application No. 62/812,161, filed on February 28,
2019, and titled
"CARTRIDGE FOR A VAPORIZER DEVICE," U.S. Provisional Application No.
62/747,099, filed on October 17, 2018, and titled "WICK FEED AND HEATING
ELEMENTS
IN A VAPORIZER DEVICE," U.S. Provisional Application No. 62/812,148, filed on
February
28, 2019, and titled "RESERVOIR OVERFLOW CONTROL WITH CONSTRICTION
POINTS," U.S. Provisional Application No. 62/747,055, filed on October 17,
2018, and titled
"RESERVOIR OVERFLOW CONTROL," U.S. Provisional Application No. 62/747,130,
filed on October 17, 2018, and titled "VAPORIZER CONDENSATE COLLECTION AND
RECYCLING," U.S. Provisional Application No. 62/913,135, filed October 9,
2019, and titled
"HEATING ELEMENT," and U.S. Patent Application No. 16/653,455, filed on
October 15,
2019, and titled "HEATING ELEMENT," the entirety of each of which is
incorporated by
reference herein, to the extent permitted.
FIELD
[0002] The
disclosed subject matter generally relates features of a cartridge for a
vaporizer,
and in some examples to management of leaks of liquid vaporizable material,
control of airflow
within and near a cartridge, heating of vaporizable material to result in
formation of an aerosol,
and/or other assembly features of the cartridge and a device to which it may
be separably
connected.
BACKGROUND
[0003]
Vaporizer devices, which are generally referred to herein as vaporizers,
include
devices that heat a vaporizable material (e.g., a liquid, a plant material,
some other solid, a wax,
etc.) to a temperature sufficient to release one or more compounds from the
vaporizable
material into a form (e.g., a gas, an aerosol, etc.) that may be inhaled by a
user of the vaporizer.
Some vaporizers, for example those in which at least one of the compounds
released from the
vaporizable material is nicotine, may be useful as an alternative to smoking
of combustible
cigarettes.
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SUMMARY
[0004] For
purposes of summarizing, certain aspects, advantages, and novel features have
been described herein. It is to be understood that not all such advantages may
be achieved in
accordance with any one particular embodiment. Thus, the disclosed subject
matter may be
embodied or carried out in a manner that achieves or optimizes one advantage
or group of
advantages without achieving all advantages as may be taught or suggested
herein. The various
features and items described herein may be incorporated together or separable,
except as would
not be feasible based on the current disclosure and what a skilled artisan
would understand
from it.
[0005] In one
aspect, a vaporizer includes a reservoir configured to contain a liquid
vaporizable material. The reservoir is at least partially defined by at least
one wall, and the
reservoir includes a storage chamber and an overflow volume. The vaporizer
further includes
a collector disposed in the overflow volume. The collector includes a
capillary structure
configured to retain a volume of the liquid vaporizable material in fluid
contact with the storage
chamber. The capillary structure includes a microfluidic feature configured to
prevent air and
liquid from bypassing each other during filling and emptying of the collector.
[0006] In an
interrelated aspect which may be included in a vaporizer of the preceding
aspect, a microfluidic gate for controlling flow of liquid vaporizable
material between a storage
chamber and an adjoining overflow volume in a vaporizer includes a plurality
of openings
connecting the storage chamber and the collector and a pinch-off point between
the plurality
of openings. The plurality of openings includes a first channel and a second
channel. The first
channel has a higher capillary drive than the second channel. Optionally, the
microfluidic gate
may include a rim of an aperture between the storage chamber and the collector
that is flatter
on a first side facing the storage compartment than a second, more rounded,
side facing the
collector.
[0007] In
another interrelated aspect that may be incorporated with other aspects, a
collector configured for insertion into a vaporizer cartridge includes a
capillary structure
configured to retain a volume of the liquid vaporizable material in fluid
contact with a storage
chamber of the vaporizer cartridge. The capillary structure includes a
microfluidic feature
configured to prevent air and liquid from bypassing each other during filling
and emptying of
the collector.
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[0008] In
optional variations, one or more of the following features may also be
included
in any feasible combination. For example, a primary passageway may be included
to provide
a fluid connection between the storage chamber and an atomizer configured to
convert the
liquid vaporizable material to a gas-phase state. The primary passageway may
be formed
through a structure of the collector.
[0009] The
primary passageway may include a first channel configured to allow for the
liquid vaporizable material to flow from the storage chamber toward a wicking
element in the
atomizer. The first channel may have a cross-sectional shape with at least one
irregularity
configured to allow liquid in the first channel to bypass an air bubble
blocking a remainder of
the first channel. The cross-sectional shape may resembles a cross. The
capillary structure
may include a secondary passageway that includes the microfluidic feature, and
the
microfluidic feature may be configured to allow the liquid vaporizable
material to move along
a length of the secondary passageway only with a meniscus fully covering a
cross-sectional
area of the secondary passageway. The cross-sectional area may be sufficiently
small that, for
a material from which walls of the secondary passageway are formed and a
composition of the
liquid vaporizable material, the liquid vaporizable material preferentially
wets the secondary
passageway around an entire perimeter of the secondary passageway.
[0010] The
storage chamber and the collector may be configured to maintain a continuous
column of the liquid vaporizable material in the collector in contact with the
liquid vaporizable
material in the storage chamber such that a reduction in pressure in the
storage chamber relative
to ambient pressure causes the continuous column of the liquid vaporizable
material in the
collector to be at least partially drawn back into the storage chamber. The
secondary
passageway may include a plurality of spaced-apart constriction points having
a smaller cross-
sectional area than parts of the secondary passageway between the constriction
points. The
constriction points may have a flatter surface directed along the secondary
passageway toward
the storage compartment and a rounder surface directed along the secondary
passageway away
from the storage compartment.
[0011] A
microfluidic gate may be positioned between the collector and the storage
compartment. The microfluidic gate may include a rim of an aperture between
the storage
chamber and the collector that is flatter on a first side facing the storage
compartment than a
second, more rounded, side facing the collector. The microfluidic gate may
include a plurality
of openings connecting the storage chamber and the collector and a pinch-off
point between
the plurality of openings. The plurality of openings may include a first
channel and a second
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channel, wherein the first channel has a higher capillary drive than the
second channel. An air-
liquid vaporizable material meniscus reaching the pinch-off point may be
routed to the second
channel due to the higher capillary drive in the first channel such that an
air bubble is formed
to escape into the liquid vaporizable material in the storage chamber.
[0012] The
liquid vaporizable material may include one or more of propylene glycol and
vegetable glycerin.
[0013] A
collector may include a primary passageway providing a fluid connection
between the reservoir and an atomizer configured to convert the liquid
vaporizable material to
a gas-phase state, wherein the primary passageway is formed through a
structure of the
collector. IN optional variations, the capillary structure may include a
secondary passageway
comprising the microfluidic feature, and the microfluidic feature may be
configured to allow
the liquid vaporizable material to move along a length of the secondary
passageway only with
a meniscus fully covering a cross-sectional area of the secondary passageway.
The cross-
sectional area may be sufficiently small that, for a material from which walls
of the secondary
passageway are formed and a composition of the liquid vaporizable material,
the liquid
vaporizable material preferentially wets the secondary passageway around an
entire perimeter
of the secondary passageway. The storage chamber and the collector may be
configured to
maintain a continuous column of the liquid vaporizable material in the
collector in contact with
the liquid vaporizable material in the storage chamber such that a reduction
in pressure in the
storage chamber relative to ambient pressure causes the continuous column of
the liquid
vaporizable material in the collector to be at least partially drawn back into
the storage chamber.
The secondary passageway may include a plurality of spaced-apart constriction
points having
a smaller cross-sectional area than parts of the secondary passageway between
the constriction
points. The constriction points may have a flatter surface directed along the
secondary
passageway toward the storage compartment and a rounder surface directed along
the
secondary passageway away from the storage compartment.
[0014] In yet
another interrelated aspect, a vaporizer cartridge includes a cartridge
housing,
a storage chamber disposed within the cartridge housing and configured to
contain a liquid
vaporizable material, an inlet configured to allow air to enter an internal
airflow path within
the cartridge housing, an atomizer configured to cause conversion of at least
some of the liquid
vaporizable material to an inhalable state, a collector as described in the
preceding aspect.
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[0015] In
optional variations, such a vaporizer cartridge may include one or more
features
as described herein, such as for example a wicking element positioned within
the internal
airflow path and in fluid communication with the reservoir. The wicking
element may be
configured to draw the liquid vaporizable material from the storage chamber
under capillary
action. A heating element may be positioned to cause heating of the wicking
element to result
in conversion of at least some of the liquid vaporizable material drawn from
the storage
chamber to a gaseous state. The inhalable state may include an aerosol formed
by condensation
of at least some of the liquid vaporizable material from the gaseous state.
The cartridge housing
may include a monolithic hollow structure having a first, open end, and a
second end opposite
the first end. The collector may be insertably received within the first end
of the monolithic
hollow structure.
[0016] In yet
another interrelated aspect, a reservoir for a cartridge usable with a
vaporizer
device is provided. In one embodiment, the reservoir comprises a storage
chamber (e.g., a
reservoir) for storing vaporizable material, as well as an overflow volume
separable from the
storage chamber and in communication with the storage chamber via a vent
leading to a
passageway in the overflow volume.
[0017] The
passageway in the overflow volume may lead to a port connected to ambient
air. The storage chamber or the reservoir may also include a first wick feed,
and optionally a
second wick feed, implemented respectively in the form of a first cavity and a
second cavity
going through a collector placed inside the cartridge The collector may
include one or more
supporting structures which form the passageway in the overflow volume. The
first and second
cavities may control flow of the vaporizable material toward a wick housing
configured to
receive a wicking element.
[0018] The
wicking element positioned in the wick housing or the wicking element housing
may be configured to absorb the vaporizable material traveling through the
first and second
wick feeds such that, in thermal interaction with an atomizer, the vaporizable
material absorbed
in the wicking element is converted to at least one of vapor or aerosol and
flowing through an
exit tunnel structure formed through the collector and the storage chamber to
reach an opening
in the mouthpiece. The mouthpiece may be formed proximate to the storage
chamber.
[0019] The
collector may have a first end and a second end. The first end may be coupled
to the opening in the mouthpiece and the second end, opposite to the first
end, may be
configured to house a wick or wicking element. A wick housing in accordance
with certain
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embodiments may include a set of prongs projecting outward from the second end
to at least
partially receive the wicking element, and one or more compression ribs
positioned in the
proximity of the first or second wick feeds and extending from the second end
of the collector
to compress the wicking element.
[0020] In yet
another interrelated aspect, a vent may be provided to maintain an equilibrium
pressure state in the cartridge's storage chamber and to prevent pressure in
the storage chamber
from increasing to a point that would cause the vaporizable material to flood
the wick housing.
The equilibrium pressure state may be maintained by way of establishing a
liquid seal at the
opening of the vent positioned at a point where the storage chamber
communicates with a
passageway in an overflow volume in the cartridge. The liquid seal is
established and
maintained at the vent by maintaining sufficient capillary pressure for the
vaporizable material
menisci to be formed at a portion of the vent leading to the passageway in the
overflow volume.
[0021] The
capillary pressure for the vaporizable material menisci may be controlled by,
for example, venting structures that form a primary channel and a secondary
channel that
effectively construct a fluidic valve to control at least a pinch-off point at
one of the primary
channel or the secondary channel. Depending on implementation, the primary
channel and the
secondary channel may have tapered geometries such that, as the menisci
continue to recede,
a capillary drive of the primary channel decreases at a greater rate than that
of the capillary
drive of the secondary channel. A gradual reduction in the capillary drives of
the primary and
the secondary channels reduces the partial headspace vacuum maintained in the
storage
chamber.
[0022] In yet
another interrelated aspect, the drain pressure of the primary channel drops
below the drain pressure of the secondary channel as a result of the gradual
reduction in the
capillary drives of the primary and the secondary channels in relation to one
another. The
meniscus in the primary channel continues to drain when the drain pressure of
the primary
channel changes, while the meniscus in the secondary channel remains static.
The drain
pressure involving receding contact angle of the primary channel may drop
below the flooding
pressure involving advancing contact angle of the secondary channel, causing
the primary and
secondary channels to fill with vaporizable material.
[0023]
Accordingly, in response to an increased pressure state inside the storage
chamber,
vaporizable material flows into the collector's passageway (i.e., the overflow
volume) through
the vent, wherein the vent is constructed to maintain a liquid seal at the
pinch-off point,
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desirably, at all times. In certain embodiments, the vent is constructed to
promote a liquid seal
at the opening from which vaporizable material flows between the reservoir's
storage chamber
and the collector's passageway in the overflow volume.
[0024] In yet
another interrelated aspect, one or more wick feed channels may be
implemented to control the direct flow of the vaporizable material toward the
wick. A first
wick feed channel may be formed through the collector positioned in the
overflow volume and
independent of the primary and secondary channels of the control valve noted
above. The
collector may include a supporting structure that forms the first channel or
additional wick feed
channels. The wick may be positioned in the wick housing such that the wick is
configured to
absorb the vaporizable material traveling through the first channel.
Depending on
implementation, the first channel may have a cross shaped cross-section or
have a partial
dividing wall. The shape of the first channel may provide for one or more non-
primary sub-
channels and one or more primary sub-channels that are larger in diameter in
comparison to
the non-primary sub-channels.
[0025]
Depending on implementation, when a primary sub-channels or non-primary sub-
channel is restricted or plugged (e.g., due to air bubble formation),
vaporizable material may
travel through an alternate sub-channel or primary channel. In a cross-shaped
wick feed, a
primary sub-channel may extend through the center of the cross-shaped wick
feed. When the
primary sub-channel is restricted due to the formation of a gas bubble in a
portion of the
primary sub-channel, vaporizable material flows through at least one of the
non-primary sub-
channels.
[0026] In some
embodiments, the collector may have a first end and a second end, the first
end facing the storage chamber and the second end facing away from the storage
chamber and
being configured to include the wick housing. A second wick feed may be
implemented in the
form of a second channel to allow for the vaporizable material stored in the
storage chamber
to flow toward the wick simultaneously as the vaporizable material flows
through the first wick
feed. The second wick feed may have a cross-shaped cross-sectional.
[0027] In
accordance with one or more aspects, a reservoir for a cartridge usable with a
vaporizer device may comprise a storage chamber configured to contain
vaporizable material.
The reservoir may be in an operational relationship with an atomizer
configured to convert the
vaporizable material from a liquid phase to a vapor or aerosol phase for
inhalation by a user of
the vaporizer device. The cartridge may also include an overflow volume for
retaining at least
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some portion of the vaporizable material, for example, when one or more
factors cause the
vaporizable material in the reservoir chamber to travel into the overflow
volume in the
cartridge.
[0028] The one
or more factors may include the cartridge being exposed to a pressure state,
which is different than an earlier ambient pressure state (e.g., by going from
a first pressure
state to a second pressure state). In some aspects, the overflow volume may
include a
passageway that connects to an opening or air control port leading to the
exterior of the
cartridge (i.e., to ambient air). The passageway in the overflow volume may
also be in
communication with the reservoir chamber such that the passageway may act as
an air vent to
allow equalization of pressure in the reservoir chamber. In response to a
negative pressure
event in the cartridges ambient environment, vaporizable material may be drawn
from the
reservoir chamber to the atomizer and converted to vapor or aerosol phases,
reducing the
volume of the vaporizable material remaining in the reservoir's storage
chamber.
[0029] The
storage chamber may be coupled to the overflow volume by way of one or more
openings between the storage chamber and the overflow volume, for example,
such that the
one or more openings lead to one or more passageways through the overflow
volume. The
flow of the vaporizable material into the passageway via the opening may be
controllable by
way of capillary properties of a fluidic vent leading to the one or more
passageways or the
capillary properties of the passageways themselves. Furthermore, the flow of
the vaporizable
material into the one or more passageways may be reversible, allowing for the
vaporizable
material to be displaced from the overflow volume back into the reservoir
chamber.
[0030] In at
least one embodiment, flow of the vaporizable material may be reversed, in
response to change in pressure state (e.g., when a second pressure state in
the cartridge reverts
back to a first pressure state). The second pressure state may be associated
with a negative
pressure event. A negative pressure event may be the result of a drop in
ambient pressure
relative to that of one or more volumes of air retained within the reservoir
chamber or other
part of the cartridge. Alternatively, a negative pressure event may result
from the compression
of an internal volume of the cartridge due to mechanical pressure on one or
more outer surfaces
of the cartridge.
[0031] A
heating element may include a heating portion and at least two legs. The
heating
portion may include at least two tines spaced apart from one another. The
heating portion may
be preformed to define an interior volume configured to receive the wicking
element such that
the heating portion secures at least a portion of the wicking element to the
heating element.
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The heating portion may be configured to contact at least two separate
surfaces of the wicking
element. The at least two legs may be coupled to the at least two tines and
spaced apart from
the heating portion. The at least two legs may be configured to electrically
communicate with
a power source. Power is configured to be supplied to the heating portion from
the power
source to generate heat, thereby vaporizing the vaporizable material stored
within the wicking
element.
[0032] In some
implementations, the at least two legs includes four legs. In some
implementations, the heating portion is configured to contact at least three
separate surfaces of
the wicking element.
[0033] In some
implementations, the at least two tines includes a first side tine portion, a
second side tine portion opposing the first side tine portion, and a platform
tine portion
connecting the first side tine portion with the second side tine portion. The
platform tine
portion may be positioned approximately perpendicular to a portion of the
first side tine portion
and the second side tine portion. The first side tine portion, the second side
tine portion, and
the platform tine portion defines the interior volume in which the wicking
element is
positioned. In some implementations, the at least two legs are located away
from the heating
portion by a bridge.
[0034] In some
implementations, each of the at least two legs includes a cartridge contact
positioned at an end of each of the at least two legs. The cartridge contact
may electrically
communicate with the power source. The cartridge contact may be angled and
extend away
from the heating portion.
[0035] In some
implementations, the at least two tines includes a first pair of tines and a
second pair of tines. In some implementations, the tines of the first pair of
tines are evenly
spaced from one another. In some implementations, the tines of the first pair
of tines are spaced
apart by a width. In some implementations, the width is greater at an inner
region of the heating
element adjacent the platform tine portion than the width at an outer region
of the heating
element adjacent an outer edge of the first side tine portion opposite the
inner region.
[0036] In some
implementations, the vaporizer device is configured to measure a resistance
of the heating element at each of the four legs to control a temperature of
the heating element.
In some implementations, the heating element includes a heat shield configured
to insulate the
heating portion from a body of the vaporizer device.
[0037] In some
implementations, the vaporizer device further includes a heat shield
configured to surround at least a portion of the heating element and insulate
the heating portion
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from a body of a wick housing configured to surround at least a portion of the
wicking element
and the heating element.
[0038] In some
implementations, the heating portion is folded between the heating portion
and the at least two legs to isolate the heating portion from the at least two
legs. In some
implementations, the heating portion further includes at least one tab that
extends from a side
of the at least two tines to allow for easier entry of the wicking element to
the interior volume
of the heating portion. In some implementations, the at least one tab extends
away from the
interior volume at an angle.
[0039] In some
implementations, the at least two legs includes a capillary feature. The
capillary feature may cause an abrupt change in capillary pressure to thereby
prevent the
vaporizable material from flowing beyond the capillary feature. In some
implementations, the
capillary feature comprises one or more bends in the at least two legs. In
some
implementations, the at least two legs extend at an angle towards the interior
volume of the
heating portion, the angled at least two legs defining the capillary feature.
[0040] In some
implementations, a vaporizer device includes a reservoir containing
vaporizable material, a wicking element in fluid communication with the
reservoir, and a
heating element. The heating element includes a heating portion and at least
two legs. The
heating portion may include at least two tines spaced apart from one another.
The heating
portion may be preformed to define an interior volume configured to receive
the wicking
element such that the heating portion secures at least a portion of the
wicking element to the
heating element. The heating portion may be configured to contact at least two
separate
surfaces of the wicking element. At least two legs may be coupled to the at
least two tines and
spaced apart from the heating portion. The at least two legs may be configured
to electrically
communicate with a power source. Power is configured to be supplied to the
heating portion
from the power source to generate heat, thereby vaporizing the vaporizable
material stored
within the wicking element.
[0041] A
method of forming an atomizer assembly for a vaporizer device may include
securing a wicking element to an interior volume of a heating element. The
heating element
may include a heating portion comprising at least two tines spaced apart from
one another, and
at least two legs spaced from the heating portion. The legs may be configured
to electrically
communicate with a power source of the vaporizer device. The heating portion
is configured
to contact at least two surfaces of the wicking element. The method may also
include coupling
the heating element to a wick housing configured to surround at least a
portion of the wicking
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element and the heating element. The securing may also include sliding the
wicking element
into the interior volume of the heating element.
[0042] In some
implementations, a vaporizer device includes a heating portion comprising
one or more heater traces integrally formed and spaced apart from one another,
the one or more
heater traces configured to contact at least a portion of a wicking element of
the vaporizer
device, a connecting portion configured to receive power from a power source
and direct the
power to the heating portion, and a plating layer having a plating material
that is different from
a material of the heating portion. The plating layer may be configured to
reduce contact
resistance between the heating element and the power source, thereby
localizing heating of the
heating element to the heating portion.
[0043] In
certain aspects of the current subject matter, challenges associated with
condensate collecting along one or more internal channels and outlets (e.g.,
along a
mouthpiece) of some vaporizer devices can be addressed by inclusion of one or
more of the
features described herein or comparable/equivalent approaches as would be
understood by one
of ordinary skill in the art. Aspects of the current subject matter relate to
systems and methods
for capturing vaporizable material condensate in a vaporizer device.
[0044] In some
variations, one or more of the following features may optionally be
included in any feasible combination.
[0045] Aspects
of the current subject matter relate to a cartridge for a vaporizer device.
The cartridge may include a reservoir including a reservoir chamber defined by
a reservoir
barrier. The reservoir may be configured to contain a vaporizable material in
the reservoir
chamber. The cartridge may include a vaporization chamber in communication
with the
reservoir and may include a wicking element configured to draw the vaporizable
material from
the reservoir chamber to the vaporization chamber to be vaporized by a heating
element. The
cartridge may include an airflow passageway that extends through the
vaporization chamber.
The cartridge may include at least one capillary channel adjacent the airflow
passageway. Each
capillary channel of the at least one capillary channel may be configured to
receive a fluid and
direct the fluid from a first location toward a second location via capillary
action.
[0046] In one
aspect consistent with the current disclosure, each capillary channel of the
at
least one capillary channel may taper in size. The taper in size may result in
an increase in
capillary drive through each capillary channel of the at least one capillary
channel. Each
capillary channel of the at least one capillary channel may be formed by a
groove defined
between a pair of walls. The at least one capillary channel may fluidly
communicates with a
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wick. The first location may be adjacent an end of the airflow passageway and
a mouthpiece.
The at least one capillary channel may collect a fluid condensate.
[0047] In an
interrelated aspect, a vaporizer device may include a vaporizer body including
a heating element configured to heat a vaporizable material. The vaporizer
device may include
a cartridge configured to be releasably coupled to the vaporizer body. The
cartridge may
include a reservoir including a reservoir chamber defined by a reservoir
barrier. The reservoir
may be configured to contain the vaporizable material in the reservoir
chamber. The cartridge
may include a vaporization chamber in communication with the reservoir and may
include a
wicking element configured to draw the vaporizable material from the reservoir
chamber to the
vaporization chamber to be vaporized by the heating element. The cartridge may
include an
airflow passageway that extends through the vaporization chamber. The
cartridge may include
at least one capillary channel adjacent the airflow passageway. Each capillary
channel of the
at least one capillary channel may be configured to receive a fluid and direct
the fluid from a
first location toward a second location via capillary action.
[0048] Each
capillary channel of the at least one capillary channel may taper in size. The
taper in size may result in an increase in capillary drive through each
capillary channel of the
at least one capillary channel. Each capillary channel of the at least one
capillary channel may
be formed by a groove defined between a pair of walls. The at least one
capillary channel may
fluidly communicates with a wick. The first location may be adjacent an end of
the airflow
passageway and a mouthpiece. The at least one capillary channel may collect a
fluid
condensate.
[0049] In an
interrelated aspect, a method of a cartridge of a vaporization device may
include collecting a condensate in a first capillary channel of at least one
capillary channel of
the cartridge. Each of the at least one capillary channel may be configured to
receive a fluid
and direct the fluid from a first location toward a second location via
capillary action. The
cartridge may include a reservoir including a reservoir chamber defined by a
reservoir barrier.
The reservoir may be configured to contain a vaporizable material in the
reservoir chamber.
The cartridge may include a vaporization chamber in communication with the
reservoir and
may include a wicking element configured to draw the vaporizable material from
the reservoir
chamber to the vaporization chamber to be vaporized by a heating element. The
cartridge may
include an airflow passageway that may extend through the vaporization
chamber. The at least
one capillary channel may be adjacent the airflow passageway. The method may
include
directing the collected condensate towards the vaporization chamber and along
the first
capillary channel.
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[0050] The
method may include vaporizing, at the vaporization chamber, the collected
condensate. The first capillary channel may taper in size. Each capillary
channel of the at least
one capillary channel may be formed by a groove defined between a pair of
walls. The at least
one capillary channel may fluidly communicates with a wick. The first location
may be
adjacent an end of the airflow passageway and a mouthpiece.
[0051] The
details of one or more variations of the subject matter described herein are
set
forth in the accompanying drawings and the description below. Other features
and advantages
of the subject matter described herein will be apparent from the description
and drawings, and
from the claims. The disclosed subject matter is not, however, limited to any
particular
embodiment disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The
accompanying drawings, which are incorporated in and constitute a part of this
specification, show certain aspects of the subject matter disclosed herein
and, together with the
description, help explain some of the principles associated with the disclosed
implementations
as provided below.
[0053] FIG. 1
illustrates a block diagram of an example vaporizer device, in accordance
with one or more implementations;
[0054] FIG. 2A
illustrates a planar view of an example vaporizer body and insertable
vaporizer cartridge, in accordance with one or more implementations;
[0055] FIG. 2B
shows a perspective view of the vaporizer device of FIG. 2A, in accordance
with one or more implementations;
[0056] FIG. 2C
shows a perspective view of the cartridge of FIG. 2A, in accordance with
one or more implementations;
[0057] FIG. 2D
shows another perspective view of the cartridge of FIG. 2C, in accordance
with one or more implementations;
[0058] FIG. 2E
illustrates a diagram of a reservoir system configured for a vaporizer
cartridge and/or vaporizer device for improving airflow in the vaporizer
device, in accordance
with one or more implementations;
[0059] FIG. 2F
illustrates a diagram of a reservoir system configured for a vaporizer
cartridge or vaporizer device for improving airflow in the vaporizer device,
in accordance with
another implementation;
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[0060] FIGS.
3A and 3B illustrate an example planar cross-sectional view of a cartridge
having a storage chamber and an overflow volume, in accordance with one or
more
implementations;
[0061] FIG. 4
illustrates an exploded perspective view of an example implementation of a
cartridge of FIGS. 3A and 3B, in accordance with one or more implementations;
[0062] FIG. 5
illustrates a planar cross-sectional side view of a selected split portion of
a
cartridge, in accordance with one or more implementations;
[0063] FIG. 6A
illustrates a cross-sectional top view of an example cartridge structure, in
accordance with one or more implementations;
[0064] FIGS.
6B illustrates a perspective side view of the example cartridge of FIG. 6A, in
accordance with one or more implementations;
[0065] FIGS.
7A through 7D illustrate example embodiments for a cartridge connecting
port having a male or a female construction, in accordance with one or more
implementations;
[0066] FIG. 8
illustrates a planar top view of cartridge with an example motif or logo, in
accordance with one or more implementations;
[0067] FIGS.
9A and 9B illustrate perspective and planar sectional views of a split portion
of an example cartridge, in accordance with one or more implementations;
[0068] FIGS.
10A and 10B illustrate closed and exploded perspective views of an example
cartridge implementation with separable structure for housing a collector
mechanism, in
accordance with one or more implementations;
[0069] FIGS.
10C through 10E illustrate perspective frontal and side views of example
cartridge structural components with a flow management collector having one or
more flow
channels, in accordance with one or more implementations;
[0070] FIG.
11A illustrates a side planar view of an example single-vent single-channel
collector structure, in accordance with one or more implementations;
[0071] FIG.
11B is a side planar view of an example cartridge with a translucent housing
structure containing an example collector, such as that shown in FIG. 11A, in
accordance with
one or more implementations;
[0072] FIGS.
11C through 11E illustrate perspective and planar side views of example
collector structures with flow management constrictors built into the flow
channels, in
accordance with one or more implementations;
[0073] FIGS.
11F and 11G illustrate frontal and side views of an example collector
structure with flow management constrictors built into the collector's flow
channels, in
accordance with one or more implementations;
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[0074] FIG.
11H illustrates a perspective close-up view of an example collector structure
with one or more vents that may control liquid flow between a storage chamber
and an overflow
volume in a cartridge, in accordance with one or more implementations;
[0075] FIGS.
111 through 11K illustrate perspective views of an example collector
structure with flow management control, in accordance with one or more
implementations;
[0076] FIG.
11L through 11N illustrate frontal planar and close-up views of an example
flow management mechanism in the collector structure, in accordance with one
implementation;
[0077] FIG.
110 through 11X illustrate snapshots in time as the flow of vaporizable
material collected in the example collector of FIGS. 11L through 11N is
managed to
accommodate proper venting as the meniscus of vaporizable material stored in
the overflow
volume continues to recede, in accordance with one implementation;
[0078] FIGS.
12A and 12B illustrate examples of single-vent multi-channel collector
structures, in accordance with one or more implementations;
[0079] FIG. 13
illustrates an example double-vent multi-channel collector structure, in
accordance with one or more implementations;
[0080] FIGS.
14A and 14B illustrate perspective and cross-sectional planar side views of
an example collector structure for a cartridge with a dual wick feed, in
accordance with one or
more implementations;
[0081] FIGS.
15A through 15C illustrate additional perspective and cross-sectional planar
side views of an example collector structure for a dual wick feed structure,
in accordance with
one or more implementations;
[0082] FIGS.
16A through 16C illustrate a cross-sectional planar side view of an example
cartridge, planar side view of an example wicking element housed in a
collector structure, and
a perspective view of the example cartridge with the collector structure,
respectively, in
accordance with one or more implementations;
[0083] FIGS.
17A and 17B illustrate a perspective view of a first side of a cartridge and a
cross-sectional view of a second side of the cartridge having a wicking
element that protrudes
into the storage chamber, in accordance with one or more implementations;
[0084] FIGS.
18A through 18D illustrate an example of a heating element and an airflow
passageway in a vaporizer cartridge in accordance with one or more
implementations;
[0085] FIGS.
19A through 19C illustrate an example of a heating element and an airflow
passageway in a vaporizer cartridge, in accordance with one or more
implementations;
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[0086] FIGS.
20A through 20C illustrate an example of a heating element and an airflow
passageway in a vaporizer cartridge, in accordance with one or more
implementations;
[0087] FIGS.
21A and 21B illustrate side views of example collector structures that include
one or more ribs or seal bead profiles that support certain manufacturing
techniques for
securing the collector to a storage chamber in the cartridge;
[0088] FIGS.
22A through 22B illustrate an example of a heating element, in accordance
with one or more implementations;
[0089] FIG. 23
illustrates an example of a portion of a wick housing, in accordance with
one or more implementations;
[0090] FIG. 24
illustrates an example of an identification chip, in accordance with one or
more implementations;
[0091] FIG. 25
illustrates perspective, frontal, side, and exploded views of an example
embodiment of a cartridge;
[0092] FIG.
26A illustrates perspective, frontal, side, bottom and top views of an example
embodiment of a collector with a V-shaped vent;
[0093] FIGS.
26B and 26C illustrate perspective and cross-sectional views of example
collector structures from different viewing angles, with a focus on structural
details for securing
the placement of a wicking element and a wick housing in relation to an
atomizer toward one
end of a cartridge, in accordance with one or more implementations;
[0094] FIGS.
26D through 26F illustrate top planar views of example wick feed
mechanisms formed or structured through the collector, in accordance with one
or more
implementations;
[0095] FIGS.
27A and 27B illustrate frontal views of example flow management
mechanisms in the collector structure, in accordance with one or more
implementations;
[0096] FIG. 28
illustrates a frontal view of an example cartridge containing an example
collector structure;
[0097] FIGS.
29A through 29C illustrate perspective, frontal, and side views, respectively,
of an example embodiment of a cartridge;
[0098] FIGS.
30A through 30F illustrate perspective views of an example cartridge at
different fill levels, in accordance with one or more embodiments;
[0099] FIGS.
31A through 31C illustrate frontal views of an example cartridge as filled
and assembled in accordance with one embodiment;
[0100] FIGS.
32A through 32C illustrate frontal, top, and bottom views of an example
cartridge air path;
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[0101] FIGS.
33A and 33B illustrate frontal and top views of an example cartridge with an
airflow path, liquid feed channels, and a condensation collection system;
[0102] FIGS.
34A and 34B illustrate frontal and side views of an example cartridge body
with an external airflow path;
[0103] FIGS.
35 and 36 illustrate a perspective view of a portion of an example cartridge
with a collector structure having an air gap at the bottom rib of the
collector structure;
[0104] FIGS.
37A through 37C illustrate top views of various example wick feed shapes
for a cartridge;
[0105] FIGS.
37D and 37E are example embodiments of a collector with a double wick
feed implementation;
[0106] FIG. 38
illustrates a close-up view of an end of the wick feed that is positioned
proximate to the wick and configured to at least partially receive the wick;
[0107] FIG. 39
illustrates a perspective view of an example collector structure having a
square-design wick feed in combination with an air gap at one end of the
overflow passageway;
[0108] FIG.
40A illustrates a rear view of the collector structure with four distinct
ejection
sites, for example;
[0109] FIG.
40B illustrates a side view of the collector structure particularly showing a
clamp-shaped end portion of a wick feed that can firmly hold the wick in the
pathway of the
wick feed, for example;
[0110] FIG.
40C illustrates a top view of the collector structure with wick feed channels
for receiving vaporizable material from the cartridge's storage chamber and
leading the
vaporizable material towards the wick being held in position at the end of the
wick feed
channels by the projecting ends of the wick feed channels;
[0111] FIG.
40D illustrates a frontal planar view of the collector structures. As shown an
air gap cavity may be formed at the lower portion of the collector structure
at the end of a lower
rib of the collector structure where the overflow passageway of the collector
leads to an air
control vent in communication with ambient air;
[0112] FIG.
40E illustrates a bottom view of the collector structure with wick feed
channels
ending in clamp-shaped projection that are configured to hold the wick in
position on each end;
[0113] FIGS.
41A and 41B illustrates planar top and side views of the collector structure
with two clamp-shaped end portions of two corresponding wick feeds;
[0114] FIGS.
42A and 42B illustrate various perspective, top and side views of an example
collector with different structural implementations;
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[0115] FIG.
43A illustrates various perspective, top and side views of an example wick
housing, in accordance with one or more embodiments;
[0116] FIG.
43B illustrates the collector and wick housing components of an example
cartridge wherein a protruding tab is configured in the structure of the wick
housing to be
insertably received into a receiving notch or cavity in a corresponding bottom
portion of the
collector;
[0117] FIG.
44A illustrates a perspective exploded view of an embodiment of a cartridge,
consistent with implementations of the current subject matter;
[0118] FIG.
44B illustrates a top perspective view of an embodiment of a cartridge
consistent with implementations of the current subject matter;
[0119] FIG.
44C illustrates a bottom perspective view of an embodiment of a cartridge
consistent with implementations of the current subject matter;
[0120] FIG. 45
shows a schematic view of a heating element for use in a vaporizer device
consistent with implementations of the current subject matter;
[0121] FIG. 46
shows a schematic view of a heating element for use in a vaporizer device
consistent with implementations of the current subject matter;
[0122] FIG. 47
shows a schematic view of a heating element for use in a vaporizer device
consistent with implementations of the current subject matter;
[0123] FIG. 48
shows a schematic view of a heating element positioned in a vaporizer
cartridge for use in a vaporizer device consistent with implementations of the
current subject
matter;
[0124] FIG. 49
shows a heating element and a wicking element consistent with
implementations of the current subj ect matter;
[0125] FIG. 50
shows a heating element and a wicking element consistent with
implementations of the current subject matter;
[0126] FIG. 51
shows a heating element and a wicking element positioned within a
vaporizer cartridge consistent with implementations of the current subject
matter;
[0127] FIG. 52
shows a heating element and a wicking element positioned within a
vaporizer cartridge consistent with implementations of the current subject
matter;
[0128] FIG. 53
shows a heating element positioned within a vaporizer cartridge consistent
with implementations of the current subject matter;
[0129] FIG. 54
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
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[0130] FIG. 55
shows a heating element in a bent position consistent with implementations
of the current subject matter;
[0131] FIG. 56
shows a heating element in a bent position consistent with implementations
of the current subject matter;
[0132] FIG. 57
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
[0133] FIG. 58
shows a heating element in a partially bent position consistent with
implementations of the current subj ect matter;
[0134] FIG. 59
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0135] FIG. 60
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0136] FIG. 61
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0137] FIG. 62
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0138] FIG. 63
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
[0139] FIG. 64
shows a heating element in a bent position consistent with implementations
of the current subject matter;
[0140] FIG. 65
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0141] FIG. 66
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0142] FIG. 67
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0143] FIG. 68
shows a heating element in a partially bent position and a wicking element
consistent with implementations of the current subject matter;
[0144] FIG. 69
shows a heating element in a bent position and a wicking element consistent
with implementations of the current subject matter;
[0145] FIG. 70
shows a heating element in a bent position and a wicking element consistent
with implementations of the current subject matter;
[0146] FIG. 71
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
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[0147] FIG. 72
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
[0148] FIG. 73
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
[0149] FIG. 74
shows a heating element in an unbent position consistent with
implementations of the current subject matter;
[0150] FIG. 75
shows a heating element coupled with a portion of a vaporizer cartridge
consistent with implementations of the current subject matter;
[0151] FIG. 76
shows a heating element and a wicking element positioned within a
vaporizer cartridge consistent with implementations of the current subject
matter;
[0152] FIG. 77
shows a heating element in a partially bent position consistent with
implementations of the current subject matter;
[0153] FIG. 78
shows a heating element in a partially bent position and a wicking element
consistent with implementations of the current subject matter;
[0154] FIG. 79
shows a heating element having a plated portion, in an unbent position
consistent with implementations of the current subject matter;
[0155] FIG. 80
shows a heating element having a plated portion, in a bent position
consistent with implementations of the current subject matter;
[0156] FIG. 81
shows a heating element having a plated portion positioned within a
vaporizer cartridge consistent with implementations of the current subject
matter;
[0157] FIG. 82
shows a perspective view of a heating element in a bent position consistent
with implementations of the current subject matter;
[0158] FIG. 83
shows a side view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0159] FIG. 84
shows a front view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0160] FIG. 85
shows a perspective view of a heating element in a bent position and a
wicking element consistent with implementations of the current subject matter;
[0161] FIG. 86
shows a heating element positioned within a vaporizer cartridge consistent
with implementations of the current subject matter;
[0162] FIG. 87
shows a perspective view of a heating element in a bent position consistent
with implementations of the current subject matter;
[0163] FIG. 88
shows a side view of a heating element in a bent position consistent with
implementations of the current subject matter;
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[0164] FIG. 89
shows a top view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0165] FIG. 90
shows a front view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0166] FIG. 91
shows a perspective view of a heating element in an unbent position
consistent with implementations of the current subject matter;
[0167] FIG. 92
shows a top view of a heating element in an unbent position consistent with
implementations of the current subject matter;
[0168] FIG.
93A shows a perspective view of a heating element in a bent position
consistent with implementations of the current subject matter;
[0169] FIG.
93B shows a perspective view of a heating element in a bent position
consistent with implementations of the current subject matter;
[0170] FIG. 94
shows a side view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0171] FIG. 95
shows a top view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0172] FIG. 96
shows a front view of a heating element in a bent position consistent with
implementations of the current subject matter;
[0173] FIG.
97A shows a perspective view of a heating element in an unbent position
consistent with implementations of the current subject matter;
[0174] FIG.
97B shows a perspective view of a heating element in an unbent position
consistent with implementations of the current subject matter;
[0175] FIG.
98A shows a top view of a heating element in an unbent position consistent
with implementations of the current subject matter;
[0176] FIG.
98B shows a top view of a heating element in an unbent position consistent
with implementations of the current subject matter;
[0177] FIG. 99
shows a top perspective view of an atomizer assembly consistent with
implementations of the current subject matter;
[0178] FIG.
100 shows a bottom perspective view of an atomizer assembly consistent with
implementations of the current subject matter;
[0179] FIG.
101 shows an exploded perspective view of an atomizer assembly consistent
with implementations of the current subject matter;
[0180] FIG.
102 shows a perspective view of a heat shield consistent with implementations
of the current subject matter;
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[0181] FIG. 103A shows a side cross-sectional view of an atomizer assembly
consistent
with implementations of the current subject matter;
[0182] FIG. 103B shows another side cross-sectional view of an atomizer
assembly
consistent with implementations of the current subject matter;
[0183] FIG. 104 schematically shows a heating element consistent with
implementations
of the current subject matter;
[0184] FIG. 105 shows a perspective view of a heating element in a bent
position consistent
with implementations of the current subject matter;
[0185] FIG. 106 shows a side view of a heating element in a bent position
consistent with
implementations of the current subject matter;
[0186] FIG. 107 shows a perspective view of a heating element in a bent
position consistent
with implementations of the current subject matter;
[0187] FIG. 108 shows a side view of a heating element in a bent position
consistent with
implementations of the current subject matter;
[0188] FIG. 109 shows a top view of a substrate material with a heating
element consistent
with implementations of the current subject matter;
[0189] FIG. 110 shows a top view of a heating element in an unbent position
consistent
with implementations of the current subject matter;
[0190] FIG. 111A shows a top perspective view of an atomizer assembly
consistent with
implementations of the current subject matter;
[0191] FIG. 111B shows a close-up view of a portion of a wick housing of an
atomizer
assembly consistent with implementations of the current subject matter;
[0192] FIG. 112 shows a bottom perspective view of an atomizer assembly
consistent with
implementations of the current subject matter;
[0193] FIG. 113 shows an exploded perspective view of an atomizer assembly
consistent
with implementations of the current subject matter;
[0194] FIGS. 114A-114C show a process of assembling an atomizer consistent
with
implementations of the current subject matter;
[0195] FIGS. 115A-115C show a process of assembling an atomizer consistent
with
implementations of the current subject matter;
[0196] FIG. 116 shows a process flow chart illustrating features of a
method of forming
and implementing a heating element consistent with implementations of the
current subject
matter;
[0197] FIG. 117 illustrates an embodiment of a vaporizer cartridge;
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[0198] FIG.
118 illustrates an embodiment of a mouthpiece of a vaporizer cartridge and/or
vaporizer device;
[0199] FIG.
119A illustrates a side cross-sectional view of a condensate recycler system
of
a vaporizer cartridge;
[0200] FIG.
119B illustrates a first perspective view of the condensate recycler system of
FIG. 119A; and
[0201] FIG.
119C illustrates a second perspective view of the condensate recycler system
of FIG. 119A.
[0202] Where
practical, the same or similar reference numbers denote the same, similar, or
equivalent structures, features, aspects, or elements, in accordance with one
or more
implementations.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0203] A
vaporizer configured to convert a liquid vaporizable material to the gas-phase
and/or aerosol phase (e.g., a suspension of gas-phase and particulate-phase
material in air that
is in a relative local equilibrium between the phases) may typically include a
reservoir or
storage container (also referred to herein as a reservoir, storage
compartment, or storage
volume) containing a volume of the liquid vaporizable material, an atomizer
(which may also
be referred to as an atomizer assembly), a heater element (e.g., an
electrically resistive element
through which electrical current is caused to pass to result in the conversion
of the electrical
current to heat energy) that heats the liquid vaporizable material to result
in the conversion at
least some of the liquid vaporizable material to the gas phase, and a wicking
element (which
may be referred to simply as a wick, but which generally refers to an element
or combination
of elements that exerts a capillary force to draw the liquid vaporizable
material from the
reservoir to where it is heated by action of the heating element). The
resulting gas-phase liquid
vaporizable material may in some cases (dependent on a variety of factors)
subsequently (and
optionally nearly immediately) begin to at least partially condense to form an
aerosol in air
passing through, over, near, around etc. the atomizer.
[0204] As the
liquid vaporizable material in the wicking element is heated and converted
to the gas phase (and subsequently optionally into an aerosol), the volume of
the liquid
vaporizable material in the reservoir is reduced. Absent a mechanism for
allowing air or some
other substance into the void space (e.g., a part of the reservoir volume not
occupied by liquid
vaporizable material) created within the reservoir when the volume of the
liquid vaporizable
material therein is reduced by conversion to the gas-/aerosol phase, a reduced
pressure state
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(e.g., an at least partial vacuum) results within the reservoir. This reduced
pressure state may
adversely affect the efficacy of the wicking element for drawing the
vaporizable material from
the storage compartment or reservoir into proximity of the heating element for
being vaporized
into the gas phase as the partial vacuum pressure acts contrary to the
capillary pressure created
within the wicking element.
[0205] More
particularly, a reduced pressure state in the reservoir can result in
insufficient
saturation of the wick and ultimately the lack of sufficient vaporizable
material being delivered
to the atomizer for dependable operation of the vaporizer. To counteract the
reduced pressure
state, ambient air may be allowed to enter the reservoir to equalize the
pressure between the
interior of the reservoir and ambient pressure. Allowing air to back-fill the
void space in the
reservoir that is created by vaporized liquid vaporizable material may occur
in some vaporizers
by air passing into the reservoir through the wicking element. However, this
process may
generally require that the wicking element be at least partially dry. As a dry
wicking element
may not be readily achievable and/or may not be desirable for dependable
operation of the
vaporizer, another typical approach is to provide a vent to allow equalization
of pressure
between ambient conditions and within the reservoir.
[0206]
Presence of air in the void space of a reservoir, whether through the wick or
through
some other vent or venting structure, may create one or more other issues. For
example, once
the air pressure within the void space of the reservoir is equalized (or at
least close to equalized)
with ambient pressure, and especially when the void space filled with air
increases in volume
relative to the total reservoir volume, creation of a negative pressure
differential (e.g., the air
in the void space being at a higher pressure than ambient) between the air in
the void space and
ambient conditions may lead to liquid vaporizable material leaking out of the
reservoir, for
example through the wick, through any vent that is provided, etc. A negative
pressure
differential between air within the reservoir and current ambient pressure may
be created by
one or more of several factors, for example, heating of the air within the
void space (e.g., by
holding the reservoir in a hand, taking the vaporizer from a cold area to a
warmer area, etc.),
mechanical forces that may distort the shape of and thereby reduce the
interior volume of the
reservoir (e.g., squeezing on a part of the vaporizer causing distortion of
the reservoir volume,
etc.), a rapid drop in the ambient pressure (e.g., such as may occur in an
airplane cabin during
air travel, when a car or train enters or exits a tunnel, when a window is
opened or closed while
a vehicle is traveling at an elevated speed, etc.), or the like.
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[0207] Leaks
of liquid vaporizable material from a reservoir of a vaporizer such as those
described above are generally undesirable, as the leaked liquid vaporizable
material may create
an unwanted mess (e.g., by staining clothes or other items in proximity to the
vaporizer), may
make its way into an inhalation path of the vaporizer and thereby being
ingested by a user, may
interfere with functioning of the vaporizer (e.g., by fouling a pressure
sensor, affecting
operability of electrical circuitry and/or switches, fouling charging ports
and/or connections
between a cartridge and a vaporizer body, etc.), or the like. Liquid
vaporizable material leaks
can thus interfere with the functionality and cleanliness of the vaporizer.
[0208]
Examples of vaporizers include, without limitation, electronic vaporizers,
electronic nicotine delivery systems (ENDS), or devices and systems with same,
similar, or
equivalent structural or functional features or capabilities. FIG. 1 shows an
example block
diagram of an example vaporizer 100. The vaporizer 100 may include a vaporizer
body 110
and a vaporizer cartridge 120 (also referred to simply as a vaporizer
cartridge 120). The
vaporizer body 110 may include a power source 112 (e.g., a battery which may
be
rechargeable), and a controller 104 (e.g., programmable logic device,
processor, or circuitry
capable of executing logic code) for controlling delivery of heat to an
atomizer 141 to cause a
vaporizable material (not shown) to be converted from a condensed form (e.g.,
a solid, a liquid,
a solution, a suspension, an at least partially unprocessed plant material,
etc.) to a gas phase, or
more generically, for the vaporizable material to be converted to an inhalable
form or a
precursor of an inhalable form. In this context, and inhalable form may be a
gas or an aerosol,
or some other airborne form. A precursor of an inhalable form may include a
gas-phase state
of the vaporizable material that condenses a least partially to form an
aerosol at some time
(optionally immediately or nearly immediately or alternatively with some delay
or after some
amount of cooling) after formation of the gas-phase state. The controller 104
may be part of
one or more printed circuit boards (PCBs) consistent with certain
implementations and may be
utilized to control certain features of the vaporizer body 110 in association
with one or more
sensors 113.
[0209] As
shown, the vaporizer body 110 may, in some implementations of the current
subject matter, include one more sensors 113, vaporizer body contacts 125, a
seal 115, and,
optionally, a cartridge receptacle 118 configured to receive at least part of
a vaporizer cartridge
120 for coupling with the vaporizer body 110 through one or more of a variety
of attachment
structures. As discussed below with reference to FIGS. 7A through 7D, a male
or a female
receptacle construction or some combination thereof may be employed to couple
the vaporizer
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cartridge 120 with the vaporizer body 110. For example, in some
implementations of the
current subj ect matter, an inner part of a first end of the cartridge may be
received in a cartridge
receptacle 118 of the vaporizer body 110 while an outer part of the first end
of the cartridge at
least partially covers some part of an outside surface of a structure on the
vaporizer body 110
that forms the cartridge receptacle 118. Such an arrangement for coupling a
vaporizer cartridge
120 to a vaporizer body 110 may allow for a convenient, easy to use method of
joining that
also provides sufficient mechanical coupling strength to avoid unwanted
separate of the
vaporizer cartridge 120 and vaporizer body 110. Such a configuration may also
provide
desirable resistance to flexing of the vaporizer formed by coupling the
vaporizer cartridge 120
to the vaporizer body 110. Regarding the vaporizer body contacts 125, it will
be understood
that these may also be referred to as "receptacle contacts 125," particularly
in implementations
in which the corresponding cartridge contacts 124 (discussed below) are on a
part of a vaporizer
cartridge 120 that is inserted into a receptacle or receptacle-like structure
on the vaporizer body
110. However, the terms "vaporizer body contacts 125" and/or "receptacle
contacts 125" are
also used herein as aspects of the current subject matter are not limited to
(and may be used to
provide various advantages in systems other than those in which) electrical
coupling between
a vaporizer cartridge 120 and a vaporizer body 110 occurs between contacts
within a cartridge
receptacle 118 on the vaporizer body 110 and on a part of the vaporizer
cartridge 120 that is
inserted into cartridge receptacle 118.
[0210] In some
examples, the vaporizer cartridge 120 may include a reservoir 140 for
containing a liquid vaporizable material and a mouthpiece 130 for delivering a
dose of an
inhalable form of the vaporizable material. The mouthpiece may optionally be a
separate
component from the structure that forms the reservoir 140, or alternatively it
may be formed
from a same part or component that forms at least part of one or more walls of
the reservoir
140. The liquid vaporizable material within the reservoir 140 may be a carrier
solution in
which active or inactive ingredients may be suspended, dissolved, or held in
solution or a neat
liquid form of the vaporizable material itself.
[0211] In
accordance with one implementation, a vaporizer cartridge 120 may include an
atomizer 141, which may include a wick or a wicking element as well as a
heater (e.g., a heating
element). As noted above, the wicking element may include any material capable
of causing
fluid absorption by capillary pressure through the wick to convey an amount of
a liquid
vaporizable material to a part of the atomizer 141 that includes the heating
element. The wick
and the heating element are not shown in FIG. 1, but are disclosed and
discussed in further
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detail herein with reference to at least FIGS. 3A, 3B and 4. Briefly, the
wicking element may
be configured to draw liquid vaporizable material from a reservoir 140
configured to contain
the liquid vaporizable material, so that the liquid vaporizable material may
be vaporized (i.e.,
converted to a gas-phase state) by heat delivered from the heating element to
the wicking
element and the liquid vaporizable material drawn into the wicking element. In
some
implementations, air may enter a reservoir 140 through the wicking element or
other opening
to at least partially equalize pressure in the reservoir 140 in response to
liquid vaporizable
material being removed from the reservoir 140 during vapor and/or aerosol
formation.
[0212] As
shown in FIG. 1, the pressure sensor (and any other sensors) 113 may be
positioned on or coupled (e.g., electrically, electronically, physically or
via a wireless
connection) to the controller 104. Controller 104 may be a printed circuit
board assembly or
other type of circuit board. To take measurements accurately and maintain
durability of the
vaporizer 100, it may be beneficial to provide a resilient seal 115 to
separate an airflow path
from other parts of the vaporizer 100. The seal 115, which may be a gasket,
may be configured
to at least partially surround the pressure sensor 113 such that connections
of the pressure
sensor 113 to internal circuitry of the vaporizer may be separated from a part
of the pressure
sensor exposed to the airflow path.
[0213] The
liquid vaporizable material used with the vaporizer 100 may be provided within
a vaporizer cartridge 120 that may be refillable when empty or disposable in
favor of a new
cartridge containing additional vaporizable material of a same or different
type. A vaporizer
may be a cartridge-using vaporizer or a multi-use vaporizer capable of use
with or without a
cartridge. For example, a multi-use vaporizer may include a heating chamber
(e.g., an oven)
configured to receive a vaporizable material directly in the heating chamber
and also to receive
a cartridge or other replaceable device having a reservoir, a volume, or other
functional or
structural equivalent for at least partially containing a usable amount of
vaporizable material.
[0214] In an
example of a cartridge-using vaporizer, the seal 115 may also separate parts
of one or more electrical connections between the vaporizer body 110 and the
vaporizer
cartridge 120. Such arrangements of the seal 115 in the vaporizer 100 may be
helpful in
mitigating against potentially disruptive impacts on vaporizer components
resulting from
interactions with one or more environmental factors, such as condensed water,
vaporizable
material that leaks from a reservoir and/or condenses after vaporization, to
reduce the escape
of air from a designed airflow path in the vaporizer, or the like.
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[0215]
Unwanted air, liquid, or other fluid passing or contacting the circuitry of
the
vaporizer 100 may cause various unwanted effects, such as altered pressure
readings, or may
result in the buildup of unwanted material (e.g., moisture, vaporizable
material, and/or the like)
in parts of the vaporizer 100 where the unwanted material may cause poor
pressure signal,
degradation of the pressure sensor or other electrical or electronic
components, and/or a shorter
life of the vaporizer. Leaks in the seal 115 may also result in a user
inhaling air that has passed
over parts of the vaporizer 100 containing or constructed of materials
unsuitable for inhalation.
[0216]
Vaporizers configured to generate at least part of an inhalable dose of a non-
liquid
vaporizable material via heating of a non-liquid vaporizable material may be
also within the
scope of the disclosed subject matter. For example, instead of or in addition
to a liquid
vaporizable material, the vaporizer cartridge 120 may include a mass of a
plant material or
other non-liquid material (e.g., a solid form of the vaporizable material
itself such as a "wax")
that is processed and formed to have direct contact with at least a portion of
one or more
resistive heating elements (or to be radiatively and/or convectively heated by
a heating
element), which may optionally be included in a vaporizer cartridge 120 or in
part of a
vaporizer body 110. A solid vaporizable material (e.g., one that includes a
plant material) may
emit only part of the plant material as the vaporizable material (e.g., such
that some part of the
plant material remains as waste after the vaporizable material is emitted for
inhalation) or may
be capable of having all of the solid material eventually be vaporized for
inhalation. A liquid
vaporizable material may likewise be capable of being completely vaporized or
may include
some part of the liquid material that remains after all of the material
suitable for inhalation has
been consumed.
[0217] When
configured with the vaporizable material and the heating element in the
vaporizer cartridge 120, the vaporizer cartridge 120 may couple mechanically
and electrically
to the vaporizer body 110, which may include a processor, a power source 112,
and one or
more vaporizer body contacts 125 for connecting to corresponding cartridge
contacts 124 to
complete a circuit with the resistive heating element included in the
vaporizer cartridge 120.
A variety of vaporizer configurations may be implemented with one or more of
the features
described herein.
[0218] In some
implementations, the vaporizer 100 may include a power source 112 as part
of the vaporizer body 110 while a heating element may be disposed in the
vaporizer cartridge
120 configured to couple with the vaporizer body 110. Configured as such, the
vaporizer 100
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may include electrical connection features for completing a circuit that
includes the controller
104, the power source 112, and the heating element included in the vaporizer
cartridge 120.
[0219] The
connection features may, in some implementations of the current subject
matter, include at least two cartridge contacts 124 on a bottom surface of the
vaporizer cartridge
120 and at least two contacts 125 disposed near a base of the cartridge
receptacle of the
vaporizer 100, such that the cartridge contacts 124 and the receptacle
contacts 125 make
electrical connections when the vaporizer cartridge 120 is inserted into and
coupled with the
cartridge receptacle 118. In some implementations of the current subject
matter, the vaporizer
body contacts 125 may be compressible pins (e.g., pogo pins) that are
retracted under pressure
of corresponding cartridge contacts 124 when a vaporizer cartridge is inserted
and secured in
the cartridge receptacle 118. Other configurations are also contemplated. For
example, brush
contacts that make electrical connections with corresponding contacts on a
mating part of a
vaporizer cartridge may be used. Such contacts need not make an electrical
connection with
cartridge contacts on a bottom end of the vaporizer cartridge 120, but may
instead be coupled
by being urged outward from one or more side walls of the cartridge receptacle
118 against
cartridge contacts 124 on a part of a side of the vaporizer cartridge 120 that
is within the
receptacle when the vaporizer cartridge 120 is properly inserted into the
cartridge receptacle
118.
[0220] The
circuit completed by the electrical connections may allow delivery of
electrical
current to the resistive heating element and may further be used for
additional functions such
as for measuring a resistance of the resistive heating element for use in
determining or
controlling a temperature of the resistive heating element based on a thermal
coefficient of
resistivity of the resistive heating element, for identifying a vaporizer
cartridge 120 based on
one or more electrical characteristics of a resistive heating element or the
other circuitry of the
vaporizer cartridge 120.
[0221] In some
examples, at least two cartridge contacts 124 and at least two vaporizer
body contacts 125 (e.g., receptacle contacts for an implementation in which
part of a vaporizer
cartridge 120 is inserted into a cartridge receptacle 118) may be configured
to electrically
connect in either of at least two orientations. In other words, one or more
circuits configured
for operation of the vaporizer 100 may be completed by insertion (or other
joining) of at least
part of a vaporizer cartridge 120 in the cartridge receptacle 118 in a first
rotational orientation
(e.g., around an axis along which the end of the vaporizer cartridge having
the vaporizer
cartridge 120 is inserted into the cartridge receptacle 118 of the vaporizer
body 110) such that
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a first cartridge contact of the at least two cartridge contacts 124 is
electrically connected to a
first receptacle contact of the at least two receptacle contacts 125 and a
second cartridge contact
of the at least two cartridge contacts 124 is electrically connected to a
second receptacle contact
of the at least two receptacle contacts 125.
[0222]
Furthermore, the one or more circuits configured for operation of the
vaporizer 100
may be completed by insertion (or other joining) of a vaporizer cartridge 120
in the cartridge
receptacle 118 in a second rotational orientation such that the first
cartridge contact of the at
least two cartridge contacts 124 is electrically connected to the second
receptacle contact of the
at least two receptacle contacts 125 and the second cartridge contact of the
at least two cartridge
contacts 124 is electrically connected to the first receptacle contact of the
at least two receptacle
contacts 125. A vaporizer cartridge 120 may be reversibly insertable into a
cartridge receptacle
118 of the vaporizer body 110 as provided in further detail herein.
[0223] In one
example of an attachment structure for coupling a vaporizer cartridge 120 to
a vaporizer body 110, the vaporizer body 110 may include a detent (e.g., a
dimple, protrusion,
etc.) protruding inwardly from an inner surface of the cartridge receptacle
118. One or more
exterior surfaces of the vaporizer cartridge 120 may include corresponding
recesses (not shown
in FIG. 1) that may fit or otherwise snap over such detents when an end of the
vaporizer
cartridge 120 is inserted into the cartridge receptacle 118 on the vaporizer
body 110.
[0224] The
vaporizer cartridge 120 and the vaporizer body 110 may be coupled, for
example, by insertion of an end of the vaporizer cartridge 120 into the
cartridge receptacle 118
of the vaporizer body 110. The detent in the vaporizer body 110 may fit within
and/or
otherwise be held within the recesses of the vaporizer cartridge 120 to hold
the vaporizer
cartridge 120 in place when assembled. Such a detent-recess assembly may
provide enough
support to hold the vaporizer cartridge 120 in place to ensure sufficient
contact between the at
least two cartridge contacts 124 and the at least two receptacle contacts 125,
while allowing
release of the vaporizer cartridge 120 from the vaporizer body 110 when a user
pulls with
reasonable force on the vaporizer cartridge 120 to disengage the vaporizer
cartridge 120 from
the cartridge receptacle 118.
[0225] Further
to the discussion above about the electrical connections between the
vaporizer cartridge 120 and the vaporizer body 110 being reversible such that
at least two
rotational orientations of the vaporizer cartridge 120 in the cartridge
receptacle 118 may be
possible, in some implementations of the vaporizer 100 the shape of the
vaporizer cartridge
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120, or at least a shape of the end of the vaporizer cartridge 120 that is
configured for insertion
into the cartridge receptacle 118 may have rotational symmetry of at least
order two. In other
words, the vaporizer cartridge 120 or at least the mechanical mating features
and the electrical
contacts on the insertable end of the vaporizer cartridge 120 may be symmetric
upon a rotation
of 180 around the axis along which the vaporizer cartridge 120 is inserted
into the cartridge
receptacle 118. In such a configuration, the circuitry of the vaporizer 100
may support identical
operation regardless of which symmetrical orientation of the vaporizer
cartridge 120 occurs. It
will be understood that the entirety of the insertable end of the cartridge
need not be
symmetrical in all implementations of the current subject matter. For example,
a vaporizer
cartridge 120 that has rotationally symmetric mechanical features for
cooperatively engaging
with corresponding features within or on the outside of a cartridge receptacle
118, that is shaped
and sized to fit within the cartridge receptacle 118 of the vaporizer body
110, and that likewise
has cartridge electrical contacts 124 with rotational symmetry and internal
circuitry (which can
optionally be in either or both of the vaporizer cartridge 120 and the
vaporizer body 110) that
is compatible with reversing the electrical contacts is consistent with the
current disclosure
even if the overall shape and appearance of the insertable end of the
vaporizer cartridge 120 is
not rotationally symmetrical.
[0226] As
noted above, in some example embodiments, the vaporizer cartridge 120, or at
least an end of the vaporizer cartridge 120, is configured for insertion in
the cartridge receptacle
118 and may have a non-circular cross-section transverse to the axis along
which the vaporizer
cartridge 120 is inserted into the cartridge receptacle 118. For example, the
non-circular cross-
section may be approximately rectangular, approximately elliptical (e.g., have
an
approximately oval shape), non-rectangular but with two sets of parallel or
approximately
parallel opposing sides (e.g., having a parallelogram-like shape), or other
shapes having
rotational symmetry of at least order two. In this context, approximately
having a shape
indicates that a basic likeness to the described shape is apparent, but that
sides of the shape in
question need not be completely linear and vertices need not be completely
sharp. Some
amount of rounding of both or either of edges or vertices of the cross-
sectional shape is
contemplated in the description of any non-circular cross-section referred to
herein.
[0227] The at
least two cartridge contacts 124 and the at least two receptacle contacts 125
may take various forms. For example, one or both sets of contacts may include
conductive
pins, tabs, posts, receiving holes for pins or posts, or the like. Some types
of contacts may
include springs or other urging features to cause better physical and
electrical contact between
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the contacts on the vaporizer cartridge and the vaporizer body. The electrical
contacts may be
gold-plated, and/or may include other materials.
[0228] A
vaporizer 100 consistent with implementations of the disclosed subject matter
may be configured to connect (e.g., wirelessly or via a wired connection) to
one or more
computing devices in communication with the vaporizer 100. To this end, the
controller 104
may include communication hardware 105. The controller 104 may also include a
memory
108. A computing device may be a component of a vaporizer system that also
includes the
vaporizer 100, and may include an independent communication hardware, which
may establish
a wireless communication channel with the communication hardware 105 of the
vaporizer 100.
[0229] A
computing device used as part of the vaporizer system may include a general-
purpose computing device (e.g., a smartphone, a tablet, a personal computer,
some other
portable device such as a smartwatch, or the like) that executes software to
produce a user
interface for enabling a user of the device to interact with a vaporizer 100.
In other
implementations, a device used as a part of the vaporizer system may be a
dedicated piece of
hardware such as a remote control or other wireless or wired device having one
or more
physical or soft interface controls (e.g., configurable on a screen or other
display device and
selectable via user interaction with a touch-sensitive screen or some other
input device like a
mouse, pointer, trackball, cursor buttons, or the like). The vaporizer 100 may
also include one
or more outputs 117 or devices for providing information to the user.
[0230] A
computing device that is part of a vaporizer system as defined above may be
used
for any of one or more functions, such as controlling dosing (e.g., dose
monitoring, dose setting,
dose limiting, user tracking, etc.), controlling sessioning (e.g., session
monitoring, session
setting, session limiting, user tracking, etc.), controlling nicotine delivery
(e.g., switching
between nicotine and non-nicotine vaporizable material, adjusting an amount of
nicotine
delivered, etc.), obtaining locational information (e.g., location of other
users,
retailer/commercial venue locations, vaping locations, relative or absolute
location of the
vaporizer itself, etc.), vaporizer personalization (e.g., naming the
vaporizer, locking/password
protecting the vaporizer, adjusting one or more parental controls, associating
the vaporizer with
a user group, registering the vaporizer with a manufacturer or warranty
maintenance
organization, etc.), engaging in social activities (e.g., social media
communications, interacting
with one or more groups, etc.) with other users, or the like. The terms
"sessioning", "session",
"vaporizer session," or "vapor session," may be used to refer to a period
devoted to the use of
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the vaporizer. The period may include a time period, a number of doses, an
amount of
vaporizable material, or the like.
[0231] In the
example in which a computing device provides signals related to activation
of the resistive heating element, or in other examples of coupling of a
computing device with
a vaporizer 100 for implementation of various control or other functions, the
computing device
executes one or more computer instructions sets to provide a user interface
and underlying data
handling. In one example, detection by the computing device of user
interaction with one or
more user interface elements may cause the computing device to signal the
vaporizer 100 to
activate the heating element, either to a full operating temperature for
creation of an inhalable
dose of vapor/aerosol. Other functions of the vaporizer 100 may be controlled
by interaction
of a user with a user interface on a computing device in communication with
the vaporizer 100.
[0232] In some
embodiments, a vaporizer cartridge 120 usable with a vaporizer body 110
may include an atomizer 141 having a wicking element and a heating element.
Alternatively,
one or both of the wicking element and the heating element may be part of the
vaporizer body
110. In implementations in which any part of the atomizer 141 (e.g., a heating
element or a
wicking element) is part of the vaporizer body 110, the vaporizer 100 may be
configured to
supply liquid vaporizable material from a reservoir 140 in the vaporizer
cartridge to the wick
and other atomizer parts, such as for example a wicking element, a heating
element, etc.
Capillary structures that include a wicking element will be understood by a
skilled artisan to
be but one potential embodiment usable with other features described herein.
[0233]
Activation of the heating element may be caused by automatic detection of the
puff
based on one or more of signals generated by one or more sensors 113, such as
for example a
pressure sensor or sensors disposed to detect pressure along the airflow path
relative to ambient
pressure (or may measure changes in absolute pressure), one or more motion
sensors of the
vaporizer 100, one or more flow sensors of the vaporizer 100, a capacitive lip
sensor of the
vaporizer 100; in response to detection of interaction of a user with one or
more input devices
116 (e.g., buttons or other tactile control devices of the vaporizer 100),
receipt of signals from
a computing device in communication with the vaporizer 100, or via other
approaches for
determining that a puff is occurring or imminent.
[0234] The
heating element may be or may include one or more of a conductive heater, a
radiative heater, and a convective heater. One type of heating element may be
a resistive
heating element, which may be constructed of or at least include a material
(e.g., a metal or
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alloy, for example a nickel-chromium alloy, or a non-metallic resistor)
configured to dissipate
electrical power in the form of heat when electrical current is passed through
one or more
resistive segments of the heating element.
[0235] In some
implementations, the atomizer 141 may include a heating element that
includes resistive coil or other heating element wrapped around, positioned
within, integrated
into a bulk shape of, pressed into thermal contact with, positioned near,
configured to heat air
to cause convective heating of, or otherwise arranged to deliver heat to a
wicking element to
cause a liquid vaporizable material drawn by the wicking element from a
reservoir 140 to be
vaporized for subsequent inhalation by a user in a gas and/or a condensed
(e.g., aerosol particles
or droplets) phase. Other wicking element, heating element, or atomizer
assembly
configurations may be also possible, as discussed further below.
[0236] After
conversion of the vaporizable material to the gas phase, and depending on the
type of vaporizer, the physical and chemical properties of the vaporizable
material, or other
factors, at least some of the gas-phase vaporizable material may condense to
form particulate
matter in at least a partial local equilibrium with the gas phase as part of
an aerosol, which may
form some or all of an inhalable dose provided by the vaporizer 100 for a
given puff or draw
on the vaporizer.
[0237] It will
be understood that the interplay between gas and condensed phases in an
aerosol generated by a vaporizer may be complex and dynamic, as factors such
as ambient
temperature, relative humidity, chemistry (e.g., acid-base interactions,
protonation or lack
thereof of a compound released from the vaporizable material by heating,
etc.), flow conditions
in airflow paths (both inside the vaporizer and in the airways of a human or
other animal),
mixing of the gas-phase or aerosol-phase vaporizable material with other air
streams, or the
like may affect one or more physical and/or chemical parameters of an aerosol.
In some
vaporizers, and particularly in vaporizers for delivery of more volatile
vaporizable materials,
the inhalable dose may exist predominantly in the gas phase (i.e., formation
of condensed phase
particles may be very limited).
[0238] As
noted elsewhere herein, certain vaporizers may also (or may alternatively) be
configured to create an inhalable dose of gas-phase and/or aerosol-phase
vaporizable material
at least in part via heating of a non-liquid vaporizable material, such as for
example a solid-
phase vaporizable material (e.g., a wax or the like) or plant material (e.g.,
tobacco leaves or
parts of tobacco leaves) containing the vaporizable material. In such
vaporizers, a resistive
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heating element may be part of or otherwise incorporated into or in thermal
contact with the
walls of an oven or other heating chamber into which the non-liquid
vaporizable material is
placed.
[0239]
Alternatively, a resistive heating element or elements may be used to heat air
passing through or past the non-liquid vaporizable material to cause
convective heating of the
non-liquid vaporizable material. In still other examples, a resistive heating
element or elements
may be disposed in intimate contact with plant material such that direct
conductive heating of
the plant material occurs from within a mass of the plant material (e.g., as
opposed to by
conduction inward form walls of an oven).
[0240] The
heating element may be activated by way of a controller 104, which may be
part of a vaporizer body 110. The controller 104 may cause current to pass
from the power
source 112 through a circuit including the resistive heating element, which
may be part of a
vaporizer cartridge 120. The controller 104 may be activated in association
with a user puffing
(e.g., drawing, inhaling, etc.) on a mouthpiece 130 of the vaporizer 100 that
may cause air to
flow from an air inlet, along an airflow path that passes an atomizer 141. An
atomizer 141 may
include a wick in combination with a heating element, for example.
[0241]
Airflow, caused by the user puffing, may pass through one or more condensation
areas or chambers in and/or downstream of the atomizer 141 and then toward an
air outlet in
the mouthpiece. Incoming air passing along the airflow path may thus pass
over, through, near,
around, etc. the atomizer 141, such that gas phase vaporizable material (or
some other inhalable
form of the vaporizable material) is entrained into the air due to the
atomizer 141 converting
some amount of the vaporizable material to the gas phase. As noted above,
entrained gas-phase
vaporizable material may condense as it passes through the remainder of the
airflow path such
that an inhalable dose of the vaporizable material in an aerosol form may be
delivered from the
air outlet (e.g., through a mouthpiece 130 for inhalation by a user).
[0242] The
temperature of a resistive heating element of a vaporizer 100 may depend on
one or more of a number of factors, including an amount of electrical power
delivered to the
resistive heating element or a duty cycle at which the electrical power is
delivered, conductive
and/or radiative heat transfer to other parts of the vaporizer 100 or to the
environment, specific
heat transfer to air and/or liquid or gas-phase vaporizable material (e.g.,
raising the temperature
of a vaporizable material to its vaporization point or elevating a temperature
of a gas such as
air and/or air mixed with vaporized vaporizable material), latent heat losses
due to vaporization
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of a vaporizable material from the wick and/or the atomizer 141 as a whole,
convective heat
losses due to airflow (e.g., air moving across the heating element or the
atomizer 141 as a whole
when a user inhales on the vaporizer 100), etc.
[0243] As
noted above, to reliably activate the heating element or heat the heating
element
to a desired temperature, a vaporizer 100 may, in some implementations, make
use of signals
from a pressure sensor to determine when a user is inhaling. The pressure
sensor may be
positioned in the airflow path or may be connected (e.g., by a passageway or
other path) to an
airflow path connecting an inlet for air to enter the device and an outlet via
which the user
inhales the resulting vapor and/or aerosol such that the pressure sensor
experiences pressure
changes concurrently with air passing through the vaporizer 100 from the air
inlet to the air
outlet. In some implementations, the heating element may be activated in
association with a
user's puff, for example by automatic detection of the puff, for example by
the pressure sensor
detecting a pressure change in the airflow path.
[0244]
Referring to FIGS. 1, 2A and 2B, the vaporizer cartridge 120 may be detachably
inserted in the vaporizer body 110 by way of the cartridge receptacle 118. As
shown in FIG.
2A, which illustrates a planar view of a vaporizer body 110 next to a
vaporizer cartridge 120,
a reservoir 140 of the vaporizer cartridge 120 may be formed in whole or in
part from
translucent material such that a level of the liquid vaporizable material 102
in the vaporizer
cartridge 120 may be visible. The vaporizer cartridge 120 may be configured
such that the
level of vaporizable material 102 in the reservoir 140 of the vaporizer
cartridge 120 remains
visible through a window in the vaporizer body 110 when the vaporizer
cartridge 120 is
received in the cartridge receptacle 118. Alternatively or in addition, a
level of liquid
vaporizable material 102 in the reservoir 140 may be viewable through a clear
or translucent
outer wall or window formed in an outer wall of the vaporizer cartridge 120.
Airflow Path Embodiments
[0245]
Referring to FIGS. 2C and 2D, an example vaporizer cartridge 120 is
illustrated in
which an airflow path 134 is created during a puff by a user on the vaporizer
100. The airflow
path 134 can direct air to a vaporization chamber 150 (see, for example, FIG.
2D) contained in
a wick housing where the air is combined with inhalable aerosol for delivery
to a user via a
mouthpiece 130, which can also be part of the vaporizer cartridge 120. The
vaporization
chamber 150 can include and/or at least partially enclose an atomizer 141
consistent with the
remainder of this disclosure. For example, when a user puffs on the vaporizer
100, the airflow
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path 134 may pass between an outer surface of the vaporizer cartridge 120
(e.g., the window
132) and an inner surface of a cartridge receptacle 118 on the vaporizer body
110. Air can then
be drawn into an insertable end 122 of the cartridge, through the vaporization
chamber 150 that
includes or contains the heating element and wicking element, and out through
an outlet 136
of the mouthpiece 130 for delivery of the inhalable aerosol to a user. Other
airflow path
configurations are also within the scope of the current disclosure, including
but not limited to
those discussed in further detail below.
[0246] FIG. 2D
shows additional features that may be included in a vaporizer cartridge 120
consistent with the current subject matter. For example, the vaporizer
cartridge 120 can include
a plurality of cartridge contacts (such as cartridge contacts 124) disposed on
the insertable end
122, which is configured to be inserted into the cartridge receptacle 118 of a
vaporizer body
110. The cartridge contacts 124 can optionally each be part of a single piece
of metal that
forms a conductive structure (such as conductive structure 126) connected to
one of two ends
of a resistive heating element. The conductive structure can optionally form
opposing sides of
a heating chamber and can optionally act as heat shields and/or heat sinks to
reduce
transmission of heat to outer walls of the vaporizer cartridge 120. Further
details of this aspect
are described below.
[0247] FIG. 2D
also shows a cannula 128 (which is an example of a more general concept
also referred to herein as an airflow passageway) within the vaporizer
cartridge 120 that defines
part of the airflow path 134 passing between a heating chamber (also referred
to herein as an
atomizer chamber, a vaporization chamber, or the like), which may be formed at
least in part
by the conductive structure 126, and the mouthpiece 130. Such configuration
causes air to
flow down around the insertable end 122 of the vaporizer cartridge 120 into
the cartridge
receptacle 118 and then flow back in the opposite direction after passing
around the insertable
end 122 (e.g., an end opposite an end that includes the mouthpiece 130) of the
vaporizer
cartridge 120 as it enters into the cartridge body toward the vaporization
chamber 150. The
airflow path 134 then travels through the interior of the vaporizer cartridge
120, for example
via one or more tubes or internal channels (such as cannula 128) and through
one or more
outlets (such as outlet 136) formed in the mouthpiece 130.
Pressure Equalization Vent
[0248] As
mentioned above, removal of vaporizable material 102 from the reservoir 140
(e.g., via capillary draw by the wicking element) can create an at least
partial vacuum (e.g., a
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reduced pressure created in a part of the reservoir that has been emptied by
consumption of
liquid vaporizable material) relative to ambient air pressure in the reservoir
140, and such
vacuum can interfere with capillary action provided by the wicking element.
This reduced
pressure may in some examples be sufficiently large in magnitude to reduce the
effectiveness
of the wicking element for drawing liquid vaporizable material 102 into the
vaporization
chamber 150, thereby reducing the effectiveness of the vaporizer 100 to
vaporize a desired
amount of vaporizable material 102, such as when a user takes a puff on the
vaporizer 100. In
extreme cases, a vacuum created in the reservoir 140 could result in the
inability to draw all of
the vaporizable material 102 into the vaporization chamber 150, thereby
leading to incomplete
usage of the vaporizable material 102. One or more venting features may be
included in
association with a vaporizer reservoir 140 (regardless of positioning of the
reservoir 140 in a
vaporizer cartridge 120 or elsewhere in a vaporizer) to enable at least
partial equalizing
(optionally completely equalizing) of pressure in the reservoir 140 with
ambient pressure (e.g.,
pressure in ambient air outside of the reservoir 140) to alleviate this issue.
[0249] In some
cases, while allowing pressure equalization within the reservoir 140
improves efficiency of delivery of the liquid vaporizable material to the
atomizer 141, it does
so by causing the otherwise empty void volume (e.g., space emptied by use of
the liquid
vaporizable material) within the reservoir 140 to be filled with air. As
discussed in further
detail below, this air-filled void volume may subsequently experience pressure
changes relative
to ambient air, which may result, under certain conditions, in leakage of
liquid vaporizable
material out of the reservoir 140 and ultimately outside of a vaporizer
cartridge 120 and/or
other part of a vaporizer that contains the reservoir 140. Implementations of
the current subject
matter may also provide advantages and benefits in regard to this issue.
[0250] Various
features and devices are described below that improve upon or overcome
these issues. For example, various features are described herein for
controlling airflow as well
as flow of the vaporizable material, which may provide advantages and
improvements relative
to existing approaches, while also introducing additional benefits as
described herein. The
vaporizer devices and/or cartridges described herein include one or more
features that control
and improve airflow in the vaporization device and/or cartridge, thereby
improving the
efficiency and effectiveness of vaporizing the liquid vaporizable material by
the vaporizer
device without introducing additional features that might lead to leaks of
liquid vaporizable
material.
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[0251] FIGS.
2E and 2F illustrate diagrams of first and second embodiments, respectively,
of reservoir systems 200A, 200B configured for a vaporizer cartridge (such as
vaporizer
cartridge 120) and/or vaporizer device (such as vaporizer 100) for improving
pressure
equalization and airflow in the vaporizer. More specifically, the reservoir
systems 200A, 200B
illustrated in FIGS. 2E and 2F improve the regulation of pressure within the
reservoir 240 such
that a vacuum created in the reservoir 240 is relieved after a user puffs on
the vaporizer while
reducing or even eliminating incidence of leakage of liquid vaporizable
material through the
venting structure. This allows the capillary action of the porous material
(e.g., a wicking
element) associated with the reservoir 240 and vaporization chamber 242 to
continue to
effectively draw a vaporizable material 202 from the reservoir 240 into the
vaporization
chamber 242 after each puff
[0252] As
shown in FIGS. 2E and 2F, the reservoir systems 200A, 200B include a reservoir
240 configured to contain a liquid vaporizable material 202. The reservoir 240
is sealed on all
sides by reservoir walls 232 except for through a wick housing area that
extends between the
reservoir 240 and the vaporization chamber 242. A heating element or heater
may be contained
within the vaporization chamber 242 and coupled to the wicking element. The
wicking element
is configured to provide the capillary action that draws the vaporizable
material 202 from the
reservoir 240 to the vaporization chamber 242 to be vaporized into aerosol by
the heater. The
aerosol is then combined with airflow 234 traveling along an airflow
passageway 238 of the
vaporizer for inhalation by a user.
[0253] The
reservoir systems 200A, 200B also include an airflow restrictor 244 that
restricts the passage of airflow 234 along the airflow passageway 238 of the
vaporizer, such as
when a user puffs on the vaporizer. The restriction of airflow 234 caused by
the airflow
restrictor 244 can allow a vacuum to be formed along a part of the airflow
passageway 238
downstream from the airflow restrictor 244. The vacuum created along the
airflow passageway
238 can assist with drawing aerosol formed in a vaporization chamber 242
(e.g., a chamber
containing at least part of the atomizer 141) along the airflow passageway 238
for inhalation
by a user. At least one airflow restrictor 244 can be included in each of the
reservoir systems
200A, 200B and the airflow restrictor 244 can include any number of features
for restricting
the airflow 234 along the airflow passageway 238.
[0254] As
shown in FIGS. 2E and 2F, each of the reservoir systems 200A, 200B can also
include a vent 246 configured to selectively allow the passage of air into the
reservoir 240 for
increasing the pressure within the reservoir 240, such as to relieve the
reservoir 240 from
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negative pressure (vacuum) relative to ambient pressure resulting from the
vaporizable material
202 being drawn out of the reservoir 240, as discussed above. At least one
vent 246 can be
associated with the reservoir 240. The vent 246 can be an active or passive
valve and the vent
246 can include any number of features for allowing air to pass into the
reservoir 240 to relieve
negative pressure created in the reservoir 240.
[0255] For
example, an embodiment of the vent 246 can include a vent passageway that
extends between the reservoir 240 and the airflow passageway 238 and includes
a diameter (or
more generally, a cross sectional area) that is sized such that a fluid
tension (also referred to as
a surface tension) of the vaporizable material 202 prevents the vaporizable
material 202 from
passing through the passageway when the pressure is equalized across the vent
246 (e.g., the
pressure in the reservoir 240 is approximately the same as the pressure in the
airflow
passageway 238). However, the diameter (or more generally, the cross-sectional
area) of the
vent 246 and/or the vent passageway can be sized such that a vacuum pressure
created in the
reservoir 240 is capable of overcoming the surface tension of the vaporizable
material 202
within the vent 246 or the vent passageway to cause an air bubble to be
released into the
reservoir 240 through the vent in response to sufficiently low pressure within
the reservoir 240
relative to ambient pressure.
[0256]
Accordingly, a volume of air may pass from the airflow passageway 238 to the
reservoir 240 and relieve the vacuum pressure. Once the volume of air is added
to the reservoir
240, the pressure is again more closely equalized across the vent 246, thereby
allowing the
surface tension of the vaporizable material 202 to prevent air from entering
the reservoir 240,
as well as preventing the vaporizable material from leaking out of the
reservoir 240 through
the vent passageway.
[0257] In one
example embodiment, a diameter of the vent 246 or vent passageway may
be in a range of approximately 0.3 mm to 0.6 mm, and may also include
diameters in a range
of approximately 0.1 mm to 2 mm. In some examples, the vent 246 and/or vent
passageway
may be non-circular, such that it may be characterized by a non-circular cross
section along a
direction of fluid flow within the vent passageway. In such an example, the
cross-section is
not defined by a diameter, but rather by a cross-sectional area. Generally
speaking, whether
the cross-sectional shape of the vent 246 and/or the vent passageway is
circular or non-circular,
in certain implementations of the current subject matter it may be
advantageous for the cross-
sectional area of the vent 246 to differ along its path between exposure to
ambient air pressure
and the interior of the reservoir 240. For example, a part of the vent 246
closer to the outside
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ambient pressure may advantageously have a smaller cross-sectional area (e.g.,
a smaller
diameter in the example in which the vent 246 has a circular cross-section)
relative a part of
the vent 246 closer to the interior of the reservoir 240. The smaller cross-
section area closer to
the exterior of the system may provide a greater resistance to escape of
liquid vaporizable
material while the larger cross-sectional area closer to the interior of the
reservoir 240 may
provide a relatively lessened resistance to escape of an air bubble from the
vent 246 into the
reservoir 240. In some implementations of the current subject matter, the
transition between
the smaller and the larger cross-sectional area can advantageously not be
continuous, but
instead involve a discontinuity along a length of the vent 246 and/or the vent
passageway. Such
a structure may be useful in providing a larger overall resistance to escape
of liquid material
than to equilibration of reservoir pressure by release of air bubbles from the
vent 246 because
the larger cross-sectional area near the reservoir may have a lower capillary
drive relative to
the smaller cross-sectional area exposed to ambient air.
[0258] The
material of the vent 246 and/or vent passageway can also assist with
controlling
the vent 246 and/or vent passageway, such as by affecting a contact angle
between the walls of
the vent 246 and/or vent passageway and the vaporizable material 202. The
contact angle can
have an effect on the surface tension created by the vaporizable material 202
and thus affects
the threshold pressure differential that can be created across the vent 246
and/or vent
passageway before a volume of fluid is allowed to pass through the vent 246,
such as described
above. The vent 246 can include a variety of shapes/sizes and configurations
that are within
the scope of this disclosure. Additionally, various embodiments of cartridges
and parts of
cartridges that include one or more of a variety of venting features are
described in greater
detail below.
[0259]
Positioning of the vent 246 (e.g., a passive vent) and the airflow restrictor
244
relative to the vaporization chamber 242 assists with effective functioning of
the reservoir
systems 200A, 200B. For example, improper positioning of either the vent 246
or the airflow
restrictor 244 can result in unwanted leaking of the vaporizable material 202
from the reservoir
240. The present disclosure addresses effective positioning of the vent 246
and airflow
restrictor 244 relative to the vaporization chamber 242 (containing the wick).
For example, a
small or no pressure differential between a passive vent and the wick can
result in an effective
reservoir system for relieving vacuum pressure in the reservoir and resulting
in effective
capillary action of the wick while preventing leaking. Configurations of the
reservoir system
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having effective positioning of the vent 246 and airflow restrictor 244
relative to the
vaporization chamber 242 is described in greater detail below.
[0260] As
shown in FIG. 2E, the airflow restrictor 244 may be positioned upstream from
the vaporization chamber 242 along the airflow passageway 238 and the vent 246
is positioned
along the reservoir 240 such that it provides fluid communication between the
reservoir 240
and a part of the airflow passageway 238 that is downstream from the
vaporization chamber
242. As such, when a user puffs on the vaporizer, a negative pressure is
created downstream
from the airflow restrictor 244 such that the vaporization chamber 242
experiences negative
pressure. Similarly, a side of the vent 246 in communication with the airflow
passageway 238
also experiences the negative pressure.
[0261] As
such, a small to nonexistent amount of pressure differential is created
between
the vent 246 and the vaporization chamber 242 during the puff (e.g., when the
user draws in or
sucks in air from the vaporization device). However, after the puff the
capillary action of the
wick will draw the vaporizable material 202 from the reservoir 240 to the
vaporization chamber
242 to replenish the vaporizable material 202 that was vaporized and inhaled
as a result of the
previous puff. As a result, a vacuum or negative pressure will be created in
the reservoir 240.
A pressure differential will then occur between the reservoir 240 and the
airflow passageway
238. As discussed above, the vent 246 can be configured such that a pressure
differential (e.g.,
a threshold pressure difference) between the reservoir 240 and the airflow
passageway 238
allows a volume of air to pass from the airflow passageway 238 into the
reservoir 240 thereby
relieving the vacuum in the reservoir 240 and returning to an equalized
pressure across the vent
246 and a stable reservoir system 200A.
[0262] In
another embodiment, as shown in FIG. 2F, the airflow restrictor 244 may be
positioned downstream from the vaporization chamber 242 along the airflow
passageway 238
and the vent 246 may be positioned along the reservoir 240 such that it
provides fluid
communication between the reservoir 240 and a part of the airflow passageway
238 that is
upstream from the vaporization chamber 242. As such, when a user puffs on the
vaporizer, the
vaporization chamber 242 and vent 246 experience little to no suction or
negative pressure as
a result of the puff, thus resulting in little to no pressure differential
between the vaporization
chamber 242 and the vent 246. Similar to the case in FIG. 2E, the pressure
differential created
across the vent 246 will be a result of the capillary action of the wick
drawing the vaporizable
material 202 to the vaporization chamber 242 after the puff. As a result, a
vacuum or negative
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pressure will be created in the reservoir 240. A pressure differential will
then occur across the
vent 246.
[0263] As
discussed above, the vent 246 can be configured such that a pressure
differential
(e.g., a threshold pressure difference) between the reservoir 240 and the
airflow passageway
238 or atmosphere allows a volume of air to pass into the reservoir 240
thereby relieving the
vacuum in the reservoir 240. This allows the pressure to be equalized across
the vent 246 and
the reservoir systems 200B to be stabilized. The vent 246 can include various
configurations
and features and can be positioned in a variety of positions along the
vaporizer cartridge 120,
such as to achieve various results. For example, one or more vents 246 can be
positioned
adjacent or forming a part of the vaporization chamber 242 or wick housing. In
such a
configuration, the one or more vents 246 can provide fluid (e.g., air)
communication between
the reservoir 240 and the vaporization chamber 242 (through which airflow
passes through
when a user puffs on the vaporizer and is thus part of the airflow pathway).
[0264]
Similarly, as described above, a vent 246 placed adjacent to or forming a part
of the
vaporization chamber 242 or wick housing can allow air from inside the
vaporization chamber
242 to travel into the reservoir 240 via the vent 246 to increase the pressure
inside the reservoir
240 thereby effectively relieving the vacuum pressure created as a result of
the vaporizable
material 202 being drawn into the vaporization chamber 242. As such, relief of
the vacuum
pressure allows for continued efficient and effective capillary action of the
vaporizable material
202 into the vaporization chamber 242 via the wick for creating inhalable
vapor during
subsequent puffs on the vaporizer by a user. The below provides various
example
embodiments of a venting vaporization chamber element (e.g., an atomizer
assembly) that
includes a wick housing 1315, 178 (that houses the vaporization chamber) and
at least one vent
596 coupled to or forming a part of the wick housing 1315, 178 for achieving
the above
effective venting of the reservoir 140.
Open-Faced Cartridge Assembly Embodiments
[0265]
Referring to FIGS. 3A and 3B, an example planar cross-sectional view of an
alternative cartridge embodiment 1320 is shown in which the cartridge 1320
includes a
mouthpiece or mouthpiece area 1330, a reservoir 1340 and an atomizer (not
shown
individually). The atomizer may include a heating element 1350 and a wicking
element 1362,
together or separately, depending on implementation, such that the wicking
element 1362 is
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thermally or thermodynamically coupled to the heating element 1350 for the
purpose of
vaporizing a vaporizable material 1302 drawn from or stored in the wicking
element 1362.
[0266] Plates
1326 may be included, in one embodiment, to provide for an electrical
connection between a heating element 1350 and a power source 112 (see FIG. 1).
An airflow
passageway 1338, defined through or on a side of reservoir 1340, may connect
an area in a
cartridge 1320 that houses the wicking element 1362 (e.g., a wick housing not
shown
separately) to an opening that leads to mouthpiece or mouthpiece area 1330 to
provide a route
for the vaporized vaporizable material 1302 to travel from the heating element
1350 area to the
mouthpiece area 1330.
[0267] As
provided above, the wicking element 1362 may be coupled to an atomizer or
heating element 1350 (e.g., a resistive heating element or coil) that is
connected to one or more
electrical contacts (e.g., plates 1326). The heating element 1350 (and other
heating elements
described herein in accordance with one or more implementations) may have
various shapes
and/or configurations and may include one or more heating elements 1350, 500,
or features
thereof, as provided in more detail below with respect to FIGS. 44A-116.
[0268] In
accordance with one or more example implementations, the heating element
1350 of the cartridge 1320 may be made (e.g., stamped) from a sheet of
material and either
crimped around at least a portion of a wicking element 1362 or bent to provide
a preformed
element configured to receive the wicking element 1362 (e.g., the wicking
element 1362 is
pushed into the heating element 1350 and/or the heating element 1350 is held
in tension and is
pulled over the wicking element 1362).
[0269] The
heating element 1350 may be bent such that the heating element 1350 secures
the wicking element 1362 between at least two or three portions of the heating
element 1350.
The heating element 1350 may be bent to conform to a shape of at least a
portion of the wicking
element 1362. Configurations of the heating element 1350 allow for more
consistent and
enhanced quality manufacturing of the heating element 1350. Consistency of
manufacturing
quality of the heating element 1350 may be especially important during scaled
and/or
automated manufacturing processes. For example, the heating element 1350 in
accordance
with one or more implementations helps to reduce tolerance issues that may
arise during
manufacturing processes when assembling a heating element 1350 having multiple
components.
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[0270] The
heating element 1350 may also improve the accuracy of measurements taken
from the heating element 1350 (e.g., a resistance, a current, a temperature,
etc.) due at least in
part to the improved consistency in manufacturability of the heating element
1350 having
reduced tolerance issues. A heating element 1350 made (e.g., stamped) from a
sheet of material
and either crimped around at least a portion of a wicking element 1362 or bent
to provide a
preformed element desirably helps to minimize heat losses and helps to ensure
that the heating
element 1350 behaves predictably to be heated to the appropriate temperature.
[0271]
Additionally, discussed further below in regards to an included embodiment
relating to a heating element formed of crimped metal, the heating element
1350 may be
entirely and/or selectively plated with one or more materials to enhance
heating performance
of the heating element 1350. Plating all or a portion of the heating element
1350 may help to
minimize heat losses. Plating may also help in concentrating heat to a portion
of the heating
element 1350, thereby providing a heating element 1350 that is more
efficiently heated and
further reducing heat losses. Selective plating may help to direct the current
provided to the
heating element 1350 to the proper location. Selective plating may also help
to reduce the
amount of plating material and/or costs associated with manufacturing the
heating element
1350.
[0272] In
addition to or in combination with the example heating elements described
and/or
discussed below, the heating element may include a flat heating element 1850
(see FIGS. 18A-
18D) positioned within a vaporizer cartridge 1800 including two airflow
passageways 1838, a
folded heating element 1950 (see FIGS. 19A-19C, 22A-22B, and 44A-116)
positioned within
a vaporizer cartridge 1900 including two airflow passageways 1938, and a
folded heating
element 2050 (see FIGS. 20A-20C) positioned within a vaporizer cartridge 2000
including a
single airflow passageway 2038.
[0273] As
noted above, a heating element 1350, in one embodiment, may contain a wicking
element 1362. For example, a wicking element 1362 may extend near or next to
plates 1326
and through resistive heating elements in contact with plates 1326. A wick
housing may
surround at least a portion of a heating element 1350 and connect a heating
element 1350
directly or indirectly to an airflow passageway 1338. Vaporizable material
1302 may be drawn
by a wicking element 1362 through one or more passageways connected to a
reservoir 1340.
In one embodiment, one or both of the primary passageway 1382 or a secondary
passageway
1384 may be utilized to help route or deliver vaporizable material 1302 to one
or both ends of
a wicking element 1362 or radially along a length of a wicking element 1362.
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Overflow Collector Embodiments
[0274] As
provided in further detail below, particularly with reference to FIGS. 3A and
3B, exchange of air and liquid vaporizable material into and out of a
cartridge reservoir 1340
may be advantageously controlled, and a volumetric efficiency of the a
vaporizer cartridge
(defined as a volume of liquid vaporizable material that is eventually
converted to inhalable
aerosol relative to a total volume of the cartridge itself) may also
optionally be improved
through incorporation of a structure referred to as a collector 1313.
[0275] In
accordance with some implementations, a cartridge 1320 may include a reservoir
1340 that is at least partially defined by at least one wall (which can
optionally be a wall that
is shared with an outer shell of the cartridge) configured to contain a liquid
vaporizable material
1302. The reservoir 1340 may include a storage chamber 1342 and an overflow
volume 1344,
which may include or otherwise contain the collector 1313. The storage chamber
1342 may
contain vaporizable material 1302 and the overflow volume 1344 may be
configured for
collecting or retaining at least some portion of the vaporizable material
1302, when one or more
factors cause vaporizable material 1302 in the reservoir storage chamber 1342
to travel into the
overflow volume 1344. In some implementations of the current subject matter,
the cartridge
may be initially filled with liquid vaporizable material such that void space
within the collector
is pre-filled with the liquid vaporizable material.
[0276] In
example embodiments, the volumetric size of the overflow volume 1344 may be
configured to be equal to, approximately equal to, or greater than the amount
of increase in the
volume of the content (e.g., vaporizable material 1302 and air) contained in
the storage
chamber 1342, when the volume of the content in the storage chamber 1342
expands due to a
maximum expected change in pressure that the reservoir may undergo relative to
ambient
pressure.
[0277]
Depending on changes in ambient pressure or temperature or other factors, a
cartridge 1320 may experience a change from a first pressure state to a second
pressure state
(e.g., a first relative pressure differential between the interior of the
reservoir and ambient
pressure and a second relative pressure differential between the interior of
the reservoir and
ambient pressure). In some aspects, the overflow volume 1344 may have an
opening to the
exterior of cartridge 1320 and may be in communication with the reservoir
storage chamber
1342 so that the overflow volume 1344 may act as a venting channel to provide
for the
equalization of pressure in the cartridge 1320 and/or to collect and at least
temporarily retain
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and optionally reversibly return liquid vaporizable material that may move out
of the storage
chamber in response to variations in pressure differential between the storage
chamber and
ambient air. As described herein, a pressure differential refers to a
difference in absolute
pressure between an internal part of the reservoir and ambient air.
Vaporizable material 1302
may be drawn from the storage chamber 1342 to the atomizer and converted to
vapor or aerosol
phases, reducing the volume of the vaporizable material remaining in storage
chamber 1342
and, absent some mechanism for returning air to the storage chamber to
equalize pressure
therein with ambient pressure, may lead to the at least partial vacuum
condition discussed
previously herein.
[0278]
Continuing to refer to FIGS. 3A and 3B, the reservoir 1340 may be implemented
to
include first and second separable areas, such that the volume of the
reservoir 1340 is divided
into a reservoir storage chamber 1342 and a reservoir overflow volume 1344.
The storage
chamber 1342 may be configured for storing the vaporizable material 1302 and
may be further
coupled to the wicking element 1362 via one or more primary passageways 1382.
In some
examples, a primary passageway 1362 may be very short in length (e.g., a pass-
through hole
from a space containing a wicking element or other parts of an atomizer). In
other examples,
the primary passageway may be part of a longer containing fluid path between
the storage
chamber and the wicking element. The overflow volume 1344 may be configured
for storing
and containing portions of the vaporizable material 1302 that may overflow
from the storage
chamber 1342 in a second pressure state in which the pressure in the storage
chamber 1342 is
greater than ambient pressure, as provided in further detail below.
[0279] In a
first pressure state, the vaporizable material 1302 may be stored in the
storage
chamber 1342 of the reservoir 1340. The first pressure state may exist, for
example, when
ambient pressure is approximately the same or more than the pressure inside
the cartridge 1320.
In this first pressure state, the structural and functional properties of the
primary passageway
1382 and the secondary passageway 1384 are such that the vaporizable material
1302 may flow
from the storage chamber 1342 toward the wicking element 1362 by way of the
primary
passageway 1382, for example under capillary action of the wicking element to
draw liquid
into proximity with a heating element that acts to convert the liquid
vaporizable material to the
gas phase.
[0280] In one
embodiment, in the first pressure state, none or limited amounts of the
vaporizable material 1302 flow into the secondary passageway 1384. In the
second pressure
state, the vaporizable material 1302 may flow from the storage chamber 1342
into the overflow
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volume 1344 of the reservoir 1340 that, for example, includes a collector 1313
to prevent or
limit an undesirable (e.g., excessive) flow of the vaporizable material 1302
out of the reservoir.
The second pressure state may exist or be caused, for example, when a bubble
of air expands
in the storage chamber 1342 (e.g., due to ambient pressure becoming less than
the pressure
inside the cartridge 1320).
[0281]
Advantageously, flow of the vaporizable material 1302 may be controlled by way
of routing vaporizable material 1302 driven from the storage chamber 1342 by a
pressure
increase to the overflow volume 1344. The collector 1313 within the overflow
volume may
include one or more capillary structures that contain at least some (and
advantageously all) of
the excess liquid vaporizable material pushed out of the storage chamber 1342
without allowing
the liquid vaporizable material to reach an outlet of the collector 1313. The
collector 1313 also
advantageously includes capillary structures that enable the liquid
vaporizable material pushed
into the collector 1313 by excess pressure in the storage chamber 1342
relative to ambient
pressure to be reversibly drawn back into the storage chamber 1342 when the
pressure
equalizes or is otherwise reduced in the storage chamber 1342 relative to
ambient pressure. In
other words, the secondary passageway 1384 of the collector 1313 may have
microfluidic
features or properties that prevent air and liquid from bypassing each other
during filling and
emptying of the collector 1313 That is, microfluidic features may be used to
manage the flow
of the vaporizable material 1302 both into and out of the collector 1313
(i.e., provide flow
reversal features) to prevent or reduce leaks of the vaporizable material 1302
or entrapment of
air bubbles into the storage chamber 1342 or overflow volume 1344.
[0282]
Depending on implementation, the microfluidic features or properties noted
above
may be related to the size, shape, surface coating, structural features, and
capillary properties
of the wicking element 1362, the primary passageway 1382, and the secondary
passageway
1384. For example, the secondary passageway 1384 in the collector 1313 may
optionally have
different capillary properties than the primary passageway 1382 that leads to
the wicking
element 1362 to allow a certain volume of the vaporizable material 1302 pass
from the storage
chamber 1342 into the overflow volume 1344, during the second pressure state.
[0283] In one
example implementation, overall resistance of the collector 1313 to allowing
liquid to flow out is larger than overall wick resistance, for example, to
allow the vaporizable
material 1302 to primarily flow through the primary passageway 1382 toward the
wicking
element 1362 during the first pressure state.
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[0284] The
wicking element 1362 may provide a capillary pathway through or into the
wicking element 1362 for vaporizable material 1302 stored in reservoir 1340.
The capillary
pathway (e.g., the primary passageway 1382) may be large enough to permit a
wicking action
or capillary action to replace vaporized vaporizable material 1302 in the
wicking element 1362,
and may be small enough to prevent leakage of vaporizable material 1302 out of
the cartridge
1320 during a negative pressure event. The wick housing or the wicking element
1362 may be
treated to prevent leakage. For example, the cartridge 1320 may be coated
after filling to
prevent leakage or evaporation through the wicking element 1362. Any
appropriate coating
may be used, including a heat-vaporizable coating (e.g., a wax or other
material), for example.
[0285] When a
user inhales from a mouthpiece area 1330, for example, air flows into the
cartridge 1320 through an inlet or opening in operational relationship with
the wicking element
1362. The heating element 1350 may be activated in response to a signal
generated by one or
more sensors 113 (see FIG. 1). The one or more sensors 113 may include at
least one of
pressure sensor, motion sensor, flow sensor, or other mechanism capable of
detecting changes
in airflow passageway 1338. When the heating element 1350 is activated, the
heating element
1350 may have a temperature increase as a result of current flowing through
the plates 1326.
Or through some other electrically resistive part of the heating element that
act to convert
electrical energy to heat energy.
[0286] In one
embodiment, the generated heat may be transferred to at least a portion of
the vaporizable material 1302 in the wicking element 1362 through conductive,
convective, or
radiative heat transfer such that at least a portion of the vaporizable
material 1302 drawn into
the wicking element 1362 is vaporized. Depending on implementation, air
entering the
cartridge 1320 flows over (or around, near, etc.) the wicking element 1362 and
the heated
elements in the heating element 1350 and strips away the vaporized vaporizable
material 1302
into the airflow passageway 1338, where the vapor may optionally be condensed
and delivered
in aerosol form, for example, through an opening in the mouthpiece area 1330.
[0287]
Referring to FIG. 3B, the storage chamber 1342 may be connected to the airflow
passageway 1338 (i.e., via secondary passageway 1384 of overflow volume 1344)
for the
purpose of allowing liquid vaporizable material driven from the storage
chamber 1342 by
increased pressure in the storage chamber 1342 relative to ambient to be
retained without
escaping from the vaporizer cartridge. While the implementations described
herein relate to a
vaporizer cartridge containing a reservoir 1340, it will be understood that
the approaches
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described are also compatible with and contemplated for use in a vaporizer
that does not have
a separable cartridge.
[0288]
Returning to the example, air admitted to the storage chamber 1342 may expand
due to a pressure differential relative to ambient air. The expansion of this
air in the void space
of the storage chamber 1342 can cause liquid vaporizable material to travel
through at least
some part of the secondary passageway 1384 in the collector 1313. Microfluidic
features of
the secondary passageway 1384 can cause the liquid vaporizable material to
move a long a
length of the secondary passageway 1384 in the collector 1313 only with a
meniscus fully
covering the cross-sectional area of the secondary passageway 1384 transverse
to the direction
of flow along the length.
[0289] In some
implementations of the current subject matter, the microfluidic features can
include a cross-sectional area sufficiently small that for the material from
which walls of the
secondary passageway are formed and the composition of the liquid vaporizable
material, the
liquid vaporizable material preferentially wets the secondary passageway 1384
around an entire
perimeter of the secondary passageway 1384. For an example in which the liquid
vaporizable
material includes one or more of propylene glycol and vegetable glycerin,
wetting properties
of such a liquid are advantageously considered in combination with geometry of
the second
passageway 1384 and materials form which the walls of the secondary passageway
are formed.
In this manner, as the sign (e.g., positive, negative, or equal) and magnitude
of the pressure
differential between the storage chamber 1340 and ambient pressure varies, a
meniscus is
maintained between liquid in the secondary passageway and air entering from
the ambient
atmosphere, and liquid and air are not able to move past one another. As
pressure in the storage
chamber 1342 drops sufficiently relative to ambient pressure and if there is
sufficient void
volume in the storage chamber 1342 to allow it, liquid in the secondary
passageway 1384 of
the collector 1313 may be withdrawn into the storage chamber 1342 sufficiently
to cause the
leading liquid-air meniscus to reach a gate or port between the secondary
passageway 1384 of
the collector 1313 and the storage chamber 1342. At such time, if the pressure
differential in
the storage chamber 1342 relative to ambient pressure is sufficiently negative
to overcome
surface tension maintaining the meniscus at the gate or port, the meniscus
becomes free of the
gate or port walls and forms and one or more air bubbles, which are released
into the storage
chamber 1342 with sufficient volume to equalize storage chamber pressure
relative to ambient.
[0290] When
air admitted into the storage chamber 1340 as discussed above (or otherwise
becomes present therein) experiences an elevated pressure condition relative
to ambient (e.g.,
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due to a drop in ambient pressure such as might occur in an airplane cabin or
other high altitude
locations, when a window of a moving vehicle is opened, when a train or
vehicle leaves a
tunnel, etc. or an elevation in internal pressure in the storage chamber 1340
such as might occur
due to local heating, mechanical pressure that distorts a shape and thereby
reduces a volume of
the storage chamber 1340, etc., or the like), the above-described process may
be reversed.
Liquid passes through the gate or port into the secondary passageway 1384 of
the collector
1313 and a meniscus forms at the leading edge of a column of liquid passing
into the secondary
passageway 1384 to prevent air from bypassing and flowing counter to the
progression of the
liquid. By maintaining this meniscus due to the presence of the aforementioned
microfluidic
properties, when the elevated pressure in the storage chamber 1340 is later
reduced, the column
of liquid is withdrawn back into the storage chamber, optionally until the
meniscus reaches the
gate or port. If the pressure differential sufficiently favors ambient
pressure relative to the
pressure in the storage chamber, the above-described bubble formation process
occurs until
pressures equalize. In this manner, the collector acts as a reversible
overflow volume that
accepts liquid vaporizable material pushed out of the storage chamber under
transient
conditions of greater storage chamber pressure relative to ambient and allows
at least some
(and desirably all or most) of this overflow volume to be returned to the
storage compartment
for later delivery to an atomizer for conversion to an inhalable form.
[0291]
Depending on implementation, the storage chamber 1342 may or may not be
connected to the wicking element 1362 via the secondary passageway 1384. In
embodiments
in which a second end of the secondary passageway 1384 leads to the wicking
element 1362,
any of the vaporizable material 1302 that may exit the secondary passageway
1384 at the
second end (opposite to a first end defining the point of connection to
storage chamber 1342)
may further saturate the wicking element 1362.
[0292] The
storage chamber 1342 may optionally be positioned closer to an end of the
reservoir 1340 that is near the mouthpiece area 1330. The overflow volume 1344
may be
positioned near an end of the reservoir 1340 closer to the heating element
1350, for example,
between the storage chamber 1342 and the heating element 1350. The example
embodiments
shown in the figures are not to be construed as limiting the scope of the
claimed subject matter
as to the position of the various components disclosed herein. For example,
the overflow
volume 1344 may be positioned at the top, middle or bottom portion of the
cartridge 1320. The
location and positioning of the storage chamber 1342 may be adjusted relative
to the position
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of the overflow volume 1344, such that the storage chamber 1342 may be
positioned at the top,
middle or bottom portion of the cartridge 1320 according to one or more
variations.
[0293] In one
implementation, when the vaporizer cartridge 1320 is filled to capacity, the
volume of liquid vaporizable material may be equal to the internal volume of
the storage
chamber 1342 plus the overflow volume 1344 (which may in some examples be the
volume of
the secondary passageway 1384 between the gate or port connecting the
secondary passageway
1384 to the storage chamber 1340) and an outlet of the secondary passageway
1384. In other
words, a vaporizer cartridge consistent with implementations of the current
subject matter may
be originally filled with liquid vaporizable material such that all or at
least some of the internal
volume of the collector is filled with liquid vaporizable material. In such an
example, liquid
vaporizable material is delivered to an atomizer as needed for delivery to a
user. The delivered
liquid vaporizable material may be drawn from the storage chamber 1340,
thereby causing
liquid in the secondary passageway 1384 of the collector 1313 to be drawn back
into the storage
chamber 1340 as air cannot enter through the secondary passageway 1384 due to
the meniscus
maintained by the microfluidic properties of the secondary passageway 1384
which prevent air
from flowing past liquid vaporizable material in the secondary passageway
1384. After
sufficient liquid vaporizable material has been delivered to the atomizer from
the storage
chamber 1340 (e.g., for vaporization and user inhalation) to cause the
original volume of the
collector 1313 to be drawn into the storage chamber 1340, the above-discussed
action occurs
¨ air bubbles may be released from a gate or port between the secondary
passage 1384 and the
storage chamber to equalize pressure in the storage compartment as more liquid
vaporizable
material is used. When air that has so entered the storage compartment
experiences elevated
pressure relative to ambient, liquid vaporizable material moves out of the
storage chamber 1340
past the gate or port into the secondary passageway until the elevated
pressure condition in the
storage compartment no longer exists, at which point the liquid vaporizable
material in the
secondary passageway 1384 may be drawn back into the storage chamber 1340.
[0294] In
certain embodiments, the overflow volume 1344 is sufficiently large to contain
a percentage of the vaporizable material 1302 stored in the storage chamber
1342, optionally
up to approximately 100%. In one embodiment, the collector 1313 is configured
to contain at
least 6% to 25% of the volume of the vaporizable material 1302 storable in the
storage chamber
1342. Other ranges are possible.
[0295] The
structure of the collector 1313 may be configured, constructed, molded,
fabricated or positioned in the overflow volume 1344, in different shapes and
having different
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properties, to allow for overflowing portions of the vaporizable material 1302
to be at least
temporarily received, contained or stored in the overflow volume 1314 in a
controlled manner
(e.g., by way of capillary pressure), thereby preventing the vaporizable
material 1302 from
leaking out of the cartridge 1320 or excessively saturating the wicking
element 1362. It will
be understood that the above description referring to a secondary passageway
is not intended
to be limiting to a single such secondary passageway 1384. One, or optionally
more than one,
secondary passageway may be connected to the storage chamber 1340 via one or
more than
one gate or port. In some implementations of the current subject matter, a
single gate or port
may connect to more than one secondary passageways, or a single secondary
passageway may
split into more than one secondary passageways to provide additional overflow
volume or other
advantages.
[0296] In some
implementations of the current subject matter, an air vent 1318 may
connect the overflow volume 1344 to the airflow passageway 1338 that
ultimately leads to
ambient air environment outside of the cartridge 1320. This air vent 1318 may
allow for a path
for air or bubbles that may have been formed or trapped in the collector 1313
to escape through
the air vent 1318, for example during a second pressure state as the secondary
passageway
1384 fills with overflowing of the vaporizable material 1302.
[0297] In
accordance with some aspects, the air vent 1318 may act as a reverse vent and
provide for the equalization of pressure within the cartridge 1320 during a
reverting back to
the first pressure state, from the second pressure state, as the overflow of
the vaporizable
material 1302 returns back to the storage chamber 1342 from the overflow
volume 1344. In
this implementation, as ambient pressure becomes larger than the internal
pressure in the
cartridge 1320, ambient air may flow through the air vent 1318 into the
secondary passageway
1384 and effectively help push the vaporizable material 1302 temporarily
stored in the
overflow volume 1344 in a reverse direction back into the storage chamber
1342.
[0298] In one
or more embodiments, the secondary passageway 1384 in a first pressure
state may include air. In the second pressure state, the vaporizable material
1302 may enter
the secondary passageway 1384, for example through an opening (i.e., vent) at
the point of
interface between the storage chamber 1342 and the overflow volume 1344. As a
result, air in
the secondary passageway 1384 is displaced and may exit through the air vent
1318. In some
embodiments, the air vent 1318 may act as or include a control valve (e.g., a
selective osmosis
membrane, a microfluidic gate, etc.) that allows for air to exit the overflow
volume 1344, but
blocks the vaporizable material 1302 from exiting from the secondary
passageway 1384 into
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the airflow passageway 1338. As noted earlier, the air vent 1318 may act as an
air exchange
port to allow air to enter and exit the collector 1313 as, for example, the
collector 1313 fills
during a negative pressure event and empties following the negative pressure
event (i.e., during
a transition between the first and second pressure states discussed earlier).
[0299]
Accordingly, the vaporizable material 1302 may be stored in the collector 1313
until pressure inside the cartridge 1320 is stabilized (e.g., when the
pressure returns to ambient
or meets a designated equilibrium) or until the vaporizable material 1302 is
removed from the
overflow volume 1344 (e.g., by way of vaporization in an atomizer). Thus, the
level of the
vaporizable material 1302 in the overflow volume 1344 may be controlled by
managing the
flow of vaporizable material 1302 into and out of the collector 1313 as
ambient pressure
changes. In one or more embodiments, overflow of the vaporizable material 1302
from the
storage chamber 1342 into the overflow volume 1344 may be reversed or may be
reversible
depending on detected changes in environment (e.g., when a pressure event that
caused the
vaporizable material 1302 overflow subsides or is concluded).
[0300] As
noted above, in some implementations of the current subject matter, in a state
when pressure inside of the cartridge 1320 becomes relatively lower than the
ambient pressure
(e.g., when going from the second pressure state noted earlier back to the
first pressure state),
flow of the vaporizable material 1302 may be reversed in a direction that
causes the vaporizable
material 1302 to flow back from the overflow volume 1344 into the storage
chamber 1342 of
the reservoir 1340. Thus, depending on implementation, the overflow volume
1344 may be
configured for temporarily containing the overflow portions of the vaporizable
material 1302
during a second pressure state. Depending on implementation, during or after a
reversal back
to a first pressure state, at least some of the overflow of the vaporizable
material 1302 retained
in the collector 1313 is returned back to the storage chamber 1342.
[0301] To
control the vaporizable material 1302 flow in the cartridge 1320, in other
implementations of the current subject matter, the collector 1313 may
optionally include
absorbent or semi-absorbent material (e.g., material having sponge-like
properties) for
permanently or semi-permanently collecting or containing the overflow of the
vaporizable
material 1302 travelling through the secondary passageway 1384. In an example
embodiment,
in which absorbent material is included in the collector 1313, the reverse
flow of the
vaporizable material 1302 from the overflow volume 1344 to the storage chamber
1342 may
not be as practical or possible as compared to embodiments that are
implemented without (or
without as much) absorbent material in the collector 1313. Accordingly, the
reversibility or
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the reversibility rate of the vaporizable material 1302 to the storage chamber
1342 may be
controlled by including more or less densities or volumes of absorbent
material in the collector
1313 or by controlling texture of the absorbent material, where such
characteristics result in a
higher or lower rate of absorption, either immediately or over longer time
periods.
[0302] FIG. 4
is an exploded perspective view of an example implementation of a cartridge
1320. As shown, the body of the cartridge 1320 may be made of two connectable
(or separable)
pieces, such as a first portion 1422 (e.g., upper housing) and a second
portion 1424 (e.g., lower
housing) that may fit together according to a top-down architectural
implementation model or
assembly process. This separable architecture simplifies assembly and
manufacturing
processes and may not involve the assembly or construction of multiple smaller
pieces to
construct a larger piece. Instead, as in the example embodiment illustrated in
FIG. 4, larger
pieces (e.g., a first portion 1422 and a second portion 1424) may be connected
to, for example,
form external cartridge features (e.g., siding) and smaller internal cartridge
components (e.g.,
opposing rib-shaped elements that form one or more of a collector 1313, a
reservoir 1340, a
storage chamber 1342, an overflow volume 1344, etc.).
[0303]
Referring to FIG. 4, a heating element 1450 may be positioned in a cavity or
housing
implemented in between a first portion 1422 and a second portion 1424 of the
body of the
cartridge 1420. In one example, a sponge or other absorbent material 1460 may
be also
positioned in a mouthpiece area 1430 for the purpose of collecting excess
liquid vaporizable
material (e.g., as might form by condensation of vaporized material and/or
water vapor to form
larger droplets that can create an unpleasant sensation when ingested during
inhalation)
traveling through an airflow passageway 1438. Accordingly, the assembly or
disassembly of
additional components (e.g., a heating element 1450 or sponge 1460) may be
performed in a
simple and efficient manner, where a large number of machinery or assembly
automation parts
may not be needed for constructing the cartridge 1320 from a small set of
components into a
unified separable two-piece housing in the example implementation disclose
herein.
[0304] The
separable two-piece construction described herein may provide one or more of
the following example advantages or improvements over an alternative
implementation: lower
part count, lower assembly or manufacturing costs (e.g., the embodiment
illustrated in FIG. 4
requires four parts to be manufacture and assembled), no or reduced tooling
requirements, no
or limited deep, fragile, low draft tooling cores, rib structures that are
relatively shallow.
Depending on implementation, ultrasonic or laser welding techniques may be
utilized to create
a solid-state weld between a first portion 1422 and a second portion 1424 of a
cartridge 1420.
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[0305]
Ultrasonic welding is a process commonly used for plastics in which high-
frequency ultrasonic acoustic vibrations are locally applied to work pieces
(e.g., a first portion
1422 and a second portion 1424) being held together under pressure to create a
solid-state weld.
Laser welding is a welding process used to join pieces of metal or
thermoplastics through the
use of a laser beam which provides a concentrated heat source (e.g., laser
beam), allowing for
narrow, deep welds at high welding rates.
[0306]
Referring to FIG. 5, a planar cross-sectional side view of a selected portion
of a
cartridge 1320 is illustrated. Referring to both FIGS. 4 and 5, a first
portion 1422 (not shown
in FIG. 5) and a second portion 1424 of the cartridge 1420 may be molded from
plastic parts
by way of injection molding (e.g., in a top-down implementation model). In one
example
embodiment, a line of draw tooling technique may be used to allow for the
separation of mold
halves (e.g., a first portion 1422 and a second portion 1424, as shown in FIG.
4) allowing each
portion to be ejected without any obstructions from the creating undercuts and
further allowing
for substantial mold cavitation, to help shorten the tooling cycle and allow
for more efficient
manufacturing time and process.
[0307]
Referring to FIGS. 6A and 6B, a cross-sectional top view and a perspective
side
view of a cartridge 1320 are shown respectively. As shown, a fill port 610 may
be implemented
in one or more embodiments of the cartridge 1320 to allow for filling the
reservoir storage
chamber 1342 by way of, for example, a fill needle 622. As shown, the fill
needle 622 may be
easily and conveniently insertable into the fill port 610 by way of, for
example, a fill
passageway 630 leading to a storage chamber 1342 (or overflow volume 1344),
depending on
implementation. Accordingly, vaporizable material 1302 may be injected into a
reservoir 1340
through a fill passageway 630, using a fill needle 622 for example. In some
embodiments, the
fill passageway 630 may be constructed or positioned on a side of the
cartridge 1320, for
example, opposite to the side where the airflow passageway 1338 is positioned.
[0308] FIGS.
7A through 7D illustrate design alternatives for a cartridge connecting port.
FIGS. 7A and 7B are perspective views and FIGS. 7C and 7D are planar cross-
sectional side
views of alternative connecting port embodiments, which by way of example may
include male
or female engagement parts. Referring to FIGS. 1, 2 and 7A-7D, a cartridge
1320 may be
implemented in different configurations at the end where the cartridge 1320
engages the
vaporizer body 110. In one embodiment, as shown in FIGS. 1 and 2, the
vaporizer body 110
may include a cartridge receptacle 118 for detachably receiving a cartridge
1320 with a male
configured port 710 (see FIGS. 7A and 7C), such that in an attached state,
cartridge contacts
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124 positioned in the male port of cartridge 1320 are received by
corresponding receptacle
contacts 125 in a cartridge receptacle 118 in a snap-lock fashion, for
example. A counterpart
configuration may be directed to a cartridge 1320 having a female configured
port 712 (see
FIGS. 7B and 7D) for receiving an end of a vaporizer body 110, that includes
receptacle
contacts 125.
[0309]
Referring to FIG. 8, a planar top view of a cartridge 1320 is illustrated. In
one
example, the cartridge 1320 may be implemented using a separable two-piece
construction,
where a relief (e.g., an owner's trademark, a serial number, a patent number,
etc.) or optionally
decorative or ornamental features may be imprinted on the external walls of
the cartridge 1320
by way of a molding process. The molding process allows for flexibility in
designing the
external shape or externally displayable logos or ornamental designs without
affecting the
positioning or formation of internal functional components (e.g., a reservoir
1340, a storage
chamber 1342, or an overflow volume 1344).
[0310]
Notably, the mark JUUL as shown in FIG. 8 is a registered trademark of JUUL
LABS, Inc. a Delaware Corporation, headquartered in San Francisco California.
All rights are
reserved by the mark's owner or assignee. Use of the example mark in FIG. 8
should not be
construed as limiting the scope of the disclosed subject matter to include
such exclusive design
or marking. Certain embodiments may be unmarked or contain no ornamental or
external
design features, whatsoever. Thus, FIG. 8 provides an illustration of a molded
relief that,
without limitation, may appear as a mark or design on one or more sides of a
cartridge 1320.
[0311]
Referring to FIGS. 9A and 9B, perspective and planar sectional views of an
example
cartridge 1320 are illustrated, where a first portion 1422 of the cartridge
1320 is split from a
second portion 1424 (see also FIG. 4). In one or more embodiments, the
cartridge 1320 may
be engineered and manufactured by way of part splitting. That is, depending on
implementation, multiple split sections of a part are connected together to
make a whole part
as shown by way of example in FIG. 4.
[0312]
Referring to FIG. 9A, part splitting may allow for molded compliance for
electrical
contact and heating element retention in a wick housing area 910 of the
cartridge 1320. As
shown in more detail in FIG. 9B, one or more vent holes 920 may be drilled or
positioned by
way of injection molding, or other suitable method, in the body of the
cartridge 1320 in an area
near the wick housing area 910 to allow for pinpoint vapor evacuation or
airflow to the wick
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to, for example, help control condensation within the cartridge 1320 or affect
capillary forces
therein.
[0313]
Referring to FIGS. 10A and 10B, assembled and exploded perspective views of an
alternative example embodiment of a cartridge 1320 are respectively
illustrated. As noted
earlier, a top-down implementation model may be employed to construct an open-
faced
cartridge structure with, for example, two attachable (or detachable) housings
including a first
portion 1422 and a second portion 1424. As shown, the first portion 1422
(e.g., the upper
housing) and the second portion 1424 (e.g., the lower housing) may provide for
a two-piece
construction having one or more internal cavities that may be utilized to
house at least one of
a heating element 1350, a wicking element 1362, or plates 1326. It will be
understood that
alternative assembly methods may be used to result in structures have some or
all of the features
described herein.
[0314]
Particularly, in the example embodiment shown in FIGS. 10A and 10B, instead or
in addition to using molded cavities and walls to form internal structures
(e.g., a reservoir 1340
in FIG. 3A) of the cartridge, some features such as the secondary passageway
1384 (see FIG.
3A) may be embodied in a removable or attachable collector 1313 that may be
independently
constructed as a separate piece and may be later either encapsulated between a
first portion
1422 and a second portion 1424 (e.g., see FIGS. 10A and 10B) or alternatively
inserted into an
optionally monolithic hollow cartridge body adapted to receive a collector
1313 from an open
end (see FIGS. 10C, 10D, 11B, 13, 16C, 17A, 22F).
[0315]
Referring to FIGS. 10A through 43B, various implementations are disclosed
which
may utilize a collector 1313 as configured, designed, manufactured, fabricated
or constructed
fully or partially independent from a cartridge 1320 housing. It is noteworthy
that the disclosed
implementations are provided by way of example. In alternate implementations
or
embodiments, a collector 1313 may be formed as shown in FIGS. 10A through 14B,
having a
construction that, at least structurally, is semi-dependent or fully
independent of the
construction of other components of the cartridge 1320.
[0316] In
certain interchangeable implementations, various embodiments or types of
collector 1313, as shown in FIGS. 10A through 14B, may be inserted or
encapsulated in, for
example, a standardized cartridge 1320 housing. As provided in further detail
herein, because
some of the main functionalities for controlling the flow of vaporizable
material 1302 in the
cartridge 1320 may be achieved by way of manipulating the collector 1313
structure or material
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properties thereof, cost savings and other efficiencies and advantages may be
derived from
having a construction that allows for interchangeable collector 1313 models
that may fit
different cartridge housings, for example.
[0317]
Referring to FIGS. 10C and 10D, for example, in some implementations, instead
of
a separable two-piece construction illustrated in FIGS. 10A and 10B, a
cartridge 1320 may
have a cartridge housing formed of a monolithic hollow structure having a
first end and a
second end. The first end (i.e., a first end, also referred to as a receiving
end of the cartridge
housing) may be configured for insertably receiving at least a collector 1313.
In one
embodiment, the second end of the cartridge housing may act as a mouthpiece
with an orifice
or opening. The orifice or opening may be situated opposite of the receiving
end of the
cartridge housing where the collector 1313 may be insertably received. In some
embodiments,
the opening may be connected to the receiving end by way of an airflow
passageway 1338 that
may extend through the body of the cartridge 1320 and the collector 1313, for
example. As in
other cartridge embodiments consistent with the current disclosure, an
atomizer, for example
one including a wicking element and a heating element as discussed elsewhere
herein, may be
positioned adjacent to or at least partially in the airflow passageway 1338
such that an inhalable
form, or optionally a precursor of the inhalable form, of the liquid
vaporizable material may be
released from the atomizer into air passing through the airflow passageway
1338 toward the
orifice or opening.
Air Exchange Port Embodiments
[0318]
Referring to FIGS. 11A and 11B, illustrative planar side views of a single-
gate,
single-channel collector 1313 are shown. In these example embodiments, a gate
1102 may be
provided at an opening toward a first portion (e.g., upper portion) of the
collector 1313 where
the collector 1313 is in contact or in communication with the reservoir's
storage chamber 1342
(see also FIGS. 3A and 3B discussed earlier). A gate 1102 may dynamically
connect the
storage chamber 1342 to an overflow volume 1344 formed by a second portion
(e.g., a middle
portion) of the collector 1313.
[0319] In one
embodiment, the second portion of the collector 1313 may have a ribbed or
multi-fin-shaped structure forming an overflow channel 1104 that spirals,
tapers or slopes in a
direction away from the gate 1102 and towards an air exchange port 1106, as
shown in FIG.
11A, to lead or cause vaporizable material 1302 to move toward the air
exchange port 1106
after vaporizable material 1302 enters the overflow volume 1344 through the
gate 1102. The
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air exchange port 1106 may be connected to ambient air by way of an air path
or airflow
passageway that is connected to the mouthpiece. This air path or airflow
passageway is not
explicitly shown in FIG. 11A.
[0320] In some
implementations, the collector 1313 is configured to have a central opening
or tunnel through which an airflow channel leading to the mouthpiece is
implemented, as
provided in further detail below (e.g., see opening referenced by numeral 1100
in FIG. 11D).
The airflow channel may be connected to the air exchange port 1106, such that
the volume
inside the overflow passageway of the collector 1313 is connected to ambient
air via the air
exchange port 1106 and also connected to the volume in the storage chamber
1342 via the gate
1102. As such, in accordance with one or more embodiments, the gate 1102 may
be utilized
as a control fluidic valve to mainly control liquid and air flow between the
overflow volume
1344 and the storage chamber 1342. The air exchange port 1106 may be utilized
to mainly
control airflow (and on occasion liquid flow) between the overflow volume 1344
and an air
path leading to the mouthpiece, for example. Overflow channel 1104 may be
diagonal, vertical,
or horizontal in relationship to the elongated body of the cartridge 1320.
[0321]
Vaporizable material 1302, at the time the cartridge 1320 is filled, may have
at least
an initial interface with the collector 1313 by way of the gate 1102. This is
because an initial
interface between vaporizable material 1302 and the gate 1102 may, for
example, prevent the
possibility for air trapped in the overflow channel 1104 to enter a cartridge
area where
vaporizable material 1302 is stored (e.g., storage chamber 1342). Furthermore,
such interface
may initiate a first capillary interaction between vaporizable material 1302
and the walls of the
overflow channel 1104, at an equilibrium state, to allow for a limited amount
of vaporizable
material 1302 to flow into the overflow channel 1104 to achieve or maintain
the equilibrium
state.
[0322]
Equilibrium state refers to a state in which vaporizable material 1302 neither
flows
in nor flows out of the overflow volume 1344, or a state in which such forward
or reverse flows
are negligible. At least in some embodiments, the capillary action (or
interaction) between the
walls of the overflow channel 1104 and vaporizable material 1302 is such that
an equilibrium
state may be maintained when the cartridge 1320 is in the first pressure
state, when the pressure
inside the storage chamber 1342 is approximately equal to the ambient
pressure.
[0323]
Establishing of an equilibrium state and further capillary interaction between
vaporizable material 1302 and the walls of the overflow channel 1104 may be
established or
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configured by way of adapting or adjusting the volumetric size of the overflow
channel 1104
along the length of the channel. As provided in further detail herein, the
diameter (which is
used herein to refer generically to a measure of the magnitude of the cross
sectional area of the
overflow channel 1104, including implementations of the current subject matter
in which the
overflow channel does not have a circular cross-section) of the overflow
channel 1104 may be
constricted at predetermined interval or points or throughout the length of
the entire channel to
allow for a sufficiently strong capillary interaction that provides for direct
and reverse flows of
vaporizable material 1302 into and out of the collector 1313, depending on
changes in pressure
and further to allow large overall volume of the overflow channel while still
maintaining gate
points for meniscus formation to prevent air from flowing past liquid in the
overflow channel
1104.
[0324] As
provided in further detail herein, the diameter of the overflow channel 1104
may
be sufficiently small or narrow such that the combination of surface tension,
caused by
cohesion within vaporizable material 1302, and wetting forces between the
vaporizable
material 1302 and the walls of the overflow channel 1104 may act to cause
formation of a
meniscus that separates liquid from air in a dimension traverse to the axis of
flow in the
overflow channel 1104 such that air and liquid cannot pass each other. It will
be understood
that menisci have an inherent curvature, so reference to a dimension
transverse to the direction
of flow is not intended to imply that the air-liquid interface is planar in
this or any other
dimension.
[0325] The
wicking element 1362 may be in a thermal or thermodynamic connection with
a heating element 1350 (see FIGS. 3B and 11B, for example) to induce the
generation of vapor
from heating the vaporizable material 1302, as discussed in detail earlier
with reference to
FIGS. 3A and 3B. Alternatively, the air exchange port 1106 may be constructed
to provide a
gas escape route but prevent flow of the vaporizable material 1302 out of the
overflow channel
1104.
[0326]
Referring to both FIGS. 11A and 11B, direct or reverse flows of the
vaporizable
material 1302 in the collector 1313 may be controlled (e.g., enhanced or
diminished) by way
of implementing suitable structures (e.g., microchannel configurations) to
introduce or take
advantage of capillary properties that may exist between the vaporizable
material 1302 and the
retaining walls of the overflow channel 1104. For example, factors associated
with length,
diameter, inner surface texture (e.g., rough vs. smooth), projections,
directional tapering of the
channel structures, constrictions or material used for constructing or coating
the surface of the
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gate 1102, the overflow channel 1104 or the air exchange port 1106 may
positively or
negatively affect the rate at which a liquid is drawn into or moves through
the overflow channel
1104 by way of capillary action or other influential forces acting on
cartridge 1320.
[0327] One or
more factors noted above, depending on implementation, may be used to
control displacement of the vaporizable material 1302 in the overflow channel
1104 to
introduce a desirable degree of reversibility, as the vaporizable material
1302 is collected in
the channel structures of the collector 1313. As such, in some embodiments,
the flow of the
vaporizable material 1302 into the collector 1313 may be fully reversible or
semi-reversible by
way of selectively controlling the various factors noted above and depending
on changes in
pressure state inside or outside of the cartridge 1320.
[0328] As
shown in FIGS. 3A, 3B, 11A, and 11B, in one or more embodiments, the
collector 1313 may be formed, constructed, or configured to have a single-
channel single-vent
structure. In such embodiments, the overflow channel 1104 may be a continuous
passageway,
tube, channel or other structure for connecting the gate 1102 to the air
exchange port 1106,
optionally positioned near the wicking element 1362 (e.g., see also FIGS. 3A
and 3B showing
a single elongated overflow channel 1104 in the overflow volume 1344).
Accordingly, in such
embodiments, the vaporizable material 1302 may enter or exit the collector
1313 from the gate
1102 and through a singularly constructed channel, where the vaporizable
material 1302 flows
in a first direction as the collector 1313 is being filled and in a second
direction when the
collector 1313 is being drained.
[0329] To help
maintain an equilibrium status or, depending on implementation, to control
flow of the vaporizable material 1302 in the overflow channel 1104, the shape
and structural
configuration of the overflow channel 1104, the gate 1102 or the air exchange
port 1106 may
be adapted or modified to balance the rate of flow of the vaporizable material
1302 in the
overflow channel 1104, at different pressure states. In one example, the
overflow channel 1104
may be tapered so that the tapered end (i.e., the end with smaller opening or
diameter) leads to
the gate 1102.
[0330] In one
implementation, the untapered end (i.e., the end of the overflow channel
1104 with the larger opening or diameter) may lead to the air exchange port
1106 which may
be connected to the ambient environment outside of the cartridge 1320 or to an
airflow path
from which vaporized vaporizable material 1302 is delivered to the mouthpiece
(see for
example FIG. 3A, air vent 1318 connected to airflow passageway 1338). In one
embodiment,
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the untapered end may also lead to an area near the wick housing, such that if
the vaporizable
material 1302 exits the overflow channel 1104, the vaporizable material 1302
may be used to
saturate the wicking element 1362.
[0331] A
tapered channel structure, depending on implementation, may reduce or increase
restriction on flow into the collector 1313. For example, in an embodiment
where the overflow
channel 1104 is tapered toward the gate 1102, a favorable capillary pressure
towards a reverse
flow is induced in the overflow channel 1104, such that direction of the
vaporizable material
1302 flow is out of the collector 1313 and into the storage chamber 1342 when
pressure state
changes (e.g., when a negative pressure event is eliminated or subsided).
Particularly,
implementing the overflow channel 1104 with a smaller opening may prevent free
flow of the
vaporizable material 1302 into the collector 1313. An untapered configuration
for the overflow
channel 1104 in a direction leading towards the air exchange port 1106
provides for efficient
storage of the vaporizable material 1302 in the collector 1313 during a second
pressure state
(e.g., a negative pressure state) as the vaporizable material 1302 flows into
the collector 1313
from narrower sections of the overflow channel 1104 into larger volumetric
sections of the
overflow channel 1104.
[0332] As
such, diameter and shape of the collector structure 1313 may be implemented so
that the flow of the vaporizable material 1302 through the gate 1102 and into
the overflow
channel 1104 is controlled at a desirable rate, during a second pressure state
(e.g., a negative
pressure event) in a manner to prevent the vaporizable material 1302 from
flowing too freely
(e.g., beyond a certain flow rate or threshold) into the collector 1313, and
also to favor a reverse
flow back into the storage chamber 1342 in a first pressure state (e.g., when
a negative pressure
event is alleviated). It is noteworthy that the combination of the
interactions between the vent
1002, the overflow channel 1104 in the collector 1313 that make up the
overflow volume 1344
and the air exchange port 1106, in one embodiment, provides for the proper
venting of air
bubbles that may be introduced into the cartridge due to various environmental
factors as well
as the controlled flow of the vaporizable material 1302 into and out of the
overflow channel
1104.
Mouthpiece Embodiments
[0333]
Referring to FIG. 11B (also see FIGS. 10C, 10D), in some embodiments, a
portion
of the cartridge 1320 that includes the storage chamber 1342 may be configured
to also include
a mouthpiece that may be utilized by a user to inhale vaporized vaporizable
material 1302. An
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airflow passageway 1338 may extend through the storage chamber 1342, thereby
connecting a
vaporization chamber. Depending on implementation, the airflow passageway 1338
may be a
straw-shaped structure or hollow cylinder, for example, which forms a channel
inside the
storage chamber 1342 to allow for passage of vaporized vaporizable material
1302. While the
airflow passage may have a circular or at least approximately circular cross-
sectional shape, it
will be understood that other cross-sectional shapes for the airflow passage
are also within the
scope of the current disclosure.
[0334] A first
end of the airflow passageway 1338 may be connected to an opening at a
first "mouthpiece" end of the storage chamber 1342 from which a user may
inhale vaporized
vaporizable material 1302. A second end of the airflow passageway 1338
(opposite the first
end) may be received in an opening at a first end of the collector 1313, as
provided in further
detail herein. Depending on implementation, the second end of the airflow
passageway 1338
may fully or partially extend through a receiving cavity that runs through the
collector 1313
and connects to a wick housing, where the wicking element 1362 may be housed.
[0335] In some
configurations, the airflow passageway 1338 may be an integral part of a
monolithic molded mouthpiece that includes the storage chamber 1342 where the
airflow
passageway 1338 extends through the storage chamber 1342. In other
configurations, the
airflow passageway 1338 may be an independent structure that may be separately
inserted into
the storage chamber 1342. In some configurations, the airflow passageway 1338
may be a
structural extension of the collector 1313 or the body of the cartridge 1320
as internally
extending from the opening in the mouthpiece portion, for example.
[0336] Without
limitation, a variety of different structural configurations may be possible
for connecting the mouthpiece (and airflow passageway 1338 internal to the
mouthpiece) to
the air exchange port 1106 in collector 1313. As provided herein, the
collector 1313 may be
inserted into the body of the cartridge 1320, which may also act as a storage
chamber 1342. In
some embodiments, the airflow passageway 1338 may be constructed as an
internal sleeve that
is an integral part of a monolithic cartridge body, such that an opening in a
first end of the
collector 1313 may receive a first end of the sleeve structure forming the
airflow passageway
1338.
[0337]
Referring to FIGS. 18A-18D, certain embodiments may include a vaporizer
cartridge 1800 including a double barrel mouthpiece 1830 connected with two
airflow
passageways 1838. In such embodiments, a higher dose of vaporized vaporizable
material
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1302 may be delivered in comparison to a single barrel mouthpiece. A double
barrel
mouthpiece 1830, depending on implementation, may also advantageously provide
a smoother
and more satisfying vaping experience.
Fluidic Gate Embodiments
[0338]
Referring to FIGS. 10A through 11H, depending on implementation, various
factors
may be considered to help monitor and control forward and reverse flows of
vaporizable
material 1302 in and out of the collector 1313. Some of these factors may
include configuring
the capillary drive of a fluidic vent, referred to herein as the gate 1102.
The capillary drive of
the gate 1102 may be, for example, smaller than that of the wicking element
1362. Further,
collector 1313 flow resistance may be larger than that of the wicking element
1362. The
overflow channel 1104 may have smooth or rippled inner surfaces to control the
flow rate of
vaporizable material 1302 through the collector 1313. The overflow channel
1104 may be
formed with a tapering curve to provide proper capillary interaction and
forces that limit the
rate of flow through the gate 1102 and into the overflow volume 1344 during a
first pressure
state to promote a reverse rate of flow through the gate 1102 and out of the
overflow volume
1344 during a second pressure state.
[0339]
Additional modifications to the shape and structure of collector 1313
components
may be possible to help further regulate or fine-tune flow of vaporizable
material 1302 into or
out of the collector 1313. For example, a smoothly curved spiral channel
configuration (i.e.,
as opposed to a channel with sharp turns or edges) as shown in FIGS. 11A
through 11H may
allow for additional features, such as one or more vents, channels, apertures
or constricting
structures to be included in the collector 1313 at predetermined intervals
along the overflow
channel 1104. As provided in further detail herein, such additional features,
structures or
configurations may help provide a higher level of flow control for vaporizable
material 1302
along the overflow channel 1104 or through the gate 1102, for example.
[0340] It is
noteworthy that regardless of the various structural elements and
implementations discussed throughout this disclosure, certain features and
functionalities (e.g.,
capillary interaction among various components) may be implemented in the
collector 1313
structure to help control flow of vaporizable material 1302 through (1) single-
vent, single-
channel structures, (2) single-vent, multi-channel structures, or (3) multi-
vent, multi-channel
structures, for example.
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[0341]
Referring to FIGS. 10E, 11A, 11C, 11D, and 11E, example structural
configurations
for the collector 1313 are presented in accordance with certain variations. As
shown, a fully
or partially sloping spiral surface may be implemented to define one or more
sides of the
internal volume of the overflow channel 1104 of the collector 1313, such that
vaporizable
material 1302 may flow freely due to capillary pressure (or the force of
gravity) through the
overflow channel 1104 as vaporizable material 1302 enters the overflow channel
1104. One
or more, optionally central, channels or tunnels, such as a central tunnel
1100, may be
configured through the longitudinal height of the collector 1313, having two
opposing ends.
[0342] At the
first end, a central shaft or central tunnel 1100 through the collector
structure
1313 may interact with or connect to a housing area in which a wicking element
1362 or an
atomizer may be positioned. At the second end, the central tunnel 1100 may
interact with,
connect to, or receive one end of a duct or a tube that forms an airflow
passageway 1338 in the
mouthpiece portion of the cartridge 1320. A first end of the airflow
passageway 1338 may
connect (e.g., by way of insertion) to the second end of the central tunnel
1100. A second end
of the airflow passageway 1338 may include an opening or orifice formed in the
mouthpiece
area.
[0343] In
accordance with one or more embodiments, vaporized vaporizable material 1302
generated by an atomizer may enter through the first end of the central tunnel
1100 in the
collector 1313, pass through the central tunnel 1100 and further out of the
second end of the
central tunnel 1100 into the first end of the airflow passageway 1338.
Vaporized vaporizable
material 1302 may then travel through the airflow passageway 1338 and exit
through the
mouthpiece opening formed at the second end of the airflow passageway 1338.
[0344] The
collector 1313 may be configured as an independent piece with a construction
or structure that is insertable into the body of the cartridge 1320 (e.g., see
FIGS. 10C, 11B,
11C-1 1E). Upon insertion, an airtight seal may be formed between the inner
walls of the shell
body of the cartridge 1320 and the outer rims of the rib-like structure of the
collector 1313 that
forms the spiral sloping surface. In other words, three walls of the overflow
channel 1104 as
enclosed by the surface of the inner walls of the shell body of the cartridge
1320 form an
overflow channel 1104 upon insertion of the collector 1313 into the body of
the cartridge 1320.
[0345]
Accordingly, an overflow channel 1104 may be formed by way of the inner walls
of the body of the cartridge 1320 enclosing the inner walls of the rib-like
structure. As shown,
a gate 1102 may be positioned at one end of the overflow channel 1104, toward
where the
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storage chamber 1342 is positioned, to control and provide for the ingress and
egress of
vaporizable material 1302 in the overflow channel 1104 in the collector 1313.
An air exchange
port 1106 may be positioned toward another end of the overflow channel 1104,
preferably
opposite the end where the gate 1102 is positioned.
[0346] The
gate 1102 may control the flow of vaporizable material 1302 into and out of
the overflow channel 1104 in the collector 1313. The air exchange port 1106
may, via a
connection path to ambient air, control the flow of air into and out of the
overflow channel
1104 to regulate air pressure in the collector 1313, and in turn in the
storage chamber 1342 of
the cartridge 1320 as provided in further detail herein. In certain
embodiments, the air
exchange port 1106 may be configured to prevent vaporizable material 1302
which may have
filled the collector 1313 overflow channel 1104 (e.g., as a result of a
negative pressure event)
to exit the overflow channel 1104.
[0347] In a
certain implementation, the air exchange port 1106 may be configured to cause
vaporizable material 1302 to exit toward a route that leads to the area in
which the wicking
element 1362 is housed. This implementation may help avoid leakage of
vaporizable material
1302 into an airflow passageway (e.g., central tunnel 1100) that leads to the
mouthpiece, during
a negative pressure event, for example. In some implementations, the air
exchange port 1106
may have a membrane that allows the ingress and egress of gaseous material
(e.g., air bubbles)
but prevents vaporizable material 1302 from entering or exiting the collector
1313 through the
air exchange port 1106.
[0348]
Referring to FIGS. 11C through 11H, the rate of flow of vaporizable material
1302
into or out of the collector 1313 through the gate 1102 may be directly
associated with the
volumetric pressure inside the overflow channel 1104. Thus, the rate of flow
into and out of
the collector 1313, through the gate 1102, may be controlled by way of
manipulating the
hydraulic diameter of the overflow channel 1104 such that reducing the overall
volume of the
overflow channel 1104 (e.g., either uniformly or by way of introducing
multiple constrictions
points) may lead to increased pressure in the overflow channel 1104 and
adjusting the rate of
flow into the collector 1313. Accordingly, in at least one implementation, the
hydraulic
diameter of the overflow channel 1104 may be decreased (e.g., narrowed,
pinched, constricted
or restricted), either uniformly or by way of introducing one or more
constriction points 1111a,
along the length of the spiral path of the overflow channel 1104.
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[0349] FIGS.
11C through 11E, by way of example, illustrate two partial-length and three
full-length levels constructed on one or more sides of the collector 1313,
with each full-length
level, on the side shown in the figures, having three constriction points
1111a, for example. It
is noteworthy that, in different implementations, more or fewer levels or
constriction points
1111a may be implemented, defined, constructed, or introduced to adjust
volumetric pressure
in the collector 1313. A constriction point 1111a, for illustration purposes,
is conspicuously
marked by a circle in the middle level of the collector 1313.
[0350]
Constriction points 1111a may be formed or introduced along the length of the
overflow channel 1104 in a variety of manners and shapes. In the following,
example
embodiments with different constriction points or shapes are disclosed to
better illustrate
certain features. It is noted, however, that these example embodiments should
not be construed
as limiting the scope of the claimed subject matter to any particular
configuration or shape.
[0351]
Referring to FIG. 11C, in one example implementation, a constriction point
1111a
may be formed by way of bumps, raised edges, protrusions or projections
(hereafter referred
to as "projections") extending from the ceiling or floor or side wall (or any
or all such) surfaces
of the overflow channel 1104 (i.e., the blades of the collector 1313). The
shape of the
projections may be defined as a bump, finger, prong, fin, edge, or any other
shape that constricts
a cross-sectional area transverse to a flow direction in the overflow channel.
In the illustration
of FIG. 11C, the cross-sectional side view of a projection is shown as being
similar to the shape
of a shark fin, for example, where the distal end of the projections is
tapered to an edge.
[0352] As
shown in FIG. 11C, the pointed or cantilevered edge of the shark fin shape may
be rounded. In other embodiments, however, the cantilevered edge may be
tapered to a sharp
end. The sharpness, size, relative location, and placement frequency of the
projections in the
overflow channel 1104 may be manipulated to further fine-tune tendency of a
meniscus
separating liquid and air to form within the overflow channel 1104.
[0353] For
example, as shown in FIG. 11C, the projections may have a rounded face on
one side and a flat face on the opposite side. The rounded face of the
projections may face
(i.e., be directed towards) the outward flow of vaporizable material 1302
(i.e., flow out of the
collector 1313 and into the storage chamber 1342), whereas the flat face of
the projections may
face the inward flow of vaporizable material 1302 (i.e., flow into the
collector 1313 and from
the storage chamber 1342) through the gate 1102.
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[0354] As
noted, in different implementations, formation of the projections along the
overflow channel 1104 may be manipulated in number, size, shape, location, and
frequency to
fine-tune the hydraulic rate of flow of vaporizable material 1302 into and out
of the collector
1313. For example, if it is desirable to instead maintain an incoming flow in
the overflow
channel 1104 at a higher rate than the outgoing flow, then the projections
maybe shaped to
have a flat surface facing the outgoing flow and a rounded surface facing the
incoming flow to
facilitate formation and retention of a meniscus resisting outward flow of
liquid (e.g., away
from the storage chamber 1340) while making it easier for the meniscus to
break free of the
side of the projection facing back toward the storage compartment 1340. In
this manner, a
series of such projections may function as a sort of "hydraulic ratchet"
system in which return
flow of liquid into the storage compartment is microfluidically encouraged
relative to outward
flow from the storage compartment. This effect may be achieved, at least in
part, by the relative
tendency of a meniscus to break from the storage chamber side of the
projections than from the
opposite side.
[0355]
Referring again to FIG. 11C, in one example implementation, in addition to (or
instead of) the projections extending from the floor or ceilings of the
overflow channel 1104,
some projections may extend from the inner walls of the overflow channel 1104.
As shown
more clearly in FIG. 11F, a projection may extend from an inner wall of the
overflow channel
1104 at the same constriction point 1111a, where two additional projections
extend from the
floor and the ceiling of the overflow channel 1104 to form a C-shaped
constriction point 1111a.
The example implementation illustrated in FIGS. 11D and 11F may more
effectively tune the
microfluidic properties of the overflow channel 1104 to encourage liquid flow
to retract toward
the storage chamber 1340 relative to the implementation in FIG. 11C, because
the hydraulic
diameter of the overflow channel 1104 is more constricted (i.e., narrowed) at
the constriction
point 1111a shown in FIGS. 11D and 11F.
[0356] The
projections formed along the overflow channel 1104 need not be uniform in
shapes, size, frequency, or symmetry. That is, depending on implementation,
different
constriction points 1111a or 1111b may be implemented in different sizes,
designs, shapes,
locations or frequency along the overflow channel 1104. In one example, the
shape of a
constriction point 1111a or 1111b may be similar to the shape of the letter C
with a round
internal diameter. In some embodiments, instead of a forming the internal
diameter as a
rounded C shape, the internal wall of the constriction point may have corners
(e.g., sharp
corners) such as those shown in FIGS. 11F and 11G.
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103571 In some
examples, the overflow channel 1104, at a first level, may have projections
extending from the ceiling of the overflow channel 1104, whereas at a second
level, the
projections may extend from the floor of the overflow channel 1104. At a third
level, the
projections may extend from the inner walls, for example. Alternatives of the
above
implementations may be possible by adjusting or changing the number of
projections and
shapes of projections or the positioning of the projections in different
sequences or levels to
help control the microfluidic effect on flow in the two directions within the
overflow channel
1104. In one example, constriction points 1111a may be implemented on one or
more (or all)
levels, sides, or widths of the collector 1313, for example.
[0358]
Referring to FIGS. 11E and 11G, in addition to defining constriction points
1111a
along longer length of the overflow channel 1104, or a wider side of the
collector 1313, one or
more extra constriction points 1111b may be defined along the narrower side of
the collector
1313. As such, the example implementation illustrated in FIGS. 11E and 11G may
improve
the adjusting of resistance to or encouragement of meniscus detachment in a
desired direction
in the overflow channel 1104 as compared to the implementation in FIG. 11D,
because the
overall hydraulic diameter (or flow volume) of the overflow channel 1104 is
more constricted
due to the addition of extra constriction points 1111b.
[0359]
Referring to FIGS. 11F and 11G, for better clarity, each full level in the
illustrated
example may include three constriction points 1111a on each side, in addition
to two more
constriction points 1111b, for example. Thus, the collector 1313 of FIG. 11D
may include a
total of 18 constrictions points, whereas the collector 1313 of FIG. 11E may
include a total of
26 constriction points. In this example, the embodiments illustrated in FIG.
11E provide for
an improved microfluidic flow control (e.g., in the outward direction) due to
the capillary
pressure being reinforced at the multiple constriction points 1111a and 1111b.
[0360]
Referring to FIG. 11H, in some embodiments, the gate 1102 may be constructed
to
include an aperture or opening configuration that, similar to a constriction
point 1111a or
1111b, has a tapered edge, rim, or flange that is more flat in one direction.
For example, the
rim of the gate 1102 aperture may be shaped to be flat on one side (e.g., the
side facing towards
the storage chamber 1342) and rounded on another side (e.g., the side facing
away from the
storage chamber 1342). In such a configuration, the microfluidic forces
encouraging flow back
toward the storage chamber 1340 over flow away from the storage chamber 1340
may be
enhanced due to easier meniscus detachment on the less-rounded side relative
to the more-
rounded side.
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[0361]
Accordingly, depending on implementation and variations in the structure or
construction of the constriction points and the gate 1102, the resistance to
flow of vaporizable
material 1302 out of the collector 1313 may be higher than the resistance to
flow of vaporizable
material 1302 into the collector 1313 and toward the storage chamber 1340. In
certain
implementations, the gate 1102 is constructed to maintain a liquid seal such
that a layer of
vaporizable material 1302 is present at the medium where the storage chamber
1342
communicates with the overflow channel 1104 in the overflow volume 1344. The
presence of
a liquid seal may help maintain a pressure equilibrium between the storage
chamber 1342 and
the overflow volume 1344 to promote a sufficient level of vacuum (e.g.,
partial vacuum) in the
storage chamber 1342 to prevent vaporizable material 1302 from completely
draining into the
overflow volume 1344, as well as avoiding the wicking element 1362 being
deprived of
adequate saturation.
[0362] In one
or more example implementations, a single passageway or channel in the
collector 1313 may be connected to the storage chamber 1342 by way of two
vents, such that
the two vents maintain a liquid seal regardless of the positioning of the
cartridge 1320. The
formation of a liquid seal at the gate 1102 may also help prevent the air in
the collector 1313
from entering the storage chamber 1342 even when the cartridge 1320 is held
diagonally with
respect to the horizon or when the cartridge 1320 is positioned with the
mouthpiece facing
downward. This is because if air bubbles from the collector 1313 enter the
reservoir, the
pressure inside the storage chamber 1342 will be equalized with that of
ambient pressure. That
is, the partial vacuum inside the storage chamber 1342 (e.g., created as a
result of vaporizable
material 1302 being drained through the wick feeds 1368) would be offset, if
ambient air flows
into the storage chamber 1342.
[0363]
Referring to FIGS. 111 through 11K, perspective views of alternative gate 1102
configurations for the collector 1313 structure are provided. These
alternative configurations
may provide advantages relating to air and/or liquid vaporizable material 1302
flow
management and control. In some scenarios, headspace vacuum may not be
maintained when
the empty space (i.e., the headspace above the vaporizable material 1302) in
the storage
chamber 1342 contacts the gate 1102. As a result, as noted earlier, the liquid
seal established
at the gate 1102 may be broken. This effect may be due to the gate 1102 being
unable to
maintain a fluidic film as the collector 1313 is drained and headspace comes
into contact with
the gate 1102, leading to a loss of partial headspace vacuum.
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[0364] In
certain embodiments, the headspace in the storage chamber 1342 may have
ambient pressure and if there exists a hydrostatic offset between the gate
1102 and the atomizer
in the cartridge 1320, the contents of the storage chamber 1342 drain into the
atomizer resulting
in wick-box flooding and leaking. To avoid leakage, one or more embodiments
may be
implemented to remove the hydrostatic offset between the gate 1102 and the
atomizer and
maintain gate 1102 functionality when the storage chamber 1342 is nearly
drained.
[0365] As
shown in the example embodiments of FIGS. 111 and 11J, miniaturized divider
walls or maze-shaped structures 1190 may be constructed around the gate 1102
to establish a
high-drive connection between the gate 1102 and the overflow channel 1104 in
the collector
1313 to maintain the liquid seal at the gate 1102. In the example of FIG. 11
J, a moat-shaped
structure 1190 is shown as a means to further improve the maintenance of the
liquid seal at the
gate 1102 in accordance with one or more implementations.
Controlled Fluidic Gate Embodiments
[0366] FIGS.
11L through 11N illustrate planar and close-up views of a controlled fluidic
gate 1102 in the collector 1313 structure, in accordance with one or more
implementations. As
shown, the passageway or overflow channel 1104 in the collector 1313 may be
connected to
the storage chamber 1342 by way of a V-shaped or horn-shaped controlled
fluidic gate 1102,
for example, such that the V-shaped gate 1102 includes at least two (and
desirably three)
openings that are connected to the storage chamber 1342. As provided in
further detail herein,
a liquid seal may be maintained at the gate 1102 regardless of the vertical or
horizontal
orientation of the cartridge 1320.
[0367] As
shown in FIG. 11L, on a first side of the vent, a vent pathway may be
maintained
between the overflow channel 1104 and the gate 1102 through which air bubbles
can escape
from the overflow channel 1104 in the collector into the reservoir. On a
second side, one or
more high-drive channels connected to the reservoir may be implemented to
encourage pinch-
off at a pinch-off point 1122 to maintain a liquid seal that prevent the
premature venting of air
bubbles out of the overflow channel 1104 and into the reservoir, as well as
the undesirable
entry of air or vaporizable material 1302 into the overflow channel 1104 from
the reservoir.
[0368]
Depending on implementation, the high-drive channels, shown by way of example
on the right side of FIG. 11L, are preferably maintained sealed due to the
capillary pressure
exerted by the liquid vaporizable material 1302 in the cartridge reservoir.
The low-drive
channels formed on the opposite side (i.e., shown on left side in FIG. 11L)
may be configured
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to have a relatively lower capillary drive in comparison to the high-drive
channels but still have
a sufficient capillary drive such that in, a first pressure state, a liquid
seal is maintained in both
the high-drive channels and the low-drive channels.
[0369]
Accordingly, in the first pressure state (e.g., when the pressure inside the
reservoir
is approximately equal to or more than the ambient air pressure), then a
liquid seal is maintained
in both the low-drive and high-drive channels, preventing any air bubbles from
flowing into
the reservoir. Conversely, in a second pressure state (e.g., when the pressure
inside the
reservoir is less than the ambient air pressure), air bubbles formed in the
overflow channel 1104
(e.g., by way of entry through the air exchange port 1106), or more generally
a leading
meniscus edge of a liquid vaporizable material-air interface may travel up and
toward the
controlled fluidic gate 1102. As the meniscus reaches the pinch-off point 1122
positioned
between the low-drive and high-drive channels of the vent 1104, the air is
preferentially routed
through the low-drive channel or channels, due to a higher capillary
resistance being present in
the high-drive channel(s).
[0370] Once
the air bubbles have passed through the low-drive channel portion of the gate
1102, the air bubbles enter the reservoir and equalize the pressure inside the
reservoir with that
of ambient air. As such, the air exchange port 1106 in combination with the
controlled fluidic
gate 1102 allows for the ambient air entering through the overflow channel
1104 to pass
through into the reservoir, until an equilibrium pressure state is established
between the
reservoir and the ambient air. As noted earlier, this process may be referred
to as the reservoir
venting. Once an equilibrium pressure state is established (e.g., a transition
from a second
pressure state back to a first pressure state) then a liquid seal is again
established at the pinch-
off point 1122, due to the presence of liquid in both the high-drive channels
and the low-drive
channels that are fed by the liquid vaporizable material 1302 stored in the
reservoir.
[0371] FIGS.
110 through 11X illustrate snapshots in time as the flow of air, collected in
the example collector 1313 of FIGS. 11L through 11N, is managed to accommodate
proper
venting as the meniscus of vaporizable material 1302 continues to recede.
[0372] FIG.
110 illustrates a receding meniscus where, as vaporizable material 1302 is
removed from the reservoir into the wick, the partial headspace vacuum
increases in strength.
This is sufficient to overcome the receding capillary drive of the meniscus,
moving the
meniscus back through the collector towards the constriction point where the
meniscus will see
the highest pressure differential across as dictated by the geometry.
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[0373] FIG.
11P illustrates how the meniscus crosses a first joint in the gate 1102, as
the
meniscus approaches the gate 1102. At this first joint, the headspace partial
vacuum is
maximized as it corresponds to the smallest geometry in the gate 1102
structure, and partial
vacuum in the reservoir continues to grow until this point.
[0374] FIG.
11Q illustrates how multiple menisci recede as the headspace reaches the
maximum partial vacuum. The menisci are at their tightest curvature across
their principal
planes and at these locations the drain pressures of the three channels are
equal and three
menisci recede simultaneously as opposed to solely from one channel. As the
curvature of
these menisci are now increasing as they recede, the pressure difference
sustained across them
decreases and the headspace partial vacuum thus begins to decrease.
[0375] FIG.
11R illustrates how secondary menisci begin to fill the capillary channels.
The
tapers on these channel geometries are such that as the menisci continue to
recede, the capillary
drive of the primary channel decreases at a greater rate than that of the
secondary channels.
This gradual reduction in capillary drive will reduce the partial headspace
vacuum maintained.
When the drain pressure of the primary meniscus drops below the drain pressure
of the
secondary channels, this meniscus will continue to drain while the other
menisci remain static.
The drain pressure, involving the receding contact angle of the primary
channel, may drop
below the flooding pressure, involving the advancing contact angle of the
secondary channels,
causing them to refill as shown in the figures.
[0376] FIG.
11S illustrates how secondary menisci from one of the two menisci in each
secondary channel will reach a point of tangency where the two menisci merge
to become one.
This combined meniscus will have increased curvature and thus a lower
capillary drive. The
higher drive of the primary meniscus may cause the system to momentarily react
by making
the primary meniscus the advancing meniscus. Subsequent receding of the
primary meniscus
will likely occur with the secondary meniscus held at this location.
[0377] FIG.
11T illustrates how the secondary meniscus moves towards the collector. In
a scenario when the storage chamber is full of liquid, the primary meniscus
will continue to
recede, further reducing the headspace partial vacuum as its curvature
increases. As the partial
vacuum drops below the advancing capillary pressure of the secondary meniscus,
the secondary
meniscus will begin to proceed once more, driving to close the gap. In a
scenario when the
storage chamber is empty or near empty, the liquid seal at the gate 1102 will
be stable until the
bubble ruptures, connecting the headspace to ambient.
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[0378] FIG.
11U illustrates how the secondary meniscus closes the joint at the gate 1102.
As the secondary meniscus will advance until it meets the apex of the corner
in the primary
channel, the geometry is designed to encourage the secondary meniscus to split
to fill both the
gate 1102 and the collector 1313 channels. These two newly formed menisci may
act to isolate
the headspace from ambient air and thus a headspace partial vacuum can be re-
established,
ensuring that leaking via the liquid feed channels is mitigated. As the newly
formed menisci
have smaller curvatures than prior to splitting, the newly formed menisci will
continue to
proceed into the channels due to increased capillary drive.
[0379] FIGS.
11V through 11X illustrate bubble release into the storage chamber 1342.
The pressure within the cartridge 1320 at this point reaches stability as the
air bubble trapped
in the main meniscus channel is ejected by the imbalance created by the
advancing and receding
menisci. Vaporizable material 1302 is then allowed to enter and displace the
bubble through
the right top channel. Accordingly, while a high drive channel structure may
be provided via
a closed moat near the gate 1102, a shorter moat may be instead utilized to
reduce the risk of
bubbles becoming trapped.
[0380] In some
implementations, tapered channels may be designed to increase drive
towards the controlled vent. Considering the pinch-off of the two advancing
menisci, the
reservoir's tank wall and channel bottom may be configured to continue to
provide drive, while
the sidewalls provide a pinch-off location for the menisci. In one
configuration, the net drive
of the advancing menisci does not exceed that of the receding menisci, thus
maintaining the
system statically stable.
Multi-gate Multi-channel Collector Embodiments
[0381]
Referring to FIGS. 12A and 12B, an example perspective side view and an
example
planar side view of embodiments of a single-vent, multi-channel collector 1200
structure are
illustrated. As shown in FIG. 12A, the collector 1200 is formed to have a
single gate 1202 and
multiple channels 1204(a) through 1204(j). As shown in FIG. 12A, in accordance
with one or
more implementations, the gate 1202 may be positioned at for example a central
or midpoint
of the longitudinal width of the collector 1313 to allow vaporizable material
1302 to enter at
least a first channel 1204(a) of the collector 1313 and gradually spread into
and through
additional channels 1204(b)-1204(j).
[0382]
Position of the gate 1202 may be modified depending on implementation to be in
the middle, side or a corner or any other location along the length or width
of the collector
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1313. A single-vent, multi-channel collector 1200 structure may have the added
advantage of
allowing the vaporizable material 1302 to enter through a single gate 1202 at
a first flow rate
and spread at a second flow rate (e.g., a faster rate than the first rate)
through multiple channels
1204(a)-1204(j) of the collector 1200.
[0383]
Advantageously, a single-gate, multi-channel collector 1200 structure allows
for
controlled flow (e.g., restricted flow) of the vaporizable material 1302 from
the storage
chamber 1342 into the overflow volume 1344 (see FIG. 3A) and further allows
for a less
controlled (e.g., less restricted) flow once the vaporizable material 1302 is
in the overflow
volume 1344. In certain embodiments, a multi-tiered multi-channel structure
may be
implemented, such that, as shown in FIG. 12B, for example, the flow of the
vaporizable
material 1302 in a first set of channels 1204(a)-1204(f) is at a second rate
and the flow of the
vaporizable material 1302 in a second set of channels 1204(g)-1204(k) is at a
third rate. The
third rate may be faster or slower than the second rate.
[0384]
Accordingly, in the example embodiment show in FIG. 12B, the vaporizable
material 1302 may flow through the gate 1202 at a first rate, through channels
1204(a)-1204(f)
at a second rate, and through channels 1204(g)-1204(k) at a third rate. In one
or more
embodiments, the second rate may be faster than both the first rate and the
third rate, for
example, so that the vaporizable material 1302 may have a restricted flow
through the gate
1202, a less restricted flow through the first set of channels (e.g., tier 1)
and a relatively more
restricted flow in the second set of channels (e.g., tier 2). This multi-tier
configuration may
help improve flow rate through the collector 1200 but maintain a controllable
restriction against
a rapid flow of the vaporizable material 1302 toward the wicking element 1362,
once the
vaporizable material 1302 has entered the collector 1200
[0385] In the
double-tier embodiment shown in FIG. 12B, the first set of channels 1204(a)-
1204(f) (e.g., tier 1) may have reversible configuration such that the
vaporizable material 1302
collected in the first set of channels may flow back to the reservoir 1340.
The second set of
channels 1204(g)-1204(k) (e.g., tier 2), conversely, may not have reversible
configurations. In
such embodiments, because of the proximity of the second set of channels to
the wicking
element 1362, the vaporizable material 1302 is primarily drawn from the second
set of channels
and then from the first set of channels (e.g., tier 1 acting as a reserve
compartment). Having a
reversible and nonreversible construction, as discussed above, may help
provide additional
improvements over the other embodiments discussed herein.
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[0386] In some
multi-tiered embodiments, by configuring the second set of channels
1204(g)-1204(k) as nonreversible, there may be an extra assurance that the
wicking element
1362 will not be starved as the vaporizable material 1302 may be available at
a close proximity
to the wicking element 1362 when stored in the second set of channels 1204(g)-
1204(k) during
an overflow event. Further, the chance for a strong flow of the vaporizable
material 1302 into
the wick housing during a negative pressure event may be prevented in multi-
tiered
implementations, because as provided earlier the second set of channels
1204(g)-1204(k) may
be configured to have a more restrictive flow as compared to the first set of
channels 1204(a)-
1204(f). Further, due to reversibility, the first set of channels 1204(a)-
1204(f) may not contain
a relatively large volume of the vaporizable material 1302. In some
embodiments, in order to
increase or limit the reversibility or the flow of the vaporizable material
1302 in the first set of
channels 1204(a)-1204(f) or the second set of channels 1204(g)-1204(k),
absorbent material
(e.g., sponges) may be introduced into one or both channel areas.
[0387]
Referring to FIG. 13, an example perspective side view of a multi-vent, multi-
channel collector 1300 structure is illustrated, in accordance with one or
more implementations.
As shown, the collector 1300 may be positioned inside a cartridge such that
the collector 1300
has dual vents 1301. This implementation may allow for the vaporizable
material 1302 to flow
into the channels 1204 at a relatively faster rate, particularly in comparison
to a single-vent
collector 1200 shown in FIGS. 21A and 12B.
Wick Feed Embodiments
[0388]
Referring back to FIGS. 10C, 10D, 11B, in certain variations, the collector
1313
may be configured to be insertably received by a receiving end of the storage
chamber 1342.
The end of the collector 1313 that is opposite to the end that is received by
the storage chamber
1342 may be configured to receive a wicking element 1362. For example, fork-
shaped
projections may be formed to securely receive the wicking element 1362. A wick
housing
1315 may be used to further secure the wicking element 1362 in a fixed
position between the
projections. This configuration may also help prevent the wicking element 1362
from
substantial swelling and becoming weak due to over saturation.
[0389]
Referring to FIGS. 11C, 11D, and 11E, depending on implementation, one or more
additional ducts, channels, tubes or cavities that travel through the
collector 1313 and may be
constructed or configured as paths that feed the wicking element 1362 with
vaporizable
material 1302 stored in the storage chamber 1342. In certain configurations,
such as those
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discussed in further detail herein, the wick feeding ducts, tubes or cavities
(i.e., wick feeds
1368) may run approximately parallel to the central tunnel 1100. In at least
one configuration,
multiple wick feeds may be present that run diagonally along the length of the
collector 1313,
for example, either independently or in connection with a wick exchange,
including one or
more other wick feeds.
[0390] In
certain embodiments, a plurality of wick feeds may be interactively connected
in
a multi-linked configuration such that an interchange of feeding paths,
possibly crossing one
another, may lead to the wick housing area. This configuration may help
prevent complete
blockage of the wick feeding mechanism if, for example, one or more feeding
paths in the wick
feed interchange are obstructed by way of the formation of gas bubbles or
other types of
clogging. Advantageously, instrumentation of multiple feeding paths may allow
for
vaporizable material 1302 to safely travel through one or more paths (or
crossover to a different
but open path) toward the wick housing area, even if some of the paths or
certain routes in the
wick feed interchange are fully or partially clogged or blocked.
[0391]
Depending on implementation, a wick feed path may be shaped to be tubular
with,
for example, a circular or multifaceted cross-diameter shape. For example, the
hollow cross-
section of the wick feed may be triangular, rectangular, pentagonal or in any
other suitable
geometrical shape. In one or more embodiments, the cross-sectional perimeter
of the wick feed
may be in shape of a hollow cross, for example, such that the arms of the
cross have a narrower
width in relationship to the diameter of the central crossover portion of the
cross from which
the arms extend. More generally, a wick feed channel (also referred to herein
as a first channel)
may have a cross-sectional shape with at least one irregularity (e.g., a
protrusion, a side channel,
etc.) that provides an alternative path for liquid vaporizable material to
flow through in the
even that an air bubble blocks the remainder of the cross-sectional area of
the wick feed. The
cross-shaped cross-section of the current example is an example of such a
structure, but a
skilled artisan will understand that other shapes are also contemplated and
feasible consistent
with the current disclosure.
[0392] A cross-
shaped duct or tube implementation that is formed through a wick feed path
may overcome clogging problems because a cross-shaped tube may be essentially
considered
as including five separate pathways (e.g., a central pathway formed at the
hollow center of the
cross and four additional pathways formed in the hollow arms of the cross). In
such
implementation, a blockage in the feeding tube by way of a gas bubble, for
example, will likely
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be formed at the central portion of the cross-shaped tube, leaving sub-
pathways (i.e., pathways
that go through the arms of the cross-shaped tube) open to flow.
[0393] In
accordance with one or more aspects, wick-feeding pathways may be sufficiently
wide to allow for free travel of vaporizable material 1302 through the feeding
pathways and
toward the wick. In some embodiments, the flow through the wick feed may be
enhanced or
accommodated by way of devising the relative diameter of certain portions of
the wick feed to
enforce capillary pull or pressure on the vaporizable material 1302 travelling
through a wick
feed path. In other words, depending on the shape and other structural or
material factors, some
wick feeding pathways may rely on gravitational or capillary forces to induce
movement of
vaporizable material 1302 toward the wick-housing portion.
[0394] In the
cross-shaped tube implementation, for example, the feeding paths that go
through the arms of the cross-shaped tube may be configured to feed the wick
by way of
capillary pressure instead of reliance on gravitational force. In such
implementation, the central
portion of the cross-shaped tube may feed the wick due to gravitational force,
for example,
while the flow of vaporizable material 1302 in the arms of the cross-shaped
tube may be
supported by capillary pressure. It is noted that the cross-shaped tube
disclosed herein is for
the purpose of providing an example embodiment. The concepts and functionality
implemented in this example embodiment may be extended to wick feed paths with
different
cross-sectional shapes (e.g., tubes with hollow star-shaped cross-sections
having two or more
arms extending from a central tunnel running along a wick feed path).
[0395]
Referring to FIG. 11C, an example collector 1313 construction is illustrated
in
which two wick feeds 1368 are positioned on two opposite sides of the central
tunnel 1100
such that vaporizable material 1302 may enter the feeds and flow directly
towards the cavity
area at the other end of the collector 1313, where the housing for the wick is
formed.
[0396] Wick
feed mechanisms may be formed through the collector 1313 such that at least
one wick feed path in the collector 1313 may be shaped as a multifaceted cross-
diameter hollow
tube. For example, the hollow cross-section of the wick feed may be in shape
of a plus sign
(e.g., a hollow cross-shaped wick feed if viewed from a top cross-sectional
view), such that the
arms of the cross have a narrower width in relationship to the diameter of the
central crossover
portion of the cross from which the arms extend.
[0397] A duct
or tube with a cross-shaped diameter formed through a wick feed path may
overcome clogging problems because a tube with a cross-shaped diameter may be
considered
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as including five separate pathways (e.g., a central pathway formed at the
hollow center of the
cross and four additional pathways formed in the hollow arms of the cross). In
such
implementation, a blockage in the feeding tube by way of a gas bubble (e.g.,
air bubble) will
likely be formed at the central portion of the cross-shaped tube.
[0398] Such
central positioning of the gas bubble would ultimately leave sub-pathways
(i.e., pathways that go through the arms of the cross-shaped tube) that remain
open to flow of
vaporizable material 1302, even when the central path is blocked by the gas
bubble. Other
implementations for a wick feed passageway structure are possible that can
accomplish the
same or similar objective as that disclosed above with respect to trapping gas
bubbles or
avoiding trapped gas bubbles from fully clogging the wick feed passageway.
[0399] The
addition of more vents in the structure of the collector 1300 may allow for
faster
flow rates, depending on implementation, as a relatively larger collective
volume of the
vaporizable material 1302 may be displaced when additional vents are
available. As such, even
though not explicitly shown, embodiments with more than two vents (e.g.,
triple-vent
implementations, quadruple-vent implementations, etc.) are also within the
scope of the
disclosed subject matter.
[0400]
Referring to FIGS. 14A and 14B, certain embodiments may include a collector
1400
structure with dual feeds for the wick. In such embodiments, the wick may have
a higher
saturation level and less starvation chance in comparison to an embodiment in
which a single
feed is provided.
[0401]
Referring to FIGS. 15A, 15B, and 15C, perspective and cross-sectional planar
side
views of an example collector structure for a dual feed wick 1562 are
provided. As shown, a
wick or wick 1562 may be disposed or housed in a cartridge 1500, such that at
least two
separate wick feeds 1566 and 1568 are provided to allow for the vaporizable
material 1302 to
travel toward an area of the cartridge 1500 where the wick 1562 is housed.
[0402] As
noted earlier, a dual wick feed may have the advantage of providing the wick
1562 with, for example, twice the flow of the vaporizable material 1302 in
comparison to a
single wick feed alternative. Advantageously, a dual wick feed implementation
provides ample
feed to the wick 1562 and helps prevent a dry wick 1562 if, for example, one
of the wick feeds
is blocked. As shown, a lower portion of the wick 1562 may extend down into an
area of the
cartridge 1500 that forms the heating chamber or the atomizer.
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[0403]
Referring to FIG. 16A, a cross-sectional planar side view of an example
cartridge
is provided in which a dual-horn or dual feed wick 1562 is positioned within a
collector
structure. FIG. 16B is a planar cross-sectional side view of an example
collector structure in
which a wick 1562 may be housed. FIG. 16C provides an example perspective view
of the
cartridge, in accordance with one or more implementations. As shown, a first
end of the wick
1562 may have two or more feeds, horns, or flanged ends for at least partially
engaging two or
more wick openings in a partition 1513 such that at least one of the flanged
ends, for example,
tangentially engages a volume in the storage chamber 1542 or, for example, at
least partially
extends into the volume in the storage chamber 1542.
[0404] In
accordance with one or more implementations, the cartridge 1500 may include a
reservoir with a storage chamber 1542 for storing the vaporizable material
1302. A secondary
volume 1510 separable from the storage chamber 1542 may be also formed inside
the cartridge
1500. The secondary volume 1510 may be in communication with the storage
chamber 1542
via one or more wick feeds 1590. The secondary volume 1510 may be configured
to at least
house a wick 1562. The wick 1562 may be configured to absorb the vaporizable
material 1302
traveling through the wick feed 1590 such that, in thermal interaction with an
atomizer, the
vaporizable material 1302 is absorbed in the wick 1562 and is converted to at
least one of vapor
or aerosol.
[0405] The
wick 1562 may be at least partially confined by one or more heating elements
of an atomizer positioned within the secondary volume 1510 A partition 1513
for at least
partially separating the storage chamber 1542 from the secondary volume 1510
may be
provided so that flow of the vaporizable material 1302 through the wick feeds
1590 is
controllable. At least a first portion of the wick feed 1590 may be formed by
at least one or
more openings in the partition 1513.
[0406] At
least a second portion of the wick feed 1590 may include a vaporizable
material
passageway connecting the one or more openings in the partition 1513 to the
secondary volume
1510. An airflow passageway 1538 may be provided for connecting the secondary
volume
1510 to a mouthpiece such that the vaporizable material 1302, which has been
converted into
vapor, travels out of the secondary volume 1510 toward the mouthpiece through
the airflow
passageway 1538.
[0407]
Referring to FIGS. 16A, 16B, 16C, 17A, and 17B, a perspective view of a first
side
of a cartridge and a cross-sectional view of a second side of the cartridge
having a wick 1562
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that protrudes into the storage chamber 1542 are provided. The wick 1562 may
include at least
a first end 1592 and a second end 1594, the first end 1592 proximate to the
partition 1513 and
the second end extending distally in an opposite direction to the first end
1592.
[0408] A first
end 1592 of the wick 1562 may at least partially protrude through a wick
opening in the partition 1530 to at least partially extend into a volume in
the storage chamber
1542. In one aspect, the first end 1592 of the wick 1562 may at least
partially protrude through
a wick opening in the partition 1530 to at least tangentially engage a volume
in the storage
chamber 1542.
[0409] FIG.
26A illustrates perspective, frontal, side, bottom and top views of an example
embodiment of a collector 1313 with a V-shaped gate 1102. As shown in FIGS. 25
and 26, the
collector 1313 may be fitted inside a hollow cavity in the cartridge 1320
along with the
additional components (e.g., wicking element 1362, heating element 1350, and
wick housing
1315). The wicking element 1362 may be positioned between a second end of the
collector
1313 with the heating element 1350 wrapped around the wicking element 1362.
During
assembly, the collector 1313, wicking element 1362 and heating element 1350
may be fit
together and covered by the wick housing 1315 before being inserted into the
cavity inside the
cartridge 1320.
[0410] The
wick housing 1315 may be inserted along with the other noted components into
an end of the cartridge 1320 that is opposite to the mouthpiece to hold the
components inside
in a pressure-sealed or pressure-fit manner. The seal or fit of the wick
housing 1315 and
collector 1313 inside the inner walls of the receiving sleeve of the cartridge
1320 is desirably
sufficiently tight to prevent leakage of vaporizable material 1302 held in the
reservoir of the
cartridge 1320. In some embodiments, the pressure seal between the wick
housing 1315 and
the collector 1313 and the inner walls of the receiving sleeve of the
cartridge 1320 is also
sufficiently tight to prevent the manual disassembly of the components with a
user's bare
hands.
[0411]
Referring to FIGS. 10C, 10D, 11B, 26B, and 26C, in certain variations, a
collector
1313 may be configured to be insertably received by a receiving end of a
storage chamber
1342. As shown in FIGS. 26B and 26C, the end of the collector 1313 that is
opposite to the
end that is received by the storage chamber 1342 may be configured to receive
a wicking
element 1362. For example, fork-shaped projections 1108 may be formed to
securely receive
the wicking element 1362. A wick housing 1315, as shown in the cross-sectional
views toward
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the bottom of FIGS 26B and 26C, may be used to further secure the wicking
element 1362 in
a fixed position between the fork-shaped projections 1108. This configuration
may also help
prevent the wicking element 1362 from substantial swelling and weakening due
to over
saturation.
[0412]
Referring to FIG. 26B, in one embodiment, a wicking element 1362 may be
constrained or compressed in certain locations along its length (e.g., toward
the longitudinal
distal ends of the wicking element 1362 positioned directly under wick feeds
1368) by way of
compression ribs 1110 to help prevent leakage by, for example, maintaining a
larger saturation
area of the vaporizable material 1302 toward the ends of the wicking element
1362, so that the
central part of the wicking element 1362 remains more dry and less leak prone.
Further, use
of compression ribs 1110 may further press the wicking element 1362 into the
atomizer housing
to prevent leakage into the atomizer.
[0413]
Referring to FIGS. 26D through 26F, top planar views of example wick feed
mechanisms formed by or structured through the collector 1313 are illustrated,
in accordance
with one or more implementations. As shown in FIG. 26D, at least one wick feed
1368 path
in the collector 1313 may be shaped as a multifaceted cross-diameter hollow
tube. For
example, the hollow cross-section of the wick feed 1368 path may be in shape
of a plus sign
(e.g., a hollow cross-shaped wick feed if viewed from a top cross-sectional
view), such that the
arms of the cross have a narrower width in relationship to the diameter of the
central crossover
portion of the cross from which the arms extend.
[0414]
Referring to FIG. 26E, a duct or tube with a cross-shaped diameter formed
through
a wick feed 1368 path may overcome clogging problems because a tube with a
cross-shaped
diameter may be considered as including five separate pathways (e.g., a
central pathway
formed at the hollow center of the cross and four additional pathways formed
in the hollow
arms of the cross). In such implementation, a blockage in the feeding tube by
way of a gas
bubble (e.g., air bubble) will likely be formed at the central portion of the
cross-shaped tube as
shown in FIG. 26E. Such central positioning of the gas bubble would ultimately
leave sub-
pathways (i.e., pathways that go through the arms of the cross-shaped tube)
that remain open
to flow of vaporizable material 1302, even when the central path is blocked by
the gas bubble.
[0415]
Referring to FIG. 26F, other implementations for a wick feed 1368 path
structure
are possible that can accomplish the same or similar objective as that
disclosed above with
respect to trapping gas bubbles or avoiding trapped gas bubbles from fully
clogging the wick
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feed 1368 path. As shown in the example illustration of FIG. 26F, one or more
droplet-shaped
projections 1368a / 1368b (e.g., similar in shape to one or more separated
nipples with a wick
feed 1368 path therebetween) may be formed at an end of the wick feed 1368
path through
which vaporizable material 1302 flows from the storage chamber 1342 into the
collector 1313
to help lead the vaporizable material 1302 through the wick feed 1368 path, if
a gas bubble is
trapped in the central region of the wick feed 1368 path. In this manner, a
reasonably
controllable and consistent flow of vaporizable material 1302 may be streamed
towards the
wick, preventing a scenario in which the wick is inadequately saturated with
the vaporizable
material 1302.
Heating Element Embodiments
[0416]
Referring to FIGS. 18A-18D, the vaporizer cartridge 1800 may also include a
heating element 1850 (e.g., a flat heating element(, as noted above. The
heating element 1850
includes a first portion 1850A positioned approximately in parallel with the
airflow
passageways 1838 and a second portion 1850B positioned approximately
perpendicular to the
airflow passageways 1838. As shown, the first portion 1850A of the heating
element 1850
may be positioned between opposite portions of a collector 1813. When the
heating element
1850 is activated, a temperature increase results due to current flowing
through the heating
element 1850 to generate heat, for example.
[0417] The
heat may be transferred to some amount of the vaporizable material 1302
through conductive, convective, and/or radiative heat transfer such that at
least a portion of the
vaporizable material 1302 vaporizes. The heat transfer can occur to
vaporizable material 1302
in the reservoir, to vaporizable material 1302 drawn from the collector 1813,
and/or to
vaporizable material 1302 drawn into a wick retained by the heating element
1850. The air
passing into the vaporizer device flows along an air path across the heating
element 1850,
stripping away the vaporized vaporizable material 1302 from the heating
element 1850, and/or
wick. The vaporized vaporizable material 1302 can be condensed due to cooling,
pressure
changes, etc., such that it exits the mouthpiece 1830 through at least one of
the airflow
passageways 1838 as an aerosol for inhalation by a user.
[0418]
Referring to FIGS. 19A-19C, a vaporizer cartridge 1900 may include a folded
heating element 1950 and two airflow passageways 1938. As mentioned above, the
heating
element 1950 may be crimped around a wick 1962 or preformed to receive the
wick 1962. The
heating element 1950 may include one or more tines 1950A. The tines 1950A may
be located
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in a heating portion of the heating element 1950 and are designed so that the
resistance of the
tines 1950A matches the appropriate amount of resistance to influence
localized heating in the
heating element 1950 to more efficiently and effectively heat the vaporizable
material 1302
from the wick 1962.
[0419] The
tines 1950A form thin path heating segments or traces in series and/or in
parallel to provide the desired amount of resistance. The particular geometry
of the tines 1950A
may be desirably selected to produce a particular localized resistance for
heating the heating
element 1950. For example, the tines 1950A may include one or more of the
various tine
configurations and features described and discussed in more detail below.
[0420] When
the heating element 1950 is activated, a temperature increase results due to
current flowing through the heating element 1950 to generate heat. The heat is
transferred to
some amount of the vaporizable material 1302 through conductive, convective,
and/or radiative
heat transfer such that at least a portion of the vaporizable material 1302
vaporizes. The heat
transfer can occur to vaporizable material 1302 in the reservoir, to
vaporizable material 1302
drawn from the collector 1913, and/or to vaporizable material 1302 drawn into
the wick 1962
retained by the heating element 1950. In some implementations, the vaporizable
material 1302
can vaporize along one or more edges of the tines 1950A.
[0421] The air
passing into the vaporizer device flows along the air path across the heating
element 1950, stripping away the vaporized vaporizable material 1302 from the
heating
element 1950 and/or the wick 1962. The vaporized vaporizable material 1302 can
be
condensed due to cooling, pressure changes, etc., such that it exits the
mouthpiece through at
least one of the airflow passageways 1938 as an aerosol for inhalation by a
user.
[0422]
Referring to FIGS. 20A-20C, a vaporizer cartridge 2000 may include the folded
heating element 2050 and a single (e.g., central) airflow passageway 2038. As
mentioned
above, the heating element 2050 may be crimped around a wick 2062 or preformed
to receive
the wick 2062. The heating element 2050 may include one or more tines 2050A.
The tines
2050A may be located in a heating portion of the heating element 2050 and are
designed so
that the resistance of the tines 2050A matches the appropriate amount of
resistance to influence
localized heating in the heating element 2050 to more efficiently and
effectively heat the
vaporizable material from the wick 2062.
[0423] The
tines 2050A form thin path heating segments or traces in series and/or in
parallel to provide the desired amount of resistance. The particular geometry
of the tines 2050A
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may be desirably selected to produce a particular localized resistance for
heating the heating
element 2050. For example, the tines 2050A may include one or more of the
various tine
configurations described in more detail below.
[0424] When
the heating element 2050 is activated, a temperature increase results due to
current flowing through the heating element 2050 to generate heat. The heat is
transferred to
some amount of the vaporizable material 1302 through conductive, convective,
and/or radiative
heat transfer such that at least a portion of the vaporizable material 1302
vaporizes. The heat
transfer can occur to vaporizable material 1302 in the reservoir, to
vaporizable material 1302
drawn from the collector 2013, and/or to vaporizable material 1302 drawn into
the wick 2062
retained by the heating element 2050.
[0425] In some
implementations, the vaporizable material 1302 can vaporize along one or
more edges of the tines 2050A. The air passing into the vaporizer device flows
along the air
path across the heating element 2050, stripping away the vaporized vaporizable
material 1302
from the heating element 2050 and/or the wick 2062 The vaporized vaporizable
material 1302
can be condensed due to cooling, pressure changes, etc., such that it exits
the mouthpiece
through at least one of the airflow passageways as an aerosol for inhalation
by a user.
[0426]
Referring to FIGS. 10C, 11B and 21A, in some embodiments, the collector 1313
may be configured to include a flat rib 2102 that extends out at the lower
perimeter of the
collector 1313 to create a suitable surface to weld the collector 1313 to the
inner walls of the
storage chamber 1342, after the collector 1313 has been inserted into a
receiving cavity or
receptacle in the storage chamber 1342.
[0427]
Depending on implementation, a full perimeter weld or tack weld option may be
employed to firmly fix the collector 1313 within a receiving cavity or
receptacle in the storage
chamber 1342. In some embodiments, a friction-tight and leak-proof coupling
may be
established without employing a welding technique. In certain embodiments,
adhesive material
may be utilized instead of or in addition to the coupling techniques noted
above.
[0428]
Referring to FIGS. 11B and 21B, in accordance with one or more aspects, a seal
bead profile 2104 may be fashioned at the perimeter of collector 1313 spiral
ribs that define an
overflow channel 1104, such that the seal bead profile 2104 may support a
quick turn injection
molding process Seal bead profile 2104 geometry may be devised in a variety of
manners
such that the collector 1313 may be inserted into a receiving cavity or
receptacle in the storage
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chamber 1342 in a friction-tight manner, where vaporizable material 1302 may
flow through
the overflow channel 1104 without any leakage along the seal bead profile
2104.
[0429]
Referring to FIGS. 22A, 22B, and 82-86, a vaporizer cartridge 2200 may include
the folded heating element, such as heating element 500 and two airflow
passageways 2238.
As mentioned above, the heating element 500 may be crimped around a wick 2262
or
preformed to receive the wick 2262. The heating element 500 may include one or
more tines
502. The tines 502 may be located in a heating portion of the heating element
500 and are
designed so that the resistance of the tines 502 matches the appropriate
amount of resistance to
influence localized heating in the heating element 500 to more efficiently and
effectively heat
the vaporizable material 1302 from the wick 2262.
[0430] The
tines 502 form thin path heating segments or traces in series and/or in
parallel
to provide the desired amount of resistance. The particular geometry of the
tines 502 may be
desirably selected to produce a particular localized resistance for heating
the heating element
500. For example, the tines 502, and heating element 500 may include one or
more of the
various tine configurations and features described in more detail below.
[0431] In some
implementations, the tines 502 include a platform tine portion 524 and side
tine portions 526. The platform tine portion 524 is configured to contact one
end of the wick
2262 and the side tine portions 526 are configured to contact opposite sides
of the wick 2262.
The platform tine portion 524 and the side tine portions 526 form a pocket
that is shaped to
receive the wick 2262 and/or conform to the shape of at least a portion of the
wick 2262. The
pocket allows the wick 2262 to be secured and retained by the heating element
500 within the
pocket.
[0432] In some
implementations, the side tine portions 526 and the platform tine portion
524 retain the wick 2262 via compression. The platform tine portion 524 and
the side tine
portions 526 contact the wick 2262 to provide a multi-dimensional contact
between the heating
element 500 and the wick 2262. Multi-dimensional contact between the heating
element 500
and the wick 2262 provides for a more efficient and/or faster transfer of the
vaporizable
material 1302 from the reservoir of the vaporizer cartridge to the heating
portion (via the wick
2262) to be vaporized.
[0433] The
heating element 500 may include one or more legs 506 extending from the tines
502, and the cartridge contacts 124 formed at the end portion and/or as part
of at least one of
the one or more legs 506. The heating element 500 shown in FIGS. 22A-22B and
82-86
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includes four legs 506 by way of example. At least one of the legs 506 may
include and/or
define one of the cartridge contacts 124 that is configured to contact a
corresponding one of
the receptacle contacts 125 of the vaporizer. In some implementations, a pair
of legs 506 (and
the cartridge contacts 124) may contact a single one of the receptacle
contacts 125.
[0434] The
legs 506 may be spring-loaded to allow the legs 506 to maintain contact with
the receptacle contacts 125. The legs 506 may include a portion that is curved
to help maintain
contact with the receptacle contacts 125. Spring-loading the legs 506 and/or
the curvature of
the legs 506 may help increase and/or maintain consistent pressure between the
legs 506 and
the receptacle contacts 125. In some implementations, the legs 506 are coupled
with a support
176 to help increase and/or maintain consistent pressure between the legs 506
and the
receptacle contacts 125. The support 176 may include plastic, rubber, or other
materials to
help maintain contact between the legs 506 and the receptacle contacts 125. In
some
implementations, the support 176 is formed as a part of the legs 506.
[0435] The
legs 506 may contact one or more wiping contacts that are configured to clean
the connection between the cartridge contacts 124 and other contacts or power
source 112. For
example, the wiping contacts would include at least two parallel, but offset,
bosses that
frictionally engage and slide against one another in a direction that is
parallel or perpendicular
to the insertion direction.
[0436] In some
implementations, the legs 506 include retainer portions 180 that are
configured to be bent around at least a portion of a wick housing 178 that
surrounds at least a
portion of the wick 2262. The retainer portions 180 form an end of the legs
506. The retainer
portions 180 help to secure the heating element 500 and wick 2262 to the wick
housing 178
(and to the vaporizer cartridge).
[0437] When
the heating element 500 is activated, a temperature increase results due to
current flowing through the heating element 500 to generate heat. The heat is
transferred to
some amount of the vaporizable material 1302 through conductive, convective,
and/or radiative
heat transfer such that at least a portion of the vaporizable material 1302
vaporizes. The heat
transfer can occur to vaporizable material 1302 in the reservoir, to
vaporizable material 1302
drawn from the collector 2213, and/or to vaporizable material 1302 drawn into
the wick 2262
retained by the heating element 500.
[0438] In some
implementations, the vaporizable material 1302 can vaporize along one or
more edges of the tines 502. The air passing into the vaporizer device flows
along the air path
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across the heating element 500, stripping away the vaporized vaporizable
material 1302 from
the heating element 500 and/or the wick 2262. The vaporized vaporizable
material 1302 can
be condensed due to cooling, pressure changes, etc., such that it exits the
mouthpiece through
at least one of the airflow passageways 2238 as an aerosol for inhalation by a
user.
[0439] FIG. 23
illustrates a cross-sectional view of the wick housing 178, consistent with
implementations of the current subject matter. The wick housing 178 may
include a wick
support rib 2296 that extends from an outer shell of the wick housing 178
towards the wick
2262 when assembled. The wick support rib 2296 helps to prevent deformation of
the wick
2262 during assembly.
[0440] FIG. 24
illustrates an example of the wick housing 178 including an identification
chip 2295. The identification chip 2295 may be retained at least in part by
the wick housing
178. The identification chip 2295 may be configured to communicate with a
corresponding
chip reader located on the vaporizer.
[0441] FIG. 25
illustrates perspective, frontal, side and exploded views of an example
embodiment of a cartridge 1320 with pressure fitted components. As shown, the
cartridge 1320
may include a mouthpiece-reservoir combination shaped in the form of a sleeve
with an airflow
passageway 1338 defined through the sleeve. An area in the cartridge 1320
houses the collector
1313, the wicking element 1362, the heating element 1350, and the wick housing
1315. An
opening at a first end of the collector 1313 leads to the airflow passageway
1338 in the
mouthpiece and provides a route for the vaporized vaporizable material 1302 to
travel from the
heating element 1350 area to the mouthpiece from which a user inhales.
Additional and/or Alternative Fluidic Vent Embodiments
[0442]
Referring to FIGS. 27A through 27B, frontal planar close-up views of example
flow
management mechanisms in the collector 1313 structure are illustrated. Similar
to the flow
management mechanism discuss with reference to FIGS. 11M and 11N, flow
management vent
mechanisms 2701 or 2702 may be implemented in various shapes in different
embodiments.
In the example of FIG. 27A, the passageways or overflow channel 1104 in the
collector 1313
may be connected to the storage chamber by way of a fluidic vent 2701, for
example, such that
the vent 2701 includes at least two openings that are connected to the
cartridge's storage
chamber.
[0443] As
provided earlier, a liquid seal may be maintained at the vent 2701 regardless
of
the positioning of the cartridge. On one side, a vent pathway may be
maintained between the
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overflow channel and the vent 2701. On another side, high-drive channels may
be
implemented to encourage pinch-off to maintain a liquid seal.
[0444] FIG.
27B illustrates an alternative vent 2702 structure with three openings that
are
connected to the cartridge's storage chamber with a pinch-off path that
prevents the liquid seal
between the vent 2701 and the storage chamber from being broken.
[0445] FIG. 28
illustrates illustrate a snapshot in time when the flow of vaporizable
material collected in the example collector of FIGS. 27A or 27B is managed to
accommodate
proper venting in the cartridge storage chamber, in accordance with one
implementation. As
shown, the vent 2701 construction in FIG. 27A is distinguishable from the vent
2702
construction in FIG. 27B, in that the latter vent 2702 construction provides
for an open area on
one side, instead of the wall structure shown in FIG. 27A. This more open
implementation
provides for an enhanced microfluidic interaction between the vaporizable
material 1302 and
the open side of the vent 2702.
[0446]
Referring to FIGS. 29A through 29C, perspective, frontal and side views of an
example embodiment of a cartridge are illustrated. The cartridge as shown may
be assembled
from multiple components including a collector, a heating element, and a wick
housing for
holding the cartridge components in place as the components are inserted into
a body of a
cartridge. In one embodiment, a laser weld may be implemented at a
circumferential juncture
positioned at approximately the point at which one end of the collector
structure meets the wick
housing. A laser weld prevents the flow of liquid vaporizable material 1302
from the collector
into the heating chamber where the atomizer is placed.
[0447]
Referring to FIGS. 30A through 30F, perspective views of an example cartridge
at
different fill capacities are illustrated. As noted earlier, the volumetric
size of the overflow
volume may be configured to be equal to, approximately equal to or greater
than the amount
of increase in the volume of the content contained in the storage chamber.
When the volume
of the content in the storage chamber expands as a result of one or more
environmental factors,
if the volume of content contained in the storage chamber is X, when the
pressure inside the
storage chamber increases to Y, then Z amounts of vaporizable material 1302
may be displaced
from the storage chamber into the overflow volume. As such, in one or more
embodiments,
the overflow volume is configured to at least be large enough to contain Z
amounts of
vaporizable material 1302.
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[0448] FIG.
30A illustrates a perspective view of an example cartridge body having a
reservoir which, when filled, accommodates the storage of a volume of
approximately 1.20 mL
of vaporizable material 1302, for example. FIG. 30B illustrates a perspective
view of an
example cartridge in full assembly, wherein the storage chamber and the
collector overflow
passageways accommodate a combined volume of approximately 1.20 mL of
vaporizable
material 1302 when both are filled, for example. FIG. 30C illustrates a
perspective view of an
example cartridge in full assembly when the collector overflow passageway is
filled to an
approximate volume of 0.173 mL, for example. FIG. 30D illustrates a
perspective view of an
example cartridge in full assembly when the storage chamber is filled to an
approximate
volume of 0.934 mL, for example. FIG. 30E illustrates a perspective view of an
example
cartridge in full assembly with wick feed channels and airflow passageway in
the mouthpiece
shown in a cross-sectional view, the wick feed channels having a volume of
approximately
0.094 mL, for example. FIG. 30F illustrates a perspective view of an example
cartridge in full
assembly with an overflow air channel incorporated into a portion of the
collector toward the
bottom rib, the airflow air channel having an approximate volume of 0.043 mL,
for example.
[0449] FIGS.
31A through 31C illustrate frontal views of an example cartridge, in
accordance with one embodiment, in which a dual-needle fill application is
implemented to fill
the cartridge's reservoir (FIG. 31A) before the collector and an enclosing
plug are inserted into
the body of the cartridge (FIG. 31B) to form a fully assembled cartridge (FIG.
31C).
[0450] FIGS
34A and 34B illustrate frontal and side views of an example cartridge body
with an external airflow path. In some embodiments, one or more gates, also
referred to as air
inlet holes may be provided on the vaporizer body 110. The inlet holes may be
positioned
inside of an air inlet channel with a width, height, and depth that is sized
to prevent the user
from unintentionally blocking the individual air inlet holes, when the user is
holding the
vaporizer 100. In one aspect, the air inlet channel construction may be
sufficiently long so as
not to significantly block or restrict airflow through the air inlet channel,
when for example a
user's fingers block an area of the air inlet channel.
[0451] In some
configurations, the geometric construction of the air inlet channel may
provide for at least one of a minimum length, a minimum depth, or a maximum
width, for
example, to ensure a user can't completely cover or block the air inlet holes
in the air inlet
channel with a hand or other body part. For example, the length of the air
inlet channel may
be longer than the width of an average human finger and the width and depth of
the air inlet
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channel may be such that when a user's finger is pressed on top of the
channel, the skin folds
created does not interface with the air inlet holes inside the air inlet
channel.
[0452] The air
inlet channel may be constructed or formed as having rounded edges or
shaped to wrap around one or more corners or areas of the vaporizer body 110,
so that the air
inlet channel cannot be easily covered by a user's finger or body part. In
certain embodiments,
an optional cover may be provisioned to protect the air inlet channel so that
a user's finger
cannot not block or completely limit airflow into the air inlet channel. In
one example
implementation, the air inlet channel may be formed at the interface between
the vaporizer
cartridge 120 and the vaporizer body 110 (e.g., at the receptacle area ¨ see
FIG. 1). In such
implementation, the air inlet channel may be protected from blockage due to
the air inlet
channel being formed inside the receptacle area. This implementation may also
allow for a
configuration in which the air inlet channel is hidden from view.
[0453] FIGS.
32A through 32C illustrate frontal, top, and bottom views of an example
cartridge body, respectively, with a condensate collector 3201 incorporated
inside the air path.
[0454]
Referring to FIG. 33A, air or vapor may flow into an airflow path in the
cartridge.
The airflow path may longitudinally extend from an aperture or opening in the
mouthpiece,
internally along the body of the cartridge such that vaporizable material 1302
inhaled through
the mouthpiece passes through a condensate collector 3201. As shown in FIG.
33B, in addition
to the condensate collector 3201 condensate recycler channels 3204 (e.g.,
micro-fluidic
channels) may be formed to travel from the opening in the mouthpiece to the
wick, for example.
[0455] The
condensate collector 3201 acts on vaporized vaporizable material 1302 that are
cooled and turned into droplets in the mouthpiece to collect and route the
condensed droplets
to the condensate recycler channels 3204. The condensate recycler channels
3204 collect and
return condensate and large vapor droplets to the wick, and prevent the liquid
vaporizable
material formed in the mouthpiece from being deposited into the user's mouth,
during the user
puffing or inhaling from the mouthpiece. The condensate recycler channels 3204
may be
implemented as micro-fluidic channels to trap any liquid droplet condensates
and thereby
eliminate the direct inhalation of vaporizable material, in liquid form, and
avoid an undesirable
sensation or taste in the user's mouth. Additional and/or alternative
embodiments of the
condensate recycler channels, and/or one or more other features for
controlling, collecting,
and/or recycling condensate in a vaporizer device are described and shown with
respect to
FIGS. 117-119C. The condensate recycler channels (and/or the one or more other
features
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described and shown with respect to FIGS. 117-119C) may alone, or in
combination with one
or more features of the vaporizer cartridge, assist in controlling,
collecting, and/or recycling
condensate in a vaporizer device
[0456]
Referring to FIGS. 35 and 36, perspective views of a portion of an example
cartridge are illustrated where the collector structure 1313 includes an air
gap 3501 at the
bottom rib of the collector structure. The positioning of the air gap 3501 may
coincide with
the location where the air exchange port is positioned in the collector
structure 1313. As
provided earlier, the collector structure 1313 may be configured to have a
central opening
through which an airflow channel leading to the mouthpiece is implemented. The
airflow
channel may be connected to the air exchange port, such that the volume inside
the overflow
passageway of the collector 1313 is connected to the ambient air via the air
exchange port and
also connected to the volume in the storage chamber via a vent.
[0457] In
accordance with one or more embodiments, the vent may be utilized as a control
valve to mainly control liquid flow between the overflow passageway and the
storage chamber.
The air exchange port may be utilized to mainly control airflow between the
overflow
passageway and an air path leading to the mouthpiece, for example. The
combination of the
interactions between the vent, the collector channels of the overflow
passageway and the air
exchange port provide for proper wick saturation and the proper venting of air
bubbles that
may be introduced into the cartridge due to various environmental factors as
well as the
controlled flow of vaporizable material 1302 into and out of the collector
channels. The
presence of an air gap 3501 at the air exchange ports allows for a more robust
venting process
as it prevents liquid vaporizable material 1302 stored in the collector from
seeping into the
wick housing area.
[0458] FIGS.
37A through 37C illustrate top views of various example wick feed shapes
and configurations for a cartridge in accordance with one or more embodiments.
As shown,
FIG. 37A illustrates a cross-shaped wick feed cross-section in accordance with
an example
embodiment. FIG. 37B illustrates a wick feed with an approximately rectangular
cross-section.
FIG. 37C illustrates a wick feed with an approximately square cross-section.
As provided
earlier, depending on implementation, one or more wick feeds 3701 may be
constructed as
ducts, channels, tubes or cavities that travel through the collector structure
1313 as paths that
feed the wick with vaporizable material 1302 stored in storage chamber. In
certain
configurations, the wick feeds 3701 may run approximately parallel to a
central channel 3700
in the collector 1313.
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[0459]
Depending on implementation, a wick feed path may be shaped to be tubular
with,
for example, a substantially rectangular or square cross-sectional shape as
shown in FIGS 37B
and 37C. A variable width cross-sectional shaped duct or tube formed through a
wick feed
path may overcome clogging problems, if such shape provides for a multi-path
configuration
that allows vaporizable material 1302 to travel through the wick feed even if
an air bubble is
formed in a certain area of the wick feed. In such implementations, a blockage
in the wick feed
tube will likely be formed at a portion of the wick feed tube, leaving sub-
pathways (e.g.,
alternate pathways) open to flow.
[0460] In
accordance with one or more aspects, wick-feeding pathways may be sufficiently
wide to allow for free travel of vaporizable material 1302 through the feeding
pathways and
toward the wick. In some embodiments, the flow through the wick feed may be
enhanced or
accommodated by way of devising the relative diameter of certain portions of
the wick feed to
enforce capillary pull or pressure on the vaporizable material 1302 travelling
through a wick
feed path. In other words, depending on the shape and other structural or
material factors, some
wick feeding pathways may rely on gravitational or capillary forces to induce
movement of
vaporizable material 1302 toward the wick-housing portion.
[0461] FIGS
37D and 37E illustrate example embodiments of a collector 1313 with a
double wick feed 3701 implementation. At least one of the wick feeds 3701 may
be formed to
include a partial demising wall. The partial demising wall may be configured
to split the
volume of the inside of a wick feed 3701 into two separate volumes (i.e.,
ventricles) as
illustrated in the cross-sectional perspective views in FIGS. 37D and 37E. The
partial wall
implementation would allow for liquid vaporizable material 1302 to easily flow
from the
reservoir toward the wick housing area to saturate the wick.
[0462] In
certain implementations, the partial wall in a single wick feed essentially
forms
two ventricles in the single wick feed. The ventricles in the wick feed may be
disjoined by
way of the partial wall and be separately utilized to allow vaporizable
material 1302 flow
toward the wick housing. In such embodiments, if a gas bubble is dislodged in
one of the
ventricles in the wick feed, the other ventricle may remain open. A ventricle
may be
volumetrically large to provide a sufficient flow of vaporizable material 1302
toward the wick
for adequate saturation.
[0463]
Accordingly, in embodiments that two wick feeds 3701 are utilized, effectively
four
ventricles may be available for carrying the vaporizable material 1302 flow
toward the wick.
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Thereby, in the event of formation of gas bubbles in one, two or even three of
the ventricles, at
least a fourth ventricle would be usable for directing the vaporizable
material 1302 flow
towards the wick, reducing the chances of wick dehydration.
[0464]
Referring to FIG. 38, a close-up view of an end of the wick feed that is
positioned
proximate to the wick (e.g., at the end configured to at least partially
receive the wick) where
optionally at least a portion of the wick is sandwiched between two or more
prongs extending
from the end of the wick feed.
[0465] FIG. 39
illustrates a perspective view of an example collector structure having a
square-design wick feed in combination with an air gap at one end of the
overflow passageway.
[0466]
Referring to FIGS. 40A through 40E, rear, side, top, frontal, and bottom views
of
an example collector structure are respectively illustrated. FIG. 40A
illustrates a rear view of
the collector structure with four distinct ejection sites, for example. FIG.
40B illustrates a side
view of the collector structure particularly showing an clamp-shaped end
portion 4002 of a
wick feed that can firmly hold the wick in the pathway of the wick feed, for
example. As
shown in FIG. 40C, the portion of the cartridge body that extends internally
to the cartridge
body from the mouthpiece can be received through a central channel 3700 in the
collector
structure forming an airway passageway for the vaporized vaporizable material
1302 to escape
from the atomizer towards the mouthpiece.
[0467] FIG.
40C illustrates a top view of the collector structure with wick feed channels
4001 for receiving vaporizable material from the cartridge's storage chamber
and leading the
vaporizable material towards the wick being held in position at the end of the
wick feed
channels 4001 by the projecting ends of the wick feed channels 4001 forming
the clamp-shaped
end portion 4002.
[0468] FIG.
40D illustrates a frontal planar view of the collector structures. As shown,
an
air gap cavity may be formed at the lower portion of the collector structure
at the end of a lower
rib of the collector structure where the overflow passageway of the collector
leads to an air
control vent 3902 in communication with ambient air. The portion of the
cartridge body that
extends from the mouthpiece can be received through the central channel 3700
in the collector
structure forming an airway passageway for the vaporized vaporizable material
1302 to escape
from the atomizer towards the mouthpiece.
[0469] FIG.
40E illustrates a bottom view of the collector 1313 structure where two wick
feed channels end in two clamp-shaped end portions 4002 configured to hold the
wick in
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position at the bottom end of the collector 1313. As shown, optionally, a
segmented ridge,
flange, or lip 4003 may be formed on the surface of the bottom end of the
collector 1313, where
the collector 1313 connects to the upper portion of the plug 760 at the time
of assembly. The
lip 4003 provides for a pressure-tight engagement between the upper portion of
the plug 760
and the lower portion of the collector 1313, functioning in a similar manner
as a flexible 0-
ring, so that a proper seal may be established during assembly. In one
embodiment, the bottom
end of the collector 1313 may be laser welded to the upper portion of the plug
760.
[0470] FIGS.
41A and 41B illustrates planar top and side views of an alternative
embodiment of the collector structure having two of the clamp-shaped end
portion 4002 and
two corresponding wick feeds. As shown, this alternative embodiment is shorter
in height in
comparison with the embodiment illustrated in FIG. 40A. This reduced height
provides
improved functionality by structurally changing the shape of the collector
1313 and the length
of the passageway in the collector 1313 in which vaporizable material 1302
flows. As such,
depending on implementation, the length of the vaporizable material 1302
passageway through
the collector 1313 may be shorter in certain embodiments to provide for a more
effective
capillary pressure and better management of the flow of vaporizable material
1302 into the
collector 1313 passageway.
[0471] FIGS.
42A and 42B illustrate various perspective, top, bottom and side views of an
example collector 1313 with different structural implementations. For example,
the
embodiment shown in FIG. 42A includes constriction points that include
vertically positioned
C-shaped walls. In contrast, in the embodiment shown in FIG. 42B, the C-shaped
walls are
diagonally positioned to promote a more controlled flow of vaporizable
material 1302 along
the collector 1313 passageway. As shown in the example embodiment of FIG. 42B,
the C-
shaped walls are positioned diagonally with respect to the bottom blade of the
collector, and
positioned vertically with respect to the blade portions in the collector that
slope downwardly.
[0472] As
noted earlier, the rate of flow into and out of the collector 1313 is
controlled by
way of manipulating the hydraulic diameter of the overflow channel 1104 in the
collector 1313
through the introduction one or more constriction points, which effectively
reduce the overall
volume of the overflow channel 1104. As shown, the introduction of multiple
constriction
points in the overflow channel 1104 divides the overflow channel into multiple
segments in
which vaporizable material 1302 may flow in either a first or a second
direction, for example,
toward or away from the air control vent 3902, respectively.
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[0473]
Introduction of the constriction points helps establish or control the
capillary
pressure state in the overflow channel 1104 such that the hydraulic flow of
vaporizable material
1302 towards the air control vent 3902 is minimized in a pressure state when
the pressure in
the cartridge reservoir is equal or less than the ambient air. In a pressure
state in which the
pressure in the reservoir is lower than the ambient pressure (e.g., beyond a
first threshold), the
constriction points are configured to control the capillary pressure or
hydraulic flow of
vaporizable material 1302 in the overflow channel 1104 such that ambient air
may enter the
overflow channel 1104 through the air control vent 3904 and travel up toward
the controlled
fluidic gate 1102 into the reservoir to vent (i.e., establish an equilibrium
pressure state in) the
cartridge.
[0474] In
certain embodiments or scenarios, the above noted venting process may not
involve or require the entrance of ambient air through the air control vent
3904. In some
example scenarios, instead of or in addition to air entering through the air
control vent 3904,
any air bubbles or gases trapped inside the overflow channel 1104 may travel
up toward the
controlled fluidic gate 1102 to help establish an equilibrium pressure state
in the cartridge by
way of venting the reservoir when the air bubbles are introduced into the
reservoir from the
overflow channel 1104 through the controlled fluidic gate 1102, as provided in
further detail
herein with reference to FIGS. 11 M and 11N, for example. The design of the
constriction
points and the C-shaped walls formed in the path of the overflow channel 1104,
as shown in
FIGS. 42A and 42B, promotes a more controlled flow of the vaporizable material
1302 through
the overflow channel 1104 by way of better managing the capillary pressure
throughout the
path of the overflow control channel 1104.
[0475] FIG.
43A illustrates various perspective, top, bottom and side views of an example
wick housing 1315, in accordance with one or more embodiments. As shown, one
or more
perforations or holes may be formed in the lower portion of the wick housing
1315 to
accommodate airflow through a wick positioned in the wick housing 760 of the
wick housing
1315. A sufficient number of holes would promote adequate airflow through the
wick housing
760 and will provide for the proper and timely vaporization of vaporizable
material 1302
absorbed into the wick in reaction to the heat generated by the heating
element positioned near
or around the wick.
[0476] FIG.
43B illustrates the collector 1313 and wick housing 760 components of an
example cartridge 1320, in accordance with one or more embodiments. As shown,
the wick
housing 1315 (which includes the wick-housing portion of the cartridge) may be
implemented
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to include a protruding member or tab 4390. The tab 4390 may be configured to
extend from
the upper end of the wick housing 1315, which during assembly mates with a
receiving end of
the collector 1313. The tab 4390 may include one or more facets that
correspond to or match
one or more facets in a receiving notch or receiving cavity 1390 in, for
example, the bottom
portion of the collector 1313. The receiving cavity 1390 may be configured to
removably
receive the tab 4390 for a snap-fit engagement, for example. The snap-fit
arrangement may
assist with holding the collector 1313 and the wick housing 1315 together
during or after
assembly.
104771 In
certain embodiments, the tab 4390 may be utilized to direct the orientation of
the
wick housing 1315 during assembly. For example, in one embodiment one or more
vibrating
mechanisms (e.g., vibrating bowls) may be utilized to temporarily store or
stage the various
components of the cartridge 1320. According to some implementations, the tab
4390 may be
helpful in orienting the upper portion of the wick housing 1315 for a
mechanical gripper for
the purpose of easy engagement and correct automated assembly.
Additional and/or Alternative Heating Element Embodiments
[0478] As
noted above, the vaporizer cartridge consistent with implementations of the
current subject matter may include one or more heating elements. FIGS. 44A-116
illustrate
embodiments of a heating element consistent with implementations of the
current subject
matter. While the features described and shown with respect to FIGS. 44A-116
may be
included in the various embodiments of the vaporizer cartridges described
above and/or may
include one or more features of the various embodiments of the vaporizer
cartridges described
above, the features of the heating elements described and shown with respect
to FIGS. 44A-
116 may additionally and/or alternatively be included in one or more other
example
embodiments of vaporizer cartridges, such as those described below.
[0479] A
heating element consistent with implementations of the current subject matter
may desirably be shaped to receive a wicking element and/or crimped or pressed
at least
partially around the wicking element. The heating element may be bent such
that the heating
element is configured to secure the wicking element between at least two or
three portions of
the heating element. The heating element may be bent to conform to a shape of
at least a portion
of the wicking element. The heating element may be more easily manufacturable
than typical
heating elements. The heating element consistent with implementations of the
current subject
matter may also be made of an electrically conductive metal suitable for
resistive heating and
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in some implementations, the heating element may include selective plating of
another material
to allow the heating element (and thus, the vaporizable material) to be more
efficiently heated.
[0480] FIG.
44A illustrates an exploded view of an embodiment of the vaporizer cartridge
120, FIG. 44B illustrates a perspective view of an embodiment of the vaporizer
cartridge 120,
and FIG. 44C illustrates a bottom perspective view of an embodiment of the
vaporizer cartridge
120. As shown in FIGS. 44A-44C, the vaporizer cartridge 120 includes a housing
160 and an
atomizer assembly (or the atomizer) 141.
[0481] The
atomizer assembly 141 (see FIGS. 99-101) may include a wicking element 162,
a heating element 500, and a wick housing 178. As explained in more detail
below, at least a
portion of the heating element 500 is positioned between the housing 160 and
the wick housing
178 and is exposed to be coupled with a portion of the vaporizer body 110
(e.g., electrically
coupled with the receptacle contacts 125). The wick housing 178 may include
four sides. For
example, the wick housing 178 may include two opposing short sides and two
opposing long
sides. The two opposing long sides may each include at least one (two or more)
recess 166
(see FIGS. 99, 111A). The recesses 166 may be positioned along the long side
of the wick
housing 178 and adjacent to respective intersections between the long sides
and the short sides
of the wick housing 178. The recesses 166 may be shaped to releasably couple
with a
corresponding feature (e.g., a spring) on the vaporizer body 110 to secure the
vaporizer
cartridge 120 to the vaporizer body 110 within the cartridge receptacle 118.
The recesses 166
provides a mechanically stable securement means to couple the vaporizer
cartridge 120 to the
vaporizer body 110.
[0482] In some
implementations, the wick housing 178 also includes an identification chip
174, which may be configured to communicate with a corresponding chip reader
located on
the vaporizer. The identification chip 174 may be glued and/or otherwise
adhered to the wick
housing 178, such as on a short side of the wick housing 178. The wick housing
178 may
additionally or alternatively include a chip recess 164 (see FIG. 100) that is
configured to
receive the identification chip 174. The chip recess 164 may be surrounded by
two, four, or
more walls. The chip recess 164 may be shaped to secure the identification
chip 174 to the
wick housing 178.
[0483] As
noted above, the vaporizer cartridge 120 may generally include a reservoir, an
air path, and an atomizer assembly 141. In some configurations, the heating
element and/or
atomizer described in accordance with implementations of the current subject
matter can be
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implemented directly into a vaporizer body and/or may not be removable from
the vaporizer
body. In some implementations, the vaporizer body may not include a removable
cartridge.
[0484] Various
advantages and benefits of the current subject matter may relate to
improvements relative to current vaporizer configurations, methods of
manufacture, and the
like. For example, a heating element of a vaporizer device consistent with
implementations of
the current subject matter may desirably be made (e.g., stamped) from a sheet
of material and
either crimped around at least a portion of a wicking element or bent to
provide a preformed
element configured to receive the wicking element (e.g., the wicking element
is pushed into
the heating element and/or the heating element is held in tension and is
pulled over the wicking
element). The heating element may be bent such that the heating element
secures the wicking
element between at least two or three portions of the heating element. The
heating element
may be bent to conform to a shape of at least a portion of the wicking
element. Configurations
of the heating element allows for more consistent and enhanced quality
manufacturing of the
heating element. Consistency of manufacturing quality of the heating element
may be
especially important during scaled and/or automated manufacturing processes.
For example,
the heating element consistent with implementations of the current subject
matter helps to
reduce tolerance issues that may arise during manufacturing processes when
assembling a
heating element having multiple components.
[0485] In some
implementations, accuracy of measurements taken from the heating
element (e.g., a resistance, a current, a temperature, etc.) may be improved
due at least in part
to the improved consistency in manufacturability of the heating element having
reduced
tolerance issues. Greater accuracy in measurements can provide an enhanced
user experience
when using the vaporizer device. For example, as mentioned above, the
vaporizer 100 may
receive a signal to activate the heating element, either to a full operating
temperature for
creation of an inhalable dose of vapor/aerosol or to a lower temperature to
begin heating the
heating element. The temperature of the heating element of the vaporizer may
depend on a
number of factors, as noted above, and several of these factors can be made
more predictable
by elimination of potential variations in fabrication and assembly of atomizer
components. A
heating element made (e.g., stamped) from a sheet of material and either
crimped around at
least a portion of a wicking element or bent to provide a preformed element
desirably helps to
minimize heat losses and helps to ensure that the heating element behaves
predictably to be
heated to the appropriate temperature.
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[0486]
Additionally, as noted above, the heating element may be entirely and/or
selectively
plated with one or more materials to enhance heating performance of the
heating element.
Plating all or a portion of the heating element may help to minimize heat
losses. Plating may
also help in concentrating the heated portion of the heating element in the
proper location,
providing a more efficiently heated heating element and further reducing heat
losses. Selective
plating may help to direct the current provided to the heating element to the
proper location.
Selective plating may also help to reduce the amount of plating material
and/or costs associated
with manufacturing the heating element.
[0487] Once
the heating element is formed into the appropriate shape via one or more
processes discussed below, the heating element may be crimped around the
wicking element
and/or bent into the proper position to receive the wicking element. The
wicking element may,
in some implementations, be a fibrous wick, formed as an at least
approximately flat pad or
with other cross-sectional shapes such as circles, ovals, etc. A flat pad can
allow for the rate
that the vaporizable material is drawn into the wicking element to be
controlled more precisely
and/or accurately. For example, a length, width, and/or thickness can be
adjusted for optimal
performance. A wicking element forming a flat pad may also provide a greater
transfer surface
area, which may allow for increased flow of the vaporizable material from the
reservoir into
the wicking element for vaporization by the heating element (in other words,
larger mass
transfer of vaporizable material), and from the wicking element to air flowing
past it. In such
configurations, the heating element may contact the wicking element in
multiple directions
(e.g., on at least two sides of the wicking element) to increase efficiency of
the process of
drawing vaporizable material into the wicking element and vaporizing the
vaporizable material.
The flat pad may also be more easily shaped and/or cut, and thus may be more
easily assembled
with the heating element. In some implementations, as discussed in more detail
below, the
heating element may be configured to contact the wicking element on only one
side of the
wicking element.
[0488] The
wicking element may include one or more rigid or compressible materials, such
as cotton, silica, ceramic, and/or the like. Relative to some other materials,
a cotton wicking
element may allow for an increased and/or more controllable flow rate of
vaporizable material
from the reservoir of the vaporizer cartridge into the wicking element to be
vaporized. In some
implementations, the wicking element forms an at least approximately flat pad
that is
configured to contact the heating element and/or be secured between at least
two portions of
the heating element. For example, the at least approximately flat pad may have
at least a first
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pair of opposing sides that are approximately parallel to one another. In some
implementations,
the at least approximately flat pad may also have at least a second pair of
opposing sides that
are approximately parallel to one another, and approximately perpendicular to
the first pair of
opposing sides.
[0489] FIGS.
45-48 illustrate schematic views of a heating element 500 consistent with
implementations of the current subject matter. For example, FIG. 45
illustrates a schematic
view of a heating element 500 in an unfolded position. As shown, in the
unfolded position, the
heating element 500 forms a planar heating element. The heating element 500
may be initially
formed of a substrate material. The substrate material is then cut and/or
stamped into the proper
shape via various mechanical processes, including but not limited to stamping,
laser cutting,
photo-etching, chemical etching, and/or the like.
[0490] The
substrate material may be made of an electrically conductive metal suitable
for
resistive heating. In some implementations, the heating element 500 includes a
nickel-
chromium alloy, a nickel alloy, stainless steel, and/or the like. As discussed
below, the heating
element 500 may be plated with a coating in one or more locations on a surface
of the substrate
material to enhance, limit, or otherwise alter the resistivity of the heating
element in the one or
more locations of the substrate material (which can be all or a portion of the
heating element
500).
[0491] The
heating element 500 includes one or more tines 502 (e.g., heating segments)
located in a heating portion 504, one or more connecting portions or legs 506
(e.g., one, two,
or more) located in a transition region 508, and a cartridge contact 124
located in an electrical
contact region 510 and formed at an end portion of each of the one or more
legs 506. The tines
502, the legs 506, and the cartridge contacts 124 may be integrally formed.
For example, the
tines 502, the legs 506, and the cartridge contacts 124 form portions of the
heating element 500
that is stamped and/or cut from the substrate material. In some
implementations, the heating
element 500 also includes a heat shield 518 that extends from one or more of
the legs 506 and
also may be integrally formed with the tines 502, the legs 506, and the
cartridge contacts 124.
[0492] In some
implementations, at least a portion of the heating portion 504 of the heating
element 500 is configured to interface with the vaporizable material drawn
into the wicking
element from the reservoir 140 of the vaporizer cartridge 120. The heating
portion 504 of the
heating element 500 may be shaped, sized, and/or otherwise treated to create a
desired
resistance. For example, the tines 502 located in the heating portion 504 may
be designed so
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that the resistance of the tines 502 matches the appropriate amount of
resistance to influence
localized heating in the heating portion 504 to more efficiently and
effectively heat the
vaporizable material from the wicking element. The tines 502 form thin path
heating segments
or traces in series and/or in parallel to provide the desired amount of
resistance.
[0493] The
tines 502 (e.g., traces) may include various shapes, sizes, and
configurations.
In some configurations, one or more of the tines 502 may be spaced to allow
the vaporizable
material to be wicked out of the wicking element and from there, vaporized off
side edges of
each of the tines 502. The shape, length, width, composition, etc., among
other properties of
the tines 502 may be optimized to maximize the efficiency of generating an
aerosol by
vaporizing vaporizable material from within the heating portion of the heating
element 500 and
to maximize electrical efficiency. The shape, length, width, composition,
etc., among other
properties of the tines 502 may additionally or alternatively be optimized to
uniformly
distribute heat across the length of the tines 502 (or a portion of the tines
502, such as at the
heating portion 504). For example, the width of the tines 502 may be uniform
or variable along
a length of the tines 502 to control the temperature profile across at least
the heating portion
504 of the heating element 500. In some examples, the length of the tines 502
may be
controlled to achieve a desired resistance along at least a portion of the
heating element 500,
such as at the heating portion 504. As shown in FIGS. 45-48, the tines 502
each have the same
size and shape. For example, the tines 502 include an outer edge 503 that is
approximately
aligned and have a generally rectangular shape, with flat or squared outer
edges 503 (see also
FIGS. 49-53) or rounded outer edges 503 (see FIGS. 54 and 55). In some
implementations,
one or more of the tines 502 may include outer edges 503 that are not aligned
and/or may be
differently sized or shaped (see FIGS. 57-62). In some implementations, the
tines 502 may be
evenly spaced or have variable spacing between adjacent tines 502 (see FIGS.
87-92). The
particular geometry of the tines 502 may be desirably selected to produce a
particular localized
resistance for heating the heating portion 504, and to maximize performance of
the heating
element 500 to heat the vaporizable material and generate an aerosol.
[0494] The
heating element 500 may include portions of wider and/or thicker geometry,
and/or differing composition relative to the tines 502. These portions may
form electrical
contact areas and/or more conductive parts, and/or may include features for
mounting the
heating element 500 within the vaporizer cartridge. The legs 506 of the
heating element 500
extend from an end of each outermost tine 502A. The legs 506 form a portion of
the heating
element 500 that has a width and/or thickness that is typically wider than a
width of each of the
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tines 502. Though, in some implementations, the legs 506 have a width and/or
thickness that
is the same as or narrower than the width of each of the tines 502. The legs
506 couple the
heating element 500 to the wick housing 178 or another portion of the
vaporizer cartridge 120,
so that the heating element 500 is at least partially or fully enclosed by the
housing 160. The
legs 506 provide rigidity to encourage the heating element 500 to be
mechanically stable during
and after manufacturing. The legs 506 also connect the cartridge contacts 124
with the tines
502 located in the heating portion 504. The legs 506 are shaped and sized to
allow the heating
element 500 to maintain the electrical requirements of the heating portion
504. As shown in
FIG. 48, the legs 506 space the heating portion 504 from an end of the
vaporizer cartridge 120
when the heating element 500 is assembled with the vaporizer cartridge 120. As
discussed in
more detail below, with respect to at least FIGS. 82-98 and 103-104, the legs
506 may also
include a capillary feature 598, which limits or prevents fluid from flowing
out of the heating
portion 504 to other portions of the heating element 500.
[0495] In some
implementations, one or more of the legs 506 includes one or more locating
features 516. The locating features 516 may be used for relative locating of
the heating element
500 or portions thereof during and/or after assembly by interfacing with other
(e.g., adjacent)
components of the vaporizer cartridge 120. In some implementations, the
locating features 516
may be used during or after manufacturing to properly position the substrate
material for
cutting and/or stamping the substrate material to form the heating element 500
or post-
processing of the heating element 500. The locating features 516 may be
sheared off and/or
cut off before crimping or otherwise bending the heating element 500.
[0496] In some
implementations, the heating element 500 includes one or more heat shields
518. The heat shields 518 form a portion of the heating element 500 that
extends laterally from
the legs 506. When folded and/or crimped, the heat shields 518 are positioned
offset in a first
direction and/or a second direction opposite the first direction in the same
plane from the tines
502. When the heating element 500 is assembled in the vaporizer cartridge 120,
the heat shields
518 are configured to be positioned between the tines 502 (and the heating
portion 504) and
the body (e.g., plastic body) of the vaporizer cartridge 120. The heat shields
518 can help to
insulate the heating portion 504 from the body of the vaporizer cartridge 120.
The heat shields
518 help to minimize the effects of the heat emanating from the heating
portion 504 on the
body of the vaporizer cartridge 120 to protect the structural integrity of the
body of the
vaporizer cartridge 120 and to prevent melting or other deformation of the
vaporizer cartridge
120. The heat shields 518 may also help to maintain a consistent temperature
at the heating
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portion 504 by retaining heat within the heating portion 504, thereby
preventing or limiting
heat losses while vaporization is occurring. In some implementations, the
vaporizer cartridge
120 may also or alternatively include a heat shield 518A that is separate from
the heating
element 500 (see FIG. 102).
[0497] As
noted above, the heating element 500 includes at least two cartridge contacts
124 that form an end portion of each of the legs 506. For example, as shown in
FIGS. 45-48,
the cartridge contacts 124 may form the portion of the legs 506 that is folded
along a fold line
507. The cartridge contacts 124 may be folded at an angle of approximately 90
degrees relative
to the legs 506. In some implementations, the cartridge contacts 124 may be
folded at other
angles, such as at an angle of approximately 15 degrees, 25 degrees, 35
degrees, 45 degrees,
55 degrees, 65 degrees, 75 degrees or other ranges therebetween, relative to
the legs 506. The
cartridge contacts 124 may be folded towards or away from the heating portion
504, depending
on the implementation. The cartridge contacts 124 may also be formed on
another portion of
the heating element 500, such as along a length of at least one of the legs
506. The cartridge
contacts 124 are configured to be exposed to the environment when assembled in
the vaporizer
cartridge 120 (see FIG. 53).
[0498] The
cartridge contacts 124 may form conductive pins, tabs, posts, receiving holes,
or surfaces for pins or posts, or other contact configurations. Some types of
cartridge contacts
124 may include springs or other urging features to cause better physical and
electrical contact
between the cartridge contacts 124 on the vaporizer cartridge and receptacle
contacts 125 on
the vaporizer body 110. In some implementations, the cartridge contacts 124
include wiping
contacts that are configured to clean the connection between the cartridge
contacts 124 and
other contacts or power source. For example, the wiping contacts would include
two parallel,
but offset, bosses that frictionally engage and slide against one another in a
direction that is
parallel or perpendicular to the insertion direction.
[0499] The
cartridge contacts 124 are configured to interface with the receptacle
contacts
125 disposed near a base of the cartridge receptacle of the vaporizer 100 such
that the cartridge
contacts 124 and the receptacle contacts 125 make electrical connections when
the vaporizer
cartridge 120 is inserted into and coupled with the cartridge receptacle 118.
The cartridge
contacts 124 may electrically communicate with the power source 112 of the
vaporizer device
(such as via the receptacle contacts 125, etc.). The circuit completed by
these electrical
connections can allow delivery of electrical current to the resistive heating
element to heat at
least a portion of the heating element 500 and may further be used for
additional functions,
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such as for example for measuring a resistance of the resistive heating
element for use in
determining and/or controlling a temperature of the resistive heating element
based on a
thermal coefficient of resistivity of the resistive heating element, for
identifying a cartridge
based on one or more electrical characteristics of a resistive heating element
or the other
circuitry of the vaporizer cartridge, etc. The cartridge contacts 124 may be
treated, as explained
in more detail below, to provide improved electrical properties (e.g., contact
resistance) using,
for example, conductive plating, surface treatment, and/or deposited
materials.
[0500] In some
implementations, the heating element 500 may be processed through a
series of crimping and/or bending operations to shape the heating element 500
into a desired
three-dimensional shape. For example, the heating element 500 may be preformed
to receive
or crimped about a wicking element 162 to secure the wicking element between
at least two
portions (e.g., approximately parallel portions) of the heating element 500
(such as between
opposing portions of the heating portion 504). To crimp the heating element
500, the heating
element 500 may be bent along fold lines 520 towards one another. Folding the
heating element
500 along fold lines 520 forms a platform tine portion 524 defined by the
region between the
fold lines 520 and side tine portions 526 defined by the region between the
fold lines 520 and
the outer edges 503 of the tines 502. The platform tine portion 524 is
configured to contact
one end of the wicking element 162. The side tine portions 526 are configured
to contact
opposite sides of the wicking element 162. The platform tine portion 524 and
the side tine
portions 526 form a pocket that is shaped to receive the wicking element 162
and/or conform
to the shape of at least a portion of the wicking element 162. The pocket
allows the wicking
element 162 to be secured and retained by the heating element 500 within the
pocket. The
platform tine portion 524 and the side tine portions 526 contact the wicking
element 162 to
provide a multi-dimensional contact between the heating element 500 and the
wicking element
162. Multi-dimensional contact between the heating element 500 and the wicking
element 162
provides for a more efficient and/or faster transfer of the vaporizable
material from the reservoir
140 of the vaporizer cartridge 120 to the heating portion 504 (via the wicking
element 162) to
be vaporized.
[0501] In some
implementations, portions of the legs 506 of the heating element 500 may
also be bent along fold lines 522 away from one another. Folding the portions
of the legs 506
of the heating element 500 along fold lines 522 away from one another locates
the legs 506 at
a position spaced away from the heating portion 504 (and tines 502) of the
heating element 500
in a first and/or second direction opposite the first direction (e.g., in the
same plane). Thus,
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folding the portions of the legs 506 of the heating element 500 along fold
lines 522 away from
one another spaces the heating portion 504 from the body of the vaporizer
cartridge 120. FIG.
46 illustrates a schematic of the heating element 500 that has been folded
along the fold lines
520 and fold lines 522 about the wicking element 162. As shown in FIG. 46, the
wicking
element is positioned within the pocket formed by folding the heating element
500 along fold
lines 520 and 522.
[0502] In some
implementations, the heating element 500 may also be bent along fold lines
523. For example, the cartridge contacts 124 may be bent towards one another
(into and out
of the page shown in FIG. 47) along the fold lines 523. The cartridge contacts
124 may be
exposed to the environment to contact the receptacle contacts, while the
remaining portions of
the heating element 500 are positioned within the vaporizer cartridge 120 (see
FIGS. 48 and
53).
[0503] In use,
when a user puffs on the mouthpiece 130 of the vaporizer cartridge 120 when
the heating element 500 is assembled into the vaporizer cartridge 120, air
flows into the
vaporizer cartridge and along an air path. In association with the user puff,
the heating element
500 may be activated, e.g., by automatic detection of the puff via a pressure
sensor, by detection
of a pushing of a button by the user, by signals generated from a motion
sensor, a flow sensor,
a capacitive lip sensor, and/or another approach capable of detecting that a
user is taking or
about to be taking a puff or otherwise inhaling to cause air to enter the
vaporizer 100 and travel
at least along the air path. Power can be supplied from the vaporizer device
to the heating
element 500 at the cartridge contacts 124, when the heating element 500 is
activated.
[0504] When
the heating element 500 is activated, a temperature increase results due to
current flowing through the heating element 500 to generate heat. The heat is
transferred to
some amount of the vaporizable material through conductive, convective, and/or
radiative heat
transfer such that at least a portion of the vaporizable material vaporizes.
The heat transfer can
occur to vaporizable material in the reservoir and/or to vaporizable material
drawn into the
wicking element 162 retained by the heating element 500. In some
implementations, the
vaporizable material can vaporize along one or more edges of the tines 502, as
mentioned
above. The air passing into the vaporizer device flows along the air path
across the heating
element 500, stripping away the vaporized vaporizable material from the
heating element 500.
The vaporized vaporizable material can be condensed due to cooling, pressure
changes, etc.,
such that it exits the mouthpiece 130 as an aerosol for inhalation by a user.
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[0505] As
noted above, the heating element 500 may be made of various materials, such
as nichrome, stainless steel, or other resistive heater materials.
Combinations of two or more
materials may be included in the heating element 500, and such combinations
can include both
homogeneous distributions of the two or more materials throughout the heating
element or
other configurations in which relative amounts of the two or more materials
are spatially
heterogeneous. For example, the tines 502 may have portions that are more
resistive and
thereby be designed to grow hotter than other sections of the tines or heating
element 500. In
some implementations, at least the tines 502 (such as within the heating
portion 504) may
include a material that has high conductivity and heat resistance.
[0506] The
heating element 500 may be entirely or selectively plated with one or more
materials. Since the heating element 500 is made of a thermally and/or
electrically conductive
material, such as stainless steel, nichrome, or other thermally and/or
electrically conductive
alloy, the heating element 500 may experience electrical or heating losses in
the path between
the cartridge contacts 124 and the tines 502 in the heating portion 504 of the
heating element
500. To help to reduce heating and/or electrical losses, at least a portion of
the heating element
500 may be plated with one or more materials to reduce resistance in the
electrical path leading
to the heating portion 504. In some implementations consistent with the
current subject matter,
it is beneficial for the heating portion 504 (e.g., the tines 502) to remain
unplated, with at least
a portion of the legs 506 and/or cartridge contacts 124 being plated with a
plating material that
reduces resistance (e.g., either or both of bulk and contact resistance) in
those portions.
[0507] For
example, the heating element 500 may include various portions that are plated
with different materials. In another example, the heating element 500 may be
plated with
layered materials. Plating at least a portion of the heating element 500 helps
to concentrate
current flowing to the heating portion 504 to reduce electrical and/or heat
losses in other
portions of the heating element 500. In some implementations, it is desirable
to maintain a low
resistance in the electrical path between the cartridge contacts 124 and the
tines 502 of the
heating element 500 to reduce electrical and/or heat losses in the electrical
path and to
compensate for the voltage drop that is concentrated across the heating
portion 504.
[0508] In some
implementations, the cartridge contacts 124 may be selectively plated.
Selectively plating the cartridge contacts 124 with certain materials may
minimize or eliminate
contact resistance at the point where the measurements are taken and the
electrical contact is
made between the cartridge contacts 124 and the receptacle contacts. Providing
a low
resistance at the cartridge contacts 124 can provide more accurate voltage,
current, and/or
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resistance measurements and readings, which can be beneficial for accurately
determining the
current actual temperature of the heating portion 504 of the heating element
500.
[0509] In some
implementations, at least a portion of the cartridge contacts 124 and/or at
least a portion of the legs 506 may be plated with one or more outer plating
materials 550. For
example, at least a portion of the cartridge contacts 124 and/or at least a
portion of the legs 506
may be plated with at least gold, or another material that provides low
contact resistance, such
as platinum, palladium, silver, copper, or the like.
[0510] In some
implementations, in order for the low resistance outer plating material to
be secured to the heating element 500, a surface of the heating element 500
may be plated with
an adhering plating material. In such configurations, the adhering plating
material may be
deposited onto the surface of the heating element 500 and the outer plating
material may be
deposited onto the adhering plating material, defining first and second
plating layers,
respectively. The adhering plating material includes a material with adhesive
properties when
the outer plating material is deposited onto the adhering plating material.
For example, the
adhering plating material may include nickel, zinc, aluminum, iron, alloys
thereof, or the like.
FIGS. 79-81 illustrate examples of the heating element 500 in which the
cartridge contacts 124
have been selectively plated with the adhering plating material and/or the
outer plating
material.
[0511] In some
implementations, the surface of the heating element 500 may be primed for
the outer plating material to be deposited onto the heating element 500 using
non-plating
priming, rather than by plating the surface of the heating element 500 with
the adhering plating
material. For example, the surface of the heating element 500 may be primed
using etching
rather than by depositing the adhering plating material.
[0512] In some
implementations, all or a portion of the legs 506 and the cartridge contacts
124 may be plated with the adhering plating material and/or the outer plating
material. In some
examples, the cartridge contacts 124 may include at least a portion that has
an outer plating
material having a greater thickness relative to the remaining portions of the
cartridge contacts
124 and/or the legs 506 of the heating element 500. In some implementations,
the cartridge
contacts 124 and/or the legs 506 may have a greater thickness relative to the
tines 502 and/or
the heating portion 504.
[0513] In some
implementations, rather than forming the heating element 500 of a single
substrate material and plating the substrate material, the heating element 500
may be formed
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of various materials that are coupled together (e.g., via laser welding,
diffusion processes, etc.).
The materials of each portion of the heating element 500 that is coupled
together may be
selected to provide a low or no resistance at the cartridge contacts 124 and a
high resistance at
the tines 502 or heating portion 504 relative to the other portions of the
heating element 500.
[0514] In some
implementations, the heating element 500 may be electroplated with silver
ink and/or spray coated with one or more plating materials, such as the
adhering plating
material and the outer plating material.
[0515] As
mentioned above, the heating element 500 may include various shapes, sizes,
and geometries to more efficiently heat the heating portion 504 of the heating
element 500 and
more efficiently vaporize the vaporizable material.
[0516] FIGS.
49-53 illustrate an example of a heating element 500 consistent with
implementations of the current subject matter. As shown, the heating element
500 includes the
one or more tines 502 located in the heating portion 504, the one or more legs
506 extending
from the tines 502, the cartridge contacts 124 formed at the end portion of
each of the one or
more legs 506, and the heat shields 518 extending from the one or more legs
506. In this
example, each of the tines 502 have the same or similar shape and size. The
tines 502 have a
squared and/or flat outer edge 503. In FIGS. 49-52, the tines 502 have been
crimped about a
wicking element 162 (e.g., a flat pad) to secure the wicking element 162
within the pocket of
the tines 502.
[0517] FIGS.
54-55 illustrate another example of a heating element 500 consistent with
implementations of the current subject matter in an unbent position (FIG. 54)
and a bent
position (FIG. 55). As shown, the heating element 500 includes the one or more
tines 502
located in the heating portion 504, the one or more legs 506 extending from
the tines 502, the
cartridge contacts 124 formed at the end portion of each of the one or more
legs 506, and the
heat shields 518 extending from the one or more legs 506. In this example,
each of the tines
502 have the same or similar shape and size and the tines 502 have a rounded
and/or semi-
circular outer edge 503.
[0518] FIG. 56
illustrates another example of a heating element 500 in a bent position
consistent with implementations of the current subject matter that is similar
to the example
heating element 500 shown in FIGS. 54-55, but in this example, each of the
tines 502 have the
same or similar shape and size and the tines 502 have a squared and/or flat
outer edge 503.
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[0519] FIGS.
57-62 illustrate other examples of the heating element 500 in which at least
one of the tines 502 has a size, shape, or position that is different from the
remaining tines 502.
For example, as shown in FIGS. 57-58, the heating element 500 includes the one
or more tines
502 located in the heating portion 504, the one or more legs 506 extending
from the tines 502,
and the cartridge contacts 124 formed at the end portion of each of the one or
more legs 506.
In this example, the tines 502 include a first set of tines 505A and a second
set of tines 505B.
The first and second sets of tines 505A, 505B are offset from one another. For
example, the
outer edges 503 of the first and second sets of tines 505A, 505B are not
aligned with one
another. As shown in FIG. 58, when the heating portion 504 is in the bent
position, the first
set of tines 505A appear to be shorter than the second set of tines 505B in
the first portion of
the heating element 500, and the first set of tines 505A appear to be longer
than the second set
of tines 505B in the second portion of the heating element 500.
[0520] As
shown in FIGS. 59-60, the heating element 500 includes the one or more tines
502 located in the heating portion 504, the one or more legs 506 extending
from the tines 502,
and the cartridge contacts 124 formed at the end portion of each of the one or
more legs 506.
In this example, the tines 502 include a first set of tines 509A and a second
set of tines 509B.
The first and second sets of tines 509A, 509B are offset from one another. For
example, the
outer edges 503 of the first and second sets of tines 509A, 509B are not
aligned with one
another. Here, the second set of tines 509B includes a single outermost tine
502A. As shown
in FIGS. 59-60, when the heating portion 504 is in the bent position, the
first set of tines 509A
appear to be longer than the second set of tines 509B. In addition, in FIGS.
59-60, the tines
502 are not bent. Rather, the tines 502 are located on a first portion and a
second portion of
the heating element 500 that is positioned approximately parallel to and
opposite the first
portion. The first set of tines positioned on the first portion of the heating
element 500 are
separated from the second set of tines positioned on the second portion of the
heating element
500 by a platform portion 530 that is positioned between and spaced from both
of the first and
second set of tines. The platform portion 530 is configured to contact an end
of the wicking
element 162. The platform portion 530 includes a cutout portion 532. The
cutout portion 532
may provide additional edges along which the vaporizable material can vaporize
from when
the heating element 500 is activated.
[0521] As
shown in FIGS. 61-62, the heating element 500 includes the one or more tines
502 located in the heating portion 504, the one or more legs 506 extending
from the tines 502,
and the cartridge contacts 124 formed at the end portion of each of the one or
more legs 506.
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In this example, the tines 502 include a first set of tines 509A and a second
set of tines 509B.
The first and second sets of tines 509A, 509B are offset from one another. For
example, the
outer edges 503 of the first and second sets of tines 509A, 509B are not
aligned with one
another. Here, each of the first and the second set of tines 509A, 509B
includes two tines 502.
As shown in FIGS. 61-62, when the heating portion 504 is in the bent position,
the first set of
tines 509A appear to be shorter than the second set of tines 509B. In
addition, in FIGS. 61-62,
the tines 502 are not bent. Rather, the tines 502 are located on a first
portion and a second
portion (that is parallel and opposite the first portion) of the heating
element 500. The first set
of tines positioned on the first portion are separated from the second set of
tines positioned on
the second portion by a platform portion that is positioned between and spaced
from both of
the first and second set of tines. The platform portion is configured to
contact an end of the
wicking element 162. The platform portion includes a cutout portion. The
cutout portion may
provide additional edges along which the vaporizable material can vaporize
from when the
heating element 500 is activated.
[0522] FIGS.
63-68 illustrate another example of a heating element 500 consistent with
implementations of the current subject matter in an unbent position (FIG. 63)
and a bent
position (FIGS. 64-68). As shown, the heating element 500 includes the one or
more tines 502
located in the heating portion 504, the one or more legs 506 extending from
the tines 502, the
cartridge contacts 124 formed at the end portion of each of the one or more
legs 506, and the
heat shields 518 extending from the one or more legs 506. In this example, the
heating element
500 is configured to be crimped around and/or bent to receive a cylindrical-
shaped wicking
element 162 or a wicking element 162 having a circular cross-section. Each of
the tines 502
include apertures 540. The apertures 540 may provide additional edges along
which the
vaporizable material can vaporize from when the heating element 500 is
activated. The
apertures 540 also reduce the amount of material used to form the heating
element 500,
reducing the weight of the heating element 500 and the amount of material used
for the heating
element 500, thereby reducing material costs.
[0523] FIGS.
69-78 illustrate a heating element 500 consistent with implementations of the
current subject matter in which the heating element 500 is pressed against one
side of the
wicking element 162. As shown, the heating element 500 includes the one or
more tines 502
located in the heating portion 504, the one or more legs 506 extending from
the tines 502, and
the cartridge contacts 124 formed at the end portion of each of the one or
more legs 506. In
these examples, the legs 506 and the cartridge contacts 124 are configured to
bend in a third
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direction, rather than in a first-second direction that is perpendicular to
the third direction. In
such a configuration, the tines 502 of the heating portion 504 form a planar
platform that faces
outwardly from the heating element 500 and is configured to be pressed against
the wicking
element 162 (e.g., on one side of the wicking element 162).
[0524] FIGS.
71-74 illustrate several examples of the heating element 500 consistent with
implementations of the current subject matter including tines 502 configured
in various
geometries. As mentioned above, the tines 502 form a planar platform that is
pressed against
one side of the wicking element 162 in use. The legs 506, rather than the
tines 502, bend in
the bent position.
[0525] FIG. 75
illustrates an example of the heating element 500 shown in FIG. 71
assembled with a component of the vaporizer cartridge 120, such as a wick
housing (e.g., the
wick housing 178) that houses the wicking element 162 and the heating element
500 and FIG.
76 illustrates the heating element 500 assembled with an example vaporizer
cartridge 120
consistent with implementations of the current subject matter. As shown the
cartridge contacts
124 are bent towards one another in a lateral direction.
[0526] FIGS.
77 and 78 illustrate another example of the heating element 500 in which the
tines 502 form a platform that is configured to be pressed against the wicking
element 162.
Here, the legs 506 may form spring-like structures that force the tines 502 to
be pressed against
the wicking element 162 when a lateral inward force is applied to each of the
legs 506. For
example, FIG. 78 illustrates an example of the tines 502 being pressed against
the wicking
element 162 when power (e.g., a current) is supplied to the heating element
500, such as via
the cartridge contacts 124.
[0527] FIGS.
82-86 illustrate another example of a heating element 500 consistent with
implementations of the current subject matter. As shown, the heating element
500 includes the
one or more tines 502 located in the heating portion 504, the one or more legs
506 extending
from the tines 502, and the cartridge contacts 124 formed at the end portion
and/or as part of
each of the one or more legs 506. In this example, each of the tines 502 have
the same or
similar shape and size, and are spaced apart from one another at equal
distances. The tines 502
have a rounded outer edge 503.
[0528] As
shown in FIG. 85, the tines 502 have been crimped about a wicking element 162
(e.g., a flat pad) to secure the wicking element 162 within the pocket formed
by the tines 502.
For example, the tines 502 may be folded and/or crimped to define the pocket
in which the
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wicking element 162 resides. The tines 502 include a platform tine portion 524
and side tine
portions 526. The platform tine portion 524 is configured to contact one side
of the wicking
element 162 and the side tine portions 526 are configured to contact other
opposite sides of the
wicking element 162. The platform tine portion 524 and the side tine portions
526 form the
pocket that is shaped to receive the wicking element 162 and/or conform to the
shape of at least
a portion of the wicking element 162. The pocket allows the wicking element
162 to be secured
and retained by the heating element 500 within the pocket.
[0529] In some
implementations, the side tine portions 526 and the platform tine portion
524 retain the wicking element 162 via compression (e.g., at least a portion
of the wicking
element 162 is compressed between the opposing side tine portions 526 and/or
the platform
tine portion 524). The platform tine portion 524 and the side tine portions
526 contact the
wicking element 162 to provide a multi-dimensional contact between the heating
element 500
and the wicking element 162. Multi-dimensional contact between the heating
element 500 and
the wicking element 162 provides for a more efficient and/or faster transfer
of the vaporizable
material from the reservoir 140 of the vaporizer cartridge 120 to the heating
portion 504 (via
the wicking element 162) to be vaporized.
[0530] The one
or more legs 506 of the example heating element 500 shown in FIGS. 82-
86 includes four legs 506. Each of the legs 506 may include and/or define a
cartridge contact
124 that is configured to contact a corresponding receptacle contact 125 of
the vaporizer 100.
In some implementations, each pair of legs 506 (and the cartridge contacts
124) may contact a
single receptacle contact 125. The legs 506 may be spring-loaded to allow the
legs 506 to
maintain contact with the receptacle contacts 125. The legs 506 may include a
portion that
extends along a length of the legs 506 that is curved to help to maintain
contact with the
receptacle contacts 125. Spring-loading the legs 506 and/or the curvature of
the legs 506 may
help to increase and/or maintain consistent pressure between the legs 506 and
the receptacle
contacts 125. In some implementations, the legs 506 are coupled with a support
176 that helps
to increase and/or maintain consistent pressure between the legs 506 and the
receptacle contacts
125. The support 176 may include plastic, rubber, or other materials to help
maintain contact
between the legs 506 and the receptacle contacts 125. In some implementations,
the support
176 is formed as a part of the legs 506.
[0531] The
legs 506 may contact one or more wiping contacts that are configured to clean
the connection between the cartridge contacts 124 and other contacts or power
source. For
example, the wiping contacts would include at least two parallel, but offset,
bosses that
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frictionally engage and slide against one another in a direction that is
parallel or perpendicular
to the insertion direction.
[0532] As
shown in FIGS. 82-98, the one or more legs 506 of the heating element 500
includes four legs 506. FIGS. 91-92, 97A-98B, and 109-110 show examples of the
heating
element 500 in the unbent position. As shown, the heating element 500 has an H-
shape, defined
by the four legs 506 and the tines 502. This configuration allows for
resistance across the
heater to be measured more accurately, and reduces variability in the
resistance measurements,
thereby allowing for more efficiency aerosol generation and higher quality
aerosol generation.
The heating element 500 includes two pairs of opposing legs 506. The tines 502
are coupled
(e.g., intersect) with each of the pairs of opposing legs 506 at or near a
center of each of the
pairs of opposing legs 506. The heating portion 504 is positioned between the
pairs of opposing
legs 506.
[0533] FIG.
109 illustrates an example of the heating element 500 before the heating
element 500 has been stamped and/or otherwise formed from a substrate material
577. Excess
substrate material 577A may be coupled with the heating element 500 at one,
two, or more
coupling locations 577B. For example, as shown, the excess substrate material
577A may be
coupled with the heating element 500 at two coupling locations 577B, near
opposing lateral
ends 173 of the platform portion of the heating element and/or heating portion
504 of the
heating element 500. In some implementations, the heating element 500 may be
first be
stamped from the substrate material 577, and then removed from the excess
substrate material
577A at the coupling locations 577B (e.g., by twisting, pulling, stamping,
cutting, etc., the
heating element 500).
[0534] As
noted above, to crimp the heating element 500, the heating element 500 may be
bent or otherwise folded along fold lines 523, 522A, 522B, 520 towards or away
from one
another (see, for example, FIG. 98A). Though the fold lines are illustrated in
FIG. 98A, the
example heating elements 500 described and shown in FIGS. 44A-115C may also be
crimped,
folded, or otherwise bent along the fold lines. Folding the heating element
500 along fold lines
520 forms a platform tine portion 524 defined by the region between the fold
lines 520 and/or
between side tine portions 526 defined by the region between the fold lines
520 and the outer
edges 503 of the tines 502. The platform tine portion 524 may contact one end
and/or support
one end of the wicking element 162. The side tine portions 526 may contact
opposite sides of
the wicking element 162. The platform tine portion 524 and the side tine
portions 526 define
an interior volume of the heating element that forms a pocket shaped to
receive the wicking
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element 162 and/or conform to the shape of at least a portion of the wicking
element 162. The
interior volume allows the wicking element 162 to be secured and retained by
the heating
element 500 within the pocket. The platform tine portion 524 and the side tine
portions 526
contact the wicking element 162 to provide a multi-dimensional contact between
the heating
element 500 and the wicking element 162. Multi-dimensional contact between the
heating
element 500 and the wicking element 162 provides for a more efficient and/or
faster transfer
of the vaporizable material from the reservoir 140 of the vaporizer cartridge
120 to the heating
portion 504 (via the wicking element 162) to be vaporized.
[0535] In some
implementations, portions of the legs 506 of the heating element 500 may
also be bent along fold lines 522A, 522B. Folding the portions of the legs 506
of the heating
element 500 along fold lines 522 away from one another locates the legs 506 at
a position
spaced away from the heating portion 504 (and tines 502) of the heating
element 500 in a first
and/or second direction opposite the first direction (e.g., in the same
plane). Thus, folding the
portions of the legs 506 of the heating element 500 along fold lines 522 away
from one another
spaces the heating portion 504 from the body of the vaporizer cartridge 120.
Folding the
portions of the legs 506 along the fold lines 522A, 522B forms a bridge 585.
In some
implementations, the bridge 585 helps to reduce or eliminate overflow of
vaporizable material
from the heating portion 504, such as due to capillary action. The bridge 585
also helps to
isolate the heating portion 504 from the legs 506, so that the heat generated
at the heating
portion 504 does not reach the legs 506. This also helps to localize heating
of the heating
element 500 to within the heating portion 504.
[0536] In some
implementations, the heating element 500 may also be bent along fold lines
523 to define the cartridge contacts 124 The cartridge contacts 124 may be
exposed to the
environment or may otherwise be accessible (and may be positioned within an
interior of a
portion of the cartridge, such as the outer shell) to contact the receptacle
contacts, while other
portions, such as the heating portion 504 of the heating element 500, are
positioned within an
inaccessible part of the vaporizer cartridge 120, such as the wick housing.
[0537] In some
implementations, the legs 506 include retainer portions 180 that are
configured to be bent around at least a portion of a wick housing 178 that
surrounds at least a
portion of the wicking element 162 and heating element 500 (such as the
heating portion 504).
The retainer portions 180 form an end of the legs 506. The retainer portions
180 help to secure
the heating element 500 and wicking element 162 to the wick housing 178 (and
the vaporizer
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cartridge 120). The retainer portions 180 may alternatively be bent away from
at least a portion
of the wick housing 178.
[0538] FIGS.
87-92 illustrate another example of a heating element 500 consistent with
implementations of the current subject matter. As shown, the heating element
500 includes the
one or more tines 502 located in the heating portion 504, the one or more legs
506 extending
from the tines 502, and the cartridge contacts 124 formed at the end portion
and/or as part of
each of the one or more legs 506.
[0539] The
tines 502 may be folded and/or crimped to define the pocket in which a wicking
element 162 (e.g., a flat pad) resides. The tines 502 include a platform tine
portion 524 and
side tine portions 526. The platform tine portion 524 is configured to contact
one side of the
wicking element 162 and the side tine portions 526 are configured to contact
other opposite
sides of the wicking element 162. The platform tine portion 524 and the side
tine portions 526
form the pocket that is shaped to receive the wicking element 162 and/or
conform to the shape
of at least a portion of the wicking element 162. The pocket allows the
wicking element 162
to be secured and retained by the heating element 500 within the pocket.
[0540] In this
example, the tines 502 have various shapes and size, and are spaced apart
from one another at the same or varying distances. For example, as shown, each
of the side
tine portions 526 includes at least four tines 502. In a first pair 570 of
adjacent tines 502, each
of the adjacent tines 502 is spaced apart at an equal distance from an inner
region 576
positioned near the platform tine portion 524 to an outer region 578
positioned near the outer
edge 503. In a second pair 572 of adjacent tines 502, the adjacent tines 502
are spaced apart
by a varying distance from the inner region 576 to the outer region 578. For
example, the
adjacent tines 502 of the second pair 572 are spaced apart by a width that is
greater at the inner
region 576 than at the outer region 578. These configurations may help to
maintain a constant
and uniform temperature along the length of the tines 502 of the heating
portion 504.
Maintaining a constant temperature along the length of the tines 502 may
provide higher quality
aerosol, as the maximum temperature is more uniformly maintainable across the
entire heating
portion 504.
[0541] As
noted above, each of the legs 506 may include and/or define a cartridge
contact
124 that is configured to contact a corresponding receptacle contact 125 of
the vaporizer 100.
In some implementations, each pair of legs 506 (and the cartridge contacts
124) may contact a
single receptacle contact 125. In some implementations, the legs 506 include
retainer portions
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180 that are configured to be bent and generally extend away from the heating
portion 504.
The retainer portions 180 are configured to be positioned within a
corresponding recess in the
wick housing 178. The retainer portions 180 form an end of the legs 506. The
retainer portions
180 help to secure the heating element 500 and wicking element 162 to the wick
housing 178
(and the vaporizer cartridge 120). The retainer portions 180 may have a tip
portion 180A that
extends from an end of the retainer portion 180 towards the heating portion
504 of the heating
element 500. This configuration reduces the likelihood that the retainer
portion will contact
another portion of the vaporizer cartridge 120, or a cleaning device for
cleaning the vaporizer
cartridge 120.
[0542] The
outer edge 503 of the tines 502 in the heating portion 504 may include a tab
580. The tab 580 may include one, two, three, four, or more tabs 580. The tab
580 may extend
outwardly from the outer edge 503 and extend away from a center of the heating
element 500.
For example, the tab 580 may be positioned along an edge of the heating
element 500
surrounding an internal volume defined by at least the side tine portions 526
for receiving the
wicking element 162. The tab 580 may extend outwardly away from the internal
volume of
the wicking element 162. The tab 580 may also extend away in a direction
opposite the
platform tine portion 524. In some implementations, tabs 580 positioned on
opposing sides of
the internal volume of the wicking element 162 may extend away from one
another. This
configuration helps to widen the opening leading to the internal volume of the
wicking element
162, thereby helping to reduce the likelihood that the wicking element 162
will catch, tear,
and/or become damaged when assembled with the heating element 500. Due to the
material
of the wicking element 162, the wicking element 162 may easily catch, tear,
and/or otherwise
become damaged when assembled (e.g., positioned within or inserted into) with
the heating
element 500. Contact between the wicking element 162 and the outer edge 503 of
the tines
502 may also cause damage to the heating element. The shape and/or positioning
of the tab
580 may allow the wicking element 162 to more easily be positioned within or
into the pocket
(e.g., the internal volume of the heating element 500) formed by the tines
502, thereby
preventing or reducing the likelihood that the wicking element 162 and/or the
heating element
will be damaged. Thus, the tabs 580 help to reduce or prevent damage caused to
the heating
element 500 and/or the wicking element 162 upon entry of the wicking element
162 into
thermal contact with the heating element 500. The shape of the tab 580 also
helps to minimize
impact on the resistance of the heating portion 504.
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[0543] In some
implementations, at least a portion of the cartridge contacts 124 and/or at
least a portion of the legs 506 may be plated with one or more outer plating
materials 550 to
reduce contact resistance at the point where the heating element 500 contacts
the receptacle
contacts 125.
[0544] FIGS.
93A-98B illustrate another example of a heating element 500 consistent with
implementations of the current subject matter. As shown, the heating element
500 includes the
one or more tines 502 located in the heating portion 504, the one or more legs
506 extending
from the tines 502, and the cartridge contacts 124 formed at the end portion
and/or as part of
each of the one or more legs 506.
[0545] The
tines 502 may be folded and/or crimped to define the pocket in which a wicking
element 162 (e.g., flat pad) resides. The tines 502 include a platform tine
portion 524 and side
tine portions 526. The platform tine portion 524 is configured to contact one
side of the wicking
element 162 and the side tine portions 526 are configured to contact other
opposite sides of the
wicking element 162. The platform tine portion 524 and the side tine portions
526 form the
pocket that is shaped to receive the wicking element 162 and/or conform to the
shape of at least
a portion of the wicking element 162. The pocket allows the wicking element
162 to be secured
and retained by the heating element 500 within the pocket.
[0546] In this
example, the tines 502 have the same shape and size and are spaced apart
from one another at equal distances. Here, the tines 502 include a first side
tine portion 526A
and a second side tine portion 526B that are spaced apart by the platform tine
portion 524.
Each of the first and second side tine portions 526A, 526B include an inner
region 576
positioned near the platform tine portion 524 to an outer region 578
positioned near the outer
edge 503. At the outer region 578, the first side tine portion 526A is
positioned approximately
parallel to the second tine portion 526A. At the inner region 576, the first
side tine portion
526A is positioned offset from the second tine portion 526B and the first and
second side tine
portions 526A, 526B are not parallel. This configuration may help to maintain
a constant and
uniform temperature along the length of the tines 502 of the heating portion
504. Maintaining
a constant temperature along the length of the tines 502 may provide higher
quality aerosol, as
the maximum temperature is more uniformly maintainable across the entire
heating portion
504.
[0547] As
noted above, each of the legs 506 may include and/or define a cartridge
contact
124 that is configured to contact a corresponding receptacle contact 125 of
the vaporizer 100.
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In some implementations, each pair of legs 506 (and the cartridge contacts
124) may contact a
single receptacle contact 125. In some implementations, the legs 506 include
retainer portions
180 that are configured to be bent and generally extend away from the heating
portion 504.
The retainer portions 180 are configured to be positioned within a
corresponding recess in the
wick housing 178. The retainer portions 180 form an end of the legs 506. The
retainer portions
180 help to secure the heating element 500 and wicking element 162 to the wick
housing 178
(and the vaporizer cartridge 120). The retainer portions 180 may have a tip
portion 180A that
extends from an end of the retainer portion 180 towards the heating portion
504 of the heating
element 500. This configuration reduces the likelihood that the retainer
portion will contact
another portion of the vaporizer cartridge 120, or a cleaning device for
cleaning the vaporizer
cartridge 120.
[0548] The
outer edge 503 of the tines 502 in the heating portion 504 may include a tab
580. The tab 580 may extend outwardly from the outer edge 503 and extend away
from a
center of the heating element 500. The tab 580 may be shaped to allow the
wicking element
162 to more easily be positioned within the pocket formed by the tines 502,
thereby preventing
or reducing the likelihood that the wicking element 162 will get caught on the
outer edge 503.
The shape of the tab 580 helps to minimize impact on the resistance of the
heating portion 504.
[0549] In some
implementations, at least a portion of the cartridge contacts 124 and/or at
least a portion of the legs 506 may be plated with one or more outer plating
materials 550 to
reduce contact resistance at the point where the heating element 500 contacts
the receptacle
contacts 125.
[0550] FIGS.
99-100 illustrate an example of the atomizer assembly 141, with the heating
element 500 assembled with the wick housing 178, and FIG. 101 illustrates an
exploded view
of the atomizer assembly 141, consistent with implementations of the current
subject matter.
The wick housing 178 may be made of plastic, polypropylene, and the like. The
wick housing
178 includes four recesses 592 in which at least a portion of each of the legs
506 of the heating
element 500 may be positioned and secured. As shown, the wick housing 178 also
includes an
opening 593 providing access to an internal volume 594, in which at least the
heating portion
504 of the heating element 500 and the wicking element 162 are positioned.
[0551] The
wick housing 178 may also include a separate heat shield 518A, which is shown
in FIG. 102. The heat shield 518A is positioned within the internal volume 594
within the wick
housing 178 between the walls of the wick housing 178 and the heating element
500. The heat
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shield 518A is shaped to at least partially surround the heating portion 504
of the heating
element 500 and to space the heating element 500 from the side walls of the
wick housing 178.
The heat shield 518A can help to insulate the heating portion 504 from the
body of the vaporizer
cartridge 120 and/or the wick housing 178. The heat shield 518A helps to
minimize the effects
of the heat emanating from the heating portion 504 on the body of the
vaporizer cartridge 120
and/or the wick housing 178 to protect the structural integrity of the body of
the vaporizer
cartridge 120 and/or the wick housing 178 and to prevent melting or other
deformation of the
vaporizer cartridge 120 and/or the wick housing 178. The heat shield 518A may
also help to
maintain a consistent temperature at the heating portion 504 by retaining heat
within the heating
portion 504, thereby preventing or limiting heat losses.
[0552] The
heat shield 518A includes one or more slots 590 (e.g., three slots) at one end
that align with one or more slots (e.g., one, two, three, four, five, six, or
seven or more slots)
596 formed in a portion of the wick housing 178 opposite the opening 593, such
as a base of
the wick housing 178 (see FIGS. 100 and 112). The one or more slots 590, 596
allow for the
escape of pressure caused by the flow of liquid vaporizable material within
the heating portion
504 and vaporization of vaporizable material, without affecting liquid flow of
the vaporizable
material.
[0553] In some
implementations, flooding may occur between the heating element 500
(e.g., the legs 506) and an outer wall of the wick housing 178 (or between
portions of the
heating element 500). For example, liquid vaporizable material may build up
due to capillary
pressure between the legs 506 of the heating element 500 and the outer wall of
the wick housing
178, as indicated by liquid path 599. In such cases, there may be sufficient
capillary pressure
to draw the liquid vaporizable material out of the reservoir and/or the
heating portion 504. To
help limit and/or prevent liquid vaporizable material from escaping the
internal volume of the
wick housing 178 (or the heating portion 504), the wick housing 178 and/or the
heating element
500 may include a capillary feature that causes an abrupt change in capillary
pressure, thereby
forming a liquid barrier that prevents the liquid vaporizable material from
passing the feature
without the use of an additional seal (e.g., a hermetic seal). The capillary
feature may define a
capillary break, formed by a sharp point, bend, curved surface, or other
surface in the wick
housing 178 and/or the heating element 500. The capillary feature allows a
conductive element
(e.g., the heating element 500) to be positioned within both a wet and dry
region.
[0554] The
capillary feature may be positioned on and/or form a part of the heating
element
500 and/or the wick housing 178 and causes an abrupt change in capillary
pressure. For
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example, the capillary feature may include a bend, sharp point, curved
surface, angled surface,
or other surface feature that causes an abrupt change in capillary pressure
between the heating
element and the wick housing, along a length of the heating element, or
another component of
the vaporizer cartridge. The capillary feature may also include a protrusion
or other portion of
the heating element and/or wick housing that widens a capillary channel, such
as a capillary
channel formed between portions of the heating element, between the heating
element and the
wick housing, and the like, that is sufficient to reduce the capillary
pressure within the capillary
channel (e.g., the capillary feature spaces the heating element from the wick
housing) such that
the capillary channel does not draw liquid into the capillary channel. Thus,
the capillary feature
prevents or limits liquid from flowing along a liquid path beyond the
capillary feature, due at
least in part to the abrupt change and/or reduction in capillary pressure. The
size and/or shape
of the capillary feature (e.g., the bend, sharp point, curved surface, angled
surface, protrusion,
and the like) may be a function of a wetting angle formed between materials,
such as the heating
element and wick housing, or other walls of a capillary channel formed between
components,
may be a function of a material of the heating element and/or the wick housing
or other
component, and/or may be a function of a size of a gap formed between two
components, such
as the heating element and/or wick housing defining the capillary channel,
among other
properties.
[0555] As an
example, FIGS. 103A and 103B illustrate the wick housing 178 having a
capillary feature 598 that causes an abrupt change in capillary pressure. The
capillary feature
598 prevents or limits liquid from flowing along the liquid path 599 beyond
the capillary
feature 598, and helps to prevent liquid from pooling between the legs 506 and
the wick
housing 178. The capillary feature 598 on the wick housing 178 spaces the
heating element
500 (e.g., a component made of metal, etc.) away from the wick housing 178
(e.g., a component
made of plastic, etc.), thereby reducing the capillary strength between the
two components.
The capillary feature 598 shown in FIGS. 103A and 103B also includes a sharp
edge at an end
of an angled surface of the wick housing that limits or prevents liquid from
flowing beyond the
capillary feature 598.
[0556] As
shown in FIG. 103B, the legs 506 of the heating element 500 may also be angled
inwardly towards the interior volume of the heating element 500 and/or wick
housing 178. The
angled legs 506 may form a capillary feature that helps to limit or prevent
liquid from flowing
over an outer surface of the heating element and along the legs 506 of the
heating element 500.
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[0557] As
another example, the heating element 500 may include a capillary feature
(e.g.,
a bridge 585) that is formed with the one or more legs 506 and spaces the legs
506 away from
the heating portion 504 (See FIGS. 82-98). The bridge 585 may be formed by
folding the
heating element 500 along the fold lines 520, 522. In some implementations,
the bridge 585
helps to reduce or eliminate overflow of vaporizable material from the heating
portion 504,
such as due to capillary action. In some examples, such as the example heating
elements 500
shown in FIGS. 93A-98B, the bridge 585 is angled and/or includes a bend to
help limit fluid
flow out of the heating portion 504.
[0558] As
another example, the heating element 500 may include a capillary feature 598
that defines a sharp point to causes an abrupt change in capillary pressure,
thereby preventing
liquid vaporizable material from flowing beyond the capillary feature 598.
FIG. 104 shows an
example of the heating element 500 having the capillary feature 598,
consistent with
implementations of the current subject matter. As shown in FIG. 104, the
capillary feature 598
may form an end of the bridge 585 that extends outwardly away from the heating
portion by a
distance that is greater than a distance between the legs 506 and the heating
portion 504. The
end of the bridge 585 may be a sharp edge to further help prevent liquid
vaporizable material
from passing to the legs 506 and/or out of the heating portion 504, thereby
reducing leaking
and increasing the amount of vaporizable material that remains within the
heating portion 504.
[0559] FIGS.
105-106 illustrate a variation of the heating element 500 shown in FIGS. 87-
92. In this variation of the heating element 500, the legs 506 of the heating
element 500 include
a bend at an inflection region 511. The bend in the legs 506 may form a
capillary feature 598,
which helps to prevent liquid vaporizable material from flowing beyond the
capillary feature
598. For example, the bend may create an abrupt change in capillary pressure,
which may also
help to limit or prevent liquid vaporizable material from flowing beyond the
bend and/or from
pooling between the legs 506 and the wick housing 178, and may help to limit
or prevent liquid
vaporizable material from flowing out of the heating portion 504.
[0560] FIGS.
107-108 illustrate a variation of the heating elements 500 shown in FIGS.
93A-98B. In this variation of the heating element 500, the legs 506 of the
heating element 500
include a bend at an inflection region 511. The bend in the legs 506 may form
a capillary
feature 598, which helps to prevent liquid vaporizable material from flowing
beyond the
capillary feature 598. For example, the bend may create an abrupt change in
capillary pressure,
which also helps to limit or prevent liquid vaporizable material from flowing
beyond the bend
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and/or from pooling between the legs 506 and the wick housing 178, and may
help to limit or
prevent liquid vaporizable material from flowing out of the heating portion
504.
[0561] FIGS.
111A-112 illustrate another example of the atomizer assembly 141, with the
heating element 500 assembled with the wick housing 178 and the heat shield
518A, and FIG.
113 illustrates an exploded view of the atomizer assembly 141, consistent with
implementations of the current subject matter. The wick housing 178 may be
made of plastic,
polypropylene, and the like. The wick housing 178 includes four recesses 592
in which at least
a portion of each of the legs 506 of the heating element 500 may be positioned
and secured.
Within the recesses 592, the wick housing 178 may include one or more wick
housing retention
features 172 (see FIG. 115A) that help to secure the heating element 500 to
the wick housing
178, such as, for example, via a snap-fit arrangement between at least a
portion of the legs 506
of the heating element 500 and the wick housing retention features 172. The
wick housing
retention features 172 may also help to space the heating element 500 from a
surface of the
wick housing 178, to help prevent heat from acting on the wick housing and
melting a portion
of the wick housing 178.
[0562] As
shown, the wick housing 178 also includes an opening 593 providing access to
an internal volume 594, in which at least the heating portion 504 of the
heating element 500
and the wicking element 162 are positioned.
[0563] The
wick housing 178 may also include one or more other cutouts that help to space
the heating element 500 from a surface of the wick housing 178 to reduce the
amount of heat
that contacts the surface of the wick housing 178. For example, the wick
housing 178 may
include cutouts 170. The cutouts 170 may be formed along an outer surface of
the wick housing
178 proximate to the opening 593. The cutouts 170 may also include a capillary
feature, such
as the capillary feature 598. The capillary feature of the cutouts 170 may
define a surface (e.g.,
curved surface) that breaks tangency points between adjacent (or intersecting)
walls (such as
the walls of the wick housing). The curved surface may have a radius that is
sufficient to
reduce or eliminate the capillarity formed between the adjacent outer walls of
the wick housing.
[0564]
Referring to FIGS. 111A-112, the wick housing 178 may include a tab 168. The
tab 168 may help to properly position and/or orient the wick housing during
assembly of the
vaporizer cartridge, with respect to one or more other components of the
vaporizer cartridge.
For example, added material forming the tab 168 shifts the center of mass of
the wick housing
178. Due to the shifted center of mass, the wick housing 178 may rotate or
slide in a certain
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orientation to align with a corresponding feature of another component of the
vaporizer
cartridge during assembly.
[0565] FIGS.
114A-114C illustrate an example method of forming the atomizer assembly
141 of the vaporizer cartridge 120, including the wick housing 178, the
wicking element 162,
and the heating element 500, consistent with implementations of the current
subject matter. As
shown in FIG. 114A, the wicking element 162 may be inserted into the pocket
formed in the
heating element 500 (e.g., formed by the side tine portions 526 and the
platform tine portion
524. In some implementations, the wicking element 162 expands after being
secured to the
heating element 500, when vaporizable material is introduced to the wicking
element 162.
[0566] FIG.
114B shows the wicking element 162 and the heating element 500 being
coupled to the wick housing 178 and FIG. 114C shows an example of the wicking
element 162
and the heating element 500 assembled with the wick housing 178. At least a
portion of the
heating element 500, such as the heating portion 504 may be positioned within
the internal
volume of the wick housing 178. The legs 506 (e.g., the retainer portions 180)
of the heating
element 500 may couple with the outer walls of the wick housing 178 via, for
example, a snap-
fit arrangement. In particular, the retainer portions 180 of the legs 506 may
couple with and
be positioned at least partially within the recesses in the wick housing 178.
[0567] FIGS.
115A-115C illustrate another example method of forming the atomizer
assembly 141 of the vaporizer cartridge 120, including the wick housing 178,
the wicking
element 162, and the heating element 500, consistent with implementations of
the current
subject matter. As shown in FIG. 115A, the heating element 500 may be coupled
to the wick
housing 178, for example, by inserting or otherwise positioning the at least a
portion of the
heating element 500, such as the heating portion 504 within the internal
volume of the wick
housing 178. The legs 506 (e.g., the retainer portions 180) of the heating
element 500 may
couple with the outer walls of the wick housing 178 via, for example, a snap-
fit arrangement.
In particular, the retainer portions 180 or another portion of the legs 506
may couple with and
be positioned at least partially within the recesses in the wick housing 178,
for example, by
coupling with the wick housing retention features 172.
[0568] As
shown in FIG. 115B, the wicking element 162 may be inserted into the pocket
formed in the heating element 500 (e.g., formed by the side tine portions 526
and the platform
tine portion 524. In some implementations, the wicking element 162 is
compressed as the
wicking element 162 is coupled with the heating element 500. In some
implementations, the
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wicking element 162 fits within the heating element 500 and expands after
being secured to
the heating element 500, when vaporizable material is introduced to the
wicking element 162.
[0569] FIG.
115C shows an example of the wicking element 162 and the heating element
500 assembled with the wick housing 178 to form the atomizer assembly 141.
[0570] FIG.
116 illustrates an example process 3600 for assembling the heating element
500 consistent with implementations of the current subject matter. The process
flow chart 3600
illustrates features of a method, which may optionally include some or all of
the following. At
block 3610, a planar substrate having resistive heating properties is
provided. At block 3612,
the planar substrate may be cut and/or stamped into the desired geometry. At
block 3614, at
least a portion of the heating element 500 may be plated. For example, as
mentioned above,
one or more layers of a plating material (e.g., an adhering plating material
and/or an outer
plating material) may be deposited onto at least a portion of an outer surface
of the heating
element 500. At block 3616, the heating portion 504 (e.g., the tines 502) may
be bent and/or
otherwise crimped about a wicking element to match the shape of the wicking
element and to
secure the wicking element to the heating element. At block 3618, the
cartridge contacts 124,
which in some implementations form an end portion of the legs 506 of the
heating element 500,
may be bent in a first or second direction along a plane or a third direction
that is perpendicular
to the first or second direction. At block 3620, the heating element 500 may
be assembled into
a vaporizer cartridge 120 and fluid communication between the wicking element
162 and a
reservoir of vaporizable material may be caused. At 3622, the vaporizable
material may be
drawn into the wicking element 162, which may be positioned in contact with at
least two
surfaces of the heating portion 504 of the heating element 500. At block 3624,
a heating means
may be provided to the cartridge contacts 124 of the heating element to heat
the heating element
500 at least the heating portion 504. The heating causes vaporization of the
vaporizable
material. At block 3626, the vaporized vaporizable material is entrained in a
flow of air to a
mouthpiece of the vaporization cartridge in which the heating element is
positioned.
Condensate Control, Collection and Recycling Embodiments
[0571] FIGS.
117-119C illustrate embodiments of a vaporizer cartridge including one or
more features for controlling, collecting, and/or recycling condensate in a
vaporizer device.
While the features described and shown with respect to FIGS. 117-119C may be
included in
the various embodiments of the vaporizer cartridges described above and/or may
include one
or more features of the various embodiments of the vaporizer cartridges
described above, the
features of the vaporizer cartridges described and shown with respect to FIGS.
117-119C may
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additionally and/or alternatively be included in one or more other example
embodiments of
vaporizer cartridges, such as those described below.
[0572] A
typical approach by which a vaporizer device generates an inhalable aerosol
from
a vaporizable material involves heating the vaporizable material in a
vaporization chamber (or
a heater chamber) to cause the vaporizable material to be converted to the gas
(or vapor) phase.
A vaporization chamber generally refers to an area or volume in the vaporizer
device within
which a heat source (e.g., conductive, convective, and/or radiative) causes
heating of a
vaporizable material to produce a mixture of air and vaporized vaporizable to
form a vapor for
inhalation by a user of the vaporization device.
[0573] Since
the introduction of vaporizer devices onto the market, vaporizer cartridges
containing free liquid (i.e., the liquid held in a reservoir and not retained
by porous material)
have gained popularity. Products on the market may either have cotton pads or
no feature at
all to collect a condensate produced by the generation of vapor in a vaporizer
device.
[0574] Liquid
from condensation may form a film on the walls of an airpath and can travel
up to the mouthpiece with the potential to leak into a user's mouth, which may
cause an
unpleasant experience. Even if the wall film does not leak out of the
mouthpiece it can be
entrained by the airflow creating large droplets which may be drawn into the
user's mouth and
throat resulting in an unpleasant user experience. Issues with using a cotton
pad to absorb such
condensate include ineffectiveness as well as additional manufacturing and
assembly cost of
integrating the cotton pad into a part of a vaporizer device. Furthermore,
buildup and loss of
condensate and/or unvaporized vaporizable material can ultimately result in an
inability to
draw all of the vaporizable material into the vaporization chamber, thereby
wasting vaporizable
material. As such, improved vaporization devices and/or vaporization
cartridges are desired.
[0575]
Vaporizing vaporizable material into an aerosol, as described in greater
detail
below, can result in condensate collecting along one or more internal channels
and outlets (e.g.,
along a mouthpiece) of some vaporizers. For example, such condensate may
include
vaporizable material that was drawn from a reservoir, formed into an aerosol,
and condensed
into the condensate prior to exiting the vaporizer. Additionally, vaporizable
material that has
circumvented the vaporization process may also accumulate along the one or
more internal
channels and/or air outlets. This can result in the condensate and/or
unvaporized vaporizable
material exiting the mouthpiece outlet and depositing into the mouth of a user
thereby creating
both an unpleasant user experience as well as decreasing the amount of
inhalable aerosol
otherwise available. Furthermore, the buildup and loss of condensate can
ultimately result in
the inability to draw all of the vaporizable material from the reservoir into
the vaporization
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chamber, thereby wasting vaporizable material. For example, as vaporizable
material
particulates accumulate in the internal channels of an air tube downstream of
a vaporization
chamber, the effective cross-sectional area of the airflow passageway narrows,
thus increasing
the flow rate of the air and thereby applying drag forces onto the accumulated
fluid
consequently amplifying the potential to entrain fluid from the internal
channels and through
the mouthpiece outlet. Various features and devices are described below that
improve upon or
overcome these issues.
[0576] As
mentioned above, drawing vaporizable material from the reservoir and
vaporizing the vaporizable material into an aerosol may result in vaporizable
material
condensate collecting adjacent and/or within one or more outlets formed in the
mouthpiece.
This can result in the condensate exiting the outlets and depositing into the
mouth of the user,
thus creating both an unpleasant user experience as well as decreasing the
amount of
consumable vapor otherwise available. Various vaporizer device features are
described below
that improve upon or overcome these issues. For example, various features are
described
herein for controlling condensate in a vaporizer device, which may provide
advantages and
improvements relative to existing approaches, while also introducing
additional benefits as
described herein. For example, vaporizer device features are described that
are configured to
collect and contain condensate that forms or collects adjacent an outlet of
the mouthpiece
thereby preventing the condensate from exiting the outlet.
[0577]
Alternatively or in addition, drawing the vaporizable material 102 from the
reservoir 140 and vaporizing the vaporizable material into an aerosol may
result in condensate
collecting within one or more tubes or internal channels (such as an air tube)
of a vaporizer
device. As will be described in greater detail below, vaporizer device
features are described
that are configured to trap the condensate and prevent vaporizable material
particulates from
exiting the air outlet of the vaporizer cartridge.
[0578] FIG.
117 illustrates an embodiment of a vaporizer cartridge 120 including a finned
condensate collector 352 configured to collect and contain condensate that
forms or collects
adjacent an outlet of the mouthpiece or other region of the vaporizer
cartridge 120 thereby
preventing the condensate from exiting the outlet. As shown in FIG. 117, the
finned condensate
collector 352 may be disposed in a chamber proximate to the outlet 136 in a
mouthpiece 130
such that aerosol passes through the finned condensate collector 352 prior to
exiting through
the outlet 136.
[0579] FIG.
118 illustrates an embodiment of a mouthpiece 330 including an embodiment
of a finned condensate collector 352 having a plurality of microfluidic fins
354. The
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mouthpiece 330 may be configured for a vaporizer cartridge (such as vaporizer
cartridge 120)
and/or a vaporizer device (such as vaporizer 100) with the microfluidic fins
354 housed in the
finned condensate collector 352 for improving condensate collection and
containment in the
vaporizer cartridge. As shown in FIG. 118, the microfluidic fins 354 include a
set of walls 355
or other protrusions and narrow grooves 353 that have microfluidic properties.
In an example
embodiment, each wall in the set of walls 355 may be positioned parallel, or
substantially
parallel, to each other such that the space between each wall creates the
grooves 353, which
define capillary channels. The walls 355 define or otherwise form one or more
capillary
channels or grooves that are configured to collect fluid or other condensate.
[0580] The
mouthpiece 330 illustrated in FIG. 118 may improve or otherwise modify the
collection and containment of condensate within the reservoir such that
condensate flowing out
an air tube outlet 332 (such as an air tube or cannula 128 as shown in FIG.
117) may get trapped
or otherwise collect between the microfluidic fins 354 as a user inhales on
the vaporizer device.
As mentioned, the microfluidic fins define one or more capillary channels
through which fluid
is collected via a capillary force formed when fluid is positioned within the
capillary channel(s).
To keep the fluid trapped by the finned condensate collector 352 without being
extracted by
the drag force of the airflow, the capillary force of the microfluidic fins
may be greater than
the airflow drag force by providing narrow grooves or channels in which the
fluid becomes
positioned. For example, an effective groove width may be 0.3 mm, and/or range
from
approximately 0.1 mm to approximately 0.8 mm.
[0581] One
benefit to this configuration is eliminating the need for the manufacture of
additional parts, thus reducing part count without loss of function. In one
embodiment, the
finned condensate collector and mouthpiece may be manufactured as a monolithic
body using
one mold, (e.g., plastic mold). Additionally, the finned condensate collector
and mouthpiece
may be separate structures that are welded together that collectively form the
finned condensate
collector. Other manufacturing methods and materials are within the scope of
this disclosure.
[0582] In
other embodiments, the microfluidic fins may be formed as a separate part and
fit into the mouthpiece. For example, the microfluidic fins may be formed into
any part of the
vaporizer device or vaporizer cartridge for collecting and containing
condensate. The
microfluidic fins may be formed with the mouthpiece or may be formed as a
second plastic
part and fitted into the mouthpiece.
[0583] In
addition to collecting in the mouthpiece, vaporizable material condensate may
build up within one or more airflow passageways or internal channels of a
vaporizer device.
Various features and devices are described below that improve upon or overcome
these issues.
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For example, various features are described herein for recycling condensate in
a vaporizer
device, such as embodiments of a condensate recycler system, as will be
described in greater
detail below.
[0584] FIGs.
119A-119C illustrate an embodiment of a condensate recycler system 360 of
a vaporizer cartridge (such as vaporizer cartridge 120) and/or vaporizer
device (such as
vaporizer 100). The condensate recycler system 360 may be configured for
collecting
vaporizable material condensate and directing the condensate back to the wick
for reuse.
[0585] The
condensate recycler system 360 may include an internally grooved air tube 334
creating an airflow passageway 338 which extends from the mouthpiece toward
the
vaporization chamber 342 and may be configured to collect any vaporizable
material
condensate and direct it (via capillary action) back to the wick for reuse.
[0586] One
function of the grooves may include that vaporizable material condensate
becomes trapped or is otherwise positioned within the grooves. The condensate,
once
positioned within the grooves, drains down to the wick due to the capillary
action created by
the wicking element. The draining of the condensate within the grooves may at
least partially
be achieved via capillary action. If any condensation exists inside the air
tube the vaporizable
material particulates fill into the grooves rather than forming or building a
wall of condensate
inside the air tube if the grooves were not present. When the grooves are
filled enough to
establish fluid communication with the wick, the condensate drains through and
from the
grooves and can be reused as vaporizable material. In some embodiments, the
grooves may be
tapered such that the grooves are narrower towards the wick and wider towards
the mouthpiece.
Such tapering may encourage fluid to move toward the vaporization chamber as
more
condensate collects in the grooves via higher capillary action at the narrower
point.
[0587] FIG.
119A shows a cross-sectional view of air tube 334. The air tube 334 includes
an airflow passageway 338 and one or more internal grooves having a decreasing
hydraulic
diameter toward the vaporization chamber 342. The grooves are sized and shaped
such that
fluid (such as condensate) disposed within the grooves can be transported from
a first location
to a second location via capillary action. The internal grooves include air
tube grooves 364
and chamber grooves 365. The air tube grooves 364 may be disposed inside of
air tube 334
and may taper such that the cross-section of the air tube grooves 364 at an
air tube first end 362
may be greater than the cross-section of the air tube grooves 364 at an air
tube second end 363.
The chamber grooves 365 may be disposed proximate to the air tube second end
363 and
coupled with air tube grooves 364. The internal grooves may be in fluid
communication with
the wick and configured to allow the wick to continually drain vaporizable
material condensate
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from the internal grooves, thus preventing the buildup of a film of condensate
in the airflow
passageway 338. The condensate may preferentially enter the internal grooves
due to the
capillary drive of the internal grooves. The gradient of capillary drive in
the internal grooves
directs fluid migration toward wick housing 346, where the vaporizable
material condensate is
recycled by resaturating the wick.
[0588] FIGs.
119B and 119C show an internal view of the condensate recycler system 360
as seen from the air tube first end 362, and the air tube second end 363,
respectively. The air
tube first end 362 may be disposed proximate to the mouthpiece and/or air
outlet. The air tube
second end 363 may be disposed proximate to the vaporization chamber 342
and/or wick
housing 346, and may be in fluid communication with the chamber grooves 365
and/or the
wick. The air tube grooves 364 may have a first diameter 366 and a second
diameter 368. The
second diameter 368 may be narrower than the first diameter 366.
[0589] As
discussed above, as the effective cross-section of the air flow passageway
narrows, either by accumulation of condensate in the airflow passageway or by
design as
discussed herein, the flow rate of the air moving through the air tube
increases, applying drag
forces on the accumulated fluid (e.g., condensate). Fluid exits the air outlet
when the drag
forces pulling the fluid out toward the user (e.g., responsive to inhalation
on the vaporizer) are
higher than the capillary forces pulling the fluid toward the wick.
[0590] To
overcome this issue and encourage the condensate away from the mouthpiece
outlet and back toward the vaporization chamber 342 and/or the wick, a tapered
airflow
passageway is provided such that a cross-section of the air tube grooves 364
proximate to the
vaporization chamber 342 is narrower than a cross-section of the air tube
grooves 364
proximate to the mouthpiece. Further, each of the internal grooves narrows
such that the width
of the internal grooves proximate to the air tube first end 362 may be wider
than the width of
the internal grooves proximate to the air tube second end 363. As such, the
narrowing
passageway increases the capillary drive of the air tube grooves 364 and
encourages fluid
movement of the condensate toward the chamber grooves 365. Further yet, the
chamber
grooves 365 proximate to the air tube second end 363 may be wider than the
width of the
chamber grooves 365 proximate to the wick. That is, each groove channel
progressively
narrows approaching the wick in addition to the airflow passageway itself
narrowing toward
the wick end.
[0591] To
maximize the effectiveness of the capillary action provided by the condensate
recycler system design, the air tube cross-sectional size relative to the
groove size may be
considered. While capillary drive may increase as groove width narrows,
smaller groove sizes
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may result in the condensate overflowing the grooves and clogging the air
tube. As such,
groove width may range from approximately 0.1 mm to approximately 0.8 mm.
[0592] In some
embodiments, the geometry or number of grooves may vary. For example,
the grooves may not necessarily have a decreasing hydraulic diameter toward
the wick. In
some embodiments, a decreasing hydraulic diameter toward the wick may improve
performance of the capillary drive, but other embodiments may be considered.
For example,
the internal grooves and channels may have a substantially straight structure,
a tapered
structure, a helical structure, and/or other arrangements.
[0593] In some
embodiments, the features required to create the capillary drive may be
integral with the housing structure of the aerosol generation unit (e.g.,
vaporization chamber),
the mouthpiece, and/or part of a separate plastic part (such as the finned
condensation collector
discussed herein).
Terminology
[0594] When a
feature or element is herein referred to as being "on" another feature or
element, it may be directly on the other feature or element or intervening
features and/or
elements may also be present. In contrast, when a feature or element is
referred to as being
"directly on" another feature or element, there may be no intervening features
or elements
present. It will also be understood that, when a feature or element is
referred to as being
"connected", "attached" or "coupled" to another feature or element, it may be
directly
connected, attached or coupled to the other feature or element or intervening
features or
elements may be present. In contrast, when a feature or element is referred to
as being "directly
connected", "directly attached" or "directly coupled" to another feature or
element, there may
be no intervening features or elements present.
[0595]
Although described or shown with respect to one embodiment, the features and
elements so described or shown may apply to other embodiments. It will also be
appreciated
by those of skill in the art that references to a structure or feature that is
disposed "adjacent"
another feature may have portions that overlap or underlie the adjacent
feature.
[0596]
Terminology used herein is for the purpose of describing particular
embodiments
and implementations only and is not intended to be limiting. For example, as
used herein, the
singular forms "a", "an" and "the" may be intended to include the plural forms
as well, unless
the context clearly indicates otherwise. It will be further understood that
the terms "comprises"
and/or "comprising," when used in this specification, specify the presence of
stated features,
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steps, operations, elements, and/or components, but do not preclude the
presence or addition
of one or more other features, steps, operations, elements, components, and/or
groups thereof
As used herein, the term "and/or" includes any and all combinations of one or
more of the
associated listed items and may be abbreviated as "r.
[0597] In the
descriptions above and in the claims, phrases such as "at least one of' or
"one
or more of' may occur followed by a conjunctive list of elements or features.
The term
"and/or" may also occur in a list of two or more elements or features. Unless
otherwise
implicitly or explicitly contradicted by the context in which it used, such a
phrase is intended
to mean any of the listed elements or features individually or any of the
recited elements or
features in combination with any of the other recited elements or features.
For example, the
phrases "at least one of A and B;" "one or more of A and B;" and "A and/or B"
are each
intended to mean "A alone, B alone, or A and B together." A similar
interpretation is also
intended for lists including three or more items. For example, the phrases "at
least one of A,
B, and C;" "one or more of A, B, and C;" and "A, B, and/or C" are each
intended to mean "A
alone, B alone, C alone, A and B together, A and C together, B and C together,
or A and B and
C together." Use of the term "based on," above and in the claims is intended
to mean, "based
at least in part on," such that an unrecited feature or element is also
permissible.
[0598]
Spatially relative terms, such as "forward", "rearward", "under", "below",
"lower",
"over", "upper" and the like, may be used herein for ease of description to
describe one element
or feature's relationship to another element(s) or feature(s) as illustrated
in the figures. It will
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 a device in the figures is inverted, elements described as "under"
or "beneath" other
elements or features would then be oriented "over" the other elements or
features. Thus, the
exemplary term "under" may encompass both an orientation of over and under.
The device
may be otherwise oriented (rotated 90 degrees or at other orientations) and
the spatially relative
descriptors used herein interpreted accordingly.
Similarly, the terms "upwardly",
"downwardly", "vertical", "horizontal" and the like may be used herein for the
purpose of
explanation only unless specifically indicated otherwise.
[0599]
Although the terms "first" and "second" may be used herein to describe various
features/elements (including steps), these features/elements should not be
limited by these
terms, unless the context indicates otherwise. These terms may be used to
distinguish one
feature/element from another feature/element. Thus, a first feature/element
discussed below
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could be termed a second feature/element, and similarly, a second
feature/element discussed
below could be termed a first feature/element without departing from the
teachings provided
herein.
[0600] As used
herein in the specification and claims, including as used in the examples
and unless otherwise expressly specified, all numbers may be read as if
prefaced by the word
"about" or "approximately," even if the term does not expressly appear. The
phrase "about"
or "approximately" may be used when describing magnitude and/or position to
indicate that
the value and/or position described is within a reasonable expected range of
values and/or
positions. For example, a numeric value may have a value that is +/- 0.1% of
the stated value
(or range of values), +/- 1% of the stated value (or range of values), +/- 2%
of the stated value
(or range of values), +/- 5% of the stated value (or range of values), +/- 10%
of the stated value
(or range of values), etc. Any numerical values given herein should also be
understood to
include about or approximately that value, unless the context indicates
otherwise.
[0601] For
example, if the value "10" is disclosed, then "about 10" is also disclosed.
Any
numerical range recited herein is intended to include all sub-ranges subsumed
therein. It is
also understood that when a value is disclosed that "less than or equal to"
the value, "greater
than or equal to the value" and possible ranges between values are also
disclosed, as
appropriately understood by the skilled artisan. For example, if the value "X"
is disclosed the
"less than or equal to X" as well as "greater than or equal to X" (e.g., where
X is a numerical
value) is also disclosed. It is also understood that the throughout the
application, data is
provided in a number of different formats, and that this data, represents
endpoints and starting
points, and ranges for any combination of the data points. For example, if a
particular data
point "10" and a particular data point "15" may be disclosed, it is understood
that greater than,
greater than or equal to, less than, less than or equal to, and equal to 10
and 15 may be
considered disclosed as well as between 10 and 15. It is also understood that
each unit between
two particular units may be also disclosed. For example, if 10 and 15 may be
disclosed, then
11, 12, 13, and 14 may be also disclosed.
[0602]
Although various illustrative embodiments are described above, any of a number
of
changes may be made to various embodiments without departing from the
teachings herein.
For example, the order in which various described method steps are performed
may often be
changed in alternative embodiments, and in other alternative embodiments, one
or more
method steps may be skipped altogether. Optional features of various device
and system
embodiments may be included in some embodiments and not in others. Therefore,
the
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foregoing description is provided primarily for exemplary purposes and should
not be
interpreted to limit the scope of the claims.
[0603] One or
more aspects or features of the subject matter described herein may be
realized in digital electronic circuitry, integrated circuitry, specially
designed application
specific integrated circuits (ASICs), field programmable gate arrays (FPGAs)
computer
hardware, firmware, software, and/or combinations thereof. These various
aspects or features
may include implementation in one or more computer programs that may be
executable and/or
interpretable on a programmable system including at least one programmable
processor, which
may be special or general purpose, coupled to receive data and instructions
from, and to
transmit data and instructions to, a storage system, at least one input
device, and at least one
output device. The programmable system or computing system may include clients
and
servers. A client and server may be remote from each other and may interact
through a
communication network. The relationship of client and server arises by virtue
of computer
programs running on the respective computers and having a client-server
relationship to each
other.
[0604] These
computer programs, which may also be referred to programs, software,
software applications, applications, components, or code, include machine
instructions for a
programmable processor, and may be implemented in a high-level procedural
language, an
object-oriented programming language, a functional programming language, a
logical
programming language, and/or in assembly/machine language.
[0605] As used
herein, the term "machine-readable medium" refers to any computer
program product, apparatus and/or device, such as for example magnetic discs,
optical disks,
memory, and Programmable Logic Devices (PLDs), used to provide machine
instructions
and/or data to a programmable processor, including a machine-readable medium
that receives
machine instructions as a machine-readable signal.
[0606] The
term "machine-readable signal" refers to any signal used to provide machine
instructions and/or data to a programmable processor. The machine-readable
medium may
store such machine instructions non-transitorily, such as for example as would
a non-transient
solid-state memory or a magnetic hard drive or any equivalent storage medium.
The machine-
readable medium may alternatively or additionally store such machine
instructions in a
transient manner, such as for example, as would a processor cache or other
random access
memory associated with one or more physical processor cores.
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[0607] The
examples and illustrations included herein show, by way of illustration and
not
of limitation, specific embodiments in which the disclosed subject matter may
be practiced.
As mentioned, other embodiments may be utilized and derived therefrom, such
that structural
and logical substitutions and changes may be made without departing from the
scope of this
disclosure. Such embodiments of the disclosed subject matter may be referred
to herein
individually or collectively by the term "invention" merely for convenience
and without
intending to voluntarily limit the scope of this application to any single
invention or inventive
concept, if more than one is, in fact, disclosed.
[0608] Thus,
although specific embodiments have been illustrated and described herein,
any arrangement calculated to achieve the same purpose may be substituted for
the specific
embodiments shown. This disclosure is intended to cover any and all
adaptations or variations
of various embodiments. Combinations of the above embodiments, and other
embodiments
not specifically described herein, will be apparent to those of skill in the
art upon reviewing
the above description.
[0609] The
disclosed subject matter has been provided here with reference to one or more
features or embodiments. Those skilled in the art will recognize and
appreciate that, despite of
the detailed nature of the exemplary embodiments provided here, changes and
modifications
may be applied to said embodiments without limiting or departing from the
generally intended
scope. These and various other adaptations and combinations of the embodiments
provided
here are within the scope of the disclosed subject matter as defined by the
disclosed elements
and features and their full set of equivalents.
[0610] A
portion of the disclosure of this patent document may contain material, which
is
subject to copyright protection. The owner has no objection to facsimile
reproduction by any
one of the patent document or the patent disclosure, as it appears in the
Patent and Trademark
Office patent file or records, but reserves all copyrights whatsoever. Certain
marks referenced
herein may be common law or registered trademarks of the applicant, the
assignee or third
parties affiliated or unaffiliated with the applicant or the assignee. Use of
these marks is for
providing an enabling disclosure by way of example and shall not be construed
to exclusively
limit the scope of the disclosed subject matter to material associated with
such marks.
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