Note: Descriptions are shown in the official language in which they were submitted.
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Compressed Cartomizer Matrix for Improved Wicking
Cross Reference to Related Applications
[0001] This application claims the benefit of priority to US Patent
Application Serial No.
17/482,251 filed on September 22, 2021 and entitled "Compressed Cartomizer
Matrix for
Improved Wicking", the contents of which are incorporated herein by reference.
Technical Field
[0002] This application relates generally to a matrix for use in a cartomizer,
and more
particularly to a cartomizer under partial compression for use in conjunction
with an
electronic cigarette or vaporizer.
Background
[0003] Electronic cigarettes and vaporizers are well regarded tools in smoking
cessation. In
some instances, these devices are also referred to as an electronic nicotine
delivery system
(ENDS). A nicotine based liquid solution, commonly referred to as e-liquid,
often paired
with a flavoring, is atomized in the ENDS for inhalation by a user. In some
embodiments,
e-liquid is stored in a cartridge or pod, which is a removable assembly having
a reservoir
from which the e-liquid is drawn towards a heating element by capillary action
through a
wick. In many such ENDS, the pod is removable, disposable, and is sold pre-
filled.
[0004] In some ENDS, a refillable tank is provided, and a user can purchase a
vaporizable
solution with which to fill the tank. This refillable tank is often not
removable, and is not
intended for replacement. A fillable tank allows the user to control the fill
level as desired.
Disposable pods are typically designed to carry a fixed amount of vaporizable
liquid, and are
intended for disposal after consumption of the e-liquid. The ENDS cartridges,
unlike the
aforementioned tanks, are not typically designed to be refilled. Each
cartridge stores a
predefined quantity of e-liquid, often in the range of 0.5 to 3m1. In ENDS
systems, the
e-liquid is typically composed of a combination of any of vegetable glycerine,
propylene
glycol, nicotine and flavorings. In systems designed for the delivery of other
compounds,
different compositions may be used.
[0005] In the manufacturing of the disposable cartridge, different techniques
are used for
different cartridge designs. Typically, the cartridge has a wick that allows e-
liquid to be
drawn from the e-liquid reservoir to an atomization chamber. In the
atomization chamber, a
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heating element in communication with the wick is heated to encourage
aerosolization of the
e-liquid. The aerosolized e-liquid can be drawn through a defined air flow
passage towards a
user's mouth. Control of the application of power to the heater is performed
by a processor
within the vaping device which can modulate charge provided by the battery.
[0006] Figures 1A, 1B and 1C provide front, side and bottom views of an
exemplary pod 50.
Pod 50 is composed of a reservoir 52 having an air flow passage 54, and an end
cap assembly
56 that is used to seal an open end of the reservoir 52. End cap assembly has
wick feed lines
58 which allow e-liquid stored in reservoir 52 to be provided to a wick (not
shown in Figure
1). To ensure that e-liquid stored in reservoir 52 stays in the reservoir and
does not seep or
leak out, and to ensure that end cap assembly 56 remains in place after
assembly, seals 60 can
be used to ensure a more secure seating of the end cap assembly 56 in the
reservoir 52. In the
illustrated embodiment, seals 60 may be implemented through the use of o-
rings.
[0007] As noted above, pod 50 includes a wick that is heated to atomize the e-
liquid. To
provide power to the wick heater, electrical contacts 62 are placed at the
bottom of the pod
50. In the illustrated embodiment, the electrical contacts 62 are illustrated
as circular. The
particular shape of the electrical contacts 62 should be understood to not
necessarily germane
to the function of the pod 50.
[0008] Because an ENDS device is intended to allow a user to draw or inhale as
part of the
nicotine delivery path, an air inlet 64 is provided on the bottom of pod 50.
Air inlet 64 allows
air to flow into a pre-wick air path through end cap assembly 56. The air flow
path extends
through an atomization chamber and then through post wick air flow passage 54.
[0009] Sitting atop pod 52 is an optional mouthpiece 68, shown in Figures 1A
and 1B in
cross section to allow a reader to see the structure of pod 50 in better
detail. Mouthpiece 68
may attach to the pod 50 through the use of a detente and protrusion, or it
may make use of a
further seal not shown in the drawing. Within mouthpiece 68 are a pair of
apertures that are
shown as being off center from a central vertical axis of the pod 50. These
apertures allow for
an airflow through the pod 50 to both entrain atomized e-liquid, and for
delivery of this
airflow to the user. Between the mouthpiece 68 and the top of the pod 50, is
an absorbent pad
66, typically made of cotton, and often annular in shape. This pad 66 is often
referred to as a
spitback pad, and is designed to absorb any large droplets of e-liquid that it
encounters. This
pad 66 may also serve to absorb e-liquid that condenses within the post wick
airflow path 54
between uses.
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[00110] Figure 2 illustrates a cross section taken along line A in Figure 1B.
This cross section
of the device is shown with a complete (non-sectioned) wick 66 and heater 68
End cap
assembly 56 resiliently mounts to an end of air flow passage 54 in a manner
that allows air
inlet 64 to form a complete air path through pod 50. This connection allows
airflow from air
inlet 64 to connect to the post air flow path through passage 54 through
atomization chamber
70. Within atomization chamber 70 is both wick 66 and heater 68. When power is
applied to
contacts 62, the temperature of the heater increases and allows for the
volatilization of
e-liquid that is drawn across wick 66.
[0011] Typically the heater 68 reaches temperatures well in excess of the
vaporization
temperature of the e-liquid. This allows for the rapid creation of a vapor
bubble next to the
heater 68. As power continues to be applied the vapor bubble increases in
size, and reduces
the thickness of the bubble wall. At the point at which the vapor pressure
exceeds the surface
tension the bubble will burst and release a mix of the vapor and the e-liquid
that formed the
wall of the bubble. The e-liquid is released in the form of aerosolized
particles and droplets of
varying sizes. These particles are drawn into the air flow and into post wick
air flow passage
54 and towards the user.
[0012] Figure 3 illustrates an alternate design for a pod 50, having a
reservoir 52 with a post
wick airflow passage 54 and an end cap 56. In place of 0-ring style seals, a
resilient top cap
78 can be affixed to the end cap 56 to provide a friction fit within reservoir
52. Although no
mouthpiece is illustrated, one could be affixed at what is illustrated as the
bottom of the pod
50. End Cap 56 and resilient top cap 78 define wick feedlines 58 that allow e-
liquid to make
contact with the wick 72. Heater 74 is connected to electrical leads 62 to
receive power so
that e-liquid drawn across the wick 72 can be volatilized. Airflow can pass
through pre-wick
airflow passage 64 and enter into the atomization chamber 70, where atomized e-
liquid can
be entrained and carried towards the user through post wick air flow passage
54. Within the
post wick airflow passage 54, and provided as a feature within the top
silicone 78 is a vortex
generator 76. Vortex generator 76 introduces turbulence into the airflow at
the start of the
post wick airflow passage 54 to encourage droplets above a threshold size to
be directed into
the wall of the post wick air flow passage 54.
[0013] The above described pods make use of a reservoir designed to directly
store e-liquid.
To aid in the avoidance of leaks, seals are employed in addition to the design
of an e-liquid
that is sufficiently viscous to prevent leaks. This results in a slowed
progression of e-liquid
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through the wick, which may result in reduced flavor generation during use. A
less viscous
e-liquid has traditionally been associated with increased flavor generation,
but is also
associated with increased difficulty in preventing leaks.
[0014] In place of a reservoir that directly stores e-liquid, a cartomizer can
be described as a
pod where the reservoir contains a matrix which is used to help in the storage
and distribution
of the e-liquid There are a variety of different materials that can be used as
the cartomizer
matrix, each with a different set of benefits and detriments. In common
implementations, the
matrix can be implemented as a sponge, made of any number of different
materials including
cellulose, cotton, wool, hemp, linen, polymer-based materials such as nylon
and other bulk
materials, or as a stack of woven sheets. In the example of the stack of woven
sheets, cotton
or other materials can be woven into cloth, the woven cloth can be cut to a
desired size and
shape, and then rolled, wrapped or otherwise shaped so that it can be placed
within the
cartomizer reservoir.
[0015] While there are a variety of different cartomizer fill materials, they
all serve the same
purpose, to provide a matrix to capture, hold and release e-liquid. In many
cartomizers, the
fill material provides a capillary structure within which the e-liquid is held
and transported.
[0016] Figure 4A illustrates a perspective view of a cartomizer pod 80 having
a reservoir 82,
a top 84 and a post wick airflow path 86. Cut line A will be used in a
subsequent Figure.
Figure 4B illustrates the base of cartomizer pod 80. The end cap 88 of the
cartomizer pod 80
has an entrance to pre-wick airflow 90 and a pair of electrical contacts 92.
[0017] Figure 5 is a cross section view of cartomizer pod 80 taken along cut
line Bin Figure
4A. Cartomizer pod 80 has a reservoir 82 defined by the sidewalls of the pod,
along with the
top wall 84. An open base is sealed by an end cap 88 having a pre-wick air
flow passage 90
and electrical contacts 92. Within pod 80 is an air flow passage spanning from
pre-wick
airflow passage 90 to post wick air flow passage 86. Within this structure is
situated a wick
96 in contact with a heater 94 that is connected to electrical contacts 92. A
matrix 98 fills the
reservoir defined within the pod 80. As noted above, this reservoir can be
used to store
e-liquid. Ends of the wick 96 are in fluid contact with the matrix 98. This
allows e-liquid
stored within the matrix 98 to be drawn across wick 96 so that it can be
atomized through the
heating of heater 94. Where in the previously illustrated pod 50, the e-liquid
filled the
reservoir 52 and was fed to the wick 72 using gravity, a less viscous e-liquid
can be stored in
matrix 98 and fed into wick 96 by capillary action. It should be understood
that the capillary
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forces within matrix 98 are a function of both the matrix material, and the
configuration of
the void spaces between the matrix material. By ensuring that wick 96 has
stronger capillary
forces acting within it than the material within matrix 98, the wick 96 can be
fed e-liquid
without strict reliance upon a gravity feed system.
[0018] Because the cartomizer matrix 98 holds the e-liquid within pod 80,
where the e-liquid
was simply filling reservoir 52 in pod 50, a less viscous e-liquid formulation
can be
employed. This allows for the e-liquid to be more rapidly drawn across the
wick, aiding in the
generation of atomized e-liquid that can be entrained within an airflow
through pod 80. Less
viscous e-liquids are typically not relied upon in a pod without a cartomizer
due to the
propensity for leakage, which is reduced due to the presence of the cartomizer
matrix.
[0019] Many cartomizers currently available are not in the format of a pod
like cartomizer
pod 80, but instead are provided within single-use e-cigarettes that are
designed to be
disposed of after use. In many of these devices, the limiting factor for the
use of the device is
the non-rechargeable battery. When the battery is exhausted, the device no
longer functions
and the user can dispose of it. In a replaceable pod device, such as a device
using pod 80, the
battery is typically re-chargeable, so the limiting factor in the lifespan of
pod 80 is the
e-liquid contained within it.
[0020] Figure 6 illustrates an alternate configuration of a cartomizer pod 80
of the existing
art. Sidewall 82 and top wall 84, and post wick airflow path 86 define an
internal reservoir.
The internal reservoir is sealed through the insertion of end cap 88 which
includes a pre-wick
airflow path 90 and electrical contacts 94. Where the previously illustrated
embodiments
make use of a wick that is perpendicular to the axial orientation of the post
wick airflow path
86, in the embodiment of Figure 6, wick 96 is inline with the pre-wick airflow
path 90 and
the post wick airflow path 86. In the illustrated embodiment, these features
are all co-axial.
Wick 96 has a hollow center that creates a vertical path through which an
airflow can be
drawn. Where in previous designs, the wick was surrounded by a heater, in this
embodiment,
the heater coil 90 is internal to the wick 96, so that it can help atomize e-
liquids into the
airflow passing through the middle of the wick 96 from pre-wick airflow
passage 90 and on
to post wick airflow passage 86. This configuration allows e-liquid to pass
from the
cartomizer matrix 98 into the wick 96 over a larger surface area. The location
of the heater 94
inside the wick allows for the e-liquid to be atomized adjacent to the airflow
within which it
is to be entrained.
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[0021] Many pod designs making use of a cartomizer matrix to store e-liquids
are integrated
within the vaping device. Because the pod is not replaceable, the device is
treated as a
disposable device, and in some devices, there is no mechanism to allow for
recharging the
battery. As such, the device is provided with enough e-liquid to exceed the
ability of the
battery to atomize e-liquid. Problems can often arise when there is still
charge in the battery,
and e-liquid within the cartomizer matrix, but due to the somewhat random
structure of a
cartomizer, the e-liquid is not evenly stored. This can result in a situation
in which the
portions of the cartomizer near the wick are effectively dry despite there
being e-liquid in
other portions of the cartomizer. This inconsistent distribution can result in
a battery still
having charge, the cartomizer matrix still storinge-liquid, but the stored e-
liquid not being
accessible to the wick.
[0022] It would therefore be beneficial to have a mechanism to provide a
mechanism for
improving the delivery of e-liquid to the wick within a vaporizing system.
Summary
[0023] It is an object of the aspects of the present invention to obviate or
mitigate the
problems of the above-discussed prior art.
[0024] In a first aspect of the present invention, there is provided a pod for
storing an
atomizable liquid. The pod has an an airflow passage that defines a vertical
axis, and wick
that is located within the pod. The wick has a vertical location in relation
to the vertical axis,
and at least a portion of the wick overlaps with the airflow passage. The pod
comprises a
cartomizer matrix having first and second sections. The cartomizer matrix is
situated within
the pod for storing the atomizable liquid for delivery to the wick. The first
section of the
cartomizer matrix is formed from a first material and exerts a first capillary
force on
atomizable liquid stored within the first material. The second cartomizer
section is aligned
vertically within the pod with the location of the wick. The second cartomizer
section is
formed from a second material and exerts a second capillary force, greater
than the first
capillary force, on atomizable liquid stored within the second material.
[0025] In an embodiment of the first aspect, the pod further comprises
sidewalls for retaining
the cartomizer and wick. In another embodiment, the atomizable liquid stored
within the
cartomizer matrix is preferentially stored within the second cartomizer
section. In a further
embodiment, a central axis of the wick is aligned with the vertical axis. In
another
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embodiment, the first cartomizer section and the second cartomizer section are
made from the
same material.
[0026] In another embodiment, the second cartomizer section is radially
compressed by a
compression member to provide smaller capillaries within the second cartomizer
section and
the greater capillary force. In one embodiment, the pod further comprises a
sidewall, and the
compression member is integrally formed within the sidewall. In another
embodiment, the
compression member is an insert placed between a sidewall of the pod and the
cartomizer
matrix. In a further embodiment, the radial compression of the second
cartomizer section
presses the second cartomizer section into the wick. Optionally, the
compression member
may comprise a silicone band radially compressing the cartomizer matrix. In
another
embodiment, the diameter of the second section of the cartomizer matrix is
greater than the
diameter of the first section of the cartomizer matrix, and that upon
insertion of the
cartomizer into the pod, the second section is radially compressed to provide
smaller
capillaries within the second section and the greater capillary force.
[0027] In a further embodiment, the first section of the cartomizer matrix is
made from a first
cartomizer material and the second section of the cartomizer matrix is made
from a second
cartomizer material different than the first cartomizer material. Optionally,
the second
cartomizer material has smaller capillaries than the first cartomizer
material.
[0028] In a further embodiment, the atomizable liquid is an e-liquid
comprising at least one
of vegetable glycerine, propylene glycol, nicotine and a flavoring. In another
embodiment,
the atomizable liquid is an e-liquid comprising a cannabinoid.
[0029] In a further embodiment, the first material comprises at least one of
cellulose, cotton,
wool, hemp, linen, nylon and other polymer based materials. Optionally, the
first material
comprises a woven sheet of at least one of cellulose, cotton, wool, hemp,
linen, nylon and
other polymer based materials.
[0030] In another embodiment, the second material comprises at least one of
cellulose,
cotton, wool, hemp, linen, nylon and other polymer based materials.
Optionally, the second
material comprises a woven sheet of at least one of cellulose, cotton, wool,
hemp, linen,
nylon and other polymer based materials.
[0031] In a second aspect of the present invention, there is provided a
vaporizer device
comprising a battery for storing charge; a processor; and a pod in accordance
with the first
aspect and any of its embodiments,
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Brief Description of the Drawings
[0032] Embodiments of the present invention will now be described in further
detail by way
of example only with reference to the accompanying figure in which:
Figure 1A is a front view of a prior art pod for use in an electronic nicotine
delivery
system;
Figure 1B is a side view of the pod of Figure 1A;
Figure 1C is a bottom view of the pod of Figure 1A,
Figure 2 is a cross section of the pod of Figures lA and 1B along cut line A
in Figure
1B;
Figure 3 is a cross section of an alternate pod design;
Figure 4A is a perspective view of a cartomizer pod;
Figure 4B is a bottom view of the pod of Figure 4A;
Figure 5 is a cross section view of the cartomizer pod of Figure 4A along cut
line B;
Figure 6 is a cross section view of an alternate cartomizer pod;
Figure 7 is a cross section view of a pod according to an embodiment of the
present
invention;
Figure 8 is a magnification of the cartomizer matrix in sections 126 and 128
of Figure
7;
Figure 9A is a cross section view of a cartomizer matrix according to an
alternate
embodiment of the present invention;
Figure 9B is a cross section view of a pod with the cartomizer matrix of
Figure 9A;
Figure 10 is a cross section view of a cartomizer pod according to an
embodiment of
the present invention;
Figure 11 is a cross section view of a cartomizer pod according to an
embodiment of
the present invention; and
Figure 12 is a cross section view of a cartomizer pod according to an
embodiment of
the present invention.
[0033] In the above described figures like elements have been described with
like numbers
where possible.
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Detailed Description
[0034] In the instant description, and in the accompanying figures, reference
to dimensions
may be made. These dimensions are provided for the enablement of a single
embodiment and
should not be considered to be limiting or essential. Disclosure of numerical
range should be
understood to not be a reference to an absolute value unless otherwise
indicated. Use of the
terms about or substantively with regard to a number should be understood to
be indicative of
an acceptable variation of up to 10% unless otherwise noted.
[0035] Although presented below in the context of use in an electronic
nicotine delivery
system such as an electronic cigarette (e-cig) or a vaporizer (vape) it should
be understood
that the scope of protection need not be limited to this space, and instead is
delimited by the
scope of the claims. Embodiments of the present invention are anticipated to
be applicable in
areas other than ENDS, including (but not limited to) other vaporizing
applications.
Furthermore, although discussions below specifically make reference to an e-
liquid, it should
be understood that other atomizable liquids can be used, including those
carrying
pharmaceutical compounds. Broadly speaking an e-liquid is typically composed
of a
combination of any of vegetable glycerine, propylene glycol, nicotine and
flavorings. Other
atomizable liquids may be used to carry compounds, such as cannabinoids, and
may use
different carriers.
[0036] A cartomizer matrix for use in a vaping device is often formed from a
material such as
woven cotton or a similar woven fabric, that is packed within a reservoir. In
many
embodiments, a woven material is rolled to create a cylindrical structure.
This rolled
cartomizer matrix is typically loaded with a wick assembly that includes a
vertical airflow
structure that provides both a post-wick airflow passage and an interface to a
pre-wick
airflow passage in the endcap. The amount of woven material used in the matrix
is generally
consistent from top to bottom, and is determined in accordance with an e-
liquid storage
capacity. The above referenced inconsistencies in the cartomizer matrix may be
attributed to
non-uniformities in the weave of the fabric among other factors. In other
embodiments, a
cartomizer matrix may be formed through a process in which nylon filaments are
blown into
a mold. This allows for the creation of a cartomizer matrix that conforms to
the shape of the
pod reservoir. Inconsistencies in such a matrix can result from the random
accumulation of
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nylon filaments during the blowing process. This can result in a similar
effect as described
above with woven sheets.
[0037] Figure 7 is a cross section of a cartomizer based pod 100 which has a
reservoir
defined by sidewall 102 and top wall 104. Into this reservoir, cartomizer
matrix 118 can be
inserted, and the cartomizer matrix 118 can be sealed within the pod 100
through the insertion
of end cap 108. End cap 108 includes electrical contacts 112 and a pre-wick
airflow passage
110. Prior to insertion of cartomizer matrix 118 into the reservoir, an
airflow channel and
wick structure comprising wick 116, heater 114, ancillary wiring connecting
heater 114 to
electrodes 112 and an airflow passage linking pre-wick airflow passage 110 to
the top of the
pod and comprising post-wick airflow passage 106, is inserted into the
cartomizer matrix 118.
[0038] In the prior art, consistent compression of the matrix 118 in both
radial and axial
directions results in a matrix that has a generally consistent degree of
compression. This can
provide a generally consistent interstitial spacing between the component
fibers or filaments
of the cartomizer matrix 118. However, any inconsistency in the cartomizer
matrix 118 will
then result in portions that have either higher compression (and higher
capillary forces) or
lower compression (and lower capillary forces). As the e-liquid within the
cartomizer matrix
118 is drawn down, it is beneficial to have e-liquid preferentially drawn to
regions of the
cartomizer matrix 118 that are located at or near the interface between the
matrix 118 and the
wick 116. This allows the wick 116 to be able to have access to e-liquid for
transport towards
the heater 114 even as e-liquid levels are reduced.
[0039] As noted above, regions in which the cartomizer matrix is compressed
demonstrate
increased capillary force, and have a greater affinity for e-liquid storage.
These compressed
regions draw e-liquid to them with greater force than other areas, and are
less likely to
surrender their stored e-liquid to the regions of the cartomizer matrix 118
that have lower
capillary forces.
[0040] In Figure 7, a radially compressed region of the cartomizer matrix is
formed through
using bulge 122 in sidewall 102. By decreasing the radial space within the pod
100, bulge
122 creates a region within a consistently sized cartomizer matrix 118 with
different
compressions. Regions 120 within the cartomizer matrix 118 above and below
bulge 122
have reduced degree of compression in comparison to the region 124 adjacent to
bulge 122. It
should be understood that the bulge 122 may take the form of a ridge
encircling pod 100,
although in some embodiments this may differ. In some embodiments there may be
two
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discrete bulges aligned with the a major axis of the pod so that the region of
compression
coincides with the location of the wick 116 within a completed pod. Most
importantly, bulge
122 acts as a compression member to provide radial compression to a region of
the
cartomizer matrix 118. The radial compression caused by a compression member
is
illustrated in Figure 8, with respect to two portions of the cartomizer
matrix, portion 126
outside the radially compression region and portion 128 which is inside the
radially
compression region.
[0041] In Figure 8, a magnification of callout 126 is illustrated to show one
of the warp or
the weft threads 130 in the first section 120 of cartomizer matrix 118. The
interstitial space
132 illustrated in callout 126 is representative of the space between the
threads in a given
layer, and between the different layers of a woven material in a stackup of
the cartomizer
matrix 118. The e-liquid is typically carried within the interstitial spacing,
and is subjected to
capillary forces that are associated with the distance between the threads
130.
[0042] Callout 128, shows a magnification of the second section 124 of the
cartomizer matrix
118 which is subject to radial compression as a result of the compression
member embodied
by bulge 122. The threads 134, and the interstitial space 132 are both
subjected to radial
compression 136 caused by the narrower diameter of the interior of pod 100 as
a result of the
bulge 122. This compression reduces both the lateral size of the threads 134
and the spacing
132 between them. This compression causes a reduction in the interstitial
spacing 132, both
the spacing between the threads 134 and the spacing between filaments within
the threads
134. This compression may reduce the quantity of e-liquid held by the second
section 122 of
the cartomizer matrix 118, but it also increases the capillary forces at play
within the
cartomizer matrix 118. This increase in the capillary forces will reduce the
likelihood of
e-liquid being drawn away from the second section 122 by the first section 120
of cartomizer
matrix 118. This will create a hydrodynamic system in which e-liquid stored in
the first
section 120 preferentially flows to the second section 124, where it can be
drawn into wick
116.
[0043] Figures 9A and 9B illustrate an embodiment of pod 100 that stores a
first section 120
of the cartomizer matrix 118 under a lower compressive force than a second
section 140 of
the matrix 118. Where previous embodiments of the pod 100 used a compression
member, in
the embodiment of Figure 9B, a different configuration of the cartomizer
matrix 118 is used,
as illustrated in Figure 9A. Where in other embodiments, and in the prior art,
a cartomizer
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matrix is generally uniform in cross section, the cross section of matrix 118
illustrated in
Figure 9A has sections with differing widths. A first section 120 is less wide
than a second
section 140. Second section 140 can be adjusted in location to place it so
that it will coincide
with the placement of wick 116 within the assembled pod 100 as shown in Figure
9B.
Because a larger quantity of the cartomizer matrix 118 is stored within the
same width,
second section 140 will be subject to higher radial compressive forces within
pod 100. This
greater compression will result in higher capillary forces within the section
section 140, as
demonstrated by the differences in callouts 126 and 128, which were previously
shown in
Figure 8. Although pod 100 in Figure 9B is not shown as having a compression
member, it is
possible for a cartomizer matrix 118 as shown in Figure 9A to be used in
conjunction with a
compression member such as a bulge or ridge as previously shown.
[0044] Figure 10 illustrates a further embodiment of pod 100. Although
structurally similar
to the description of pod 100 in Figure 9, in the embodiment of Figure 10, pod
100 makes use
of a cartomizer matrix 150 composed of different materials. To obtain the
different capillary
sizes required for the first and second sections, instead of a radial
compression, pod 100
makes use of a cartomizer 150 that has a first section made of a first
material 152 and a
second section made of a second material 154. It should be understood that the
first and
second materials have different capillary sizes, even if made of the same
underlying material.
In one embodiment, material 152, corresponding to the first section, may be
made of an
absorbent nylon, while material 154, corresponding to the second section, may
be made of a
super absorbent nylon (or other super absorbent fiber). The different material
structure
provides for higher capillary forces in the second section without requiring
compression of
the matrix. In another embodiment, the two sections could be formed of first
and second
cellulose sponges, with the first cellulose sponge 152 having a larger pore
structure than the
second cellulose sponge 154. It should be understood that using different
underlying
materials for the first and second materials has also been considered, so that
a cartomizer
matrix 150 made up of a first material 152 such as cotton and a second
material 154 such as a
cellulose based sponge with smaller capillaries could be used. The smaller
capillaries in the
second material 154, much like the compressed material in the above described
embodiments,
results in a greater capillary force that acts to hold the e-liquid. As a
result, e-liquid will be
preferentially drawn from the first material 152 into the second material 154
and from there
can be drawn into wick 116. Second material 154 will preferentially store e-
liquid within the
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13
cartomizer matrix 150, and will allow for its interface with wick 116 to
function to allow
wick 116 to draw e-liquid across towards heater 114
[0045] In the above illustrations, a horizontally aligned wick is illustrated.
Vertically oriented
wicks allow for a replacement of some of the airflow path between the pre-wick
airflow path
and the post wick airflow path. This can provide for a large interface area
between the wick
and the cartomizer matrix, while minimizing the distance through the wick that
the e-liquid
has to traverse to before it is atomized so that it can be entrained within
the airflow.
Conventional vertical wicks demonstrate some desirable user experience
characteristics
including a desirable flavor and vapor delivery with a sufficiently high power
delivered to the
heater, but often have poor wicking characteristics that can result in
negative user
experiences. The application of high power to the heater to generate the
desired flavor can
burn the wick if the wick has not been able to draw in enough e-liquid.
Although this is a
problem also faced by horizontal wicks, it may be more pronounced with
vertical wicks due
to the higher power required by their heaters.
[0046] Figure 11 illustrates a pod 160 making use of a vertical wick 176. Pod
160 has
sidewalls 162 and a top wall 164, and defines a post wick airflow passage 166.
An end cap
168 having pre-wick airflow passage 170 and electrical contacts 172, is sized
to seal the
reservoir within pod 160 created by the sidewalls 162 and top wall 164.
Connecting the pre
wick airflow passage 170 to the post wick airflow passage 166 is vertical wick
176. As with
conventional vertical wicks, vertical wick 176 is illustrated as a hollow
cylinder of wick
material, such as cotton, with an open central column. The vertical wick 176
houses a heater
174 that is connected to electrical leads 172. The heater is at the interface
of the vertical wick
with its open central column. When activated, heater 174 will volatilize e-
liquid drawn from
cartomizer matrix 178 across wick 176.
[0047] Within pod 160, e-liquid will be preferentially drawn to the second
section 182 of
cartomizer matrix 178. E-liquid drawn from the second section 182 by wick 176
will result
in the higher capillary forces within the second section 182 drawing e-liquid
from the first
section 180 of cartomizer matrix 178 which has lower capillary forces. As a
result, even
when the e-liquid within pod 160 is approaching a lower limit to enable
vaporization, the
e-liquid will be stored in the section closest to wick 176, which will enable
transfer of
e-liquid into the wick 176 for a longer period of time.
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14
[0048] Whereas in prior art pods, the interface between a vertical wick and
the cartomizer
matrix was a possible failure point, as the cartomizer and vertical wick have
to be in direct
physical contact to allow for e-liquid transfer, the use of a compression
member 184 to create
radial compression of the second section 182 also ensures that the cartomizer
178 and the
vertical wick 176 are in direct physical contact in a section in line with the
heater 174.
[0049] Although Figure 11 illustrates the use of a compression member 184 to
create the
radial compression of the second section 182, it should be understood that the
substantially
similar effect could be accomplished through the use of a cartomizer matrix
similar to matrix
118 shown in Figure 9B, with or without the use of the compression member 184
shown in
Figure 11.
[0050] It should also be understood that while compression members, such as
compression
member 184, or bulge 122 are illustrated as features within the pod and
attached to the
interior of the sidewall, this is one of a number of different possible
embodiments. In some
other embodiments, an insert into the reservoir may be used to provide a
compression
member located to create radial compression of the cartomizer matrix in the
area surrounding
the interface between the wick and the cartomizer matrix. In other embodiments
a
compression member may take the form of a resilient band wrapped around a
cartomizer
matrix before insertion into the pod reservoir. This compression member could
be made from
a resilient material such as silicone, and could be used to create radial
compression of the
cartomizer matrix to surround the interface between the cartomizer matrix and
the wick.
Other embodiments may use techniques other than compression to create zones
with different
capillary forces.
[0051] Figure 12 illustrates a cross section of an alternate embodiment of pod
160 in which
the cartomizer 184 is formed from sections with different capillary
properties. Where the
structure of the overall pod 160 is similar to that of the pod illustrated in
Figure 11, vertical
wick 176 engages with a cartomizer 182 made of a second section 186 surrounded
by a first
section 184.
To obtain the different capillary sizes required for the first and second
sections, instead of a
radial compression, pod 160 makes use of a cartomizer 182 that has a first
section made of a
first material 184 and a second section made of a second material 186. It
should be
understood that the first and second materials have different capillary sizes,
even if made of
the same underlying material. In one embodiment, material 184, corresponding
to the first
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section, may be made of an absorbent nylon, while material 186, corresponding
to the second
section, may be made of a super absorbent nylon (or other super absorbent
fiber). The
different material structure provides for higher capillary forces in the
second section without
requiring compression of the matrix. In another embodiment, the two sections
could be
formed of first and second cellulose sponges, with the first cellulose sponge
184 having a
larger pore structure than the second cellulose sponge 186. It should be
understood that using
different underlying materials for the first and second materials has also
been considered, so
that a cartomizer matrix 182 made up of a first material 184 such as cotton
and a second
material 186 such as a cellulose based sponge with smaller capillaries could
be used. The
smaller capillaries in the second material 186, much like the compressed
material in the
above described embodiments, results in a greater capillary force that acts to
hold the
e-liquid. As a result, e-liquid will be preferentially drawn from the first
material 185 into the
second material 186 and from there can be drawn into wick 176. Second material
186 will
preferentially store e-liquid within the cartomizer matrix 182, and will allow
for its interface
with wick 176 to function to allow wick 176 to draw e-liquid across towards
heater 174.
[0052] As shown above, the differing capillary forces can be achieved through
the use of
sections in which different capillary forces may be a result of differing
sizes of pores or
interstitial spaces. These differing pore sizes or sizing of interstitial
spaces can be a result of
material selection or it could be the result of a radial compression applied
to one of the
sections. As shown above, radial compression can be achieved through the use
of a
compression feature that is built into the internal reservoir of the pod, or
it can be achieved
through the use of a separate element. Those skilled in the art will
appreciate that a
cartomizer matrix of a non-uniform width could also be used in a pod either
with or without a
compression feature. The radial compression allows for defined boundaries
between the first
and second sections. A cartomizer matrix made of two materials can also make
use of radial
compression as described above, though it may not be strictly necessary based
on the
selection of the different cartomizer materials.
[0053] The location of the second section of the cartomizer matrix can be
designed to overlap
with the interface between the cartomizer matrix and the wick. In embodiments
with a
vertical wick, radial compression of the cartomizer matrix to create the
second section can
also encourage a tighter interface between the cartomizer matrix and the wick
which may
obviate some issues presented in prior art designs.
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[0054] In the instant description, and in the accompanying figures, reference
to dimensions
may be made These dimensions are provided for the enablement of a single
embodiment and
should not be considered to be limiting or essential.The sizes and dimensions
provided in the
drawings are provided for exemplary purposes and should not be considered
limiting of the
scope of the invention, which is defined solely in the claims.
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