Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Compressed Cartomizer Matrix for Improved Flavor
Delivery
Cross Reference to Related Applications
[0001] This application claims the benefit of priority to US Patent
Application Serial No.
17/482,243 filed on September 22, 2021 and entitled "Compressed Cartomizer
Matrix for
Improved Flavor Delivery", 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.
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[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
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.
[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 lA
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
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pad 66 may also serve to absorb e-liquid that condenses within the post wick
airflow path 54
between uses.
[0010] 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.
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[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
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, as a stack of woven sheets, or. 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
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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
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
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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.
[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. One problem that has been observed relates to the
delivery of
flavor in the use of a vaping device using a cartomizer matrix. E-liquid is
stored within the
cartomizer matrix and drawn from the matrix across the wick towards the heater
where it is
atomized. It has been observed that there is a change in the flavor of the
vapor produced by a
vaping device over the life of the cartomizer_ This phenomenon has been
referred to as flavor
drop off. Many users complain about the changing nature of the flavor in the
generated vapor
during the lifetime of a vaporizer using a cartomizer matrix. This is now a
typical problem
with a conventional pod that directly stores liquid within a reservoir. It
should be understood
by those skilled in the art that the role of a cartomizer matrix is to help
store a less viscous
e-liquid that would otherwise cause leakage if it were directly stored within
a reservoir.
[0022] It should be understood that the cartomizer matrix is able to hold the
less viscous
e-liquid within the reservoir through the use of capillary forces that hold
the e-liquid within
the interstitial spaces of the cartomizer matrix. However, it should also be
understood that the
e-liquid is not a homogeneous solution, and instead is a combination of
components, as noted
above. Some of these components may be dissolved within the e-liquid while
others may be
in suspension. Although all the mechanics of the flavor drop off are not yet
clear, it is
understood that it does not appear to be associated with a change in the
flavorants (such as a
denaturing of the flavorant compounds), and instead is associated with the
volatile flavorants
being consumed in greater quantities early in the life of the cartomizer. This
may be
associated with migration of flavorants through the e-liquid stored within the
reservoir.
Although e-liquid may be referred to as being trapped within pockets within
the cartomizer
matrix, components within the e-liquid can still migrate within the e-liquid,
and the e-liquid
itself may migrate but only when replaced by other e-liquid. This migration
may allow
flavorants to migrate into the wick more rapidly than other components of the
e-liquid. This
results in the flavorants being consumed more quickly than other e-liquid
components. As
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this continues the flavoring of the e-liquid varies over time, and can result
in a drop off in the
concentration of flavorants in the e-liquid being atomized. As the amount of e-
liquid left
within the cartomizer matrix decreases, it becomes less flavored, which
results in a bad user
experience.
[0023] It would therefore be beneficial to have a mechanism to provide a
mechanism for
improving the consistency in flavor delivery of e-liquid to the wick within a
vaporizing
system.
Summary
[0024] It is an object of the aspects of the present invention to obviate or
mitigate the
problems of the above-discussed prior art.
[0025] In accordance with a first aspect of the present invention, there is
provided a pod for
storing an atomizable liquid. The pod has an airflow path defining a vertical
axis, and a wick
located within the pod. The pod comprises a cartomizer matrix having first and
second
sections The cartomizer matrix is situated within the pod and stores the
atomizable liquid for
delivery to the wick. The first section of the cartomizer matrix stores the
atomizable liquid
with a first capillary force. It is aligned with a location of the wick within
the pod. The
second section of the cartomizer matrix stores the atomizable liquid with a
second capillary
force greater than the first capillary force, and is aligned to not overlap
with the location of
the wick within the pod.
[0026] In an embodiment of the first aspect, the second section of the
cartomizer matrix has
disjoint first and second parts located on opposite sides of the first section
of the cartomizer
matrix.
[0027] In another embodiment, the second section of the cartomizer matrix is
made from the
same material as the first section of the cartomizer matrix. Optionally, the
second section of
the cartomizer matrix is under greater radial compression than the first
section of cartomizer
matrix. In another embodiment, a compression member radially compresses the
second
section of the cartomizer matrix. In a further embodiment, the compression
member is
integrally formed within a sidewall of the pod. In another embodiment, the
compression
member is wrapped around the cartomizer matrix and applies a greater radial
compression to
the second section of the cartomizer matrix than to the first section of the
cartomizer matrix.
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[0028] In another embodiment, the second section of the cartomizer matrix is
made from a
different material as the first section of the cartomizer matrix.
[0029] In a further embodiment, the ratio of the volume of the first section
of the cartomizer
matrix to the second section of the cartomizer matrix is a function of the
capillary sizes
within the first and second sections of the cartomizer matrix. Optionally, the
ratio is also a
function of the carrying capacity of the first and second sections with
respect to the
atomizable liquid. In another embodiment, the second section is sized to store
a volume of
e-liquid determined in accordance with a determined volume of atomizable
liquid associated
with flavor drop off.
[0030] In some embodiments, the atomizable liquid is an e-liquid comprising at
least one of
vegetable glycerine, propylene glycol, nicotine and a flavoring. In some
embodiments, the
atomizable liquid is an e-liquid containing a cannabinoid
[0031] In an embodiment the cartomizer matrix comprises at least one of
cellulose, cotton,
wool, hemp, linen, nylon and other polymer based materials. Optionally, the
cartomizer
matrix comprises a woven sheet of at least one of cellulose, cotton, wool,
hemp, linen, nylon
and other polymer based materials. In a further embodiment, the first and
section sections of
the cartomizer matrix comprise blown nylon filaments with different densities.
[0032] In another embodiment, the first section of the cartomizer matrix is
comprises at least
one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based
materials, and the
second section of the cartomizer matrix is a different material than the first
section of the
cartomizer matrix.
Brief Description of the Drawings
[0033] 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 IA and 1B along cut line A
in Figure
1B;
Figure 3 is a cross section of an alternate pod design;
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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 configuration for the
cartomizer pod of
Figure 4A cut along cut line B showing the use of a vertical heater coil;;
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.
[0034] In the above described figures like elements have been described with
like numbers
where possible.
Detailed Description
[0035] 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.
[0036] Although presented below in the context of use in an electronic
nicotine delivery
system such as an electronic cigarette (c-cig) or a vaporizer (vapc) 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
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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, which
may use
different carriers. It should also be noted that although discussed in the
context of a pod, it
should be understood that a pod according to the disclosed embodiments does
not necessarily
have to be removable from the vaping device that it is associated with.
Accordingly, a vaping
device comprising a battery for storing electrical charge, a processor for
regulating the
application of charge to the pod, and the pod itself may be embodied as a
single item, or the
device and pod may be embodied as separate elements
[0037] A cartomizer matrix for use in a vaping device is often formed from a
material such as
woven cotton, woven spun nylon, or a similar fabric structure, that is packed
into a reservoir
within the pod. In some 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 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 filament or thread, such as a nylon, can be heated and then
blown into a mold
so that it forms to a desired shape. Irregularities in the placement of
filaments within the mold
may result in small differences in the density of the cartomizer matrix.
[0038] The e-liquid is stored within interstitial spaces within the matrix,
such as the spaces
between the threads in the woven matrix, the spaces between adjacent woven
sheets, and to a
limited extent the spaces between filaments within the threads. In embodiments
in which the
cartomizer matrix is a result of blowing filament into a mold, the
interstitial spaces are a
function of the volume of filament blown into the mold. The e-liquid is held
within these
spaces as a result of capillary forces. As e-liquid is drawn out of the
matrix, there is a general
equalizing force caused by the capillary forces in other areas of the matrix.
It has also been
observed that sections of the matrix with smaller capillary sizes (either
because of the design
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of the substrate forming the matrix, or because of compression of the
capillary matrix) exert a
stronger capillary force on the e-liquid than sections with larger capillary
sizes. Thus,
although sections of cartomizer matrix with larger capillary sizes can hold
more e-liquid, they
will effectively surrender this e-liquid to sections of the cartomizer matrix
with smaller
capillary sizes (assuming that the section with smaller capillary sizes is not
at its e-liquid
carrying capacity).
[0039] This preferential e-liquid storage phenomenon can be used to address
the e-liquid
flavor drop off If, for example, it is believed that flavor drop off,
resulting from rapid
consumption of the flavorant, becomes a noticeable phenomenon in the last 15%
of the life of
the cartomizer matrix pod, cartomizer matrix sections with smaller capillary
sizes can be
employed to act as e-liquid traps to prevent use of the last 15-20% of the e-
liquid. A pod
containing a cartomizer matrix may be advertised as storing a defined volume
of liquid, it can
then be filled with more liquid than advertised to ensure that the advertised
volume is
available for consumption. The retention of the intentional excess e-liquid
allows for the
flavorless (or flavor-reduced) e-liquid to be retained so that the user is not
subjected to the
worst effects of the flavor drop off. Embodiments of pods designed to provide
this function
will now be discussed with reference to the figures.
[0040] 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.
[0041] 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, and thus a
generally consistent interstitial spacing between the fibers within the weave
of the cartomizer
matrix 118. In the illustrated embodiment, controlled compression of the
cartomizer matrix
118 is applied to create high compression sections 124 and low compression
sections 120. It
should be understood that the terms high and low compression are only applied
in
comparison to the other sections of the cartomizer matrix 118. Compression is
controlled
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through the use of compression members 122 which effectively reduce the radius
of the
reservoir, causing increased compression of a cartomizer matrix 118 in the
high compression
sections.
[0042] As noted above, regions 124 in which the cartomizer matrix 118 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 120 of the cartomizer
matrix 118 that
have lower capillary forces.
[0043] In Figure 7, a radially compressed region of the cartomizer matrix is
formed through
using a compression member implemented as bulge 122 in sidewall 102. By
decreasing the
radial space within the pod 100, bulge 122 creates a high compression section
124within a
consistently sized cartomizer matrix 118 Regions 120 within the cartomizer
matrix 118
where the compressive effects of bulge 122 are not present have reduced degree
of
compression in comparison to the region 1124 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 the illustrated embodiment, a low compression
region 120 is
provided adjacent the wick 116 to allow for the e-liquid provided to the wick
116 to be
preferentially drawn from this region. By ensuring that sufficient e-liquid is
inserted into the
cartomizer matrix to allow low compression region 120 to store approximately
80-85% of the
e-liquid, it is possible to substantially sequester 15-20% of the e-liquid
within the high
compression sections 124. This allows the low compression section 120 to house
enough
e-liquid accessible to the wick 116 so that it will be exhausted of usable e-
liquid before flavor
drop off is observed by the user. Those skilled in the art will appreciate
that if a different
e-liquid composition, or different cartomizer matrix composition is used, the
15-20% vs
80-85% e-liquid ratios can be varied if flavor drop off occurs at a different
point. Most
importantly, it should be understood that 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 compressed region and
portion 128 which
is inside the radially compression region.
[0044] 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
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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.
[0045] 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.
[0046] 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
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 each of the
second sections 140. First section 120 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. Second sections 140 are placed away from alignment with the wick so that
they will
sequester a quantity of e-liquid away from the wick 116.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 second sections 140, as demonstrated by the
differences in
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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.
[0047] 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 second
sections 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. This will result in more e-liquid being stored in the first
section, but the e-liquid
stored in the second sections being more tightly held. 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 within the first material 152 can be drawn
into wick 116, while
the e-liquid within the second material 154 may be available for flavorant
migration, but will
be otherwise substantially sequestered. Second material 154 will
preferentially store e-liquid
within the cartomizer matrix 150, and will allow the e-liquid within the first
material 152 to
be exhausted to aid in the pre-emption of flavor drop off.
[0048] 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
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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.
[0049] 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.
The interior of
pod 160 forms a reservoir. 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 prewick 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.
[0050] Within pod 160, e-liquid will be preferentially drawn to the second
section 180of
cartomizer matrix 178, while the first cartomizer section 182 is used to hold
a larger quantity
of e-liquid under a lower capillary force. E-liquid is drawn from the first
section 182 by wick
176 to replenish the wick 176 after each use. As e-liquid is consumed, there
may be an
exchange of liquid between the first cartomizer matrix section 182 and the
second cartomizer
matrix section 180. In such an exchange, the second cartomizer section matix
180 will tend to
keep the same amount of e-liquid, so this exchange is not typically associated
with
replenishing e-liquid within the first cartomizer section 182. It should be
noted however, that
this exchange is typically, at least for the early part of the pod life, an
exchange of fully
flavored e-liquid from the second cartomizer matrix section for less flavored
e-liquid from
the first cartomizer section. Additionally, there may be a migration of
flavorants within the
e-liquid from high density locations within the second cartomizer matrix
sections 182 to the
less flavorant dense regions of e-liquid within the first cartomizer matrix
section 180. As
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e-liquid is consumed, it is drawn largely from the first section 182 of the
cartomizer matrix
178. The higher capillary forces within the second sections 180 will result in
e-liquid being
substantively sequestered within these sections of the cartomizer matrix 178
to allow for the
pre-emption of flavor drop off.
[0051] 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.
[0052] 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. In
embodiments where the reservoir is not directly accessible to a user, for
example, where the
vaping device has an integral pod, the compression members may be external to
the pod but
applying a radial compression to sections of the pod. Other embodiments may
use different
techniques to create zones with different capillary forces.
[0053] Figure 12 illustrates a cross section of an alternate embodiment of pod
160 in which
the cartomizer 186 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 186 made of a first section 188 surrounded
by a second
section 190.
[0054] 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 186 that
has a first section
made of a first material 188 and a second section made of a second material
190. It should be
understood that the first and second materials have different capillary sizes,
even if made of
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the same underlying material. In one embodiment, material 188, corresponding
to the first
section, may be made of an absorbent nylon, while material 190, 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
188 having a
larger pore structure than the second cellulose sponge 190. It should be
understood that using
different underlying materials for the first and second materials has also
been considered, so
that a cartomizer matrix 186 made up of a first material 188 such as cotton
and a second
material 190 such as a cellulose based sponge with smaller capillaries could
be used. The
smaller capillaries in the second material 190, 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 substantially sequestered within the
second material 190
so that as e-liquid is drawn from the first material 188 into wick 176 a
portion of the e-liquid
is effectively sequestered. Second material 190 will preferentially store e-
liquid within the
cartomizer matrix 186, and will allow for substantial pre-emption of the
flavor drop off by
preventing the use of a portion of e-liquid stored within cartomizer matrix
186.
[0055] 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.
[0056] In embodiments using a cartomizer matrix formed through a process of
blowing
threads, filaments or fibers into a mold, regions of different density may be
produced through
blowing more or less of the material into the mold in a given time interval,
or through the use
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of differential heating of the material as it is being blown into the mold.
This may allow for
the creation of a matrix that has smaller interstitial spaces in some areas,
and larger interstitial
spaces in other areas. In such an embodiment, the pod 160 shown in Figure 12
can be
integrally formed with different cartomizer sections having different
capillary forces within
the sections.
[0057] 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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