CA3232746A1 - Compressed cartomizer matrix for improved wicking - Google Patents
Compressed cartomizer matrix for improved wicking Download PDFInfo
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- CA3232746A1 CA3232746A1 CA3232746A CA3232746A CA3232746A1 CA 3232746 A1 CA3232746 A1 CA 3232746A1 CA 3232746 A CA3232746 A CA 3232746A CA 3232746 A CA3232746 A CA 3232746A CA 3232746 A1 CA3232746 A1 CA 3232746A1
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- Prior art keywords
- cartomizer
- pod
- matrix
- wick
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- 239000011159 matrix material Substances 0.000 title claims abstract description 110
- 239000007788 liquid Substances 0.000 claims abstract description 110
- 238000007906 compression Methods 0.000 claims abstract description 59
- 230000006835 compression Effects 0.000 claims abstract description 59
- 239000000463 material Substances 0.000 claims description 85
- -1 wool Substances 0.000 claims description 18
- 229920002678 cellulose Polymers 0.000 claims description 17
- 239000001913 cellulose Substances 0.000 claims description 17
- 229920000742 Cotton Polymers 0.000 claims description 15
- 239000004677 Nylon Substances 0.000 claims description 15
- 229920001778 nylon Polymers 0.000 claims description 15
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 claims description 12
- SNICXCGAKADSCV-JTQLQIEISA-N (-)-Nicotine Chemical compound CN1CCC[C@H]1C1=CC=CN=C1 SNICXCGAKADSCV-JTQLQIEISA-N 0.000 claims description 9
- 244000025254 Cannabis sativa Species 0.000 claims description 9
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 9
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 9
- 235000009120 camo Nutrition 0.000 claims description 9
- 235000005607 chanvre indien Nutrition 0.000 claims description 9
- 239000011487 hemp Substances 0.000 claims description 9
- 229960002715 nicotine Drugs 0.000 claims description 9
- SNICXCGAKADSCV-UHFFFAOYSA-N nicotine Natural products CN1CCCC1C1=CC=CN=C1 SNICXCGAKADSCV-UHFFFAOYSA-N 0.000 claims description 9
- 229920000642 polymer Polymers 0.000 claims description 9
- 210000002268 wool Anatomy 0.000 claims description 9
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 8
- 238000003780 insertion Methods 0.000 claims description 6
- 230000037431 insertion Effects 0.000 claims description 6
- 235000011187 glycerol Nutrition 0.000 claims description 4
- 229920001296 polysiloxane Polymers 0.000 claims description 4
- 239000006200 vaporizer Substances 0.000 claims description 4
- 235000013311 vegetables Nutrition 0.000 claims description 4
- 229930003827 cannabinoid Natural products 0.000 claims description 3
- 239000003557 cannabinoid Substances 0.000 claims description 3
- 230000008016 vaporization Effects 0.000 abstract description 5
- 230000002745 absorbent Effects 0.000 description 7
- 239000002250 absorbent Substances 0.000 description 7
- 238000013461 design Methods 0.000 description 7
- 238000000889 atomisation Methods 0.000 description 6
- 239000000796 flavoring agent Substances 0.000 description 4
- 235000019634 flavors Nutrition 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000011148 porous material Substances 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 3
- 239000003571 electronic cigarette Substances 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000009834 vaporization Methods 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 1
- 238000012387 aerosolization Methods 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 229940065144 cannabinoids Drugs 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 229910000078 germane Inorganic materials 0.000 description 1
- 239000012669 liquid formulation Substances 0.000 description 1
- 239000006193 liquid solution Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000012858 resilient material Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 230000005586 smoking cessation Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
- A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
- A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
- A24F40/42—Cartridges or containers for inhalable precursors
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
- A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
- A24F40/10—Devices using liquid inhalable precursors
Landscapes
- Valves And Accessory Devices For Braking Systems (AREA)
- Catching Or Destruction (AREA)
Abstract
A pod for use in a vaporizing system stores e-liquid within a cartomizer matrix that has differing regions of compression. In alignment with the wick within the pod, the cartomizer matrix is radially compressed to create a region that both compresses against the wick and will draw e-liquid from adjacent regions of the cartomizer matrix as a result of the smaller capillaries that exert a greater capillary force to draw and retain e-liquid.
Description
2 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
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.
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 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.
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.
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.
[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 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 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.
[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 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, 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.
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 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 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 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 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.
[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 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.
[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.
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.
[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 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 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.
[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 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, 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.
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 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 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 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 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.
[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 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.
[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.
Claims (20)
1. A pod for storing an atomizable liquid, the pod having an airflow passage defining a vertical axis and a wick located within the pod at least a portion of the wick overlapping with the airflow passage, the pod comprising:
a cartomizer matrix within the pod for storing the atomizable liquid for delivery to the wick, the cartomizer matrix comprising:
a first cartomizer section, formed from a first material, exerting a first capillary force on atomizable liquid stored within the first material, and a second cartomizer section, aligned vertically within the pod with the location of the wick, formed from a second material, exerting a second capillary force, greater than the first capillary force, on atomizable liquid stored within the second material.
a cartomizer matrix within the pod for storing the atomizable liquid for delivery to the wick, the cartomizer matrix comprising:
a first cartomizer section, formed from a first material, exerting a first capillary force on atomizable liquid stored within the first material, and a second cartomizer section, aligned vertically within the pod with the location of the wick, formed from a second material, exerting a second capillary force, greater than the first capillary force, on atomizable liquid stored within the second material.
2. The pod of claim 1 further comprising sidewalls for retaining the cartomizer and wick.
3. The pod of any one of claims 1 and 2 wherein atomizable liquid stored within the cartomizer matrix is preferentially stored within the second cartomizer section.
4. The pod of any one of claims 1 to 3 wherein a central axis of the wick is aligned with the vertical axis.
5. The pod of any one of claims 1 to 4 wherein the first cartomizer section and the second cartomizer section are made from the same material.
6. The pod of any one of claims 1 to 5 wherein 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.
7. The pod of claim 6 wherein the pod further comprises a sidewall, and wherein the compression member is integrally formed within the sidewall.
8. The pod of any one of claims 6 and 7 wherein the compression member is an insert placed between a sidewall of the pod and the cartomizer matrix.
9. The pod of any one of claims 6 to 8 wherein the radial compression of the second cartomizer section presses the second cartomizer section into the wick.
10. The pod of claim 8 wherein the compression member comprises a silicone band radially compressing the cartomizer matrix.
11. The pod of any one of claims 6 to 10 wherein 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.
12. The pod of any one of claims 1 to 11 wherein 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.
13. The pod of claim 12 wherein the second cartomizer material has smaller capillaries than the first cartomizer material.
14. The pod of any one of claims 1 to 13 wherein the atomizable liquid is an e-liquid comprising at least one of vegetable glycerine, propylene glycol, nicotine and a flavoring.
15. The pod of any one of claims 1 to 13 wherein the atomizable liquid is an e-liquid comprising a cannabinoid.
16. The pod of any one of claims 1 to 15 wherein the first material comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.
17. The pod of claim 16 wherein the first material comprises a woven sheet of at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.
18. The pod of any one of claims 1 to 17 wherein the second material comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.
19. The pod of claim 17 wherein the second material comprises a woven sheet of at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.
20. A vaporizer device comprising.
a battery for storing charge;
a processor; and a pod as recited in any one of claims 1 to 19.
a battery for storing charge;
a processor; and a pod as recited in any one of claims 1 to 19.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202117482251A | 2021-09-22 | 2021-09-22 | |
| US17/482,251 | 2021-09-22 | ||
| PCT/IB2022/058939 WO2023047312A1 (en) | 2021-09-22 | 2022-09-21 | Compressed cartomizer matrix for improved wicking |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3232746A1 true CA3232746A1 (en) | 2023-03-30 |
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| CA3232746A Pending CA3232746A1 (en) | 2021-09-22 | 2022-09-21 | Compressed cartomizer matrix for improved wicking |
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| CA (1) | CA3232746A1 (en) |
| WO (1) | WO2023047312A1 (en) |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US12011033B2 (en) * | 2018-09-27 | 2024-06-18 | Philip Morris Products S.A. | Mouthpiece for aerosol-generating device with woven fiber liner |
| CN111528524A (en) * | 2019-01-21 | 2020-08-14 | 浙江迈博高分子材料有限公司 | Aerial fog dispersing device with liquid guide element |
| CN110403246B (en) * | 2019-06-17 | 2022-08-30 | 深圳麦克韦尔科技有限公司 | Electronic atomization device and atomizer thereof |
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2022
- 2022-09-21 WO PCT/IB2022/058939 patent/WO2023047312A1/en active Application Filing
- 2022-09-21 CA CA3232746A patent/CA3232746A1/en active Pending
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| WO2023047312A1 (en) | 2023-03-30 |
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