CA3232747A1 - Partially compressed cartomizer matrix - Google Patents

Abstract

A visual indication of the level of an atomizable liquid, in a vaping pod using a cartomizer matrix, is provided through the use of multiple cartomizer sections with differing capillary forces. A cartomizer section with a higher capillary force than an adjacent section will hold the absorbed liquid better than the adjacent section. This effect can be used to create an indication to a user that a vaporizer pod using a cartomizer matrix is approaching a low fill level which can be used to determine that the pod should be disposed of.

Description

Partially Compressed Cartomizer Matrix Cross Reference to Related Applications [0001] This application claims the benefit of priority to US Patent Application Serial No.
17/482,002 filed September 22, 2021 and entitled "Partially Compressed Cartomizer Matrix"
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 tillable tank allows the user to control the fill level as desired.
Disposable pods are typically designed to carry a fixed amount of vaporizable liquid, and are intended for disposal after consumption of the e-liquid. The ENDS cartridges, unlike the aforementioned tanks, are not typically designed to be refilled. Each cartridge stores a predefined quantity of e-liquid, often in the range of 0.5 to 3m1. In ENDS
systems, the e-liquid is typically composed of a combination of any of vegetable glycerine, propylene glycol, nicotine and flavorings. In systems designed for the delivery of other compounds, different compositions may be used.

[0005] In the manufacturing of the disposable cartridge, different techniques are used for different cartridge designs. Typically, the cartridge has a wick that allows e-liquid to be drawn from the e-liquid reservoir to an atomization chamber. In the atomization chamber, a 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 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 detent 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.

[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.

[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, cut to a desired size and shape, and then 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] One problem that arises from this situation is that with a conventional cartomizer pod, there is no mechanism to allow the user to discern that the e-liquid within the pod is sufficiently low that the pod should be replaced. When there is insufficient e-liquid within the pod, the wick 96 is unable to draw e-liquid from the cartomizer matrix 98, and is considered to be dry. The heating of a dry wick will not result in sufficient vaporization of e-liquid, and instead will result in heating of the wick to the point of combustion. This results in burning the wick, and a result which is often referred to as a burnt hit.
This exposes the user to combustion products, which is undesirable. In a pod without a cartomizer, such as pod 50, if the reservoir is made from a transparent, or substantially transparent, material such as a variety of different plastics, the user is able to see e-liquid fill levels, and there is typically e-liquid remaining within the feed lines when the reservoir appears empty, which indicates to the user the that pod is empty before the wick it too dry. With a cartomizer pod, such as pod 80, this visual indication is absent because the matrix 98 is sufficiently random in its makeup that there may be liquid pressed between the matrix 98 and the pod sidewall 82, giving an indication that the pod is retaining e-liquid, when there is insufficient e-liquid to be drawn across the wick 96.

[0021] It would therefore be beneficial to have a mechanism to provide a visual indication of the fill level of a pod to the user.
Summary

[0022] It is an object of the aspects of the present invention to obviate or mitigate the problems of the above-discussed prior art.

[0023] Through the use of a differential compression of the cartomizer matrix, disclosed embodiments may provide the ability to provide a visual indicator to a user that a cartomizer based pod, or a device using a cartomizer, is approaching an empty state.

[0024] In a first aspect of the present invention, there is provided a pod for storing an atomizable liquid. The pod has an airflow passage that defines a vertical axis. The pod comprises a cartomizer matrix having a first cartomizer section and a second cartomizer section. The cartomizer matrix is situated within the pod, and it stores the atomizable liquid for delivery to a wick. The first cartomizer section 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 formed from a second material and exerts a second capillary force that is greater than the first capillary force on atomizable liquid stored within the second material.

[0025] In an embodiment of the first aspect, the pod comprises sidewalls for retaining the cartomizer and wick. Optionally, at least a portion of the sidewalls is formed from a material that is at least one of translucent, transparent and tinted. In further embodiments, a portion of the atomizable liquid within the first and second cartomizer sections is visible at the interface between the cartomizer matrix and the sidewalls.

[0026] In another embodiment, the first cartomizer section and the second cartomizer section are made from the same material.

[0027] In a further 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. Optionally, the pod further comprises a sidewall, and wherein the compression member is integrally formed within the sidewall. In another embodiment, the pod further comprises an end cap for sealing the cartomizer matrix within the pod, and wherein the compression member is integrally formed on the end cap. In a further embodiment, the compression member is a part of a top cap that engages with an end cap to seal the cartomizer matrix within the pod. Optionally, the compression member is a silicone projection from the top cap. In another embodiment the diameter of the second cartomizer section is greater than the diameter of the first cartomizer section, and that upon insertion of the cartomizer into the pod, the second cartomizer section is radially compressed to provide smaller capillaries within the second cartomizer section and the greater capillary force.

[0028] In a further embodiment, the first cartomizer section is made from a first cartomizer material and the second cartomizer section 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.

[0029] In another embodiment, 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 comprising a cannabinoid.

[0030] 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. 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] Those of skill in the art will appreciate that embodiments of described in association with one aspect may be combined with other embodiments of that aspect, or with other aspects and their embodiments unless otherwise stated, or unless it would be clear that two embodiments are clearly incompatible.
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 IA 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 IC 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 pod of Figure 4A along cut line B;
Figure 6 is a cross section view of a pod according to an embodiment of the present invention;
Figure 7 is a magnification of the cartomizer matrix in sections 126 and 128 of Figure 6;
Figure 8 is a cross section view of a pod according to an alternate embodiment of the present invention;
Figure 9 is a cross section view of a pod according to an alternate embodiment of the present invention;
Figure 10 is a cross section view of a pod according to an alternate embodiment; and Figure 11 is a cross section view of a pod according to an alternate embodiment.

[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 c-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, including cannabinoids, and may use different carriers.

[0036] As noted above, pods filled with atomizable liquids typically provide the end user with a simple visual indicator that the pod is nearing empty, but they make use of a more viscous e-liquid than cartomizer pods to reduce leakage at the expense of flavor generation.
The ability of the cartomizer based devices to deliver improved flavor generation is appreciated by many end users, which has driven growth of disposable vaping devices in which a battery, a control system and a cartomizer pod are integrated into a disposable device. As noted earlier, firing of such a disposable device when empty is avoided by designing the device to exhaust its non-rechargeable battery before the e-liquid stored within the cartomizer matrix are exhausted

[0037] In many prior art cartomizer designs, the cartomizer matrix is typically formed from cotton or other woven materials with layers stacked upon each other. These designs provide a relatively consistent interstitial spacing within the matrix, that is there is a consistent gap between warp and weft threads, and a consistent gap between the stacked layers. These interstitial spaces, along with gaps between filaments within the warp and weft threads, provides the storage capacity of the cartomizer matrix. Compression of the matrix increases the capillary forces that retain liquid within the matrix. With very low compression levels, liquid will not be retained (or the viscosity of the liquid has to be increased), so it is common that the design of the cartomizer reservoir and the cartomizer matrix are done so that a desired viscosity range of e-liquid can be supported, with final adjustments being made to the e-liquid viscosity (typically through adjusting the ratio of vegetable glycerine and propylene glycol) to round out the process. In the prior art, a wick and air passage assembly is inserted into the cartomizer matrix, and wire leads connected to the heater are threaded through the matrix, and the cartomizer matrix - wick assembly is then inserted into a cylindrical or ovoid pod. The cartomizer matrix is designed to fit within the reservoir, providing a set amount of both radial and axial compression to allow, as noted earlier, for retention of the e-liquid within the matrix.

[0038] The consistent compression of the cartomizer matrix results in a somewhat random consumption of the e-liquid within the matrix during the life of a pod. Due to inconsistencies within each of the warp and weft threads, there will be local inconsistencies in the cartomizer matrix. In a conventional cartomizer, this can result in sections of the cartomizer matrix at the edge of a pod retaining e-liquid while other areas of the cartomizer matrix are exhausted of the e-liquid. Some cartomizer matrices are formed using nylon that is blown into a mold so that it forms to a shape that can mirror the reservoir within a pod. In such matrices, there may be inconsistencies based on the random accumulation of nylon filaments during the formation process that can yield a similar result. This can be confusing to end users that have typically been trained to recognize liquid at the wall of a pod reservoir to be indicative of available e-liquid.

[0039] Figure 6 illustrates a cross section view of a pod 100 that makes use of a cartomizer matrix, and creates two regions of differing radial compression on the matrix.
Pod 100 has a reservoir wall 102, and a top wall 104. Within the pod 100 is a central air flow passage 106.
An end cap 108 is used to seal the assembled pod 100_ End Cap 108 includes a pre-wick air flow passage 110 and electrical contacts 112. Electrical contacts 112 are connected to the heater coil 114, through leads that pass through the cartomizer matrix.
Electrical contacts 112 provide an interface through which an electrical connection can be created between pod 100 and a corresponding device.

[0040] Due to the somewhat random nature of the capillaries within a cartomizer matrix in a conventional pod, it is not always possible for an end user to visually determine a fill level, or even for an end user to determine that the cartomizer pod is effectively empty. End users are accustomed to a visual indicator of pod fill level to allow identification of an empty pod. As a result of this lack of indicator, there has been some resistance to the development of a cartomizer pod, substantially limiting the use of cartomizers to disposable devices where burnt hits can be managed through ensuring that the battery of the disposable device will expire prior to the depletion of the e-liquid.

[0041] It is known that when the capillary structure of the cartomizer structure is compressed, the capillary forces increase and the e-li qui d is retained by these stronger forces A novel design of a cartomizer pod can take advantage of the differential capillary forces of cartomizer matrix materials to generate a user discernable indication of a low level of e-liquid within the matrix. This pod structure will first be discussed with respect to Figure 6, which is a cross section of a cartomizer based pod 100, with some similarities to the prior art cartomizer pod 80.

[0042] The cartomizer pod 100 of Figure 6, has a sidewall 102 and top 104, which may also define all or part of post wick airflow path 106. It should be understood that in some embodiments, the airflow path from pre-wick airflow path 110 within end cap 108 to a point within post wick airflow path 106 may be provided by a separate element, such as a fiberglass tube that has an aperture to hold the wick 116. Such an optional tube may be used to provide structure and to hold the wick 116 at a desired location within the cartomizer. It should be understood that such a structure is optional, and as such is not clearly illustrated.
The pod 100 has a central axis that coincides with the airflow path from pre-wick airflow path 110 through post wick airflow path 106. Movement with respect to this central axis will be referred to as axial movement, with the elements closer to the top wall 104 being described as above those further from the top wall. The cartomizer matrix within the pod will be understood to be extending radially from this central axis It should be understood that this naming convention is used here for consistency and ease of understanding, but renaming is possible in different embodiments.

[0043] Where in the prior art, the cartomizer matrix is inserted into a reservoir defined solely by the sidewalls of the pod, the illustrated pod 100 stores the cartomizer matrix 118 under two different radial compressions. A first section 120 of the cartomizer matrix 118 under a first radial compression, and a second section 122 of the cartomizer matrix 118 is under a higher radial compression. These two sections are positioned so that the first section 120 is above the second section 122 along the axial direction. As illustrated in Figure 6, the higher radial compression of the second section 122 is a result of pod 100 including a compression region 124 affixed to (and in some embodiments integral with) the sidewall 102. Although shown here as being angled and applying differential radial compression along a vertical direction, in some embodiments this may be provided by a vertical wall, providing even radial compression throughout the second section 122. By creating different radial compression between sections of the cartomizer matrix 118, different capillary forces are at play within each of these regions. The higher capillary force will be present in the more compressed region (the section region 122). Thus, e-liquid within this section will be less prone to migrating through the first section 120 towards the interface with wick 116. By positioning the more compressed region 122 below the less compressed region 120 the pod 100 will be less likely to draw e-liquid from the region lower along the axial direction than it is to draw e-liquid from the higher region.

[0044] As a result, when used, e-liquid stored within cartomizer matrix 118 will be drawn through wick 116 and atomized as a result of the activation of heater 114. E-liquid will then be drawn from cartomizer matrix 118 across wick 116 as a result of capillary forces. Due to the compressed nature of the second section 122 of cartomizer 120, the capillary forces acting on the e-liquid will reduce the amount of e-liquid drawn from the second section 122 towards the wick 116 through the first section 120 of the cartomizer matrix 118. This will result in e-liquid being preferentially drawn from the first section 120 of cartomizer matrix 118, leading it to lose e-liquid faster than the second section 122.

[0045] Those skilled in the art will appreciate that to an end user looking at the pod 100, this will show that the first section 120 will no longer show e-liquid in the interface between sidewall 102 and the cartomizer matrix 118. However, due to the higher capillary forces, the second section 122 will still show e-liquid at the interface between the sidewall 102 (and the compression region 124) and the cartomizer matrix 118. Because end users are familiar with a conventional pod having e-liquid levels dropping from full to empty being represented by e-liquid only being at the bottom of the pod, this use of distinct first and second sections 120, 122, each with a different radial compression, will result in the same effect.

[0046] As such, through the use of radial compression, a section of the cartomizer is able to provide higher capillary forces than the rest of the cartomizer. By placing this higher capillary force region at the bottom of the pod, the end user is provided a visual cue to indicate that the pod is low on e-liquid. This can serve to prompt the end user to replace a cartomizer pod, avoiding the burning of a dry wick. This, thus addresses a problem posed by cartomizers that has traditionally reduced demand for cartomizer pods.

[0047] Within the first section 120 of cartomizer matrix 118, and the second section 122 of cartomizer matrix 118, are shown callouts 126 and 128 that will be shown in magnification in Figure 7.Figure 8 illustrates an alternate embodiment of pod 100. Where in previously described embodiments, compression element 124 was affixed to (or integrated with) sidewall 102, in this embodiment, end cap 108 includes a radial compression member 138 that protrudes into the space that would otherwise be occupied by the cartomizer matrix 118.
The region that compression member 138 extends into, is the second section 122 of cartomizer matrix 118. The compression member 138 may be integral with the end cap 108 as illustrated, or it may take the form of a top cap placed atop end cap 108. In such embodiments, the compression member may be made of a rigid or semi-rigid material, such as a plastic or silicone. The compression member may be translucent, transparent or tinted so that the user can discern e-liquid retained within the second section 122 of cartomizer matrix 118. When the compression member is formed of silicone, it may be a part of a silicone top cap that sits atop end cap 108. Those skilled in the art will appreciate that the sidewall 102 of pod 100 may also be formed of a material that is translucent, transparent or tinted to allow the user to view the cartomizer matrix.

[0048] In assembling a cartomizer pod, such as pod 100, a cartomizer matrix 118 will have an air flow passage member inserted within it, the airflow passage member may contain the wick 116, heater 114 and electrical leads. The airflow passage member will also define post-wick airflow passage 106 and a connection to the pre-wick airflow passage 110. After insertion into the cartomizer matrix 118, the leads can be drawn through the matrix 118 and connected to the electrical contacts 112. This results in a cartomizer matrix 118, with embedded wick 116, attached to the end cap 108. At this point, the pod 100 can be assembled by having the above described assembly inserted into the reservoir, defined by the sidewall 102 and top wall 104. In such a process, it may be simpler to have the second section 122 of the cartomizer compressed by a compression feature 138 on end cap 108 prior to assembly into completed pod 100. However, it should be understood that insertion of the cartomizer matrix 118 and end cap 108 assembly into the reservoir shown in Figure 6 can also be accomplished.

[0049] It should be understood that the use of radial compression thus far has been illustrated as constriction of a radius that the matrix 118 is inserted into. Figure 9 illustrates an alternate embodiment. The exterior of pod 100 is defined by top wall 104, sidewall 102 and end cap 108. The combination of top wall 104 and sidewall 102 define a reservoir into which a cartomizer matrix 118 can be inserted. As before, cartomizer matrix 118 has within it, an airflow passage 106, a wick 116 and heater 114 which is connected by electrical leads to electrical contacts 112 in end cap 108. However, in the absence of a radial compression member, pod 100 makes use of a cartomizer matrix 118 that has a first section 120 and a second section 140. Prior to insertion into the reservoir, the second section 140 of cartomizer matrix 118 has a larger diameter than that of the first section 120 of cartomizer matrix 118.

[0050] Because it has a larger diameter, the second section 140 has to be compressed to fit within the same diameter of the reservoir. This radial compression of the first section 120 and second section 140 will differ due to the differences in their initial diameters, and the similarities in the diameters when installed within pod 100. This differential compression will result in an increase in the capillary forces as described above.

[0051] 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 lower 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 wick 116, but will be drawn at a much lower rate from the second material 154 into the first material 152. This will result in the consumption of e-liquid in the first material 152 exceeding the consumption of e-liquid in the second material 154. Accordingly, the user will see low e-liquid levels in the interface between the cartomizer matrix 150 and the sidewall 102.

[0052] In the above examples, a cartomizer matrix is divided into two sections with capillary forces of different strengths acting in each section. Stronger capillary forces are manifested in the lower section, typically through ensuring that the sizes of the capillaries in this section are smaller. The weaker capillary forces in the top section allow for the e-liquid to be preferentially drawn from this section first. The stronger capillary forces in the bottom section will allow e-liquid to remain at the interface between the bottom section of the cartomizer matrix and the sidewall to provide the visual indication of a low e-liquid level.

[0053] Figure 11 illustrates a further embodiment of a pod 100 applying differential radial pressure to a cartomizer matrix 160. Pod 100 has a similar structure to the pod 100 described above, with sidewalls 102, top wall 104, post wick airflow path 106, and an endcap 108 for insertion into an open end of the pod 100. As in other illustrated embodiments, end cap 108 defines a pre-wick airflow path 110 and houses electrical contacts 112. A
cartomizer 160, wick 116 and heater 114 assembly is inserted into the reservoir within pod 100 before the endcap 106. Where previous embodiments had a compression member that created a small but defined region where the cartomizer matrix was under radial compression, the compression member 156 exerts a compression on the cartomizer matrix 160 that varies with the progression along the vertical axis defined by the central air flow passage At region 158, the cartomizer 160 is minimally compressed, while by region 162, the radial compression of the cartomizer 162 is higher. This gradient of compression is caused by the shape of the compression member 156. It should be noted that compression member 156 may be an element or an insert to the reservoir of pod 100, or it may be an element of the end cap 106.
In some embodiments, compression member 156 may be a resilient sleeve that the cartomizer matrix is inserted into prior to insertion into the reservoir of pod 100. It should be understood that in an embodiment providing a gradient of compression, such as that illustrated in Figure 11, there can still be first and second sections of the cartomizer matrix. The location of the boundary between first and second sections of the cartomizer matrix can be defined in any of a number of different ways including through a simple distance from top or bottom of the pod, or through the specification of a boundary based on the capillary strength, or through the amount of radial compression applied.

[0054] 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 on one or both of the end cap and the sidewalls of the pod, or it can be achieved through the use of a cartomizer matrix that is not uniform in width being inserted into a generally uniform width cavity. Those skilled in the art will appreciate that a cartomizer matrix of a non-uniform width could also be used in a pod with 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.

[0055] 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 (19)

PCT/IB2022/058942

1. A pod for storing an atomizable liquid, the pod having an airflow passage defining a vertical axis and comprising:
a cartomizer matrix within the pod for storing the atomizable liquid for delivery to a 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, 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 claim 2 wherein at least a portion of the sidewalls is formed from a material that is at least one of translucent, transparent and tinted.

4. The pod of claim 3 wherein a portion of the atomizable liquid within the first and second cartomizer sections is visible at the interface between the cartomizer matrix and the sidewalls.

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 pod further comprises an end cap for sealing the cartomizer matrix within the pod, and wherein the compression member is integrally formed on the end cap.

9. The pod of any one of claims 6 to 8 wherein the compression member is a part of a top cap that engages with an end cap to seal the cartomizer matrix within the pod.

10. The pod of claim 9 wherein the compression member is a silicone projection from the top cap.

11. The pod of any one of claims 6 to 10 wherein the diameter of the second cartomizer section is greater than the diameter of the first cartomizer section, and that upon insertion of the cartomizer into the pod, the second cartomizer section is radially compressed to provide smaller capillaries within the second cartomizer section and the greater capillary force.

12. The pod of any one of claims 1 to 11 wherein the first cartomizer section is made from a first cartomizer material and the second cartomizer section 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 14 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 18 wherein the second material comprises a woven sheet of at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.