CN216906817U

CN216906817U - Microfluidic shutter for controlling the flow of liquid vaporizable material

Info

Publication number: CN216906817U
Application number: CN202120392208.8U
Authority: CN
Inventors: A·阿特金斯; S·克里斯滕森; A·M·胡派; E·J·约翰逊; J·金; E·利昂迪盖; C·J·罗瑟; A·J·斯特拉顿; A·他韦尔; N·韦斯特利; J·P·韦斯特利
Original assignee: Juul Labs Inc
Current assignee: Juul Labs Inc
Priority date: 2018-10-17
Filing date: 2019-10-17
Publication date: 2022-07-08
Anticipated expiration: 2029-10-17
Also published as: AU2019361098A1; GB2608918A; DK3664631T3; GB2580214B; CN111134366A; CN220326832U; WO2020081849A3; CA3104210A1; JP6963037B2; GB2587742B; PL3664631T3; NL2024037A; CN219330724U; EP3664631B1; DE112019005228T5; GB2608918B; GB2580214A; SG11202103749YA; BE1026673A1; PH12021550818A1

Abstract

A microfluidic gate for controlling a flow of a liquid vaporizable material, the microfluidic gate comprising: a plurality of openings connecting the reservoir and the collector, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel; and a condensation point located between the plurality of openings. Related systems, methods, and articles of manufacture are also described.

Description

Microfluidic shutter for controlling the flow of liquid vaporizable material

The application is a divisional application of a Chinese utility model patent application No. 201921746466.0 filed on 17/10/2019.

Cross Reference to Related Applications

The present application claims U.S. provisional application No. 62/915,005 entitled "CARTRIDGE FOR A VAPORIZER DEVICE" filed on 14/10/2019, U.S. provisional application No. 62/812,161 entitled "CARTRIDGE FOR A VAPORIZER DEVICE" filed on 28/2/2019, U.S. provisional application No. 62/747,099 entitled "WICK FEED AND HEATING ELEMENTS IN A VAPORIZER DEVICE" filed on 17/10/2018, U.S. provisional application No. 62/812,148 entitled "resetoir OVERFLOW CONTROL WITH compatibility inputs" filed on 28/2/2019, U.S. provisional application No. 62/747,055 entitled "resetoir OVERFLOW CONTROL" filed on 17/2018, U.S. provisional application No. 62/812,161 entitled "vapoizer condensation AND RECYCLING" filed on 17/10/2018, and U.S. provisional application No. 62/747,130 entitled "vapoir condensation CONTROL AND RECYCLING" filed on 15/10/9, These priorities are given in U.S. provisional application No. 16/653,455 entitled "HEATING ELEMENT," which is hereby incorporated by reference in its entirety.

Technical Field

The disclosed subject matter relates generally to features of cartridges for vaporizers, and in some examples to management of leakage of liquid vaporizable material, control of airflow within and near the cartridge, heating of the vaporizable material to cause formation of an aerosol, and/or other assembly features of the cartridge and the devices to which it can be detachably connected.

Background

Vaporizer devices, which are generally referred to herein as vaporizers, include devices that heat a vaporizable material (e.g., a liquid, a plant material, some other solid, a wax, etc.) to a temperature sufficient to release one or more components from the vaporizable material into a form (e.g., a gas, an aerosol, etc.) that can be inhaled by a user of the vaporizer. Some vaporizers, such as those in which at least one of the components released from the vaporizable material is nicotine, can be used as a smoking substitute for a combustible cigarette.

SUMMERY OF THE UTILITY MODEL

For purposes of summarizing, certain aspects, advantages, and novel features have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, the disclosed subject matter may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages without achieving all advantages as may be taught or suggested herein. The various features and items described herein may be combined together or may be separated, except where not feasible based on the present disclosure and what those skilled in the art will understand.

In one aspect, an evaporator includes a reservoir configured to hold a liquid vaporizable material. The receptacle is at least partially defined by at least one wall, and the receptacle includes a storage chamber and an overflow volume. The evaporator further includes a collector disposed in the overflow volume. The collector includes a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with the reservoir. The capillary structure includes microfluidic features configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

In a related aspect that may be included in the vaporizer of the preceding aspect, a microfluidic gate (gate) for controlling flow of liquid vaporizable material between the reservoir and an adjacent overflow volume in the vaporizer includes a plurality of openings connecting the reservoir and the collector, and a condensation point between the plurality of openings. The plurality of openings includes a first channel and a second channel. The first channel has a higher capillary drive than the second channel. Optionally, the microfluidic shutter may comprise a rim of the orifice between the reservoir and the collector, the rim of the orifice being flatter on a first side facing the reservoir than on a second, more rounded side facing the collector.

In another related aspect that may be combined with other aspects, a collector configured for insertion into a vaporizer cartridge includes a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with a storage chamber of the vaporizer cartridge. The capillary structure includes microfluidic features configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

In an alternative variant, one or more of the following features may also be included in any feasible combination. For example, a primary channel may be included to provide a fluid connection between the reservoir and an atomizer configured to convert the liquid vaporizable material into a vapor phase. The primary channel may be formed through the structure of the collector.

The primary channel may include a first channel configured to allow the liquid vaporizable material to flow from the reservoir to the wicking element in the atomizer. The first channel may have a cross-sectional shape with at least one irregular shape configured to allow liquid in the first channel to bypass bubbles that block the remainder of the first channel. The cross-sectional shape may resemble a cross. The capillary structure may include a secondary channel comprising microfluidic features, and the microfluidic features may be configured to allow the liquid vaporizable material to flow along the secondary channel for a length only in which the meniscus completely covers the cross-sectional area of the secondary channel. The cross-sectional area may be sufficiently small that, for the material forming the walls of the secondary channels and the composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary channels around their entire periphery.

The reservoir and the collector may be configured to maintain the continuous column of liquid vaporizable material in the collector in contact with the liquid vaporizable material in the reservoir such that a decrease in pressure in the reservoir relative to ambient pressure causes the continuous column of liquid vaporizable material in the collector to be at least partially drawn back into the reservoir. The secondary channel may include a plurality of spaced apart pinch points having a smaller cross-sectional area than portions of the secondary channel between the pinch points. The pinch point may have a flatter surface oriented along the minor channel toward the reservoir and a more rounded surface oriented along the minor channel away from the reservoir.

A microfluidic gate may be located between the collector and the reservoir. The microfluidic shutter may comprise an edge of the aperture between the reservoir and the collector, the edge of the aperture being flatter on a first side facing the reservoir than on a second, more rounded side facing the collector. The microfluidic gate may include a plurality of openings connecting the reservoir chamber and the collector and a condensation point between the plurality of openings. The plurality of openings may include a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel. Due to the higher capillary drive in the first channel, the meniscus of gas-liquid vaporizable material reaching the condensation point can be directed to the second channel, thereby forming a bubble to escape the liquid vaporizable material into the reservoir.

The liquid vaporizable material may include one or more of propylene glycol and vegetable glycerin/vegetable glycerin.

The collector may include a primary channel providing fluid connection between the reservoir and an atomizer configured to convert the liquid vaporizable material to a vapor phase, wherein the primary channel is formed through the structure of the collector. In an alternative variation, the capillary structure may include a secondary channel having microfluidic features, and the microfluidic features may be configured to allow the liquid vaporizable material to move along a secondary channel of a length only in which the meniscus completely covers the cross-sectional area of the secondary channel. The cross-sectional area of the secondary channels may be sufficiently small that, for the material forming the walls of the secondary channels and the composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary channels around the entire perimeter of the secondary channels. The reservoir and the collector may be configured to maintain the continuous column of liquid vaporizable material in the collector in contact with the liquid vaporizable material in the reservoir such that a decrease in pressure in the reservoir relative to ambient pressure causes the continuous column of liquid vaporizable material in the continuous collector to be at least partially drawn back into the reservoir. The secondary channel may include a plurality of spaced apart pinch points having a cross-sectional area smaller than the portion of the secondary channel between the pinch points. The pinch point may have a flatter surface oriented along the minor channel toward the reservoir and a more rounded surface oriented along the minor channel away from the reservoir.

In yet another related aspect, an evaporator cartridge includes: a cartridge housing, a storage chamber disposed within the cartridge housing and configured to contain a liquid vaporizable material, an inlet configured to allow air to enter an internal airflow path within the cartridge housing, an atomizer configured to convert at least some of the liquid vaporizable material into an inhalable state, a collector as described above.

In an optional variation, such an evaporator cartridge may include one or more features as described herein, such as, for example, a wicking element located within the internal airflow path and in fluid communication with the reservoir. The wicking element may be configured to wick liquid vaporizable material away from the reservoir. The heating element may be positioned to cause heating of the wicking element, thereby causing at least some of the liquid vaporizable material drawn from the reservoir to transition to a gaseous state. The inhalable state may include an aerosol formed by condensing at least some of the liquid vaporizable material from a gaseous state. The cartridge housing may comprise a unitary hollow structure having a first open end and a second end opposite the first end. The collector may be insertably received within the first end of the unitary hollow structure.

In another related aspect, a receptacle for a cartridge usable with an evaporator device is provided. In one embodiment, the receptacle includes a storage chamber (e.g., a receptacle) for storing the vaporizable material, and an overflow volume that is separable from the storage chamber and communicates with the storage chamber via a vent that opens into a channel in the overflow volume.

The channel in the overflow volume may lead to a port connected to ambient air. The reservoir or reservoir may also comprise a first wick supply and optionally a second wick supply, realized in the form of a first and second cavity, respectively, through a collector placed in the cartridge. The collector may comprise one or more support structures that form a channel in the overflow volume. The first and second chambers may control the flow of the vaporizable material toward a wick housing configured to house the wicking element.

The wicking element or wicking element housing within the wick housing may be configured to absorb the vaporizable material traveling through the first and second wick supplies such that, in thermal interaction with the atomizer, the vaporizable material absorbed within the wick is converted to at least one of a vapor or an aerosol and flows through an outlet channel structure formed through the collector and storage chamber to reach the opening in the mouthpiece. A mouthpiece may be formed adjacent the storage chamber.

The collector may have a first end and a second end. The first end may be connected to an opening in the mouthpiece and the second end, opposite the first end, may be configured to receive a wicking portion or element. A wicking portion housing according to certain embodiments can include a set of prongs projecting outwardly from the second end to at least partially receive the wicking element, and one or more compression ribs positioned adjacent the first or second wicking portion supply and extending from the second end of the collector to compress the wicking element.

In an exemplary embodiment, a vent may be provided to maintain an equilibrium pressure state in the reservoir of the cartridge and prevent the pressure in the reservoir from increasing to a point that would cause the vaporizable material to flood/flush out of the wick housing. The equilibrium pressure state may be maintained by establishing a liquid seal at the opening of a vent located at the point where the reservoir chamber communicates with the passage in the overflow volume in the cartridge. By maintaining a sufficient capillary pressure against a meniscus of vaporizable material that will form at a portion of the vent that leads out of the channel into the overflow volume, a liquid seal is established and maintained at the vent.

The capillary pressure of the vaporizable material meniscus can be controlled by, for example, venting structures forming a primary channel and a secondary channel that effectively configure a fluid valve to control the condensation point at least one of the primary channel or the secondary channel. According to embodiments, the primary and secondary channels may have a narrowing geometry such that as the meniscus continues to recede, the capillary drive of the primary channel decreases at a greater rate than the capillary drive of the secondary channel. The gradual reduction in capillary drive of the primary and secondary channels reduces the partial headspace vacuum maintained in the reservoir.

In another related aspect, the discharge pressure of the primary channel drops below the discharge pressure of the secondary channel due to the capillary drive of the primary and secondary channels being progressively reduced relative to each other. As the discharge pressure of the primary channel changes, the meniscus in the primary channel continues to discharge while the meniscus in the secondary channel remains stationary. The discharge pressure, which relates to the receding contact angle of the primary channel, may drop below the overflow pressure, which relates to the advancing contact angle of the secondary channel, resulting in the primary and secondary channels being filled with vaporizable material.

Thus, in response to an increased pressure condition within the storage chamber, the vaporizable material flows into the channel (i.e., overflow volume) of the collector through the vent, where the vent is configured to maintain a liquid seal at the condensation point, desirably at all times. In certain embodiments, the vent is configured to promote a liquid seal at an opening from which the vaporizable material flows between the storage chamber of the receptacle and the passageway of the collector in the overflow volume.

In another related aspect, one or more wick feed channels may be implemented to control the direct flow of vaporizable material toward the wick. The first wicking feed passage may be formed through the accumulator in the overflow volume independently of the primary and secondary passages of the control valve. The collector may include a support structure forming the first channel or an additional wick supply channel. The wick may be positioned in the wick housing such that the wick is configured to absorb the vaporizable material traveling through the first channel. According to embodiments, the first channel may have a cross-shaped cross-section or have a partial partition wall. The shape of the first channel may provide one or more non-primary sub-channels and one or more primary sub-channels having a larger diameter than the non-primary sub-channels.

According to embodiments, when the primary or non-primary sub-channels are restricted or blocked (e.g., due to bubble formation), the vaporizable material can travel through the alternate sub-channels or the primary channel. In a cross-shaped wick supply, the primary sub-channel may extend through the center of the cross-shaped wick supply. The vaporizable material flows through the at least one non-primary sub-channel when the primary sub-channel is restricted due to the formation of a bubble in a portion of the primary sub-channel.

In some embodiments, the collector can have a first end facing the reservoir and a second end facing away from the reservoir and configured to include a wicking portion housing. The second wick section supply may be implemented in the form of a second channel to allow the vaporizable material stored in the reservoir to flow to the wick section while the vaporizable material flows through the first wick section supply. The second wicking portion supply may have a cruciform cross-section.

According to one or more aspects, a receptacle for a cartridge usable with a vaporizer device may include a storage chamber configured to contain a vaporizable material. The reservoir may be in operative relationship with an atomizer configured to convert the vaporizable material from a liquid phase to a vapor phase or an aerosol phase for inhalation by a user of the vaporizer apparatus. The cartridge may also include an overflow volume for retaining at least some portion of the vaporizable material when one or more factors cause the vaporizable material in the reservoir chamber to enter the overflow volume in the cartridge.

The one or more factors may include exposure of the cartridge to a pressure state different from an earlier ambient pressure state (e.g. by changing from a first pressure state to a second pressure state). In some aspects, the overflow volume may comprise a channel connected to an opening or air control port leading to the outside of the cartridge (i.e. to ambient air). The channel in the overflow volume may also be in communication with the reservoir chamber such that the channel may act as a vent to allow pressure equalization in the reservoir chamber. In response to a negative pressure event in the environment surrounding the cartridge, the vaporizable material can be drawn from the storage chamber to the atomizer and converted to a vapor phase or an aerosol phase, thereby reducing the volume of vaporizable material remaining in the storage chamber of the reservoir.

The reservoir chamber may be coupled to the overflow volume through one or more openings between the reservoir chamber and the overflow volume, e.g., such that the one or more openings lead to one or more channels through the overflow volume. The flow of vaporizable material into the channel via the opening can be controlled by the capillary properties of the fluid vent leading to the channel or channels or the capillary properties of the channel itself. Further, the flow of vaporizable material into the one or more channels can be reversible, thereby allowing the vaporizable material to be transferred from the overflow volume back into the storage chamber.

In at least one embodiment, the flow of vaporizable material may be reversed in response to a change in pressure state (e.g., when the second pressure state in the cartridge reverts to the first pressure state). The second pressure state may be associated with a negative pressure event. The negative pressure event may be the result of a drop in ambient pressure relative to the pressure of the volume or volumes of air held in the reservoir chamber or other portion of the cartridge. Alternatively, the negative pressure event may result from compression of the internal volume of the cartridge due to mechanical pressure on one or more external surfaces of the cartridge.

The heating element may comprise a heating portion and at least two legs. The heating section may include at least two rake wings (tine) spaced apart from each other. The heating portion may be preformed to define an interior volume configured to receive the wicking element such that the heating portion secures at least a portion of the wicking element to the heating element. The heating portion may be configured to contact at least two separate surfaces of the wicking element. The at least two legs may be connected to the at least two rake wings and spaced apart from the heating portion. The at least two legs may be configured to be in electrical communication with a power source. Electrical power is configured to be supplied from a power source to the heating portion to generate heat to vaporize the vaporizable material stored within the wicking element.

In some embodiments, the at least two legs comprise four legs. In some embodiments, the heating portion is configured to contact at least three separate surfaces of the wicking element.

In some embodiments, the at least two rake wings comprise a first side rake wing portion, a second side rake wing portion opposite the first side rake wing portion, and a platform rake wing portion connecting the first side rake wing portion and the second side rake wing portion. The platform rake wing portion may be positioned substantially perpendicular to a portion of the first side rake wing portion and the second side rake wing portion. The first side rake wing portion, the second side rake wing portion, and the platform rake wing portion define an interior volume in which the wicking element is positioned. In some embodiments, the at least two legs are positioned away from the heated portion by a bridge.

In some embodiments, each of the at least two legs includes a cartridge contact positioned at an end of each of the at least two legs. The cartridge contacts may be in electrical communication with a power source. The cartridge contacts may be angled and extend away from the heating portion.

In some embodiments, the at least two rake wings comprise a first pair of rake wings and a second pair of rake wings. In some embodiments, the rake wings of the first pair of rake wings are evenly spaced apart from each other. In some embodiments, the rake wings of the first pair of rake wings are spaced apart by a width. In some embodiments, the width of the heating element at an inner region adjacent the platform wing portion is greater than the width of the heating element at an outer region adjacent an outer edge of the first side wing portion opposite the inner region.

In some embodiments, the evaporator device is configured to measure the resistance of the heating element at each of the four legs to control the temperature of the heating element. In some embodiments, the heating element includes a thermal barrier configured to isolate the heating portion from a body of the evaporator apparatus. In some embodiments, the evaporator device further comprises a thermal barrier configured to surround at least a portion of the heating element and isolate the heating portion from a body of a wick housing configured to surround the wicking element and at least a portion of the heating element.

In some embodiments, the heating portion is folded between the heating portion and the at least two legs to isolate the heating portion from the at least two legs. In some embodiments, the heating portion further comprises at least one protrusion extending from one side of the at least two rake wings to allow the wicking element to more easily enter the interior volume of the heating portion. In some embodiments, the at least one protrusion extends away from the interior volume at an angle.

In some embodiments, the at least two legs comprise capillary features. The capillary feature may cause a sudden change in capillary pressure, thereby preventing the vaporizable material from flowing beyond the capillary feature. In some embodiments, the capillary feature comprises one or more folds in the at least two legs. In some embodiments, the at least two legs extend at an angle toward the interior volume of the heated portion, the angled at least two legs defining the capillary feature.

In some embodiments, the vaporizer device includes a reservoir containing a vaporizable material, a wicking element in fluid communication with the reservoir, and a heating element. The heating element includes a heating portion and at least two legs. The heating part may include at least two rake wings spaced apart from each other. The heating portion may be preformed to define an interior volume configured to receive the wicking element such that the heating portion secures at least a portion of the wicking element to the heating element. The heating portion may be configured to contact at least two separate surfaces of the wicking element. At least two legs may be coupled to the at least two rake wings and spaced apart from the heating portion. The at least two legs may be configured to be in electrical communication with a power source. Electrical power is configured to be supplied from a power source to the heating portion to generate heat to vaporize the vaporizable material stored within the wicking element.

A method of forming an atomizer assembly for an evaporator device can include securing a wicking element to an interior volume of a heating element. The heating element may comprise a heating section comprising at least two rake wings spaced apart from each other and at least two legs spaced apart from the heating section. The legs may be configured to be in electrical communication with a power source of the evaporator device. The heating portion is configured to contact at least two surfaces of the wicking element. The method may further include coupling the heating element to a wick housing configured to surround the wick element and at least a portion of the heating element. Securing may also include sliding the wicking element into the interior volume of the heating element.

In some embodiments, an evaporator device includes: a heating section comprising one or more heater traces integrally formed and spaced apart from one another, the one or more heater traces configured to contact at least a portion of a wicking element of the evaporator device; a connection portion configured to receive electric power from a power supply and to guide the electric power to the heating portion; and a plating layer having a plating material different from a material of the heating portion. The plating layer may be configured to reduce contact resistance between the heating element and the power source, thereby localizing heating of the heating element to the heating portion.

In certain aspects of the present disclosure, challenges associated with collecting condensate along one or more internal passages and outlets of some evaporator devices (e.g., along a mouthpiece) may be addressed by including one or more features described herein or equivalent/equivalent methods as understood by one of ordinary skill in the art. Aspects of the present invention relate to systems and methods for capturing vaporizable material condensate in an evaporator apparatus.

In some variations, one or more of the following features may optionally be included in any feasible combination.

Aspects of the present subject matter relate to a cartridge for an evaporator device. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to hold a vaporizable material in the reservoir chamber. The cartridge may include an evaporation chamber in communication with the reservoir, and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may comprise an air flow passage extending through the evaporation chamber. The cartridge may include at least one capillary channel adjacent the gas flow channel. Each capillary channel of the at least one capillary channel can be configured to receive a fluid and to direct the fluid from a first location to a second location by capillary action.

In one aspect consistent with the present invention, each of the at least one capillary channels is narrowed in size. Narrowing in size can result in an increase in capillary drive through each of the at least one capillary channel. Each of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wicking portion. The first position may be adjacent the end of the airflow passage and the mouthpiece. The at least one capillary channel may collect fluid condensate.

In a related aspect, a vaporizer apparatus can include a vaporizer body including a heating element configured to heat a vaporizable material. The vaporizer apparatus may include a cartridge configured to be releasably coupled to the vaporizer body. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to hold a vaporizable material in the reservoir chamber. The cartridge may include an evaporation chamber in communication with the reservoir, and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may comprise an air flow passage extending through the evaporation chamber. The cartridge may include at least one capillary channel adjacent the gas flow channel. Each capillary channel of the at least one capillary channel can be configured to receive a fluid and to direct the fluid from a first location to a second location by capillary action.

Each of the at least one capillary channel may be narrowed in size. Narrowing in size can result in an increase in capillary drive through each of the at least one capillary channel. Each of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wicking portion. The first position may be adjacent the end of the airflow passage and the mouthpiece. The at least one capillary channel may collect fluid condensate.

In a related aspect, a method of vaporizing a cartridge of a device can include collecting condensate in a first capillary channel of at least one capillary channel of the cartridge. Each of the at least one capillary channel may be configured to receive a fluid and direct the fluid from a first location to a second location by capillary action. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to hold a vaporizable material in the reservoir chamber. The cartridge may include an evaporation chamber in communication with the reservoir, and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may comprise an air flow passage extending through the evaporation chamber. The at least one capillary channel may be adjacent to the gas flow channel. The method may include directing the collected condensate to an evaporation chamber and along a first capillary channel.

The method may include evaporating the collected condensate at an evaporation chamber. The first capillary channel narrows in size. Each of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wicking portion. The first position may be adjacent the end of the airflow passage and the mouthpiece.

According to an aspect of the present application, there is provided an evaporator including:

a receptacle configured to contain a liquid vaporizable material, the receptacle defined at least in part by at least one wall, the receptacle comprising a storage chamber and an overflow volume; and

a collector disposed within the overflow volume, the collector comprising a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with the reservoir, the capillary structure comprising a microfluidic feature configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

Optionally, the vaporizer further comprises a main channel providing a fluid connection between the reservoir chamber and a vaporizer configured to transition the liquid vaporizable material to a vapor phase state.

Optionally, the primary channel is formed by a structure of the collector.

Optionally, the primary channel comprises a first channel configured to allow the liquid vaporizable material to flow from the reservoir toward a wicking element within the nebulizer, the first channel comprising a cross-sectional shape having at least one irregularity configured to allow fluid within the first channel to bypass air bubbles blocking a remainder of the first channel.

Optionally, the cross-sectional shape resembles a cross.

Optionally, the capillary structure comprises a secondary channel comprising microfluidic features, and wherein the microfluidic features are configured to allow movement of the liquid vaporizable material along a length of the secondary channel only in which length a meniscus completely covers a cross-sectional area of the secondary channel.

Optionally, the cross-sectional area is sufficiently small such that, for the material used to form the secondary channel walls and the composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary channel around its entire periphery.

Optionally, the reservoir chamber and the collector are configured to maintain the continuous column of liquid vaporizable material within the collector in contact with the liquid vaporizable material within the reservoir chamber such that a pressure drop within the reservoir chamber relative to ambient pressure causes the continuous column of liquid vaporizable material within the collector to be at least partially drawn back into the reservoir chamber.

Optionally, the secondary channel comprises a plurality of spaced constriction points having a smaller cross-sectional area than the portion of the secondary channel between the constriction points.

Optionally, the constriction point has a flatter surface oriented along the secondary channel toward the storage compartment and a more rounded surface oriented along the secondary channel away from the storage compartment.

Optionally, the evaporator further comprises a microfluidic gate located between the collector and the storage compartment, the microfluidic gate comprising a rim of an aperture located between the storage chamber and the collector that is flatter on a first side facing the storage compartment than a more rounded second side facing the collector.

Optionally, the microfluidic gate comprises a plurality of openings connecting the reservoir to the collector and a condensation point between the plurality of openings, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel.

Optionally, the meniscus of air-liquid vaporizable material reaching the condensation point is directed to the second channel due to higher capillary drive in the first channel such that a bubble is formed to escape into the liquid vaporizable material within the storage chamber.

Optionally, the liquid vaporizable material comprises one or more of propylene glycol and vegetable glycerin. According to another aspect of the present application, there is provided a microfluidic shutter for controlling a flow of liquid vaporizable material between a storage chamber and an adjacent overflow volume in a vaporizer, the microfluidic shutter comprising:

A plurality of openings connecting the reservoir and the collector, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel; and

a condensation point located between the plurality of openings.

Optionally, the microfluidic shutter comprises a rim of an aperture between the storage chamber and the collector that is flatter on a first side facing the storage compartment than a more rounded second side facing the collector.

According to another aspect of the present application, there is provided a collector configured to be inserted into an evaporator cartridge, the collector comprising:

a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with a storage chamber of the vaporizer cartridge, the capillary structure comprising a microfluidic feature configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

Optionally, the collector further comprises the aforementioned microfluidic shutter.

Optionally, the collector further comprises a primary channel providing a fluid connection between the reservoir and an atomizer configured to transform the liquid vaporizable material into a gas phase state, wherein the primary channel is formed by the structure of the collector.

Optionally, the cross-sectional area is sufficiently small that, for the material used to form the secondary channel walls and the composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary channel around its entire perimeter.

Optionally, the secondary channel comprises a plurality of spaced apart pinch points having a smaller cross-sectional area than the portion of the secondary channel between the pinch points.

According to another aspect of the application, there is provided an evaporator cartridge comprising:

a cartridge housing;

a reservoir chamber disposed within the cartridge housing and configured to contain a liquid vaporizable material;

an inlet configured to allow air to enter an internal airflow path within the cartridge housing; an atomizer configured to transform at least some of the liquid vaporizable material into an inhalable state; and

according to the collector described above.

Optionally, the nebulizer comprises:

a wicking element located in the internal airflow path and in fluid communication with the reservoir, the wicking element configured to wick the liquid vaporizable material from the storage chamber; and

a heating element positioned such that the wicking element heats to cause at least some of the liquid vaporizable material drawn from the storage chamber to transition to a gaseous state.

Optionally, the inhalable state comprises an aerosol formed by condensation of at least some liquid vaporizable material from the gaseous state.

Optionally, the cartridge housing comprises an integral hollow structure having an open first end and a second end opposite the first end.

Optionally, the collector is insertably received in the first end of the unitary hollow structure.

According to another aspect of the present application, there is also provided an evaporator comprising an evaporator body and an evaporator cartridge according to the preceding, wherein the evaporator body and the evaporator cartridge are attachable separately from each other to form the evaporator.

Optionally, the heating element comprises:

a heating portion comprising at least two rake wings spaced apart from one another, the heating portion being preformed to define an inner volume configured to receive a wicking element such that the heating portion secures at least a portion of the wicking element to the heating element, the heating portion configured to contact at least two separate surfaces of the wicking element; and

at least two legs coupled to the at least two rake wings and spaced apart from the heating portion, the at least two legs configured to be in electrical communication with a power source,

Wherein power is configured to be supplied from a power source to the heating portion to generate heat to vaporize the vaporizable material stored within the wicking element.

Optionally, the at least two legs comprises four legs.

Optionally, the heating portion is configured to contact at least three separate surfaces of the wicking element.

Optionally, the at least two rake wings comprise:

a first side rake wing;

a second side rake wing opposite the first side rake wing; and

a platform rake wing connecting the first side rake wing to the second side rake wing, the platform rake wing positioned substantially perpendicular to a portion of the first side rake wing and the second side rake wing,

wherein the first side rake wing, the second side rake wing, and the platform rake wing define the inner volume in which the wicking element is positioned.

Optionally, the at least two legs are positioned away from the heated portion by a bridge portion.

Optionally, each of the at least two legs includes a cartridge contact positioned at an end of each of the at least two legs, the cartridge contact configured to be in electrical communication with a power source, the cartridge contact being angled and extending away from the heating portion.

Optionally, the at least two rake wings comprise a first pair of rake wings and a second pair of rake wings.

Optionally, the rake wings of the first pair of rake wings are evenly spaced apart from each other.

Optionally, the rake wings of the first pair of rake wings are spaced apart by a width.

Optionally, the width at an inner region of the heating element is greater than the width at an outer region of the heating element, the inner region being adjacent to the platform rake wings, the outer region being adjacent to an outer edge of the first side rake wings, opposite the inner region.

Optionally, the evaporator apparatus is configured to measure the resistance of the heating element at each of the four legs to control the temperature of the heating element.

Optionally, a thermal barrier configured to isolate the heating portion from a body of the evaporator apparatus is further included.

Optionally, the evaporator device further comprises a thermal barrier configured to surround at least a portion of the heating element and isolate the heating portion from a body of a wicking housing configured to surround at least a portion of the heating element and the wicking element.

Optionally, the heating portion is folded between the heating portion and the at least two legs to isolate the heating portion from the at least two legs.

Optionally, the heating section further comprises at least one protrusion extending from one side of the at least two rake wings to allow the wicking element to more easily enter the internal volume of the heating section.

Optionally, the at least one protrusion extends away from the inner volume at an angle.

Optionally, the at least two legs comprise a capillary feature that causes an abrupt change in capillary pressure, thereby preventing the vaporizable material from flowing beyond the capillary feature.

Optionally, the capillary feature comprises one or more folds in the at least two legs.

Optionally, the at least two legs extend at an angle towards the internal volume of the heating portion, the at least two legs of the angled corner defining the capillary feature.

Optionally, the heating element comprises:

a heating portion comprising one or more heater traces integrally formed and spaced apart from one another, the one or more heater traces configured to contact at least a portion of a wicking element of an evaporator device;

a connection portion configured to receive power from a power supply and to guide the power to the heating portion; and

a plating layer having a plating material different from a material of the heating portion, the plating layer configured to reduce a contact resistance between the heating element and the power source, thereby localizing heating of the heating element to the heating portion.

Optionally, the plating layer comprises one or more layers deposited onto the connection portion.

Alternatively, the plating layer is formed integrally with the connection portion.

Optionally, the plating layer comprises an adhesive plating layer and an outer plating layer.

Optionally, at least the outer plating layer is configured to reduce contact resistance between the heating element and the power source.

Optionally, the adherent coating is deposited onto the heating element to adhere the outer coating to the heating element.

Optionally, the material of the heating portion includes nichrome.

Optionally, the plating layer comprises gold.

Optionally, further comprising a wicking housing, the wicking housing comprising:

an outer wall; and

an inner volume defined by the outer wall, the inner volume configured to receive a portion of the wicking element and the heating element of the evaporator device.

Optionally, the heating element comprises a heating portion configured to heat the vaporizable material stored in the wicking element to generate the aerosol and a connection portion configured to be in electrical communication with a power source to provide power to the heating portion, and wherein the portion of the heating element is the heating portion.

Optionally, the outer wall is configured to be located between the heating portion and the connection portion.

Optionally, the outer wall comprises two opposing short sides and two opposing long sides.

Optionally, each of the two opposing long sides comprises a recess configured to releasably couple the evaporator cartridge to a corresponding feature of the evaporator body.

Optionally, the recess is located adjacent to an intersection between one of the two opposing long sides and one of the two opposing short sides.

Optionally, each of the two opposing long sides comprises two recesses.

Optionally, the outer wall further comprises a base positioned substantially perpendicular to the two opposing short sides and the two opposing long sides.

Optionally, the base comprises one or more slots, wherein gas pressure caused by the flow of the vaporizable material within the heater portion is configured to escape through the one or more slots.

Optionally, at least one of the two opposing short sides comprises a chip recess configured to receive an identification chip.

Optionally, the chip recess comprises at least two walls configured to enclose and retain an identification chip.

Optionally, the at least two walls comprise at least four walls.

Optionally, the outer wall comprises:

two opposing short sides;

two opposing long sides;

a base positioned substantially perpendicular to the two opposing short sides and the two opposing long sides; and

an opening opposite the base.

Optionally, the evaporator cartridge further comprises an outer rim surrounding the opening and extending away from the opening.

Optionally, the outer wall includes a capillary feature that causes an abrupt change in capillary pressure between the heating element and the wick housing, thereby preventing the vaporizable material from flowing beyond the capillary feature.

Optionally, the capillary feature comprises a curved surface formed at an interface between the outer rim and at least one of the two opposing long sides.

Optionally, the curved surface has a radius sufficient to break a tangent point between the outer surface and the outer rim.

Optionally, the capillary feature is positioned within a cutout in the outer wall, the cutout configured to space the heating element from the outer wall, thereby preventing excessive thermal contact with the outer wall.

Optionally, further comprising a cut-out in the outer wall, the cut-out configured to space a heating element from the outer wall, thereby preventing excessive thermal contact with the outer wall.

According to another aspect of the present application, there is also provided a collector component for an evaporator for use with a liquid vaporizable material, the collector component comprising:

a fluid channel;

an external port disposed at a first end of the fluid passage and configured to be in fluid communication with ambient air external to the evaporator;

a control vent disposed at a second end of the fluid channel distal from the first end and configured to manage flow between the fluid channel and a reservoir of the evaporator configured to hold the liquid vaporizable material, the control vent configured to provide at least:

a first fluidic resistance when air is in the fluid passage adjacent the control vent and a void volume within the reservoir is at a lower pressure than ambient air outside the evaporator to condense the bubbles into the reservoir; and

a second fluidic resistance when the void volume within the reservoir is at a higher pressure than ambient air outside of the evaporator to allow the liquid vaporizable material to enter the fluid passageway through the control vent; and

at least one first wick supply implemented in the form of a first channel to allow vaporizable material stored in the reservoir to flow toward a wick disposed in a wick housing positioned in the overflow volume,

The control vent maintains an equilibrium state in the reservoir chamber to prevent the pressure in the reservoir chamber from increasing to a point that would cause the vaporizable material to flood the wick housing.

Optionally, the equilibrium state is maintained by establishing a liquid seal at the opening of the control vent where the reservoir chamber communicates with the passage in the overflow volume.

Optionally, a liquid seal is established and maintained at the vent by maintaining sufficient capillary pressure for a vaporizable material meniscus to form at a portion of a channel of the control vent into the overflow volume.

Optionally, the capillary pressure for the meniscus of vaporizable material is controlled by a V-shaped structure forming a primary channel and a secondary channel constituting the control vent to control at least one condensation point at one of the primary channel or the secondary channel.

Optionally, the primary and secondary channels have a narrowing geometry such that as the meniscus continues to recede, the capillary drive of the primary channel decreases at a greater rate than the capillary drive of the secondary channel.

Optionally, the gradual reduction in capillary drive of the primary channel and the secondary channel reduces a partial headspace vacuum maintained in the storage chamber.

Optionally, the discharge pressure of the primary channel drops below the discharge pressure of the secondary channel due to the capillary drive of the primary and secondary channels being progressively reduced relative to each other.

Optionally, as the discharge pressure of the primary channel changes, the meniscus in the primary channel continues to discharge while the meniscus in the secondary channel remains stationary.

Alternatively, the discharge pressure related to the receding contact angle of the primary channel may be lowered below the flooding pressure related to the advancing contact angle of the secondary channel, thereby filling the primary and secondary channels with vaporizable material.

Optionally, in response to an increased pressure within the storage chamber, vaporizable material flows into the channel of the collector through the vent, wherein the vent is configured to maintain the liquid seal at all times.

According to another aspect of the present application, there is also provided a cartridge for an evaporator device, the cartridge comprising:

a receptacle comprising a receptacle chamber defined by a receptacle barrier, the receptacle configured to hold a vaporizable material in the receptacle chamber;

an evaporation chamber in communication with the reservoir and comprising a wicking element configured to draw the vaporizable material from the reservoir chamber to the evaporation chamber to be evaporated by a heating element;

An air flow passage extending through the evaporation chamber; and

at least one capillary channel adjacent to the gas flow channel, each capillary channel of the at least one capillary channel configured to receive and wick fluid from the first location to the second location.

Optionally, each of the at least one capillary channel narrows in size.

Optionally, the narrowing in size results in an increase in capillary drive through each of the at least one capillary channel.

Optionally, each capillary channel of the at least one capillary channel is formed by a groove defined between a pair of walls.

Optionally, the at least one capillary channel is in fluid communication with the wicking portion.

Optionally, the first location is adjacent an end of the airflow passage and the mouthpiece.

Optionally, the at least one capillary channel collects fluid condensate.

According to another aspect of the present application, there is also provided an evaporator device comprising:

a vaporizer body comprising a heating element configured to heat a vaporizable material; and

a cartridge configured to be releasably coupled to the evaporator body, the cartridge comprising:

An evaporation chamber in communication with the reservoir and comprising a wicking element configured to wick the vaporizable material from the reservoir chamber to the evaporation chamber to be evaporated by the heating element;

an air flow passage extending through the evaporation chamber; and

at least one capillary channel adjacent to the gas flow channel, each of the at least one capillary channel configured to receive and wick fluid from the first location to the second location.

Optionally, each capillary channel of the at least one capillary channel narrows in size.

Optionally, the at least one capillary channel collects fluid condensate.

According to another aspect of the present application, there is also provided a method comprising:

Condensate collected in a first capillary channel of at least one capillary channel of a cartridge of an evaporation device, each of the at least one capillary channel configured to receive and wick fluid from a first location to a second location, the cartridge comprising:

an evaporation chamber in communication with the reservoir and comprising a wicking element configured to wick the vaporizable material from the reservoir chamber to the evaporation chamber to be evaporated by a heating element; and

a gas flow channel extending through the evaporation chamber, the at least one capillary channel being adjacent to the gas flow channel; and

the collected condensate is directed towards the evaporation chamber and along the first capillary channel.

Optionally, the method further comprises evaporating the collected condensate at the evaporation chamber.

Optionally, the first capillary channel narrows in size.

The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. However, the disclosed subject matter is not limited to any particular embodiment disclosed.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the subject matter disclosed herein and together with the description, help explain some of the principles associated with the disclosed implementations as provided below.

FIG. 1 illustrates a block diagram of an exemplary evaporator apparatus in accordance with one or more embodiments;

FIG. 2A illustrates a plan view of an exemplary evaporator body and insertable evaporator cartridge in accordance with one or more embodiments;

FIG. 2B illustrates a perspective view of the evaporator apparatus of FIG. 2A in accordance with one or more embodiments;

fig. 2C shows a perspective view of the cartridge of fig. 2A according to one or more embodiments;

fig. 2D shows another perspective view of the cartridge of fig. 2C according to one or more embodiments;

Fig. 2E shows a schematic view of a reservoir system configured for an evaporator cartridge and/or an evaporator device for improving airflow within the evaporator device, according to one or more embodiments;

FIG. 2F shows a schematic view of a reservoir system configured for an evaporator cartridge or evaporator device for improving air flow within the evaporator device, according to another embodiment;

figures 3A and 3B show exemplary plan cross-sectional views of a cartridge with a reservoir chamber and an overflow volume according to one or more embodiments;

fig. 4 shows an exploded perspective view of an exemplary embodiment of the cartridge of fig. 3A and 3B according to one or more embodiments;

FIG. 5 shows a plan cross-sectional side view of selected separated portions of a cartridge according to one or more embodiments;

FIG. 6A shows a cross-sectional top view of an exemplary cartridge structure according to one or more embodiments;

fig. 6B shows a perspective side view of the exemplary cartridge of fig. 6A according to one or more embodiments;

fig. 7A to 7D show an exemplary embodiment of a cartridge connection port having a male or female configuration according to one or more embodiments;

Fig. 8 shows a top plan view of a cartridge with an exemplary pattern or logo according to one or more embodiments;

fig. 9A and 9B show perspective and plan cut views of separate portions of an exemplary cartridge according to one or more embodiments;

10A and 10B illustrate closed and exploded perspective views of an exemplary filter media cartridge embodiment having a separable structure for receiving a collector mechanism, according to one or more embodiments;

10C-10E illustrate perspective front and side views of an exemplary cartridge structural member with a flow management collector having one or more flow channels in accordance with one or more embodiments;

fig. 11A illustrates a side plan view of an exemplary single-vent, single-channel collector structure in accordance with one or more embodiments;

FIG. 11B is a side plan view of an exemplary cartridge having a translucent shell structure containing an exemplary collector, such as shown in FIG. 11A, in accordance with one or more embodiments;

11C-11E illustrate perspective and planar side views of an exemplary collector structure in which a flow management constriction is built into a flow channel in accordance with one or more embodiments;

11F and 11G illustrate front and side views of an example collector structure with a flow management constriction built into the flow channel of the collector, according to one or more embodiments;

fig. 11H illustrates a perspective close-up view of an example collector structure having one or more vents that can control liquid flow between a storage chamber and an overflow volume in a cartridge, according to one or more embodiments;

11I-11K illustrate perspective views of example collector structures with flow management control in accordance with one or more embodiments;

11L-11N illustrate front plan and close-up views of an exemplary flow management mechanism in a collector structure, according to one embodiment;

11O-11X illustrate snapshots when the flow of vaporizable material collected in the example collector of FIGS. 11L-11N is managed to accommodate proper draining as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment;

12A and 12B illustrate an example of a single vent multi-channel collector structure in accordance with one or more embodiments;

FIG. 13 illustrates an exemplary dual vent multi-channel collector structure in accordance with one or more embodiments;

Fig. 14A and 14B show perspective and cross-sectional planar side views of an example collector structure for a cartridge with a dual wick feed in accordance with one or more embodiments;

15A-15C illustrate additional perspective and cross-sectional plan side views of an example collector structure for a dual wick supply structure in accordance with one or more embodiments;

16A-16C show a cross-sectional plan side view of an exemplary cartridge, a plan side view of an exemplary wicking element housed in a collector structure, and a perspective view of an exemplary cartridge with a collector structure, respectively, according to one or more embodiments;

17A and 17B show a perspective view of a first side of a cartridge and a cross-sectional view of a second side of a cartridge with a wicking element protruding into a storage chamber according to one or more embodiments;

18A-18D illustrate examples of heating elements and air flow channels in a vaporizer cartridge according to one or more embodiments;

19A-19C illustrate examples of heating elements and air flow channels in a vaporizer cartridge according to one or more embodiments;

20A-20C illustrate examples of heating elements and air flow channels in a vaporizer cartridge according to one or more embodiments;

21A and 21B show side views of example collector structures that include one or more rib or sealing flange profiles that support certain manufacturing techniques for securing the collector to a storage chamber in a cartridge;

22A-22B illustrate an example of a heating element according to one or more embodiments;

fig. 23 shows an example of a portion of a wicking housing in accordance with one or more embodiments;

FIG. 24 shows an example of an identification chip in accordance with one or more embodiments;

FIG. 25 shows perspective, front, side and exploded views of an exemplary embodiment of a cartridge;

fig. 26A shows perspective, front, side, bottom, and top views of an exemplary embodiment of a collector with a V-shaped vent;

26B and 26C show perspective and cross-sectional views of an example collector structure from different perspectives in accordance with one or more embodiments, focusing on structural details for securing placement of the wicking element and wicking portion housing relative to the atomizer toward one end of the cartridge;

26D-26F illustrate top plan views of example wick supply mechanisms formed or constructed by a collector, according to one or more embodiments;

27A and 27B illustrate front views of exemplary flow management mechanisms in a collector structure in accordance with one or more embodiments;

FIG. 28 shows a front view of an example cartridge containing an example collector structure;

fig. 29A to 29C show a perspective view, a front view and a side view, respectively, of an exemplary embodiment of a cartridge;

fig. 30A to 30F show perspective views of an exemplary cartridge at different filling levels according to one or more embodiments;

31A-31C show front views of an exemplary cartridge upon filling and assembly, according to one embodiment;

32A-32C show front, top and bottom views of an exemplary cartridge air path;

33A and 33B show front and top views of an exemplary cartridge with an airflow path, a liquid supply channel, and a condensate collection system;

34A and 34B show front and side views of an exemplary cartridge body with external airflow paths;

fig. 35 and 36 show perspective views of a portion of an exemplary cartridge with a collector structure having an air gap at its bottom rib;

37A-37C show top views of various example wick supply shapes for cartridges;

Figures 37D and 37E are example embodiments of a collector with a dual wick feed;

figure 38 shows an enlarged view of the end of the wicking portion supply located adjacent the wicking portion and configured to at least partially receive the wicking portion;

FIG. 39 shows a perspective view of an example collector structure with a wicking supply of square design and an air gap at one end of the overflow channel;

FIG. 40A shows a rear view of a collector structure having, for example, four different ejection locations;

figure 40B shows a side view of the collector structure particularly illustrating the clip-shaped end of the wick supply, for example, capable of holding a wick securely in the path of the wick supply;

figure 40C shows a top view of a collector structure with a wick supply channel for receiving vaporizable material from a storage chamber of a cartridge and directing the vaporizable material toward the wick, the wick being held in place at the end of the wick supply channel by the protruding end of the wick supply channel;

fig. 40D shows a front plan view of the collector structure. As shown, the air gap cavity may be formed in the lower portion of the collector structure at the end of the lower rib of the collector structure where the overflow channel of the collector leads to an air control outlet communicating with ambient air;

Figure 40E shows a bottom view of the collector structure where the wick supply channel terminates in a clip-like protrusion configured to hold the wicks in place on each end; 41A and 41B show plan top and side views of a collector structure with two respective wick supplies having two pinched ends;

42A and 42B illustrate various perspective, top, and side views of an example collector with different structural embodiments;

figure 43A illustrates various perspective, top, and side views of an example wicking portion housing in accordance with one or more embodiments;

figure 43B shows the collector and wick housing components of an exemplary cartridge, with protruding tabs configured in the structure of the wick housing to be insertably received in receiving recesses or cavities in the respective bottom portion of the collector;

fig. 44A shows a perspective exploded view of an embodiment of a cartridge according to an embodiment of the present subject matter;

fig. 44B shows a top perspective view of an embodiment of a cartridge according to an embodiment of the present subject matter;

fig. 44C shows a bottom perspective view of an embodiment of a cartridge according to an embodiment of the present subject matter;

FIG. 45 illustrates a schematic view of a heating element for an evaporator apparatus consistent with embodiments of the present subject matter;

FIG. 46 illustrates a schematic view of a heating element for an evaporator apparatus consistent with embodiments of the present subject matter;

FIG. 47 illustrates a schematic view of a heating element for an evaporator apparatus consistent with embodiments of the present subject matter;

FIG. 48 shows a schematic view of a heating element positioned in an evaporator cartridge for an evaporator device consistent with embodiments of the present subject matter;

FIG. 49 illustrates a heating element and wicking element consistent with embodiments of the present subject matter;

FIG. 50 illustrates a heating element and wicking element consistent with embodiments of the present subject matter;

FIG. 51 shows a heating element and wicking element within an evaporator cartridge consistent with an embodiment of the invention;

FIG. 52 shows a heating element and wicking element within an evaporator cartridge consistent with an embodiment of the invention;

FIG. 53 illustrates a heating element located within an evaporator cartridge consistent with an embodiment of the invention;

FIG. 54 illustrates a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 55 illustrates a heating element in a bent position consistent with an embodiment of the present subject matter;

FIG. 56 illustrates a heating element in a bent position consistent with an embodiment of the present subject matter;

FIG. 57 illustrates a heating element in an unbent position consistent with an embodiment of the present subject matter;

FIG. 58 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 59 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 60 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 61 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 62 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 63 illustrates a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 64 illustrates a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 65 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 66 illustrates a heating element in a partially bent position consistent with embodiments of the present subject matter;

FIG. 67 illustrates a heating element in a partially bent position consistent with an embodiment of the present subject matter;

FIG. 68 illustrates a heating element and wicking element in a partially bent position consistent with an embodiment of the present subject matter;

FIG. 69 illustrates the heating element and wicking element in a bent position consistent with an embodiment of the present subject matter;

FIG. 70 illustrates a heating element and wicking element in a bent position consistent with embodiments of the present subject matter;

FIG. 71 illustrates a heating element in an unbent position consistent with an embodiment of the present subject matter;

FIG. 72 illustrates a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 73 illustrates a heating element in an unbent position consistent with an embodiment of the present subject matter;

FIG. 74 illustrates a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 75 illustrates a heating element coupled with a portion of an evaporator cartridge according to an embodiment of the present subject matter;

FIG. 76 illustrates a heating element and wicking element within an evaporator cartridge consistent with embodiments of the present subject matter;

FIG. 77 illustrates a heating element in a partially bent position consistent with an embodiment of the present invention;

FIG. 78 illustrates the heating element and wicking element in a partially bent position consistent with an embodiment of the present subject matter;

FIG. 79 illustrates a heating element with plated portions in an unbent position consistent with embodiments of the present subject matter;

FIG. 80 illustrates a heating element with plated portions in a bent position consistent with embodiments of the present subject matter;

FIG. 81 illustrates a heating element having a plated portion within an evaporator cartridge consistent with embodiments of the present subject matter;

FIG. 82 illustrates a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 83 illustrates a side view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 84 illustrates a front view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 85 shows a perspective view of a heating element and wicking element in a bent position consistent with embodiments of the present subject matter;

FIG. 86 illustrates a heating element within an evaporator cartridge consistent with embodiments of the present subject matter;

FIG. 87 shows a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

Fig. 88 illustrates a side view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 89 illustrates a top view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 90 illustrates a front view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 91 illustrates a perspective view of a heating element in an unbent position consistent with an embodiment of the present subject matter;

FIG. 92 illustrates a top view of a heating element in an unbent position consistent with embodiments of the present subject matter;

fig. 93A illustrates a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 93B illustrates a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 94 illustrates a side view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 95 illustrates a top view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 96 illustrates a front view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 97A illustrates a perspective view of a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 97B illustrates a perspective view of a heating element consistent with embodiments of the present subject matter in an unbent position;

FIG. 98A illustrates a top view of a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 98B illustrates a top view of a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 99 illustrates a top perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

FIG. 100 illustrates a bottom perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

FIG. 101 illustrates an exploded perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

FIG. 102 illustrates a perspective view of a thermal barrier consistent with an embodiment of the present subject matter;

fig. 103A illustrates a side cross-sectional view of a nebulizer assembly consistent with embodiments of the present subject matter;

fig. 103B illustrates another side cross-sectional view of a nebulizer assembly consistent with embodiments of the present subject matter;

FIG. 104 schematically illustrates a heating element consistent with an embodiment of the present subject matter;

FIG. 105 illustrates a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 106 illustrates a side view of a heating element in a bent position consistent with embodiments of the present subject matter;

Fig. 107 shows a perspective view of a heating element in a bent position consistent with embodiments of the present subject matter;

fig. 108 illustrates a side view of a heating element in a bent position consistent with embodiments of the present subject matter;

FIG. 109 illustrates a top view of a substrate material having a heating element according to an embodiment of the present subject matter;

FIG. 110 illustrates a top view of a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 111A illustrates a top perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

fig. 111B shows a close-up view of a portion of a wicking portion housing of a nebulizer assembly, consistent with an embodiment of the invention;

FIG. 112 illustrates a bottom perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

FIG. 113 illustrates an exploded perspective view of a nebulizer assembly consistent with embodiments of the present subject matter;

114A-114C illustrate an assembly process of a nebulizer according to embodiments of the present subject matter;

115A-115C illustrate an assembly process of a nebulizer according to embodiments of the present subject matter;

FIG. 116 illustrates a process flow diagram illustrating features of a method of forming and implementing a heating element consistent with embodiments of the present subject matter;

FIG. 117 illustrates one embodiment of an evaporator cartridge;

FIG. 118 illustrates an embodiment of an evaporator cartridge and/or an interface of an evaporator device;

FIG. 119A shows a side cross-sectional view of a condensate recirculation system of an evaporator cartridge;

FIG. 119B illustrates a first perspective view of the condensate recirculation system of FIG. 119A; and moreover

FIG. 119C illustrates a second perspective view of the condensate recirculation system of FIG. 119A.

In practice, the same or similar reference numbers indicate the same, similar or equivalent structures, features, aspects or elements according to one or more embodiments.

Detailed Description

Vaporizers configured to convert a liquid vaporizable material into a vapor phase and/or an aerosol phase (e.g., a suspension of vapor and particulate phase materials in air that is in a relatively local equilibrium between the phases) can generally include a reservoir or storage container (also referred to herein as a reservoir, storage compartment, or storage volume) that contains a volume of liquid vaporizable material, a nebulizer (also referred to herein as a nebulizer assembly), a heating element (e.g., a resistive element through which an electrical current is passed to cause the conversion of the electrical current into thermal energy), the heating element heats the liquid vaporizable material to cause at least some of the liquid vaporizable material to convert to a vapor phase, and a wicking element (which may be referred to simply as a wick, but which generally refers to an element or combination of elements that exert a capillary force to draw the liquid vaporizable material from the reservoir to a location where it is heated by the action of the heating element). In some cases (depending on a number of factors), the resulting vapor phase liquid vaporizable material then (and optionally almost immediately) begins to at least partially condense to form an aerosol in the air passing over, near, around the atomizer, or the like.

As the liquid vaporizable material in the wicking element is heated and transformed into a vapor phase (and then optionally into an aerosol), the volume of the liquid vaporizable material in the reservoir decreases. A reduced pressure state (e.g., at least a partial vacuum) is created within the receptacle without a mechanism for allowing air or some other substance to enter void space created within the receptacle (e.g., a portion of the receptacle volume not occupied by the liquid vaporizable material) when the volume of the liquid vaporizable material in the receptacle is reduced by conversion to a gas/aerosol phase. Such reduced pressure conditions may adversely affect the efficacy of the wicking element used to draw vaporizable material from the storage compartment or reservoir into proximity with the heating element to be vaporized into the vapor phase, since the partial vacuum pressure acts against the capillary pressure generated within the wicking element.

More particularly, a reduced pressure condition in the reservoir may result in insufficient saturation of the wicking portion and, ultimately, a lack of sufficient vaporizable material being delivered to the vaporizer for reliable operation of the vaporizer. To counteract the reduced pressure condition, ambient air may be admitted to the reservoir to equalize the pressure between the interior of the reservoir and the ambient pressure. Allowing air to backfill void spaces in the reservoir created by the evaporated liquid vaporizable material may occur in some vaporizers by air entering the reservoir through the wicking element. However, this process typically requires that the wicking element be at least partially dry. Since a dry wicking element may not be readily achievable and/or may not be desirable for reliable operation of the vaporizer, another typical approach is to provide a vent to allow pressure equalization between ambient conditions and the interior of the container.

The presence of air in the void space of the reservoir, whether through the wicking portion or through some other venting portion or structure, may create one or more other problems. For example, once the air pressure within the void space of the reservoir is balanced (or at least nearly balanced) with the ambient pressure, and particularly as the volume of the air-filled void space increases relative to the total reservoir volume, the creation of a negative pressure differential between the air in the void space and the ambient conditions (e.g., the air in the void space is at a higher pressure than ambient) may cause the liquid vaporizable material to leak out of the reservoir, for example, through the wicking, through any vents provided, or the like. The negative pressure differential between the air within the reservoir and the current ambient pressure may result from one or more of several factors, such as, for example, heating the air within the void space (e.g., by holding the reservoir in the hand, bringing the evaporator from a cold area to a warmer area, etc.), mechanical forces that may deform the shape of the reservoir and thereby reduce the interior volume of the reservoir (e.g., squeezing on a portion of the evaporator, causing deformation of the reservoir volume, etc.), a rapid drop in ambient pressure (e.g., such as may occur in an aircraft cabin during air travel, when a car or train enters or exits a tunnel, when a window is open or closed while the vehicle is traveling at a high speed, etc.), and the like.

Leakage of liquid vaporizable material from a reservoir of a vaporizer such as those described above is generally undesirable because the leaked liquid vaporizable material can cause undesirable mess (e.g., due to soiling of clothing or other items near the vaporizer), can enter the suction path of the vaporizer and thereby be inhaled by the user, can interfere with the functioning of the vaporizer (e.g., due to soiling of the pressure sensor, affecting the operability of the electrical circuit and/or switch, soiling of the charging port and/or connection between the cartridge and the vaporizer body, etc.), and so forth. Thus, leakage of the liquid vaporizable material interferes with the functioning and cleaning of the vaporizer.

Examples of vaporizers include, but are not limited to, electronic vaporizers, Electronic Nicotine Delivery Systems (ENDS), or devices and systems having the same, similar, or equivalent structural or functional features or capabilities. Fig. 1 shows an example block diagram of an example evaporator 100. The evaporator 100 may include an evaporator body 110 and an evaporator cartridge 120 (also referred to simply as evaporator cartridge 120). The vaporizer body 110 may include a power source 112 (e.g., a battery, which may be rechargeable) and a controller 104 (e.g., a programmable logic device, a processor, or circuitry capable of executing logic code) for controlling the delivery of heat to the vaporizer 141 to convert the vaporizable material (not shown) from a condensed form (e.g., a solid, a liquid, a solution, a suspension, at least a portion of untreated plant material, etc.) to a gas phase, or more generally, to convert the vaporizable material to an inhalable form or an inhalable form of a precursor (precursor). In this regard, and inhalable form may be a gas or aerosol, or some other airborne form. The inhalable form of the precursor may include a gas phase state of the vaporizable material that at least partially condenses to form an aerosol some time (optionally immediately or near-immediately or alternatively with some delay or after some amount of cooling) after forming the gas phase state. The controller 104 may be part of one or more Printed Circuit Boards (PCBs) consistent with particular embodiments, and may be used to control particular features of the evaporator body 110 associated with the one or more sensors 113.

As shown, in some embodiments of the present subject matter, the evaporator body 110 can include one or more sensors 113, evaporator body contacts 125, seals 115, and, optionally, a cartridge receptacle 118 configured to receive at least a portion of an evaporator cartridge 120, the evaporator cartridge 120 for coupling with the evaporator body 110 through one or more various attachment structures. As discussed below with reference to fig. 7A-7D, the evaporator cartridge 120 can be coupled with the evaporator body 110 using a male or female receptacle configuration, or some combination thereof. For example, in some embodiments of the present subject matter, an inner portion of the first end of the cartridge may be received in the cartridge receptacle 118 of the evaporator body 110 while an outer portion of the first end of the cartridge at least partially covers some portions of the outer surface of the evaporator body 110 that form the structure of the cartridge receptacle 118. Such an arrangement for coupling evaporator cartridge 120 to evaporator body 110 may allow for a convenient, easy to use bonding method that also provides sufficient mechanical coupling strength to avoid undesired separation of evaporator cartridge 120 and evaporator body 110. Such a configuration may also provide a desired resistance to deflection of the evaporator formed by coupling the evaporator cartridge 120 to the evaporator body 110. With respect to the evaporator body contacts 125, it should be understood that these contacts may also be referred to as "receptacle contacts 125," particularly in embodiments where the respective cartridge contacts 124 (discussed below) are located on a receptacle or a portion of a receptacle-like structure of the evaporator cartridge 120 that is inserted onto the evaporator body 110. However, the terms "evaporator body contacts 125" and/or "receptacle contacts 125" are also used herein, as aspects of the present subject matter are not limited to (and may be used to provide various advantages in a system in addition to those herein) electrical coupling between the evaporator cartridge 120 and the evaporator body 110 occurring between contacts within the cartridge receptacle 118 on the evaporator body 110 and a portion of the evaporator cartridge 120 inserted into the cartridge receptacle 118.

In some examples, the vaporizer cartridge 120 may include a reservoir 140 for containing a liquid vaporizable material and a mouthpiece 130 for delivering a dose of a vaporizable material in inhalable form. The mouthpiece may optionally be a separate component from the structure forming the reservoir 140, or alternatively, it may be formed from the same portion or component that forms at least a portion of one or more walls of the reservoir 140. The liquid vaporizable material within reservoir 140 can be a carrier solution in which the active or inactive ingredients can be suspended, dissolved or held in solution or pure liquid form within the vaporizable material itself.

According to one embodiment, the vaporizer cartridge 120 may include an atomizer 141, which atomizer 141 may include a wick or wicking element and a heater (e.g., a heating element). As described above, the wicking element may comprise any material capable of causing fluid to be absorbed through the wicking portion by capillary pressure to transfer an amount of liquid vaporizable material to a portion of the atomizer 141 that includes the heating element. The wicking portion and heating element are not shown in fig. 1, but are disclosed and discussed in further detail herein with reference to at least fig. 3A, 3B, and 4. Briefly, the wicking element may be configured to extract liquid vaporizable material from reservoir 140 configured to hold the liquid vaporizable material so that the liquid vaporizable material can be vaporized (i.e., converted to a vapor phase) by heat transferred from the heating element to the wicking element and to the liquid vaporizable material extracted into the wicking element. In some embodiments, in response to removing the liquid vaporizable material from reservoir 140 during vapor and/or aerosol formation, air may enter reservoir 140 through a wicking element or other opening to at least partially equalize the pressure in reservoir 140.

As shown in fig. 1, the pressure sensor (and any other sensors) 113 may be located on the controller 104 or coupled (e.g., electrically, electronically, physically, or via a wireless connection) to the controller 104. The controller 104 may be a printed circuit board assembly or other type of circuit board. In order to accurately make measurements and maintain the durability of the evaporator 100, it may be beneficial to provide a resilient seal 115 to separate the airflow path from the rest of the evaporator 100. The seal 115, which may be a gasket, may be configured to at least partially surround the pressure sensor 113 such that the connection of the pressure sensor 113 to the internal circuitry of the evaporator may be separate from the portion of the pressure sensor exposed to the airflow path.

The liquid vaporizable material used with vaporizer 100 can be disposed within a vaporizer cartridge 120, which vaporizer cartridge 120 can be refilled when empty, or can be disposable to facilitate a new cartridge containing additional vaporizable material of the same or a different type. The evaporator may be an evaporator using the cartridge or a multi-purpose evaporator capable of being used with or without the cartridge. For example, the multi-purpose vaporizer may include a heating chamber (e.g., an oven) configured to receive vaporizable material directly within the heating chamber, and also to receive a cartridge or other alternative device having a reservoir, volume, or other functional or structural equivalent for at least partially containing the vaporizable material that is available.

In the example of an evaporator using a cartridge, the seal 115 may also separate one or more electrically connected components between the evaporator body 110 and the evaporator cartridge 120. Such an arrangement of seals 115 in the evaporator 100 can help mitigate potentially damaging effects on evaporator components due to interaction with one or more environmental factors (e.g., condensed water, vaporizable material leaking from a reservoir and/or condensing after evaporation), to reduce air escape from a designed airflow path in the evaporator, and so forth.

Undesired air, liquid, or other fluid passing through or contacting the electrical circuitry of the vaporizer 100 may cause various undesired effects, such as altered pressure readings, or may result in the accumulation of undesired materials (e.g., moisture, vaporizable materials, and/or the like) in portions of the vaporizer 100 where the undesired materials may cause poor pressure signals, degradation of pressure sensors or other electrical or electronic components, and/or a shorter life of the vaporizer. Leakage of the seal 115 may also cause a user to inhale air that has passed through the portion of the vaporizer 100 containing or constructed of a material that is not suitable for inhalation. Vaporizers configured to generate at least a portion of the inhalable dose of the non-liquid vaporizable material by heating the non-liquid vaporizable material are also within the scope of the disclosed subject matter. For example, instead of or in addition to the liquid vaporizable material, the vaporizer cartridge 120 can contain a mass of plant material or other non-liquid material (e.g., a solid form of the vaporizable material itself, such as a "wax") that is treated and formed in direct contact with (or radiantly and/or convectively heated by) at least a portion of the one or more resistive heating elements, which can optionally be included in the vaporizer cartridge 120 or in a portion of the vaporizer body 110. The solid vaporizable material (e.g., one that includes plant material) may release only a portion of the plant material as vaporizable material (e.g., such that some portion of the plant material remains as waste after the vaporizable material is released for inhalation), or may be capable of causing all of the solid material to eventually be vaporized for inhalation. The liquid vaporizable material can also be completely vaporized or can include some portion of the liquid material remaining after all of the material suitable for inhalation has been consumed.

When the vaporizable material and heating elements are configured in the vaporizer cartridge 120, the vaporizer cartridge 120 can be mechanically and electrically coupled to the vaporizer body 110, which vaporizer body 110 can include a processor, a power source 112, and one or more vaporizer body contacts 125 for connection to corresponding cartridge contacts 124 to complete an electrical circuit with the resistive heating elements included in the vaporizer cartridge 120. Various evaporator configurations may be implemented with one or more of the features described herein.

In some embodiments, the evaporator 100 can include a power source 112 as part of the evaporator body 110, while the heating elements can be disposed in an evaporator cartridge 120 configured to couple with the evaporator body 110. So configured, the vaporizer 100 may include electrical connection features for completing an electrical circuit including the controller 104, the power source 112, and the heating elements included in the vaporizer cartridge 120.

In some embodiments of the present subject matter, the connection features may include at least two cartridge contacts 124 on a bottom surface of the evaporator cartridge 120 and at least two contacts 125 disposed near a base of the cartridge receptacle of the evaporator 100 such that when the evaporator cartridge 120 is inserted into and coupled with the cartridge receptacle 118, the cartridge contacts 124 and the receptacle contacts 125 form an electrical connection. In some embodiments of the present subject matter, the evaporator body contacts 125 may be compressible pins (e.g., spring pins) that retract under pressure of the respective cartridge contacts 124 when the evaporator cartridge is inserted and secured in the cartridge receptacle 118. Other configurations are also contemplated. For example, brush contacts may be used that make electrical connection with corresponding contacts on a mating portion of the vaporizer cartridge. Such contacts need not make electrical connection with cartridge contacts on the bottom end of the evaporator cartridge 120, but may instead be coupled by pushing the contacts outward from one or more side walls of the cartridge receptacle 118 against cartridge contacts 124 on a portion of the side of the evaporator cartridge 120 within the receptacle when the evaporator cartridge 120 is properly inserted into the cartridge receptacle 118.

The electrical circuit completed by the electrical connection may allow for delivery of electrical current to the resistive heating element and may also be used for additional functions, such as for measuring the resistance of the resistive heating element, for determining or controlling the temperature of the resistive heating element based on the thermal resistivity of the resistive heating element, for identifying the evaporator cartridge 120 based on one or more electrical characteristics of the resistive heating element or other electrical circuits of the evaporator cartridge 120.

In some examples, at least two cartridge contacts 124 and at least two evaporator body contacts 125 (e.g., receptacle contacts for embodiments in which a portion of the evaporator cartridge 120 is inserted into the cartridge receptacle 118) may be configured to electrically connect in any of at least two orientations. In other words, one or more circuits configured for operation of the vaporizer 100 may be completed by inserting (or otherwise joining) at least a portion of the vaporizer cartridge 120 in the cartridge receptacle 118 in a first rotational orientation (e.g., about an axis along which an end of the vaporizer cartridge 120 is inserted into the cartridge receptacle 118 of the vaporizer body 110) such that a first of the at least two cartridge contacts 124 is electrically connected to a first of the at least two receptacle contacts 125 and a second of the at least two cartridge contacts 124 is electrically connected to a second of the at least two receptacle contacts 125.

Further, one or more circuits configured for operation of the vaporizer 100 may be completed by inserting (or otherwise coupling) the vaporizer cartridge 120 in the cartridge receptacle 118 in a second rotational orientation such that a first cartridge contact of the at least two cartridge contacts 124 is electrically connected to a second receptacle contact of the at least two receptacle contacts 125 and a second cartridge contact of the at least two cartridge contacts 124 is electrically connected to a first receptacle contact of the at least two receptacle contacts 125. The evaporator cartridge 120 may be reversibly insertable into the cartridge receptacle 118 of the evaporator body 110, as provided in further detail herein.

In one example of an attachment structure for coupling the evaporator cartridge 120 to the evaporator body 110, the evaporator body 110 can include stops (e.g., indentations, protrusions, etc.) that protrude inwardly from an inner surface of the cartridge receptacle 118. One or more of the outer surfaces of the evaporator cartridge 120 may include corresponding recesses (not shown in fig. 1) that may fit or otherwise snap over such stops when one end of the evaporator cartridge 120 is inserted into the cartridge receptacle 118 on the evaporator body 110.

The evaporator cartridge 120 and the evaporator body 110 can be coupled, for example, by inserting one end of the evaporator cartridge 120 into the cartridge receptacle 118 of the evaporator body 110. A stop in the evaporator body 110 can fit and/or otherwise be retained within a recess of the evaporator cartridge 120 to hold the evaporator cartridge 120 in place when assembled. Such a stop-recess assembly may provide sufficient support to hold the evaporator cartridge 120 in place to ensure adequate contact between the at least two cartridge contacts 124 and the at least two receptacle contacts 125, while allowing the evaporator cartridge 120 to be released from the evaporator body 110 when a user pulls the evaporator cartridge 120 with reasonable force to disengage the evaporator cartridge 120 from the cartridge receptacle 118.

In addition to the above discussion regarding the electrical connection between the evaporator cartridge 120 and the evaporator body 110 being reversible such that at least two rotational orientations of the evaporator cartridge 120 in the cartridge receptacle 118 are possible, in some embodiments of the evaporator 100, the shape of the evaporator cartridge 120, or at least the shape of the end of the evaporator cartridge 120 configured to be inserted into the cartridge receptacle 118, may have at least two-order (order two) rotational symmetry. In other words, the mechanical mating features and the electrical contacts on the evaporator cartridge 120, or at least the insertable end of the evaporator cartridge 120, are symmetrical when rotated 180 about the axis along which the evaporator cartridge 120 is inserted into the cartridge receptacle 118. In this configuration, the electrical circuit of the evaporator 100 can support the same operation regardless of the symmetric orientation of the evaporator cartridge 120. It will be appreciated that in all embodiments of the present subject matter, the entire insertable end of the cartridge need not be symmetrical. For example, a vaporizer cartridge 120 having rotationally symmetric mechanical features for co-operatively engaging corresponding features on the inside or outside of the cartridge receptacle 118, shaped and sized to fit within the cartridge receptacle 118 of the vaporizer body 110, and also having rotationally symmetric cartridge electrical contacts 124 and internal circuitry compatible by reversing the electrical contacts (which may optionally be located in one or both of the vaporizer cartridge 120 and the vaporizer body 110), is consistent with the present invention even if the overall shape and appearance of the insertable end of the vaporizer cartridge 120 is not rotationally symmetric. As described above, in some exemplary embodiments, the evaporator cartridge 120 or at least one end of the evaporator cartridge 120 is configured for insertion into the cartridge receptacle 118 and may have a non-circular cross-section transverse to an axis along which the evaporator cartridge 120 is inserted into the cartridge receptacle 118. For example, the non-circular cross-section may be approximately rectangular, approximately elliptical (e.g., having an approximately oval shape), non-rectangular but with two sets of parallel or approximately parallel opposing sides (e.g., having a parallelogram shape), or other shapes having rotational symmetry of at least two orders. In this context, approximating a shape indicates that substantial similarity to the described shape is apparent, but the sides of the shape in question need not be perfectly linear and the vertices need not be perfectly sharp. In the description of any non-circular cross-section referred to herein, some amount of rounding of both or either of the edges or vertices of the cross-sectional shape is contemplated.

The at least two cartridge contacts 124 and the at least two receptacle contacts 125 may take various forms. For example, one or both sets of contacts may include conductive pins, tabs, posts, receiving holes for pins or posts, and the like. Some types of contacts may include springs or other urging features to create better physical and electrical contact between the contacts on the vaporizer cartridge and the vaporizer body. The electrical contacts may be gold plated, and/or may comprise other materials.

The evaporator 100, consistent with embodiments of the disclosed subject matter, may be configured to connect (e.g., wirelessly or by a wired connection) to one or more computing devices in communication with the evaporator 100. To this end, the controller 104 may include communication hardware 105. The controller 104 may also include a memory device 108. The computing device may be a component of a vaporizer system that also includes the vaporizer 100, and may include separate communication hardware that can establish a wireless communication channel with the communication hardware 105 of the vaporizer 100.

The computing device used as part of the vaporizer system may comprise a general purpose computing device (e.g., a smartphone, a tablet, a personal computer, some other portable device such as a smartwatch, etc.) that executes software to generate a user interface for enabling a user of the device to interact with the vaporizer 100. In other embodiments, the device used as part of the vaporizer system may be dedicated hardware, such as a remote control or other wireless or wired device having one or more physical or soft interface controls (e.g., configurable on a screen or other display device and selectable via user interaction with a touch screen or some other input device like a mouse, pointer, trackball, cursor buttons, etc.). The vaporizer 100 may also include one or more outputs 117 or means for providing information to a user.

The computing device that is part of the vaporizer system as defined above may be used for any of one or more functions, such as controlling dosage (e.g., dose monitoring, dose setting, dose limiting, user tracking, etc.), controlling interaction (e.g., interaction monitoring, interaction setting, interaction limiting, user tracking, etc.), controlling nicotine delivery (e.g., switching between nicotine and non-nicotine vaporizable material, adjusting the amount of nicotine delivered, etc.), obtaining location information (e.g., location of other users, retailer/commercial site location, e-smoking location, relative or absolute location of the vaporizer itself, etc.), vaporizer personalization (e.g., naming the vaporizer, locking/password protecting the vaporizer, adjusting one or more parental controls, associating the vaporizer with a user group, registering the vaporizer with a manufacturer or warranty maintenance organization, etc.), or the like, Engage in social activities with other users (e.g., social media communications, interacting with one or more groups, etc.), and so forth. The terms "interaction", "vaporizer interaction" or "vapor interaction" may be used to refer to a period dedicated to the use of the vaporizer. The period may include a time period, a number of doses, an amount of vaporizable material, and the like.

In examples where the computing device provides a signal related to activation of the resistive heating element, or in other examples where the computing device is coupled to the vaporizer 100 for implementing various controls or other functions, the computing device executes one or more sets of computer instructions to provide a user interface and underlying data processing. In one example, detection by the computing device of user interaction with one or more user interface elements may cause the computing device to send a signal to vaporizer 100 to activate a heating element, or to a full operating temperature for generating an inhalable dose of vapor/aerosol. Other functions of the vaporizer 100 may be controlled by user interaction with a user interface on a computing device in communication with the vaporizer 100.

In some embodiments, the evaporator cartridge 120 that can be used with the evaporator body 110 can include an atomizer 141 having a wicking element and a heating element. Alternatively, one or both of the wicking element and the heating element can be part of the evaporator body 110. In embodiments where any portion of the atomizer 141 (e.g., a heating element or wicking element) is part of the evaporator body 110, the evaporator 100 can be configured to supply liquid vaporizable material from a reservoir 140 in the evaporator cartridge to the wicking portion and other atomizer components, such as, for example, wicking elements, heating elements, and the like. One skilled in the art will appreciate that a capillary structure including a wicking element is but one potential embodiment that may be used with other features described herein.

Activation of the heating element may be caused by automatic detection of suction based on one or more signals generated by one or more sensors 113, such as one or more pressure sensors arranged to detect pressure (or may measure changes in absolute pressure) along the airflow path relative to ambient pressure, one or more motion sensors of the vaporizer 100, one or more flow sensors of the vaporizer 100, a capacitive lip sensor of the vaporizer 100; in response to detecting user interaction with one or more input devices 116 (e.g., buttons or other tactile control devices of the vaporizer 100), receiving a signal from a computing device in communication with the vaporizer 100, or by other methods for determining that a puff is occurring or about to occur.

The heating element may be or may include one or more of a conduction heater, a radiant heater, and a convection heater. One type of heating element may be a resistive heating element, which may be composed of or at least include a material (e.g., a metal or alloy, such as nichrome, or a non-metallic resistor) configured to dissipate electrical power in the form of heat when an electrical current is passed through one or more resistive segments of the heating element.

In some embodiments, the atomizer 141 may include a heating element comprising a resistive coil or other heating element wound, positioned within, integrated into the overall shape of, extruded in thermal contact with, positioned near, configured to heat air to cause convective heating of, or otherwise arranged to transfer heat to, the wicking element to cause liquid vaporizable material drawn from the reservoir 140 by the wicking element to be vaporized for subsequent inhalation by a user in a gaseous and/or condensed (e.g., aerosol particles or droplets). Other wicking element, heating element, or atomizer assembly configurations are also possible, as discussed further below.

After the vaporizable material is converted to the vapor phase, and depending on the type of vaporizer, the physical and chemical properties of the vaporizable material, or other factors, at least some of the vapor phase vaporizable material may condense to form particulate matter that is at least partially in partial equilibrium with the vapor phase, which as part of an aerosol, may form some or all of the inhalable dose provided by vaporizer 100 for a given puff or puff on the vaporizer.

It will be appreciated that the interaction between the gas phase and the condensed phase in the aerosol generated by the vaporizer may be complex and dynamic, as factors such as ambient temperature, relative humidity, chemistry (e.g., acid-base interaction, protonation or lack of compounds released from the vaporizable material by heating, etc.), flow conditions in the airflow path (inside the vaporizer and in the airways of humans or other animals), mixing of the gas or aerosol phase vaporizable material with other air streams, etc. may affect one or more physical and/or chemical parameters of the aerosol. In some vaporizers, and in particular in vaporizers used to deliver more volatile vaporizable materials, the inhalable dose can be present primarily in the gas phase (i.e., formation of condensed phase particles can be very limited).

As described elsewhere herein, a particular vaporizer can also (or alternatively) be configured to generate an inhalable dose of a vapor-phase and/or aerosol-phase vaporizable material at least in part by heating a non-liquid vaporizable material, such as, for example, a solid-phase vaporizable material (e.g., a wax, etc.) or a plant material (e.g., tobacco leaf or portion of tobacco leaf) that includes a vaporizable material. In such evaporators, the resistive heating element may be part of, or otherwise incorporated into or in thermal contact with, a wall of an oven or other heating chamber in which the non-liquid vaporizable material is disposed.

Alternatively, one or more resistive heating elements may be used to heat air passing through or over the non-liquid vaporizable material to cause convective heating of the non-liquid vaporizable material. In still other embodiments, one or more resistive heating elements may be disposed in intimate contact with the plant material such that direct conductive heating of the plant material occurs from within the block of plant material (e.g., as opposed to conduction inwardly from the walls of the oven).

The heating element may be activated by a controller 104, and the controller 104 may be part of the evaporator body 110. The controller 104 may pass current from the power source 112 through an electrical circuit that includes a resistive heating element, which may be part of the evaporator cartridge 120. The controller 104 may be activated in association with a user drawing on (e.g., lifting, inhaling, etc.) the mouthpiece 130 of the vaporizer 100, which may cause air to flow from the air inlet along the airflow path through the nebulizer 141. The atomizer 141 may include a wicking portion, for example, in combination with a heating element.

The airflow caused by the user's puff may pass through one or more condensation zones or chambers in and/or downstream of the atomizer 141 and then towards the air outlet in the mouthpiece. The incoming air passing along the airflow path may thus pass over, through, near, around, etc. the atomizer 141 such that the vapor phase vaporizable material (or some other inhalable form of vaporizable material) is entrained into the air as a result of the atomizer 141 converting a quantity of vaporizable material to a vapor phase. As described above, entrained vapor phase vaporizable material may condense as it passes through the remainder of the airflow path, such that an inhalable dose of vaporizable material in aerosol form may be delivered from the air outlet (e.g., through mouthpiece 130 for inhalation by a user).

The temperature of the resistive heating element of the vaporizer 100 may depend on one or more of a number of factors, including the amount of electrical power delivered to the resistive heating element or duty cycle of the delivered electrical power, conductive and/or radiative heat transfer to other portions of the vaporizer 100 or to the environment, specific heat transfer to air and/or liquid or vapor phase vaporizable material (e.g., raising the temperature of the vaporizable material to its vaporization point or raising the temperature of a gas (e.g., air and/or air mixed with vaporizable material)), latent heat loss due to the bulk vaporization of the vaporizable material from the wick and/or vaporizer 141, heat loss convection due to airflow (e.g., when a user inhales on the vaporizer 100, the bulk movement of air across the heating element or vaporizer 141), and the like.

As described above, to reliably activate or heat the heating element to a desired temperature, in some embodiments, vaporizer 100 may utilize signals from a pressure sensor to determine when a user inhales. The pressure sensor may be located in or may be connected (e.g., by a channel or other pathway) to an airflow pathway connecting an inlet for air to the device and an outlet via which the user inhales the generated vapor and/or aerosol such that the pressure sensor undergoes a pressure change concurrently with air passing through the vaporizer 100 from the air inlet to the air outlet. In some embodiments, the heating element may be activated in association with a user's puff, for example by automatic detection of the puff, for example by a pressure sensor detecting a pressure change in the airflow path.

Referring to fig. 1, 2A and 2B, the evaporator cartridge 120 may be removably inserted into the evaporator body 110 through the cartridge receptacle 118. As shown in fig. 2A, which shows a plan view of evaporator body 110 next to evaporator cartridge 120, reservoir 140 of evaporator cartridge 120 may be formed, in whole or in part, of a translucent material such that the level of liquid vaporizable material 102 in evaporator cartridge 120 may be visible. The evaporator cartridge 120 can be configured such that when the evaporator cartridge 120 is received in the cartridge receptacle 118, the level of vaporizable material 102 in the reservoir 140 of the evaporator cartridge 120 remains visible through the window in the evaporator body 110. Alternatively or additionally, the level of the liquid vaporizable material 102 in the reservoir 140 can be seen through a light transmissive or translucent outer wall or window formed in the outer wall of the vaporizer cartridge body 120.

Air flow path embodiments

Referring to fig. 2C and 2D, an exemplary evaporator cartridge 120 is shown in which an airflow path 134 is created during user suction of the evaporator 100. The airflow path 134 may direct air to an evaporation chamber 150 (see, e.g., fig. 2D) contained in the wick housing where the air is mixed with the inhalable aerosol for delivery to the user through a mouthpiece 130, which may also be part of the evaporator cartridge 120. The evaporation chamber 150 may include and/or at least partially enclose an atomizer 141 consistent with the remainder of the present disclosure. For example, when a user draws on the evaporator 100, the airflow path 134 may pass between an outer surface of the evaporator cartridge 120 (e.g., the window 132) and an inner surface of the cartridge receptacle 118 on the evaporator body 110. The air may then be drawn into the insertable end 122 of the cartridge, through the evaporation chamber 150 comprising or housing the heating element and wick, and out through the outlet 136 of the mouthpiece 130 to deliver the inhalable aerosol to the user. Other airflow path configurations are also within the scope of the present disclosure, including but not limited to those discussed in further detail below.

Fig. 2D illustrates additional features that may be included in an evaporator cartridge 120 consistent with the present subject matter. For example, the evaporator cartridge 120 may include a plurality of cartridge contacts (e.g., cartridge contacts 124) disposed on an insertable end 122, the insertable end 122 configured to be inserted into the cartridge receptacle 118 of the evaporator body 110. The cartridge contacts 124 may optionally each be part of a single piece of metal forming a conductive structure (e.g., conductive structure 126) connected to one of the two ends of the resistive heating element. The conductive structures can optionally form opposite sides of the heating chamber and can optionally act as heat shields and/or heat sinks to reduce the transfer of heat to the outer walls of the evaporator cartridge 120. Further details of this aspect are described below.

Fig. 2D also shows a sleeve 128 (which is an example of a more general concept, also referred to herein as an airflow channel) within the evaporator cartridge 120 that defines a portion of the airflow path 134 that passes between a heating chamber (also referred to herein as an atomizer chamber, an evaporation chamber, etc.) that may be at least partially formed by the conductive structure 126 and the mouthpiece 130. This configuration causes air to flow down around the insertable end 122 of the evaporator cartridge 120 into the cartridge receptacle 118 and then back up in the opposite direction after passing around the insertable end 122 of the evaporator cartridge 120 (e.g., the end opposite the end comprising the mouthpiece 130) as it enters the cartridge body towards the evaporation chamber 150. The airflow path 134 then travels through the interior of the evaporator cartridge 120, such as through one or more tubes or internal passages (e.g., the sleeve 128) and through one or more outlets (e.g., the outlet 136) formed in the mouthpiece 130.

Pressure balance vent

As described above, removal of the vaporizable material 102 from the reservoir 140 (e.g., by capillary suction of the wicking element) may create a vacuum in the reservoir 140 that is at least partial with respect to ambient air pressure (e.g., a reduced pressure created in a portion of the reservoir that has been evacuated by consumption of the liquid vaporizable material), and such a vacuum may interfere with the capillary action provided by the wicking element. This reduced pressure may be sufficiently large in some examples in terms of a gradient to reduce the efficiency of the wicking element in drawing vaporizable material 102 into vaporizing chamber 150, thereby reducing the efficiency of vaporizer 100 in vaporizing a desired amount of vaporizable material 102 when, for example, a user draws on vaporizer 100. In extreme cases, the vacuum created in reservoir 140 may result in the inability to draw all of vaporizable material 102 into vaporization chamber 150, resulting in incomplete use of vaporizable material 102. One or more venting features may be included in association with the evaporator reservoir 140 (whether the reservoir 140 is positioned in the evaporator cartridge 120 or elsewhere in the evaporator) to at least partially balance (optionally fully balance) the pressure in the reservoir 140 with the ambient pressure (e.g., the pressure in the ambient air outside the reservoir 140) to mitigate this problem.

In some cases, while allowing pressure equalization within the reservoir 140 increases the efficiency of the transfer of the liquid vaporizable material to the atomizer 141, this is accomplished by filling an otherwise empty void volume within the reservoir 140 (e.g., a space evacuated by use of the liquid vaporizable material) with air. As discussed in further detail below, this air-filled void volume may then experience a pressure change relative to ambient air, which may result in liquid vaporizable material leaking out of the reservoir 140 under certain conditions and eventually outside of the evaporator cartridge 120 and/or other portions of the evaporator containing the reservoir 140. Embodiments of the present subject matter may also provide advantages and benefits with respect to this problem.

Various features and devices are described below that ameliorate or overcome these problems. For example, various features are described herein for controlling the airflow and flow of vaporizable material, which features can provide advantages and improvements over existing methods while also introducing additional benefits as described herein. The vaporizer apparatus and/or cartridge described herein includes one or more features that control and improve the airflow in the vaporizer apparatus and/or cartridge, thereby increasing the efficiency and effectiveness of the vaporizer apparatus to vaporize liquid vaporizable material without introducing additional features that may lead to leakage of the liquid vaporizable material. Fig. 2E and 2F show schematic diagrams of first and second embodiments of reservoir systems 200A, 200B, respectively, configured for use with an evaporator cartridge (e.g., evaporator cartridge 120) and/or an evaporator device (e.g., evaporator 100) to improve pressure equalization and airflow in the evaporator. More specifically, the reservoir systems 200A, 200B shown in fig. 2E and 2F improve pressure regulation within the reservoir 240 such that after a user draws on the evaporator, the vacuum created in the reservoir 240 is relieved, while reducing or even eliminating the incidence of leakage of the liquid vaporizable material through the vent structure. This allows the capillary action of the porous material (e.g., wicking element) associated with reservoir 240 and evaporation chamber 242 to continue after each draw to efficiently draw vaporizable material 202 from reservoir 240 into evaporation chamber 242.

As shown in fig. 2E and 2F, the receptacle systems 200A, 200B include a receptacle 240 configured to hold the liquid vaporizable material 202. Reservoir 240 is sealed on all sides by reservoir wall 232 except through the wick housing area extending between reservoir 240 and evaporation chamber 242. A heating element or heater may be contained within the vaporization chamber 242 and coupled to the wicking element. The wicking element is configured to provide a capillary action that draws vaporizable material 202 from reservoir 240 to vaporization chamber 242 for vaporization into an aerosol by the heater. The aerosol then combines with the airflow 234 traveling along the airflow path 238 of the vaporizer for inhalation by the user. The reservoir systems 200A, 200B also include an airflow restrictor 244 that restricts the passage of the airflow 234 along the airflow path 238 of the evaporator, such as when a user draws on the evaporator. The restriction of airflow 234 caused by airflow restrictor 244 may allow a vacuum to form along a portion of airflow passageway 238 downstream of airflow restrictor 244. The vacuum created along the airflow channel 238 may help draw the aerosol formed in the vaporization chamber 242 (e.g., the chamber containing at least a portion of the nebulizer 141) along the airflow channel 238 for inhalation by the user. At least one air flow restrictor 244 may be included in each reservoir system 200A, 200B, and the air flow restrictor 244 may include any number of features for restricting the air flow 234 along the air flow passage 238.

As shown in fig. 2E and 2F, each reservoir system 200A, 200B may further include a vent 246 configured to selectively allow air to pass into the reservoir 240 to increase the pressure within the reservoir 240, thereby releasing the reservoir 240 from the negative pressure (vacuum) relative to the ambient pressure created by the vaporizable material 202 drawn from the reservoir 240, as described above. At least one vent 246 may be associated with reservoir 240. Vent 246 may be an active or passive valve, and vent 246 may include any number of features that allow air to enter reservoir 240 to relieve negative pressure created in reservoir 240.

For example, embodiments of vent 246 may include a vent channel extending between reservoir 240 and airflow channel 238, and the diameter (or more generally, the cross-sectional area) of the vent channel is sized such that when pressure is equalized across vent 246 (e.g., the pressure in reservoir 240 is approximately the same as the air pressure in airflow channel 238), the fluid tension (also referred to as surface tension) of vaporizable material 202 prevents vaporizable material 202 from passing through the channel. However, the diameter (or more generally, the cross-sectional area) of the vent 246 and/or vent channel is sized such that the vacuum pressure created in the reservoir 240 can overcome the surface tension of the vaporizable material 202 within the vent 246 or vent channel, thereby releasing air bubbles through the vent into the reservoir 240 in response to a sufficiently low pressure within the reservoir 240 relative to ambient pressure.

Accordingly, a volume of air may flow from the airflow channel 238 to the reservoir 240 and release the vacuum pressure. Once the volume of air is added to reservoir 240, the pressure again more closely equalizes across vent 246, thereby allowing the surface tension of vaporizable material 202 to prevent air from entering reservoir 240, and to prevent vaporizable material from leaking out of reservoir 240 through the vent channel.

In one exemplary embodiment, the diameter of the breather 246 or breather passage may be in the range of about 0.3 mm to 0.6mm, and may also include a diameter in the range of about 0.1mm to 2 mm. In some examples, the breather 246 and/or breather passage may be non-circular such that it is characterized by a non-circular cross-section along the direction of fluid flow within the breather passage. In such an example, the cross-section is not defined by a diameter, but rather by a cross-sectional area. In general, regardless of whether the cross-sectional shape of the vent 246 and/or vent passage is circular or non-circular, in particular embodiments of the present subject matter, it may be advantageous for the cross-sectional area of the vent 246 to vary along its path between its exposure to ambient air pressure and the interior of the reservoir 240. For example, the portion of vent 246 closer to the outside ambient pressure may advantageously have a smaller cross-sectional area (e.g., a smaller diameter in the example where vent 246 has a circular cross-section) relative to the portion of vent 246 closer to the interior of vessel 240. A smaller cross-sectional area closer to the outside of the system may provide greater resistance to the escape of liquid vaporizable material, while a larger cross-sectional area closer to the inside of the reservoir 240 may provide relatively less resistance to the escape of air bubbles from the vent 246 into the reservoir 240. In some embodiments of the present subject matter, the transition between the smaller and larger cross-sectional areas may advantageously not be continuous, but rather contain discontinuities along the length of the vent 246 and/or vent channel. Such a configuration may be used to provide a greater total resistance to escape of liquid material than would be possible by releasing air bubbles from vent 246 to equalize reservoir pressure, as a larger cross-sectional area near the reservoir may have a lower capillary drive relative to a smaller cross-sectional area exposed to ambient air.

The material of breather 246 and/or breather passage may also help control breather 246 and/or breather passage, for example, by affecting the contact angle between the walls of breather 246 and/or breather passage and vaporizable material 202. The contact angle may have an effect on the surface tension created by vaporizable material 202 and, thus, the threshold pressure differential created across vent 246 and/or vent channel before a volume of fluid is allowed to pass through vent 246, for example, as described above. Vent 246 may include various shapes/sizes and configurations within the scope of the present disclosure. In addition, various embodiments of the cartridge and portions of the cartridge that include one or more various venting features will be described in more detail below.

The positioning of the vent 246 (e.g., passive vent) and airflow restrictor 244 relative to the evaporation chamber 242 facilitates efficient operation of the reservoir system 200A, 200B. For example, improper positioning of vent 246 or air flow restrictor 244 may result in undesired leakage of vaporizable material 202 from reservoir 240. The present disclosure addresses the effective positioning of the vent 246 and airflow restrictor 244 relative to the evaporation chamber 242 (including the wicking portion). For example, a small or no pressure differential between the passive vent and the wicking portion may result in an effective reservoir system for relieving vacuum pressure in the reservoir and resulting in effective capillary action of the wicking portion while preventing leakage. The configuration of the reservoir system with the vent 246 and airflow restrictor 244 effectively positioned relative to the evaporation chamber 242 will be described in more detail below.

As shown in fig. 2E, an air flow restrictor 244 may be located upstream of the evaporation chamber 242 along the air flow passage 238, while a vent 246 is located along the reservoir 240 such that it provides fluid communication between the reservoir 240 and a portion of the air flow passage 238 downstream of the evaporation chamber 242. As such, when a user draws on the evaporator, a negative pressure is generated downstream of the airflow restrictor 244, such that the evaporation chamber 242 experiences a negative pressure. Similarly, the side of vent 246 in communication with air flow passage 238 is also subjected to negative pressure.

As such, during a puff (e.g., when a user draws or inhales air from the vaporization device), a small to nonexistent amount of pressure differential is generated between vent 246 and vaporization chamber 242. However, after aspiration, the capillary action of the wicking portion will cause vaporizable material 202 to be drawn from reservoir 240 to vaporization chamber 242 to replenish vaporizable material 202 that is vaporized and drawn in as a result of the prior aspiration. As a result, a vacuum or negative pressure will be created in reservoir 240. A pressure differential will then be created between reservoir 240 and air flow path 238. As described above, vent 246 may be configured such that a pressure differential (e.g., a threshold pressure differential) between reservoir 240 and airflow channel 238 allows a volume of air from airflow channel 238 to enter reservoir 240, thereby releasing the vacuum in reservoir 240 and returning to an equilibrium pressure and stable reservoir system 200A across vent 246.

In another embodiment, as shown in fig. 2F, an air flow restrictor 244 may be located downstream of the evaporation chamber 242 along the air flow channel 238, while a vent 246 may be located along the reservoir 240 such that it provides fluid communication between the reservoir 240 and a portion of the air flow channel 238 upstream of the evaporation chamber 242. Thus, when a user draws on the vaporizer, little or no suction or negative pressure is experienced by the vaporization chamber 242 and vent 246 due to the drawing, resulting in little or no pressure differential between the vaporization chamber 242 and vent 246. Similar to the situation in fig. 2E, after suction, the pressure differential created across vent 246 will be a result of capillary action that draws vaporizable material 202 into the wicking portion of vaporization chamber 242. As a result, a vacuum or negative pressure will be created in reservoir 240. Thus, a pressure differential will be created across vent 246.

As described above, vent 246 may be configured such that a pressure differential (e.g., a threshold pressure differential) between reservoir 240 and airflow channel 238 or atmosphere allows a volume of air to enter reservoir 240, thereby releasing a vacuum in reservoir 240. This allows pressure to be equalized across vent 246 and reservoir system 200B to be stabilized. The breather 246 may include various structures and features, and may be positioned at various locations along the evaporator cartridge 120, for example, to achieve various results. For example, one or more vents 246 may be positioned adjacent to or form a portion of the evaporation chamber 242 or the wick housing. In this configuration, one or more vents 246 may provide fluid (e.g., air) communication between the reservoir 240 and the evaporation chamber 242 (through which air flows when a user draws on the evaporator, such that the vent is part of the air flow path).

Similarly, as described above, vent 246 placed adjacent to or forming a part of evaporation chamber 242 or wick housing may allow air to enter reservoir 240 from the interior of evaporation chamber 242 via vent 246 to increase the pressure within reservoir 240, thereby effectively relieving the vacuum pressure created by the lifting of vaporizable material 202 into evaporation chamber 242. In this manner, the release of vacuum pressure allows vaporizable material 202 to continue to effectively and efficiently wick into vaporization chamber 242 via the wicking portion to generate an inhalable vapor during subsequent suctioning of the vaporizer by the user. Various exemplary embodiments of a vented evaporation chamber element (e.g., atomizer assembly) comprising a wick housing 1315, 178 (which houses an evaporation chamber) and at least one vent 596, the at least one vent 596 being coupled to the

wick housing

1315, 178 or forming a part of the

wick housing

1315, 178 to enable the above-described effective venting of the reservoir 140 are provided below.

Open-faced (open-faced) cartridge assembly embodiments

Referring to fig. 3A and 3B, an exemplary plan cross-sectional view of an alternative cartridge embodiment 1320 is shown, where cartridge 1320 includes mouthpiece or mouthpiece region 1330, reservoir 1340, and an atomizer (not separately shown). The atomizer may include a heating element 1350 and a wicking element 1362, either together or separately depending on the embodiment, such that the wicking element 1362 is thermally or thermodynamically coupled to the heating element 1350 for the purpose of vaporizing the vaporizable material 1302 that is drawn from or stored in the wicking element 1362.

In one embodiment, plate 1326 may be included to provide an electrical connection between heating element 1350 and power supply 112 (see FIG. 1). An air flow channel 1338 defined through or on the side of the reservoir 1340 may connect the region of the cartridge 1320 containing the wicking element 1362 (e.g., a wicking housing, not separately shown) to an opening to the mouthpiece or mouthpiece region 1330 to provide a route for the vaporized vaporizable material 1302 to travel from the heating element 1350 region to the mouthpiece region 1330.

As described above, wicking element 1362 may be coupled to atomizer or heating element 1350 (e.g., a resistive heating element or coil) that is connected to one or more electrical contacts (e.g., plate 1326). The heating element 1350 (as well as other heating elements described herein according to one or more embodiments) can have various shapes and/or configurations, and can include one or

more heating elements

1350, 500 or features thereof, as provided in more detail below with respect to fig. 44A-116.

According to one or more exemplary embodiments, the heating element 1350 of the cartridge 1320 may be made of a sheet material (e.g., stamped) and crimped or bent around at least a portion of the wicking element 1362 to provide a preformed element configured to receive the wicking element 1362 (e.g., the wicking element 1362 is pushed into the heating element 1350 and/or the heating element 1350 is held in tension and pulled onto the wicking element 1362).

The heating element 1350 may be bent such that the heating element 1350 secures the wicking element 1362 between at least two or three portions of the heating element 1350. The heating element 1350 can be bent to conform to the shape of at least a portion of the wicking element 1362. The configuration of the heating element 1350 allows for more consistent and higher quality manufacturing of the heating element 1350. Consistency in the manufacturing quality of the heating elements 1350 may be particularly important during large scale and/or automated manufacturing processes. For example, the heating element 1350 according to one or more embodiments helps to reduce tolerance issues that may arise during manufacturing processes that assemble the heating element 1350 having multiple components.

The heating element 1350 may also improve the accuracy of measurements (e.g., resistance, current, temperature, etc.) obtained from the heating element 1350, which may be due, at least in part, to reduced tolerance issues due to improved consistency in manufacturability of the heating element 1350. Heating element 1350, which is made from a sheet material (e.g., stamped) and crimped or bent around at least a portion of wicking element 1362 to provide a preformed element, desirably helps to minimize heat loss and helps to ensure that heating element 1350 is predictably heated to an appropriate temperature.

Additionally, as discussed further below with respect to included embodiments involving heating elements formed from crimped metal, heating element 1350 may be fully and/or selectively plated with one or more materials that enhance the heating performance of heating element 1350. Coating all or a portion of the heating element 1350 can help minimize heat loss. Plating may also help to concentrate heat to a portion of heating element 1350, thereby providing more efficient heating of heating element 1350 and further reducing heat loss. Selective plating may help direct the current provided to the heating element 1350 into place. Selective plating may also help to reduce the amount of plating material and/or the costs associated with manufacturing heating element 1350.

In addition to or in conjunction with the example heating elements described and/or discussed below, the heating elements can include flat heating elements 1850 (see fig. 18A-18D) located within an evaporator pod 1800 including two air flow channels 1838, folded heating elements 1950 (see fig. 19A-19C, 22A-22B, and 44A-116) located within an evaporator pod 1900 including two air flow channels 1938, and folded heating elements 2050 (see fig. 20A-20C) located within an evaporator pod 2000 including a single air flow channel 2038.

As described above, in one embodiment, the heating element 1350 may comprise a wicking element 1362. For example, wicking element 1362 may extend adjacent to or next to plate 1326 and through the resistive heating element in contact with plate 1326. A wicking housing may surround at least a portion of heating element 1350 and connect heating element 1350 directly or indirectly to airflow channel 1338. The vaporizable material 1302 can be wicked by the wicking element 1362 through one or more channels connected to the reservoir 1340. In one embodiment, one or both of the primary channels 1382 or secondary channels 1384 may be used to help direct or convey the vaporizable material 1302 to one or both ends of the wicking element 1362, or radially along the length of the wicking element 1362.

Overflow collector embodiment

As provided in further detail below, with particular reference to fig. 3A and 3B, the exchange of air and liquid vaporizable material into and out of cartridge reservoir 1340 can be advantageously controlled, and the volumetric efficiency of the vaporizer cartridge (defined as the volume of liquid vaporizable material ultimately converted into an inhalable aerosol relative to the total volume of the cartridge itself) can also optionally be increased by incorporating a structure referred to as a collector 1313.

According to some embodiments, the cartridge 1320 may comprise a reservoir 1340 at least partially defined by at least one wall (which may optionally be a wall shared with the housing of the cartridge) configured to contain the liquid vaporizable material 1302. The reservoir 1340 may include a storage chamber 1342 and an overflow volume 1344 that may contain or otherwise house the collector 1313. The storage chamber 1342 may contain the vaporizable material 1302, and the overflow volume 1344 may be configured to collect or retain at least some portion of the vaporizable material 1302 when one or more factors cause the vaporizable material 1302 in the reservoir storage chamber 1342 to travel into the overflow volume 1344. In some embodiments of the present subject matter, the cartridge may be initially filled with a liquid vaporizable material such that the void space within the collector is pre-filled with the liquid vaporizable material.

In an exemplary embodiment, the volumetric size of overflow volume 1344 may be configured to be equal to, approximately equal to, or greater than the increase in the volume of the contents (e.g., vaporizable material 1302 and air) contained in storage chamber 1342 when the volume of the contents in storage chamber 1342 expands due to the maximum expected pressure change that the reservoir may experience relative to ambient pressure.

The cartridge 1320 may undergo a change from a first pressure state to a second pressure state (e.g., a first relative pressure differential between the interior of the reservoir and the ambient pressure and a second relative pressure differential between the interior of the reservoir and the ambient pressure) depending on changes in ambient pressure or temperature or other factors. In some aspects, the overflow volume 1344 may have an opening to the exterior of the cartridge 1320 and may be in communication with the reservoir storage chamber 1342 such that the overflow volume 1344 may serve as a vent channel to provide pressure equalization and/or collect and at least temporarily hold and optionally reversibly return liquid vaporizable material in the cartridge 1320 that may move out of the storage chamber in response to changes in the pressure differential between the storage chamber and ambient air. Vaporizable material 1302 can be drawn from reservoir 1342 to the atomizer and converted to a vapor or aerosol phase, thereby reducing the volume of vaporizable material remaining in reservoir 1342 and causing at least a partial vacuum condition as previously discussed herein absent some mechanism for returning air to the reservoir to equalize the pressure in the reservoir with the ambient pressure.

With continued reference to fig. 3A and 3B, the reservoir 1340 may be implemented to include first and second separable regions such that the volume of the reservoir 1340 is divided into a reservoir storage chamber 1342 and a reservoir overflow volume 1344. Storage chamber 1342 may be configured to store vaporizable material 1302 and may be further coupled to wicking element 1362 via one or more primary channels 1382. In some examples, the primary channel 1382 may be very short in length (e.g., a through hole from a space housing a wicking element or other portion of the atomizer). In other examples, the primary channel may be part of a longer containment fluid path between the reservoir and the wicking element. As provided in further detail below, overflow volume 1344 may be configured to store and contain a portion of vaporizable material 1302 that can overflow from storage chamber 1342 at a second pressure state in which the pressure in storage chamber 1342 is greater than ambient pressure.

In the first pressure state, the vaporizable material 1302 can be stored in the storage chamber 1342 of the reservoir 1340. The first pressure state may exist, for example, when the ambient pressure is approximately equal to or greater than the pressure within the cartridge 1320. In this first pressure state, the structural and functional characteristics of primary channel 1382 and secondary channel 1384 are such that vaporizable material 1302 can flow from reservoir 1342 toward wicking element 1362 through primary channel 1382, e.g., under the capillary action of the wicking element to draw liquid into proximity in conjunction with a heating element that acts to convert the liquid vaporizable material to a vapor phase.

In one embodiment, no or a limited amount of vaporizable material 1302 flows into secondary channel 1384 at the first pressure state. In the second pressure state, the vaporizable material 1302 can flow from the storage chamber 1342 into an overflow volume 1344 of a reservoir 1340, which reservoir 1340 includes, for example, a collector 1313 to prevent or limit undesired (e.g., excessive) flow of the vaporizable material 1302 out of the reservoir. For example, the second pressure state may exist or be induced when bubbles expand in the storage chamber 1342 (e.g., due to the ambient pressure becoming less than the pressure within the cartridge 1320).

Advantageously, the flow of vaporizable material 1302 can be controlled by directing vaporizable material 1302 to drive the vaporizable material from storage chamber 1342 to the overflow volume by a pressure increase. The collector 1313 in the overflow volume may include one or more capillary structures that contain at least some (and advantageously all) of the excess liquid vaporizable material pushed out of the reservoir 1342 without allowing the liquid vaporizable material to reach the outlet of the collector 1313. The collector 1313 also advantageously includes a capillary structure that enables liquid vaporizable material that is pushed into the collector 1313 by excessive pressure in the storage chamber 1342 relative to ambient pressure to be reversibly drawn back into the storage chamber 1342 when the pressure in the storage chamber 1342 relative to ambient pressure is equal or otherwise reduced. In other words, the secondary passages 1384 of the collector 1313 may have microfluidic features or characteristics that prevent air and liquid from bypassing each other during filling and emptying of the collector 1313. That is, microfluidic features may be used to manage the flow of vaporizable material 1302 into and out of collector 1313 (i.e., provide flow reversal features) to prevent or reduce leakage or air bubbles of vaporizable material 1302 from becoming trapped in storage chamber 1342 or overflow volume 1344.

Depending on the embodiment, the microfluidic features or characteristics described above may be related to the size, shape, surface coating, structural features, and capillary characteristics of wicking element 1362, primary channel 1382, and secondary channel 1384. For example, secondary channels 1384 in collector 1313 may optionally have different capillary properties than primary channels 1382, which primary channels 1382 open into wicking element 1362 to allow a particular volume of vaporizable material 1302 to pass from storage chamber 1342 into overflow volume 1344 during the second pressure state.

In an exemplary embodiment, the collector 1313 allows the total resistance to liquid flow out to be greater than the total wicking resistance, e.g., to allow the vaporizable material 1302 to flow primarily through the primary channel 1382 toward the wicking element 1362 during the first pressure state.

The wicking element 1362 can provide a capillary path for the vaporizable material 1302 stored in the reservoir 1340 to pass through or into the wicking element 1362. The capillary paths (e.g., primary channels 1382) may be large enough to allow wicking or capillary action to displace the evaporated vaporizable material 1302 in the wicking element 1362, and small enough to prevent the vaporizable material 1302 from leaking out of the cartridge 1320 during a negative pressure event. The wicking housing or wicking element 1362 may be treated to prevent leakage. For example, the cartridge 1320 may be coated after filling to prevent leakage or evaporation through the wicking element 1362. Any suitable coating may be used including, for example, a thermally vaporizable coating (e.g., wax or other material).

When a user inhales from the mouthpiece region 1330, for example, air flows into the cartridge 1320 through an inlet or opening in operative relationship with the wicking element 1362. The heating element 1350 may be activated in response to a signal generated by one or more sensors 113 (see fig. 1). The one or more sensors 113 may include at least one of a pressure sensor, a motion sensor, a flow sensor, or other mechanism capable of detecting a change in the airflow passage 1338. When heating element 1350 is activated, heating element 1350 may have a temperature increase due to the flow of current through plate 1326. Or some other resistive portion that is acted upon by the heating element to convert electrical energy into thermal energy.

In one embodiment, the generated heat may be transferred to at least a portion of the vaporizable material 1302 in the wicking element 1362 by conductive, convective, or radiative heat transfer such that at least a portion of the vaporizable material 1302 drawn into the wicking element 1362 is vaporized. According to an embodiment, air entering the cartridge 1320 flows over (or bypasses, is adjacent to, etc.) the elements heated in the wicking element 1362 and the heating element 1350, and disengages the evaporated vaporizable material 1302 into the airflow channel 1338 where the vapor may optionally be condensed and delivered in aerosol form, for example, through openings in the mouthpiece region 1330.

Referring to fig. 3B, the storage chamber 1342 may be connected to the airflow channel 1338 (i.e., via a secondary channel 1384 of the overflow volume 1344) so as to allow liquid vaporizable material driven from the storage chamber 1342 by the increased pressure in the storage chamber 1342 relative to the ambient environment to be retained from escaping the vaporizer cartridge. While the embodiments described herein relate to a vaporizer cartridge containing reservoir 1340, it should be understood that the methods are also compatible with and contemplated for use in vaporizers without a detachable cartridge.

Returning to the example, air admitted to storage chamber 1342 may expand due to a pressure differential relative to ambient air. This expansion of air in the void spaces of the storage chamber 1342 can cause the liquid vaporizable material to travel through at least some portion of the secondary passages 1384 in the collector 1313. The microfluidic features of the secondary channel 1384 may move the liquid vaporizable material along a length of the secondary channel 1384 in the collector 1313, where for only that length, the meniscus completely covers a cross-sectional area of the secondary channel 1384 transverse to the direction of flow along the length. In some embodiments of the present subject matter, the microfluidic features may include a cross-sectional area small enough to accommodate the material forming the walls of the secondary channels and the composition of the liquid vaporizable material that wets the secondary channels 1384, preferably around the entire perimeter of the secondary channels 1384. For examples in which the liquid vaporizable material comprises one or more of propylene glycol and vegetable glycerin, the wetting characteristics of such liquid are advantageously considered in combination with the geometry of the secondary channel 1384 and the material forming the walls of the secondary channel. In this manner, as the sign (e.g., positive, negative, or equal) and magnitude of the pressure differential between the storage chamber 1340 and the ambient pressure changes, a meniscus is maintained between the liquid in the secondary channel and the air entering from the ambient atmosphere, and the liquid and air cannot move past each other. When the pressure in the reservoir 1342 drops sufficiently relative to ambient pressure, and if there is sufficient void volume in the reservoir 1342 to allow it, the liquid in the secondary passage 1384 of the collector 1313 may be drawn into the reservoir 1342 sufficiently so that the liquid-air meniscus is directed to the gate or port between the secondary passage 1384 of the collector 1313 and the reservoir 1342. At this point, if the pressure differential in the reservoir chamber 1342 relative to ambient pressure is negative enough to overcome the surface tension holding the meniscus at the gate or port, the meniscus becomes detached from the gate or port wall and forms one or more bubbles that are released into the reservoir chamber 1342 with sufficient volume to equalize the reservoir chamber pressure relative to ambient.

The above-described process may be reversed when the air admitted into storage chamber 1340 (or otherwise present therein) experiences elevated pressure conditions relative to the ambient environment as described above (e.g., due to a drop in ambient pressure, such as may occur in an aircraft cabin or other high-altitude location, when a window of a moving vehicle is open, when a train or vehicle leaves a tunnel or the like, or due to an increase in internal pressure within storage chamber 1340, such as may occur due to localized heating, mechanical pressure that deforms the shape and thereby reduces the volume of storage chamber 1340, or the like). The liquid enters the secondary channel 1384 of the collector 1313 through a gate or port and forms a meniscus at the leading edge of the liquid column entering the secondary channel 1384 to prevent air from bypassing and flowing against the progression of the liquid. By maintaining this meniscus due to the presence of the aforementioned microfluidic properties, when the elevated pressure in the reservoir chamber 1340 is subsequently reduced, the liquid column is drawn back into the reservoir chamber, optionally until the meniscus reaches the gate or port. If the pressure difference is sufficient to favor the ambient pressure with respect to the pressure in the reservoir, the above-described bubble formation process occurs until the pressures equalize. In this manner, the collector acts as a reversible overflow volume that receives liquid vaporizable material pushed out of the storage chamber under transient conditions of greater storage chamber pressure relative to the ambient environment and allows at least some (and desirably all or most) of this overflow volume to be returned to the storage chamber for later delivery to the atomizer for conversion to a respirable form.

According to embodiments, reservoir 1342 may be connected to wicking element 1362 via or not via secondary channel 1384. In embodiments where the second end of the secondary channel 1384 opens into the wicking element 1362, any vaporizable material 1302 that may exit the secondary channel 1384 at the second end (opposite the first end defining the connection point to the reservoir 1342) may further saturate the wicking element 1362.

Storage chamber 1342 may optionally be positioned closer to an end of reservoir 1340 proximate mouthpiece area 1330. The overflow volume 1344 may be located near the end of the receptacle 1340 closer to the heating element 1350, e.g., between the storage chamber 1342 and the heating element 1350. The exemplary embodiments shown in the figures should not be construed as limiting the scope of the claimed subject matter to the locations of the various components disclosed herein. For example, the overflow volume 1344 may be positioned at the top, middle, or bottom of the cartridge 1320. According to one or more variations, the location and positioning of the storage chamber 1342 may be adjusted relative to the location of the overflow volume 1344 such that the storage chamber 1342 may be positioned at the top, middle, or bottom of the magazine 1320.

In one embodiment, when the vaporizer cartridge 1320 is full, the volume of liquid vaporizable material may be equal to the internal volume of the storage chamber 1342 plus an overflow volume 1344 (which in some examples may be the volume of the secondary channel 1384 between the gate or port connecting the secondary channel 1384 to the storage chamber 1340 and the outlet of the secondary channel 1384). In other words, an evaporator cartridge consistent with an embodiment of the present subject matter may be initially filled with a liquid vaporizable material such that all or at least some of the interior volume of the collector is filled with the liquid vaporizable material. In such examples, the liquid vaporizable material is delivered to the atomizer for delivery to the user as needed. The transported liquid vaporizable material can be drawn from the reservoir 1340, causing the liquid in the secondary channel 1384 of the collector 1313 to be drawn back into the reservoir 1340 because air cannot enter through the secondary channel 1384 because the meniscus maintained by the microfluidic properties of the secondary channel 1384 prevents air from flowing through the liquid vaporizable material in the secondary channel 1384. This occurs after sufficient liquid vaporizable material has been delivered from the storage chamber 1340 to the atomizer (e.g., for vaporization and user inhalation) such that the original volume of the collector 1313 is drawn into the storage chamber 1340, and air bubbles can be released from the gate or port between the secondary channel 1384 and the storage chamber to equalize the pressure in the storage chamber as more liquid vaporizable material is used. When the air that has entered the storage compartment experiences an elevated pressure relative to the ambient environment, the liquid vaporizable material moves out of the storage chamber 1340 through the gate or port into the secondary channel until the elevated pressure condition in the storage compartment is no longer present, at which point the liquid vaporizable material in the secondary channel 1384 can be drawn back into the storage chamber 1340.

In certain embodiments, the overflow volume 1344 is large enough to contain a percentage of the vaporizable material 1302 stored in the storage chamber 1342, optionally up to about 100%. In one embodiment, the collector 1313 is configured to hold at least 6% to 25% by volume of the vaporizable material 1302 that can be stored in the storage chamber 1342. Other ranges are also possible.

The structure of collector 1313 may be configured, constructed, molded, fabricated, or positioned in different shapes and different characteristics in overflow volume 1344 to allow an overflow portion of vaporizable material 1302 to be at least temporarily received, contained, or stored in overflow volume 1314 in a controlled manner (e.g., by capillary pressure) to prevent vaporizable material 1302 from leaking from cartridge 1320 or over-saturating wicking element 1362. It should be understood that the above description of the secondary passages is not intended to be limited to a single such secondary passage 1384. One or optionally more secondary channels may be connected to the storage chamber 1340 via one or more gates or ports. In some embodiments of the present subject matter, a single gate or port may be connected to more than one secondary channel, or a single secondary channel may be split into more than one secondary channel to provide additional overflow volume or other advantages.

In some embodiments of the present subject matter, the air vent 1318 may connect the overflow volume 1344 to the air flow channel 1338, which is ultimately open to the ambient air environment outside the cartridge 1320. This air vent 1318 may allow a path for air or bubbles that have formed or become trapped in the collector 1313 to escape through the air vent 1318, for example, during a second pressure state when the secondary passages 1384 are filled with overflow of the vaporizable material 1302.

According to some aspects, the air vent 1318 may function as a reverse vent and provide pressure equalization within the cartridge 1320 during a reversal from the second pressure state back to the first pressure state when overflow of the vaporizable material 1302 returns from the overflow volume 1344 to the storage chamber 1342. In such embodiments, when the ambient pressure becomes greater than the internal pressure in the cartridge 1320, ambient air may flow through the vent 1318 into the secondary channel 1384 and effectively help push the vaporizable material 1302 temporarily stored in the overflow volume 1344 back into the storage chamber 1342 in the reverse direction.

In one or more embodiments, the secondary passage 1384 at the first pressure state may include air. In the second pressure state, vaporizable material 1302 can enter secondary channel 1384, for example, through an opening (i.e., vent) at an interface point between storage chamber 1342 and overflow volume 1344. As a result, air in the secondary passage 1384 is displaced and may be exhausted through the air vent 1318. In some embodiments, air vent 1318 may function as or include a control valve (e.g., a selectively permeable membrane, a microfluidic gate, etc.) that allows air to exit overflow volume 1344, but prevents vaporizable material 1302 from exiting secondary channel 1384 into airflow channel 1338. As previously described, the air vent 1318 may serve as an air exchange port to allow air to enter and exit the collector 1313, for example, when the collector 1313 fills during a negative pressure event and empties after the negative pressure event (i.e., during a transition between the aforementioned first and second pressure states).

Thus, the vaporizable material 1302 can be stored in the collector 1313 until the pressure within the cartridge 1320 stabilizes (e.g., when the pressure returns to ambient or meets a specified equilibrium) or until the vaporizable material 1302 is removed from the overflow volume 1344 (e.g., by vaporization in the atomizer). Thus, the level of vaporizable material 1302 in overflow volume 1344 can be controlled by managing the flow of vaporizable material 1302 in and out of collector 1313 as ambient pressure changes. In one or more embodiments, the overflow of vaporizable material 1302 from storage chamber 1342 to overflow volume 1344 can be reversed or can be reversible depending on the detected environmental change (e.g., when the pressure event that caused the overflow of vaporizable material 1302 subsides or ends).

As described above, in some embodiments of the present subject matter, in a state where the pressure within the cartridge 1320 becomes relatively lower than ambient pressure (e.g., when returning to the first pressure state from the second pressure state previously mentioned), the flow of the vaporizable material 1302 may be reversed in a direction such that the vaporizable material 1302 flows from the overflow volume 1344 back into the storage chamber 1342 of the reservoir 1340. Thus, depending on the embodiment, overflow volume 1344 may be configured to temporarily contain an overflow portion of vaporizable material 1302 during the second pressure state. According to an embodiment, at least some of the overflow of vaporizable material 1302 held in collector 1313 is returned to storage chamber 1342 during or after reversal back to the first pressure state.

To control the flow of the vaporizable material 1302 in the cartridge 1320, in other embodiments of the present subject matter, the collector 1313 can optionally include an absorbent or semi-absorbent material (e.g., a material having sponge-like properties) for permanently or semi-permanently collecting or containing overflow of the vaporizable material 1302 traveling through the secondary channel 1384. In an exemplary embodiment where absorbent material is included in the collector 1313, a reverse flow of the vaporizable material 1302 from the overflow volume 1344 to the storage chamber 1342 may not be practical or possible as compared to an embodiment implemented without (or as much) absorbent material in the collector 1313. Thus, by including more or less density or volume of absorbent material in the collector 1313, or by controlling the texture of the absorbent material, the rate of reversibility or reversibility of the vaporizable material 1302 to the storage chamber 1342 can be controlled, where such a characteristic results in a higher or lower rate of absorption either immediately or over a longer period of time.

Fig. 4 is an exploded perspective view of an exemplary embodiment of the cartridge 1320. As shown, the body of the cartridge 1320 can be made of two connectable (or separable) parts, such as a first part 1422 (e.g., an upper housing) and a second part 1424 (e.g., a lower housing), which can be assembled together according to a building implementation model or assembly process above and below each other. This separable structure simplifies the assembly and manufacturing process and may not involve assembling or constructing multiple smaller components to construct a larger component. In contrast, as in the exemplary embodiment shown in fig. 4, the larger components (e.g., first portion 1422 and second portion 1424) may be connected to form, for example, outer cartridge features (e.g., sides) and smaller inner cartridge components (e.g., opposing rib elements forming one or more of the collector 1313, reservoir 1340, storage chamber 1342, overflow volume 1344, etc.).

Referring to fig. 4, the heating element 1450 may be located in a cavity or housing implemented between the first part 1422 and the second part 1424 of the body of the cartridge 1420. In one example, a sponge or other absorbent material 1460 may also be positioned in the mouthpiece region 1430 in order to collect excess liquid vaporizable material (e.g., as formed by the vaporized material and/or water vapor condensation to form larger droplets that create an unpleasant sensation when swallowed during inhalation) traveling through the air flow channel 1438. Thus, assembly or disassembly of additional components (e.g., the heating element 1450 or the sponge 1460) may be performed in a simple and efficient manner, and in the exemplary embodiments disclosed herein, a large number of machines or assembly automation components are not required to construct the cartridge 1320 from a small set of components into a unified separable two-piece housing.

The separable two-piece construction described herein may provide one or more of the following exemplary advantages or improvements over alternative embodiments: fewer part counts, lower assembly or manufacturing costs (e.g., the embodiment shown in fig. 4 requires four parts to be manufactured and assembled), no or reduced tooling requirements, no or limited deep, fragile, low draft tooling cores, relatively shallow rib structures. According to embodiments, a solid state weld may be formed between first portion 1422 and second portion 1424 of cartridge 1420 using ultrasonic or laser welding techniques.

Ultrasonic welding is a process commonly used for plastics in which high frequency ultrasonic acoustic vibrations are applied locally to workpieces (e.g., first portion 1422 and second portion 1424) that are held together under pressure to form a solid state weld. Laser welding is a welding process for joining metal or thermoplastic workpieces by using a laser beam that provides a concentrated heat source (e.g., a laser beam), allowing narrow, deep welds to be made at high welding rates.

Referring to fig. 5, a plan cross-sectional side view of selected portions of the magazine 1320 is shown. Referring to fig. 4 and 5, first portion 1422 (not shown in fig. 5) and second portion 1424 of cartridge 1420 may be molded from plastic parts (e.g., in a master mold on top of each other) by injection molding. In one exemplary embodiment, a line of drawing process techniques may be used to allow separation of the mold halves (e.g., first portion 1422 and second portion 1424 as shown in fig. 4), allowing each portion to be ejected without any impediment from creating undercuts, and further allowing significant mold cavitation to help shorten the process cycle and allow for more efficient manufacturing times and processes.

Referring to fig. 6A and 6B, a cross-sectional top view and a perspective side view of the magazine 1320 are shown, respectively. As shown, the filling port 610 may be implemented in one or more embodiments of the magazine 1320 to allow for filling of the reservoir storage chamber 1342, for example, through the filling needle 622. As shown, according to embodiments, the fill needle 622 can be easily and conveniently inserted into the fill port 610 through, for example, a fill channel 630 leading to the reservoir 1342 (or overflow volume 1344). Thus, for example, using filling needle 622, vaporizable material 1302 can be injected into reservoir 1340 through filling channel 630. In some embodiments, the fill channel 630 may be configured or positioned on a side of the cartridge 1320, e.g., opposite the side where the airflow channel 1338 is positioned.

Fig. 7A to 7D show design alternatives for the cartridge connection port. Fig. 7A and 7B are perspective views and fig. 7C and 7D are plan cross-sectional side views of alternative connection port embodiments, which may include male or female engagement portions, as examples. Referring to fig. 1, 2 and 7A-7D, cartridge 1320 may take on different configurations at the end of cartridge 1320 that engages evaporator body 110. In one embodiment, as shown in fig. 1 and 2, the evaporator body 110 may include a cartridge receptacle 118 for removably receiving a cartridge 1320 (see fig. 7A and 7C) having a male port 710 such that, in an attached state, cartridge contacts 124 located in the male port of the cartridge 1320 are received, e.g., in a snap-fit manner, by corresponding receptacle contacts 125 in the cartridge receptacle 118. The opposing structure may be used with a cartridge 1320 having a female configured port 712 (see fig. 7B and 7D) for receiving an end of the evaporator body 110 containing the receptacle contacts 125.

Referring to fig. 8, a top plan view of the magazine 1320 is shown. In one example, cartridge 1320 may be implemented using a separable two-piece structure, wherein a relief (e.g., the owner's trademark, serial number, patent number, etc.) or optional ornamental or decorative feature may be imprinted on the outer wall of cartridge 1320 by a molding process. The molding process allows flexibility in designing external shapes or externally displayable logos or decorative designs without affecting the positioning or formation of internal functional components (e.g., the reservoir 1340, the storage chamber 1342 or the overflow volume 1344).

Notably, the markers JUUL @, as shown in FIG. 8, are registered trademarks of JUUL LABS Inc. Delaware Inc. having a division in California, san Francisco. All rights are reserved by the owner or the assignee of the token. The use of example indicia in fig. 8 should not be construed to limit the scope of the disclosed subject matter to include such exclusive designs or indicia. Some embodiments may be unmarked or contain no decorative or external design features whatsoever. Thus, fig. 8 provides an illustration of a molded relief, which may be present without limitation as a mark or design on one or more sides of the cartridge 1320.

Referring to fig. 9A and 9B, perspective and plan cross-sectional views of an exemplary cartridge 1320 are shown with a first portion 1422 of the cartridge 1320 separate from a second portion 1424 (see also fig. 4). In one or more embodiments, the cartridge 1320 may be designed and manufactured by way of a split of parts. That is, according to an embodiment, multiple split sections of the component are connected together to form the entire component, as shown in the example in fig. 4.

Referring to fig. 9A, the component split may allow for compatibility/moldability of the molding for the electrical contacts and heating elements to remain in the core shell region 910 of the cartridge 1320. As shown in more detail in fig. 9B, one or more vents 920 may be drilled or positioned by injection molding or other suitable methods in the body of cartridge 1320 in a region proximate to wick housing region 910 to allow precise channeling of vapor egress or air flow to the wick, e.g., to help control condensation within cartridge 1320 or affect capillary forces therein.

Referring to fig. 10A and 10B, assembled and exploded perspective views of an alternative exemplary embodiment of a cartridge 1320 are shown, respectively. As previously mentioned, a top-down implementation model may be employed to construct a cartridge structure having an open face, e.g., two attachable (or detachable) housings, including a first portion 1422 and a second portion 1424. As shown, first portion 1422 (e.g., upper housing) and second portion 1424 (e.g., lower housing) can provide a two-piece structure having one or more internal cavities that can be used to house at least one of heating element 1350, wicking element 1362, or plate 1326. It will be appreciated that alternative methods of assembly may be used to produce structures having some or all of the features described herein.

In particular, in the exemplary embodiment shown in fig. 10A and 10B, instead of or in addition to using molded cavities and walls to form the internal structure of the cartridge (e.g., the reservoir 1340 in fig. 3A), some features such as the secondary passage 1384 (see fig. 3A) may be implemented in a removable or attachable collector 1313, which collector 1313 may be separately constructed as a separate component and may be subsequently enclosed between the first and second portions 1422 and 1424 (see, e.g., fig. 10A and 10B), or alternatively inserted into an optional unitary hollow cartridge body adapted to receive the collector 1313 from the open end (see fig. 10C, 10D, 11B, 13, 16C, 17A, 22B).

Referring to fig. 10A through 43B, various embodiments are disclosed that may utilize a collector 1313 that is constructed, designed, manufactured, assembled, or constructed entirely or partially independent of the cartridge 1320 housing. It is noted that the disclosed implementations are provided as examples. In alternative embodiments or examples, the collector 1313 may be formed as shown in fig. 10A to 14B, having a structure that is at least structurally semi-related or completely independent of the structure of the other components of the cartridge 1320.

In certain interchangeable embodiments, as shown in fig. 10A-14B, various embodiments or types of collectors 1313 may be inserted or enclosed in, for example, a standardized magazine 1320 housing. As provided in further detail herein, because some of the primary functions for controlling the flow of vaporizable material 1302 in the cartridge 1320 can be accomplished by manipulating the structure of the collector 1313 or its material properties, cost savings and other efficiencies and advantages can be obtained from having a configuration that allows, for example, interchangeable collector 1313 models that can fit different cartridge shells.

For example, referring to fig. 10C and 10D, in some embodiments, cartridge 1320 may have a cartridge housing formed from a unitary hollow structure having a first end and a second end, rather than the separable two-piece structure shown in fig. 10A and 10B. The first end (i.e. the first end also referred to as receiving end of the cartridge housing) may be configured for insertably receiving the at least one collector 1313. In one embodiment, the second end of the cartridge housing may serve as a mouthpiece having an aperture or opening. The aperture or opening may be located opposite the receiving end of the cartridge housing where the collector 1313 may be insertably received. In some embodiments, the opening may be connected to the receiving end by, for example, an airflow channel 1338 extending through the body of the cartridge 1320 and the collector 1313. As in other cartridge embodiments according to the present disclosure, an atomizer, e.g., one containing the wicking element and the heating element discussed elsewhere herein, may be positioned adjacent to or at least partially in the air flow passage 1338 such that an inhalable form, or alternatively an inhalable form, precursor of the liquid vaporizable material may be released from the atomizer into the air passing through the air flow passage 1338 towards the orifice or opening.

Air exchange port embodiments

Referring to fig. 11A and 11B, illustrative plan side views of a single gate, single pass collector 1313 are shown. In these exemplary embodiments, the gate 1102 can be disposed at an opening toward a first portion (e.g., an upper portion) of the collector 1313, wherein the collector 1313 is in contact or communication with the storage chamber 1342 of the receptacle (see also fig. 3A and 3B, discussed previously). The gate 1102 can dynamically connect the storage chamber 1342 to an overflow volume 1344 formed by a second portion (e.g., an intermediate portion) of the collector 1313.

In one embodiment, the second portion of the collector 1313 may have a rib-like or multi-fin-like structure that forms an overflow channel 1104, as shown in fig. 11A, the overflow channel 1104 spirals, narrows, or slopes in a direction away from the gate 1102 and toward the air exchange port 1106 to direct or cause the vaporizable material 1302 to move toward the air exchange port 1106 after the vaporizable material 1302 enters the overflow volume 1344 through the gate 1102. The air exchange port 1106 may be connected to ambient air through an air path or airflow channel connected to the mouthpiece. This air path or airflow channel is not explicitly shown in fig. 11A.

In some embodiments, the collector 1313 is configured with a central opening or channel through which airflow access to the mouthpiece is achieved, as provided in further detail below (see, for example, the opening identified by reference numeral 1100 in fig. 11D). The airflow channel may be connected to the air exchange port 1106 such that the volume within the overflow channel of the collector 1313 is connected to ambient air via the air exchange port 1106 and also to the volume in the storage chamber 1342 via the shutter 1102. As such, according to one or more embodiments, the gate 1102 may act as a control fluid valve to primarily control the flow of liquid and air between the overflow volume 1344 and the storage chamber 1342. For example, the air exchange port 1106 may be used to primarily control air flow (and, if desired, liquid flow) between the overflow volume 1344 and the air path to the mouthpiece. The overflow channel 1104 may be inclined, vertical, or horizontal with respect to the elongated body of the cartridge 1320.

As cartridge 1320 is filled, vaporizable material 1302 can have at least an initial interface with collector 1313 via shutter 1102. This is because the initial interface between vaporizable material 1302 and shutter 1102, for example, can prevent the possibility of air trapped in overflow channel 1104 from entering the cartridge area (e.g., storage chamber 1342) where vaporizable material 1302 is stored. Further, in an equilibrium state, this interface may initiate a first capillary interaction between vaporizable material 1302 and the walls of overflow channel 1104 to allow a limited amount of vaporizable material 1302 to flow into overflow channel 1104 to achieve or maintain an equilibrium state.

An equilibrium state refers to a state where vaporizable material 1302 neither flows into nor out of overflow volume 1344, or a state where such forward or reverse flow is negligible. In at least some embodiments, capillary action (or interaction) between the walls of overflow channel 1104 and vaporizable material 1302 is such that an equilibrium state can be maintained when cartridge 1320 is in a first pressure state when the pressure within storage chamber 1342 is approximately equal to ambient pressure.

By adapting or adjusting the volume size of overflow channel 1104 along the channel length, a state of equilibrium and further capillary interaction between vaporizable material 1302 and the walls of overflow channel 1104 can be established or configured. As provided in further detail herein, the diameter of overflow channel 1104 (used herein generally to refer to a measure of the size of the cross-sectional area of overflow channel 1104, including embodiments of the present subject matter in which the overflow channel does not have a circular cross-section) may be constricted at predetermined intervals or points or throughout the length of the channel to allow sufficiently strong capillary interactions that provide direct and reverse flow of vaporizable material 1302 into and out of collector 1313 as a function of pressure changes, and further allow for a large volume of overflow channel while still maintaining a choke point for meniscus formation to prevent air from flowing through the liquid in overflow channel 1104.

As provided in further detail herein, the diameter of overflow channel 1104 may be sufficiently small or narrow that a combination of surface tension caused by cohesive forces within vaporizable material 1302 and wetting forces between vaporizable material 1302 and the walls of overflow channel 1104 may act to form a meniscus that separates liquid from air in a dimension transverse to the flow axis in overflow channel 1104 such that air and liquid cannot pass each other. It will be appreciated that the meniscus has an inherent curvature and therefore reference to a dimension transverse to the direction of flow is not intended to imply that the air-liquid interface is flat in that dimension or any other dimension.

The wicking element 1362 may be thermally or thermodynamically connected to the heating element 1350 (see, e.g., fig. 3B and 11B) to cause vapor generation by heating the vaporizable material 1302, as discussed in detail previously with reference to fig. 3A and 3B. Alternatively, the air exchange port 1106 can be configured to provide a gas escape path, but prevent the vaporizable material 1302 from flowing out of the overflow channel 1104.

Referring to fig. 11A and 11B, the direct or reverse flow of vaporizable material 1302 in collector 1313 can be controlled (e.g., enhanced or reduced) by implementing suitable structures (e.g., microchannel configurations) to introduce or take advantage of capillary properties that may exist between vaporizable material 1302 and the retaining walls of overflow channel 1104. For example, factors related to length, diameter, inner surface texture (e.g., rough vs. smooth), protrusions, directional narrowing of the channel structure, shrinkage or material used to construct or coat the surface of the gate 1102, overflow channel 1104 or air exchange port 1106 may positively or negatively affect the rate at which liquid is drawn or moved through the overflow channel 1104 by capillary action or other influential forces acting on the cartridge 1320.

Depending on the embodiment, one or more of the factors described above may be used to control the displacement of the vaporizable material 1302 in the overflow channel 1104 as the vaporizable material 1302 collects in the channel structure of the collector 1313 to introduce a desired degree of reversibility. As such, in some embodiments, the flow of vaporizable material 1302 into collector 1313 can be fully or semi-reversible by selectively controlling the various factors described above and depending on changes in pressure conditions inside or outside cartridge 1320.

As shown in fig. 3A, 3B, 11A, and 11B, in one or more embodiments, the collector 1313 may be formed, constructed, or configured to have a single-channel, single-vent configuration. In such embodiments, overflow channel 1104 can be a continuous passage, tube, channel, or other structure for connecting gate 1102 to air exchange port 1106, optionally positioned adjacent to wicking element 1362 (see also fig. 3A and 3B, for example, showing a single elongated overflow channel 1104 in overflow volume 1344). Thus, in such embodiments, vaporizable material 1302 can enter or exit collector 1313 from gate 1102 and pass through a separately configured passageway, wherein vaporizable material 1302 flows in a first direction when collector 1313 is filled and vaporizable material flows in a second direction when collector 1313 is emptied.

To help maintain an equilibrium state, or depending on the implementation, to control the flow of vaporizable material 1302 in overflow channel 1104, the shape and structural configuration of overflow channel 1104, gate 1102, or air exchange port 1106 can be adapted or modified to balance the rate of flow of vaporizable material 1302 in overflow channel 1104 at different pressure conditions. In one example, the overflow passage 1104 may be narrowed such that a narrowed end (i.e., an end having a smaller opening or diameter) leads to the gate 1102.

In one embodiment, the non-narrowed end (i.e., the end of the overflow channel 1104 having the larger opening or diameter) may open into an air exchange port 1106, which air exchange port 1106 may be connected to the ambient environment outside of the cartridge 1320, or to an airflow path from which the vaporized vaporizable material 1302 is delivered to a mouthpiece (see, e.g., fig. 3A, air vent 1318 connected to airflow channel 1338). In one embodiment, the non-narrowed end may also open into an area near the wick housing, such that if the vaporizable material 1302 leaves the overflow channel 1104, the vaporizable material 1302 can be used to saturate the wicking element 1362.

Narrowing the channel structure may reduce or increase restriction of flow into the collector 1313, depending on the embodiment. For example, in embodiments where overflow channel 1104 narrows toward gate 1102, capillary pressure is induced in overflow channel 1104 that is directed toward the preponderance of reverse flow, such that when the pressure state changes (e.g., when the negative pressure event is eliminated or subsided), the direction of flow of vaporizable material 1302 is out of collector 1313 and into reservoir 1342. In particular, implementing overflow channel 1104 with a smaller opening may prevent vaporizable material 1302 from freely flowing into collector 1313. The non-narrowing configuration for the overflow channel 1101 in the direction leading to the air exchange port 1106 provides for efficient storage of the vaporizable material 1302 in the collector 1313 during the second pressure state (e.g., negative pressure state) because the vaporizable material 1302 flows into the collector 1313 from the narrower section of the overflow channel 1104 into the larger volume section of the overflow channel 1104.

In this way, the diameter and shape of collector structure 1313 may be achieved such that during a second pressure state (e.g., a negative pressure event), the flow of vaporizable material 1302 through gate 1102 and into overflow passage 1104 is controlled at a desired rate in a manner that prevents vaporizable material 1302 from flowing too freely (e.g., above a particular flow rate or threshold) into collector 1313 and also facilitates backflow into storage chamber 1342 at a first pressure state (e.g., when the negative pressure event is mitigated). Notably, in one embodiment, the combination of the interaction between vent 1002, overflow channel 1104 in collector 1313 and air exchange port 1106, which constitute overflow volume 1344, provides for the proper evacuation of air bubbles that may be introduced into the cartridge due to various environmental factors, as well as a controlled flow of vaporizable material 1302 into and out of overflow channel 1104.

Mouthpiece embodiments

Referring to fig. 11B (see also fig. 10C, 10D), in some embodiments, a portion of the cartridge 1320 including the storage chamber 1342 can be configured to further include a mouthpiece that can be used by a user to inhale the vaporized vaporizable material 1302. An airflow passage 1338 may extend through the storage chamber 1342 to connect the evaporation chambers. Depending on the embodiment, the airflow channel 1338 may be, for example, a straw-shaped structure or hollow cylinder that forms a channel within the storage chamber 1342 to allow the vaporized vaporizable material 1302 to pass through. Although the airflow passage may have a circular or at least approximately circular cross-sectional shape, it should be understood that other cross-sectional shapes of the airflow passage are also within the scope of the present disclosure.

A first end of airflow passage 1338 may be connected to an opening at a first "mouthpiece" end of storage chamber 1342, from which a user may inhale vaporized vaporizable material 1302. A second end (opposite the first end) of the airflow channel 1338 may be received in an opening at the first end of the collector 1313, as provided in further detail herein. According to an embodiment, the second end of the airflow channel 1338 may extend completely or partially through a receiving chamber that passes through the collector 1313 and connects to the wicking portion housing where the wicking element 1362 may be housed.

In some configurations, the airflow passage 1338 may be an integral part of an integrally molded mouthpiece that includes a storage chamber 1342, with the airflow passage 1338 extending through the storage chamber 1342. In other configurations, airflow passage 1338 may be a separate structure that may be separately inserted into storage chamber 1342. In some configurations, the airflow passage 1338 may be, for example, a structural extension of the body or collector 1313 of the cartridge 1320 that extends inwardly from an opening in the mouthpiece portion.

Without limitation, a variety of different structural configurations may be used to connect the mouthpiece (and the airflow passage 1338 inside the mouthpiece) to the air exchange port 1106 in the collector 1313. As provided herein, the collector 1313 may be inserted into the body of the magazine 1320, which may also serve as the storage chamber 1342. In some embodiments, the air flow channel 1338 may be configured as an internal sleeve as an integral part of the unitary cartridge body, such that an opening in the first end of the collector 1313 may receive the first end of the sleeve structure forming the air flow channel 1338.

Referring to fig. 18A-18D, certain embodiments may include an evaporator cartridge 1800 that includes a dual bucket mouthpiece 1830 connected with two airflow channels 1838. In such embodiments, a higher dose of vaporized vaporizable material 1302 can be delivered than a single barrel mouthpiece. Depending on the implementation, the dual barrel mouthpiece 1830 may also advantageously provide a smoother and more satisfactory evaporation experience.

Fluid gate embodiment

Referring to fig. 10A through 11H, various factors may be considered to help monitor and control the forward and reverse flow of vaporizable material 1302 into and out of collector 1313, depending on the embodiment. Some of these factors may include capillary actuation of the fluid vent (referred to herein as gate 1102) configuration. The capillary drive of gate 1102 may be, for example, less than the capillary drive of wicking element 1362. Further, the flow resistance of the collector 1313 can be greater than the flow resistance of the wicking element 1362. Overflow channel 1104 may have a smooth or corrugated inner surface to control the flow rate of vaporizable material 1302 through collector 1313. Overflow channel 1104 may be formed with a narrowed bend to provide suitable capillary interaction and forces that restrict flow rate through gate 1102 and into overflow volume 1344 during a first pressure state to facilitate a reverse flow rate through gate 1102 and out of overflow volume 1344 during a second pressure state.

Additional modifications to the shape and configuration of the collector 1313 components may be possible to help further adjust or fine tune the flow of the vaporizable material 1302 into and out of the collector 1313. For example, the smoothly curved spiral channel configuration shown in fig. 11A-11H (i.e., as opposed to a channel having sharp bends or edges) may allow additional features, such as one or more vents, channels, orifices, or constrictions, to be included in the collector 1313 at predetermined intervals along the overflow channel 1104. As provided in further detail herein, these additional features, structures, or configurations may help provide a higher level of flow control of vaporizable material 1302, for example, along overflow channel 1104 or through gate 1102.

It is worthy to note that regardless of the various structural elements and implementations discussed in this disclosure, certain features and functions (e.g., capillary action between various components) may be implemented in the collector 1313 structure to help control the flow of the vaporizable material 1302 through (1) a single vent, single channel structure, (2) a single vent, multi-channel structure, or (3) a multi-vent, multi-channel structure.

With reference to fig. 10E, 11A, 11C, 11D, and 11E, an exemplary structural configuration for collector 1313 is given according to some variations. As shown, a fully or partially sloped spiral surface may be employed to define one or more sides of the interior volume of overflow channel 1104 of collector 1313, such that vaporizable material 1302 may flow freely through overflow channel 1104 due to capillary pressure (or gravity) as vaporizable material 1302 enters overflow channel 1104. One or more, optionally central, channels or channels, such as central channel 1100, may be configured to pass through the longitudinal height of collector 1313, with two opposing ends.

At the first end, a central shaft or channel 1100 through the collector structure 1313 can interact with or connect to a housing region in which the wicking element 1362 or atomizer can be positioned. At a second end, the central channel 1100 may interact with, connect to, or receive an end of a conduit or tube that forms an airflow channel 1338 in the mouthpiece portion of the cartridge 1320. A first end of the airflow passage 1338 may be connected (e.g., by insertion) to a second end of the central channel 1100. The second end of the airflow passage 1338 may include an opening or aperture formed in the interface region.

In accordance with one or more embodiments, the vaporized vaporizable material 1302 produced by the atomizer can enter through a first end of the central channel 1100 in the collector 1313, pass through the central channel 1100 and further exit a second end of the central channel 1100 into a first end of the airflow channel 1338. The vaporized vaporizable material 1302 can then travel through the airflow passageway 1338 and exit through a mouthpiece opening formed at a second end of the airflow passageway 1338.

The collector 1313 may be configured as a separate piece having a structure or configuration that is insertable into the body of the cartridge 1320 (see, e.g., fig. 10C, 11B, 11C-11E). Upon insertion, an airtight seal may be formed between the inner wall of the housing of the cartridge 1320 and the outer edge of the rib structure of the collector 1313 forming the helical inclined surface. In other words, when the collector 1313 is inserted into the body of the cartridge 1320, the three walls of the overflow channel 1104 surrounded by the surface of the inner wall of the housing of the cartridge 1320 form the overflow channel 1104.

Thus, the overflow channel 1104 may be formed by the inner wall of the body of the cartridge 1320 surrounding the inner wall of the rib structure. As shown, a gate 1102 can be located at one end of overflow channel 1104, toward the location where storage chamber 1342 is located, to control and provide for the entry and exit of vaporizable material 1302 into overflow channel 1104 in collector 1313. An air exchange port 1106 may be located toward the other end of the overflow passage 1104, preferably opposite the end where the gate 1102 is located.

Shutter 1102 may control the flow of vaporizable material 1302 into and out of overflow 1104 in collector 1313. The air exchange port 1106 may control the flow of air into and out of the overflow channel 1104 through a connection path to ambient air to regulate the air pressure in the collector 1313 and thus in the storage chamber 1342 of the cartridge 1320, as provided in further detail herein. In certain embodiments, the air exchange port 1106 can be configured to prevent vaporizable material 1302 that may have filled the collector 1313 overflow channel 1104 (e.g., due to a negative pressure event) from exiting the overflow channel 1104.

In particular embodiments, the air exchange port 1106 can be configured such that the vaporizable material 1302 exits toward a route leading to an area in which the wicking element 1362 is housed. Such an embodiment may help avoid leakage of the vaporizable material 1302 into the airflow path (e.g., central channel 1100) leading to the mouthpiece, for example, during a negative pressure event. In some embodiments, the air exchange port 1106 can have a membrane that allows gaseous material (e.g., air bubbles) to enter and exit, but prevents the vaporizable material 1302 from entering or exiting the collector 1313 through the air exchange port 1106.

Referring to fig. 11C-11H, the flow rate of vaporizable material 1302 into or out of collector 1313 through gate 1102 can be directly related to the volumetric pressure inside overflow channel 1104. Thus, the flow rate into and out of the collector 1313 through the gate 1102 may be controlled by controlling the hydraulic diameter of the overflow channel 1104 such that a reduction in the total volume of the overflow channel 1104 (e.g., uniformly or by introducing multiple pinch points) may result in an increase in pressure in the overflow channel 1104 and an adjustment of the flow rate into the collector 1313. Thus, in at least one embodiment, the hydraulic diameter of overflow channel 1104 may be reduced uniformly along the length of the spiral path of overflow channel 1104 or by introducing one or more constriction points 1111a (e.g., narrowing, constriction, or restriction).

Fig. 11C-11E show, by way of example, two partial-length levels and three full-length levels configured on one or more sides of the collector 1313, with each full-length level on the side shown in the figures having, for example, three pinch points 1111 a. It is noted that in various embodiments, more or fewer stages or constriction points 1111a may be implemented, defined, configured or introduced to adjust the volumetric pressure in the collector 1313. For illustrative purposes, the pinch point 111a is marked with a circle at the middle level of the collector 1313.

The pinch points 1111a may be formed or introduced along the length of the overflow channel 1104 in various ways and shapes. In the following, exemplary embodiments having different pinch points or shapes are disclosed to better illustrate certain features. It should be noted, however, that these example embodiments should not be construed as limiting the scope of the claimed subject matter to any particular configuration or shape.

Referring to fig. 11C, in an exemplary embodiment, constriction point 1111a may be formed by a ridge, raised edge, protrusion, or protrusion (hereinafter "protrusion") extending from the top or bottom or sidewall (or any or all of these) surfaces of overflow channel 1104 (i.e., the vanes of collector 1313). The shape of the protrusion may be defined as a bump, a finger, a cusp, a fin, an edge or any other shape that constrains the cross-sectional area transverse to the direction of flow in the overflow channel. In the illustration of fig. 11C, a cross-sectional side view of a protrusion, for example, resembling a shark fin shape is shown, wherein the distal end of the protrusion narrows towards the edge.

As shown in fig. 11C, the sharp or cantilevered edge of the shark fin shape may be rounded. However, in other embodiments, the cantilever edge may be narrowed to a tip. The sharpness, size, relative position, and frequency of placement of the protrusions in the overflow channel 1104 may be controlled to further fine tune the tendency of the meniscus of separated liquid and air to form within the overflow channel 1104.

For example, as shown in fig. 11C, the protrusion may have a rounded face on one side and a flat face on the opposite side. The rounded faces of the protrusions may face (i.e., point) the outward flow of the vaporizable material 1302 (i.e., the flow exiting the collector 1313 and entering the storage chamber 1342), while the flat faces of the protrusions may face the inward flow of the vaporizable material 1302 through the gate 1102 (i.e., the flow entering the collector 1313 and exiting the storage chamber 1342).

As described above, in various embodiments, the formation of protrusions along overflow channel 1104 may be controlled in number, size, shape, location, and frequency in order to fine tune the hydraulic/hydraulic flow rate of the flow of vaporizable material 1302 into and out of collector 1313. For example, if it is desired to instead maintain the rate of the incoming flow in the overflow channel 1104 higher than the rate of the outgoing flow, the protrusion can be shaped with a flat face facing the outgoing flow and a rounded face facing the incoming flow, so as to form and maintain a meniscus that resists the outward flow of liquid (e.g., away from the reservoir 1340), while making it easier for the meniscus to break free of the side of the protrusion that faces back toward the reservoir 1340. In this way, the series of such projections can act as a "hydraulic ratchet" system in which the back flow of liquid into the reservoir is promoted by microfluidic means with respect to the flow outwards from the reservoir. This effect may be achieved, at least in part, by the relative tendency of the meniscus to rupture from the reservoir side of the protrusion than from the opposite side.

Referring again to FIG. 11C, in an exemplary embodiment, some protrusions can extend from the inner walls of isopipe 1104 in addition to (or instead of) protrusions extending from the bottom or top of isopipe 1104. As shown more clearly in FIG. 11F, the protrusions can extend from the inner wall of isopipe 1104 at the same constriction point 1111a, with two additional protrusions extending from the bottom and top of isopipe 1104, forming a C-shaped constriction point 1111 a. The exemplary embodiment shown in fig. 11D and 11F may more effectively adjust the microfluidic characteristics of the overflow channel 1104 to facilitate retraction of the liquid flow toward the reservoir 1340 relative to the embodiment shown in fig. 11C, as the hydraulic diameter of the overflow channel 1104 is more constricted (i.e., narrowed) at the constriction point 1111a shown in fig. 11D and 11F.

The projections formed along the overflow channel 1104 need not be uniform in shape, size, frequency, or symmetry. That is, depending on the implementation,

different constriction points

1111a or 1111b may be implemented at different sizes, designs, shapes, locations, or frequencies along the overflow channel 1104. In one example, the shape of the

pinch point

1111a or 1111b may resemble the shape of a letter C having a circular inner diameter. In some embodiments, instead of forming the inner diameter as a rounded C-shape, the inner wall of the pinch point may have corners (e.g., sharp corners), such as those shown in fig. 11F and 11G.

In some examples, overflow channel 1104 may have a protrusion extending from the top of overflow channel 1104 at a first elevation, and a protrusion extending from the bottom of overflow channel 1104 at a second elevation. At the third height, for example, a protrusion may extend from the inner wall. Alternatives to the above embodiments are possible by adjusting or changing the number of projections and the shape of the projections or the positioning of the projections in different orders or heights to help control the effect of microfluidic flow in both directions within overflow channel 1104. In one example, pinch points 1111a may be implemented on one or more (or all) of the height, side, or width of collector 1313, for example.

Referring to fig. 11E and 11G, in addition to defining pinch points 1111a along the longer length of overflow channel 1104 or the wider side of collector 1313, one or more additional pinch points 1111b may be defined along the narrower side of collector 1313. As such, the exemplary embodiment shown in fig. 11E and 11G may improve the regulation of resistance in overflow channel 1104 or facilitate meniscus separation in a desired direction as compared to the embodiment in fig. 11D, since the overall hydraulic diameter (or flow) of overflow channel 1104 is more constricted due to the addition of additional constriction point 1111 b.

Referring to fig. 11F and 11G, for greater clarity, each full height in the example shown may include three pinch points 1111a on each side, e.g., in addition to two or more pinch points 1111 b. Thus, the collector 1313 of fig. 11D may include a total of 18 pinch points, while the collector 1313 of fig. 11E may include a total of 26 pinch points. In this example, the embodiment shown in fig. 11E provides improved microfluidic flow control (e.g., in an outward direction) due to the enhanced capillary pressure at the

multiple pinch points

1111a and 1111 b.

Referring to fig. 11H, in some embodiments, gate 1102 can be configured to include an aperture or opening configuration, similar to

pinch points

1111a or 1111b, with a narrowed edge, rim, or flange that is flatter in one direction. For example, the edges of the gate 1102 aperture may be shaped to be flat on one side (e.g., the side facing the reservoir 1342) and rounded on the other side (e.g., the side facing away from the reservoir 1342). In this configuration, since meniscus separation on the less rounded side is easier relative to the more rounded side, microfluidic forces that promote backflow toward reservoir 1340 over flow away from reservoir 1340 can be enhanced.

Accordingly, depending on the implementation and variations of the constriction point and the structure or configuration of the gate 1102, the resistance to flow of the vaporizable material 1302 out of the collector 1313 can be higher than the resistance to flow of the vaporizable material 1302 into the collector 1313 and to the storage chamber 1340. In certain embodiments, the gate 1102 is configured to maintain a liquid seal such that a layer of vaporizable material 1302 is present at the medium where the storage chamber 1342 communicates with the overflow channel 1104 in the overflow volume 1344. The presence of a liquid seal can help maintain a pressure balance between storage chamber 1342 and overflow volume 1344 to promote a sufficient level of vacuum (e.g., a partial vacuum) in storage chamber 1342 to prevent evaporative material 1302 from completely draining into overflow volume 1344 and to avoid wicking element 1362 losing sufficient saturation.

In one or more exemplary embodiments, a single through-flow or channel in the collector 1313 may be connected to the storage chamber 1342 through two vents, such that the two vents maintain a liquid seal regardless of the positioning of the cartridge 1320. The formation of a liquid seal at the gate 1102 may help prevent air in the collector 1313 from entering the storage chamber 1342 even when the cartridge 1320 is held diagonally relative to horizontal or the cartridge 1320 is positioned with the mouthpiece facing down. This is because if air bubbles from the accumulator 1313 enter the reservoir, the pressure within the storage chamber 1342 will equalize with the ambient pressure. That is, if ambient air flows into storage chamber 1342, a partial vacuum within storage chamber 1342 (e.g., due to evaporative material 1302 being expelled through wick supply 1368) will be counteracted.

Referring to fig. 11I-11K, perspective views of an alternative shutter 1102 configuration for the collector 1313 structure are provided. These alternative configurations may provide advantages with respect to flow management and control of the air and/or liquid vaporizable material 1302. In some cases, when an empty space in storage chamber 1342 (i.e., a headspace above vaporizable material 1302) contacts shutter 1102, a headspace vacuum may not be maintained. As a result, the hydraulic seal established at gate 1102 may be broken, as previously described. This effect may be due to the inability of the gate 1102 to maintain a fluid film as the collector 1313 is evacuated and the headspace is in contact with the gate 1102, resulting in a loss of partial headspace vacuum.

In certain embodiments, the headspace in the reservoir chamber 1342 may have ambient pressure, and if there is a hydrostatic offset (hydrostatic offset) between the gate 1102 and the nebulizer in the cartridge 1320, the contents of the reservoir chamber 1342 drain into the nebulizer, causing the wick cartridge to submerge and leak. To avoid leakage, one or more embodiments may be implemented to remove the hydrostatic offset between the shutter 1102 and the nebulizer and maintain the function of the shutter 1102 when the storage chamber 1342 is nearly empty.

As shown in the exemplary embodiments of fig. 11I and 11J, a miniaturized dividing wall or labyrinth 1190 may be constructed around gate 1102 to establish a high drive connection between gate 1102 and overflow channel 1104 in collector 1313 to maintain a liquid seal at gate 1102. In the example of fig. 11J, a gutter structure 1190 is shown to further improve the means of maintaining a fluid seal at gate 1102, in accordance with one or more embodiments.

Controlled flow gate embodiments

Fig. 11L-11N illustrate plan and close-up views of a controlled fluid gate 1102 in a collector 1313 configuration, according to one or more embodiments. As shown, the passage or overflow channel 1104 in the collector 1313 may be connected to the reservoir 1342 by, for example, a V-shaped or flared controlled flow gate 1102, such that the V-shaped gate 1102 includes at least two (and desirably three) openings that connect to the reservoir 1342. As provided in further detail herein, a liquid seal may be maintained at the gate 1102 regardless of the vertical or horizontal orientation of the cartridge 1320.

As shown in fig. 11L, on a first side of the vent, a vent path may be maintained between the overflow channel 1104 and the gate 1102 through which bubbles may escape from the overflow channel 1104 in the collector into the reservoir. On the second side, one or more high drive channels connected to the receptacle may be implemented to facilitate polycondensation at the polycondensation point 1122, thereby maintaining a liquid seal that prevents air bubbles from prematurely exiting the overflow channel 1104 and entering the receptacle, as well as preventing air or vaporizable material 1302 from undesirably entering the overflow channel 1104 from the receptacle.

According to an embodiment, the high drive channel, shown by way of example on the right side of fig. 11L, preferably remains sealed due to capillary pressure exerted by the liquid vaporizable material 1302 in the cartridge reservoir. The low-drive channel formed on the opposite side (i.e., shown on the left in fig. 11L) may be configured to have a relatively lower capillary drive than the high-drive channel, but still have sufficient capillary drive such that, in the first pressure state, a liquid seal is maintained in both the high-drive channel and the low-drive channel.

Accordingly, in the first pressure state (e.g., when the pressure inside the reservoir is approximately equal to or greater than ambient air pressure), a liquid seal is maintained in both the low and high drive channels, thereby preventing any air bubbles from flowing into the reservoir. Conversely, in a second pressure state (e.g., when the pressure inside the reservoir is less than ambient air pressure), air bubbles formed in the overflow channel 1104 (e.g., by entering through the air exchange port 1106), or more generally the front meniscus edge of the liquid vaporizable material-air interface, can travel up and toward the controlled flow gate 1102. When the meniscus reaches the condensation point 1122 between the low drive channel and the high drive channel of the vent 1104, air is preferentially directed through the low drive channel or channels due to the higher capillary resistance in the high drive channel.

Once the air bubbles have passed through the low drive channel portion of the gate 1102, the air bubbles enter the reservoir and equalize the pressure inside the reservoir with the pressure of the ambient air. Thus, the air exchange port 1106 in conjunction with the controlled flow gate 1102 allows ambient air entering through the overflow passage 1104 to enter the reservoir until an equilibrium pressure condition is established between the reservoir and the ambient air. As previously described, this process may be referred to as reservoir venting. Once the equilibrium pressure state is established (e.g., transitioning from the second pressure state back to the first pressure state), a liquid seal is again established at the condensation point 1122 due to the presence of liquid in both the high and low drive channels fed by the liquid vaporizable material 1302 stored in the reservoir.

Fig. 11O-11X show snapshots when the airflow collected in the example collector 1313 of fig. 11L-11N is managed to accommodate proper drainage as the meniscus of the vaporizable material 1302 continues to recede.

Fig. 11O shows a receding meniscus where the strength of the partial headspace vacuum increases as the vaporizable material 1302 is removed from the reservoir into the wicking portion. This is sufficient to overcome the receding capillary drive of the meniscus, causing the meniscus to move back through the collector towards the constriction point where the meniscus will see the highest pressure differential as dictated by the geometry.

Fig. 11P shows how the meniscus passes over a first junction in gate 1102 as the meniscus approaches gate 1102. At this first juncture, the headspace partial vacuum is maximized because it corresponds to the smallest geometry in the gate 1102 configuration, and the partial vacuum in the reservoir continues to grow until that point.

FIG. 11Q shows how multiple menisci recede when the headspace reaches a maximum partial vacuum. The meniscus is at a tight bend across its major plane and at these locations the exhaust pressure of the three channels is equal and the three menisci recede simultaneously as opposed to from only one channel. Since the curvature of these menisci increases as they recede, the pressure differential experienced across the menisci decreases and the partial vacuum of the headspace begins to decrease.

Fig. 11R shows how the secondary meniscus begins to fill the capillary channel. These channel geometry constrictions are such that as the meniscus continues to recede, the capillary drive of the primary channel decreases at a greater rate than the capillary drive of the secondary channel. This gradual reduction in capillary drive will reduce the partial headspace vacuum that is maintained. When the discharge pressure of the primary meniscus drops below the discharge pressure of the secondary channel, the meniscus will continue to discharge while the other meniscus remains stationary. The discharge pressure, which relates to the receding contact angle of the primary channels, may drop below the relief pressure, which relates to the advancing contact angle of the secondary channels, causing them to be refilled as shown in the figure.

Fig. 11S shows how the secondary meniscus from one of the two menisci in each secondary channel reaches the tangent point where the two menisci merge into one meniscus. Such a combined meniscus will have an increased curvature and thus a lower capillary drive. The higher actuation of the main meniscus may cause the system to react instantaneously by making the main meniscus an advancing meniscus. Then, with the secondary meniscus held at this position, a back-off of the first meniscus will likely occur.

Fig. 11T shows how the secondary meniscus moves towards the collector. With the reservoir filled with liquid, the main meniscus will continue to recede, further reducing the partial vacuum of the headspace as its curvature increases. When the partial vacuum drops below the advancing capillary pressure of the secondary meniscus, the secondary meniscus will begin to advance again, driving to close the gap. In the case where the reservoir is empty or nearly empty, the liquid seal at the gate 1102 will stabilize until the bubble collapses, connecting the headspace to the surrounding environment.

Fig. 11U shows how the secondary meniscus closes the junction at gate 1102. Since the secondary meniscus will advance until it encounters the apex of a corner in the primary channel, the geometry is designed to cause the secondary meniscus to separate to fill both the gate 1102 and collector 1313 channels. These two newly formed menisci can be used to isolate the headspace from ambient air, and thus the headspace partial vacuum can be re-established, thereby ensuring that leakage through the liquid supply channel is mitigated. Since the newly formed meniscus has less curvature than before the break-up, the newly formed meniscus will continue into the channel due to the increased capillary drive.

Fig. 11V to 11X illustrate release of bubbles into the storage chamber 1342. At this point the pressure within the cartridge 1320 reaches stability as bubbles trapped in the main meniscus channel are expelled due to the imbalance created by the advancing and receding menisci. Thus, vaporizable material 1302 is allowed to enter and displace the bubbles through the right top channel. Accordingly, while a high drive channel structure may be provided via a closed channel near the gate 1102, a shorter channel may alternatively be used to reduce the risk of bubbles being trapped.

In some embodiments, narrowing the channel may be designed to increase the drive toward the controlled vent. To allow for polycondensation of two advancing menisci, the vessel walls and channel bottom of the vessel may be configured to continue to provide actuation while the sidewalls provide polycondensation sites for the menisci. In one configuration, the net drive of the advancing meniscus does not exceed the net drive of the receding meniscus, thereby keeping the system statically stable.

Multiple gate multiple channel collector embodiments

Referring to fig. 12A and 12B, an exemplary perspective side view and an exemplary plan side view of an embodiment of a single vent multi-channel collector 1200 structure are shown. As shown in fig. 12A, the collector 1200 is formed with a single shutter 1202 and a plurality of passages 1204(a) to 1204 (j). As shown in fig. 12A, according to one or more embodiments, a gate 1202 can be positioned, for example, at a center or midpoint of the longitudinal width of the collector 1313, to allow the vaporizable material 1302 to enter at least a first channel 1204(a) of the collector 1313 and to gradually expand to and through additional channels 1204(b) through 1204 (j).

Depending on the embodiment, the position of the gate 1202 may be modified to be located at a middle, side, or corner, or any other location along the length or width of the collector 1313. The single-vent multi-channel collector 1200 structure may have the additional advantage of allowing the vaporizable material 1302 to enter through the single gate 1202 at a first flow rate and diffuse through the multiple channels 1204(a) through 1204(j) of the collector 1200 at a second flow rate (e.g., a faster rate than the first flow rate).

Advantageously, the single gate multi-channel collector 1200 structure allows for controlled flow (e.g., restricted flow) of the vaporizable material 1302 from the storage chamber 1342 into the overflow volume 1344 (see fig. 3A), and further allows for less controlled (e.g., less restricted) flow once the vaporizable material 1302 is in the overflow volume 1344. In certain embodiments, a multi-layer, multi-channel structure may be implemented such that, for example, as shown in fig. 12B, the flow of vaporizable material 1302 in a first set of channels 1204(a) through 1204(f) is at a second rate, while the flow of vaporizable material 1302 in a second set of channels 1204(g) through 1204(k) is at a third rate. The third rate may be faster or slower than the second rate.

Accordingly, in the exemplary embodiment shown in fig. 12B, vaporizable material 1302 can flow through gate 1202 at a first rate, through channels 1204(a) through 1204(f) at a second rate, and through channels 1204(g) through 1204(k) at a third rate. In one or more embodiments, the second rate may be faster than both the first rate and the third rate, e.g., such that the vaporizable material 1302 can have a restricted flow through the gate 1202, a less restricted flow through the first set of channels (e.g., layer 1), and a relatively more restricted flow in the second set of channels (e.g., layer 2). Such a multi-layer construction can help increase the flow rate through the collector 1200, but once the vaporizable material 1302 enters the collector 1200, a controlled restriction to the rapid flow of the vaporizable material 1302 toward the wicking element 1362 is maintained.

In the bi-layer embodiment shown in fig. 12B, the first set of channels 1204(a) to 1204(f) (e.g., layer 1) can have a reversible configuration such that the vaporizable material 1302 collected in the first set of channels can flow back into the reservoir 1340. In contrast, the second set of channels 1204(g) -1204 (k) (e.g., layer 2) may not have a reversible construction. In such embodiments, as the second set of channels is proximate to the wicking element 1362, the vaporizable material 1302 is primarily drawn from the second set of channels and then from the first set of channels (e.g., layer 1, which acts as a retention compartment). As noted above, having reversible and irreversible configurations can help provide additional improvements over other embodiments described herein.

In some multi-layer embodiments, by configuring the second set of channels 1204(g) to 1204(k) to be irreversible, it may be additionally ensured that the wicking element 1362 will not be starved because the vaporizable material 1302 may be available proximate to the wicking element 1362 when stored in the second set of channels 1204(g) to 1204(k) during an overflow event. Furthermore, in a multi-layer embodiment, the opportunity for strong flow of vaporizable material 1302 into the wick housing during a negative pressure event may be prevented because, as previously described, the second set of channels 1204(g) to 1204(k) may be configured to have a more restricted flow than the first set of channels 1204(a) to 1204 (f). Furthermore, due to reversibility, the first set of channels 1204(a) to 1204(f) may not contain a relatively large volume of vaporizable material 1302. In some embodiments, to increase or limit the reversibility or flow of the vaporizable material 1302 in the first set of channels 1204(a) to 1204(f) or the second set of channels 1204(g) to 1204(k), an absorbent material (e.g., sponge) can be introduced into one or both channel regions.

Referring to fig. 13, an exemplary perspective side view of a multi-vent multi-channel collector 1300 structure is shown in accordance with one or more embodiments. As shown, the collector 1300 may be positioned inside the cartridge such that the collector 1300 has dual vents 1301. This embodiment may allow the vaporizable material 1302 to flow into the channel 1204 at a relatively fast rate, particularly as compared to the single vent collector 1200 shown in fig. 21A and 12B.

Wicking feed embodiment

Referring back to fig. 10C, 10D, 11B, in certain variations, the collector 1313 may be configured to be insertably received by a receiving end of the storage chamber 1342. The end of the collector 1313 opposite the end received by the storage chamber 1342 can be configured to receive the wicking element 1362. For example, fork-shaped projections can be formed to securely receive the wicking element 1362. The wicking housing 1315 may be used to further secure the wicking element 1362 in a fixed position between the projections. Such a configuration may also help prevent the wicking element 1362 from significantly expanding and weakening due to over-saturation. With reference to fig. 11C, 11D, and 11E, according to embodiments, one or more additional conduits, channels, tubes, or lumens traveling through the collector 1313 may be constructed or configured to feed the wicking element 1362 with a path of the vaporizable material 1302 stored in the storage chamber 1342. In certain configurations, such as those discussed in further detail herein, the wick supply conduit, tube, or lumen (i.e., wick supply 1368) may extend generally parallel to central channel 1100. In at least one configuration, there can be a plurality of wick feeds extending diagonally along the length of collector 1313, for example, either independently or in relation to a wick exchange comprising one or more other wick feeds.

In certain embodiments, multiple wick supplies may be interactively connected in a multi-linked configuration such that interchanging of supply paths that may cross each other may lead to a wick housing region. Such a configuration may help prevent complete blockage of the wick feed mechanism in the event that one or more feed paths in the wick feed interchange are obstructed, for example, via the formation of air bubbles or other types of blockages. Advantageously, the multiple feed path approach may allow vaporizable material 1302 to safely travel through one or more paths (or cross to a different but open path) toward the wick housing region even if some or some of the paths in the wick feed interchange are completely or partially blocked or obstructed.

According to embodiments, the wick supply path may be shaped as a tube, having a cross-shaped diameter shape, e.g., circular or multi-faceted. For example, the hollow cross-section of the wick supply may be triangular, rectangular, pentagonal, or in any other suitable geometry. In one or more embodiments, the cross-sectional perimeter of the wick supply may be a hollow cross shape, e.g., such that the arms of the cross have a narrower width related to the diameter of the central intersection of the cross from which the arms extend. More generally, the wick supply channel (also referred to herein as the "first channel") can be a cross-sectional shape having at least one irregularity (e.g., protrusion, side channel, etc.) that provides an alternative flow path for the liquid vaporizable material in the event that an air bubble blocks the remainder of the cross-sectional area of the wick supply. The cruciform cross-section of the present example is one example of such a structure, but those skilled in the art will appreciate that other shapes consistent with the present disclosure are also contemplated and are possible.

The cross-shaped conduit or tube embodiment formed by the wick feed path may overcome the clogging problem, as the cross-shaped tube may be considered to include essentially five separate paths (e.g., a central path formed at the hollow center of the cross and four additional paths formed in the hollow arms of the cross). In such an embodiment, a blockage in the supply tube via the air bubbles would, for example, be likely to form at a central portion of the cross-shaped tube, leaving the sub-paths (i.e., the paths through the arms of the cross-shaped tube) open to convection.

In accordance with one or more aspects, the wick supply channel can be wide enough to allow the vaporizable material 1302 to travel freely through the supply channel and toward the wick. In some embodiments, flow through the wick feed may be enhanced or regulated by designing the relative diameters of certain portions of the wick feed to enhance the capillary traction or pressure on the vaporizable material 1302 traveling through the wick feed path. In other words, depending on shape and other structural or material factors, some wick supply paths may rely on gravity or capillary forces to cause movement of the vaporizable material 1302 toward the wick housing portion.

In embodiments of a cross-shaped tube, for example, the supply path through the arms of the cross-shaped tube may be configured to supply the wicking portion via capillary pressure rather than relying on gravity. In such an embodiment, the central portion of the cross-shaped tube may be gravity fed to the wicking portion, for example, while the flow of vaporizable material 1302 in the arms of the cross-shaped tube may be supported by capillary pressure. It is noted that the cross-shaped tubes disclosed herein are for the purpose of providing exemplary embodiments. The concepts and functions implemented in this example embodiment can be extended to wick supply paths having different cross-sectional shapes (e.g., a tube with a hollow star-shaped cross-section having two or more arms extending from a central channel extending along the wick supply path).

Referring to fig. 11C, a configuration of an example collector 1313 is illustrated in which two wick feeds 1368 are positioned on opposite sides of the central channel 1100 so that the vaporizable material 1302 can enter the feeds and flow directly to the cavity area at the other end of the collector 1313 where the housing for the wicks is formed.

The wick feed mechanism can be formed through the collector 1313 such that at least one wick feed path in the collector 1313 can be shaped as a faceted cross-diameter hollow tube. For example, the hollow cross-section of the wick supply may be in the shape of a plus sign (e.g., a hollow cross-shaped wick supply if viewed from a top cross-sectional view) such that the arms of the cross have a narrower width relative to the diameter of the central intersection of the cross from which they extend.

A conduit or tube having a cruciform diameter formed through the capillary feed path may overcome the clogging problem because a tube having a cruciform diameter may be considered to include five separate paths (e.g., a central path formed at the hollow center of the cross and four additional paths formed in the hollow arms of the cross). In such an embodiment, blockage in the supply tube due to air bubbles (e.g., air bubbles) would likely form at the central portion of the cross-shaped tube.

This central positioning of the bubble will eventually leave the sub-path (i.e., the path through the arms of the cross-shaped tube) open to the flow of vaporizable material 1302 even when the central path is obstructed by the bubble. Other embodiments are possible for the wick supply channel structure that achieve the same or similar objectives as disclosed above with respect to trapping air bubbles or avoiding complete clogging of the wick supply channel with trapped air bubbles.

Adding more vents in the structure of the collector 1300 may allow for faster flow rates (depending on the implementation) because a relatively larger collective volume of vaporizable material 1302 may be displaced when additional vents are available. Accordingly, embodiments having more than two vents (e.g., a three-vent embodiment, a four-vent embodiment, etc.) are within the scope of the disclosed subject matter, even if not explicitly shown.

Referring to fig. 14A and 14B, certain embodiments may include a collector 1400 structure with dual feeds for the wicking portion. In such embodiments, the wicking portion may have a higher degree of saturation and less chance of starvation than embodiments in which a single supply portion is provided.

Referring to fig. 15A, 15B, and 15C, perspective and plan cross-sectional side views of an example collector structure for dual-feed wicking 1562 are provided. As shown, the wick 1562 may be provided or housed in the cartridge 1500 so as to provide at least two

separate wick

1566 and 1568 allowing the vaporizable material 1302 to travel towards the area of the cartridge 1500 that houses the wick 1562.

As previously described, a dual wick supply may have the advantage of providing, for example, double the flow of vaporizable material 1302 to wick 1562 as compared to the single wick supply alternative. Advantageously, the dual wick supply embodiment provides sufficient supply to wick 1562 and helps prevent wick 1562 from drying out in the event, for example, one of the wick supplies becomes clogged. As shown, a lower portion of the wick 1562 may extend down into an area of the cartridge 1500 that forms a heating chamber or atomizer.

Referring to fig. 16A, a flat-section side view of an example cartridge is provided with a dual trumpet or dual feed wicking portion 1562 located within the collector structure. Fig. 16B is a flat sectional side view of an example collector structure in which wicking portion 1562 may be housed. Fig. 16C provides an example perspective view of a cartridge according to one or more embodiments. As shown, the first end of wick 1562 may have two or more feeds, horns, or flanged ends for at least partially engaging two or more wick openings in divider 1513, such that at least one of the flanged ends engages, e.g., tangentially, the volume in storage chamber 1542 or extends, e.g., at least partially, into the volume in storage chamber 1542.

According to one or more embodiments, the cartridge 1500 may include a reservoir having a storage chamber 1542 for storing the vaporizable material 1302. An auxiliary volume 1510 that is separable from the storage chamber 1542 may also be formed within the cartridge 1500. Auxiliary volume 1510 may be in communication with storage chamber 1542 via one or more wick feeds 1590. Auxiliary volume 1510 may be configured to house at least wicking portion 1562. Wick 1562 may be configured to absorb vaporizable material 1302 traveling through wick feed 1590 such that in thermal interaction with the nebulizer vaporizable material 1302 is absorbed in wick 1562 and converted into at least one of a vapor or an aerosol. The wicking portion 1562 may be defined at least in part by one or more heating elements of the atomizer located within the secondary volume 1510. A partition 1513 may be provided for at least partially separating the storage chamber 1542 from the auxiliary volume 1510 so that flow of the vaporizable material 1302 through the wick feed 1590 is controllable. At least a first portion of wick supply 1590 may be formed by at least one or more openings in partition 1513.

At least a second portion of wick supply 1590 may include vaporizable material channels connecting one or more openings in partition 1513 to auxiliary volume 1510. An air flow channel 1538 may be provided for connecting the auxiliary volume 1510 to the mouthpiece, such that vaporizable material 1302 that has been converted to a vapor travels away from the auxiliary volume 1510 toward the mouthpiece through the air flow channel 1538.

With reference to fig. 16A, 16B, 16C, 17A, and 17B, a perspective view of a first side of a cartridge and a cross-sectional view of a second side of the cartridge are provided, the cartridge having a wicking portion 1562 protruding into a storage chamber 1542. Wick 1562 may include at least a first end 1592 and a second end 1594, with the first end 1592 being proximate to divider 1513 and the second end extending distally in a direction opposite from first end 1592.

A first end 1592 of wick 1562 may protrude at least partially through the wick opening in partition 1530 to extend at least partially into the volume in storage chamber 1542. In one aspect, the first end 1592 of wick 1562 can protrude at least partially through the wick opening in partition 1530 to at least tangentially engage the volume in storage chamber 1542.

Fig. 26A illustrates a perspective view, a front view, a side view, a bottom view, and a top view of an example embodiment of a collector 1313 with a V-shaped gate 1102. As shown in fig. 25 and 26, the collector 1313 may be fitted with additional components (e.g., wicking element 1362, heating element 1350, and wicking housing 1315) within a cavity in the cartridge 1320. The wicking element 1362 may be located between the second end of the collector 1313 and the heating element 1350 surrounding the wicking element 1362. During assembly, the collector 1313, wicking element 1362, and heating element 1350 may be assembled together and covered by the wick housing 1315 prior to insertion into the cavity within the cartridge 1320. The wick housing 1315 may be inserted into the end of the cartridge 1320 opposite the mouthpiece, along with the other mentioned components, to hold the components inside in a pressure-tight or press-fit manner. The sealing or fit of the wick housing 1315 and collector 1313 within the inner wall of the receiving sleeve of the cartridge 1320 is desirably tight enough to prevent leakage of the vaporizable material 1302 held in the reservoir of the cartridge 1320. In some embodiments, the pressure seal between the wicking housing 1315 and collector 1313 and the inner wall of the receiving sleeve of the cartridge 1320 is also sufficiently tight to prevent manual disassembly of the components by the user's hand.

Referring to fig. 10C, 10D, 11B, 26B, and 26C, in certain variations, the collector 1313 may be configured to be insertably received by a receiving end of the storage chamber 1342. As shown in fig. 26B and 26C, an end of the collector 1313 opposite the end received by the storage chamber 1342 can be configured to receive the wicking element 1362. For example, the fork-shaped projections 1108 can be formed to securely receive the wicking element 1362. As shown in the cross-sectional views toward the bottom of fig. 26B and 26C, the wick housing 1315 can be used to further secure the wicking element 1362 in a fixed position between the prong projections 1108. This configuration may also help prevent the wicking element 1362 from significantly expanding and weakening due to over-saturation.

Referring to fig. 26B, in one embodiment, the wicking element 1362 may be restrained or compressed via the compression ribs 1110 at certain locations along its length (e.g., toward the longitudinal distal end of the wicking element 1362 positioned directly below the wick supply 1368) to help prevent leakage by, for example, maintaining a larger saturated area of the vaporizable material 1302 toward the ends of the wicking element 1362, such that a central portion of the wicking element 1362 remains drier and less prone to leakage. In addition, the use of compression ribs 1110 can further press the wicking element 1362 into the atomizer housing to prevent leakage into the atomizer.

Referring to fig. 26D-26F, top plan views of an example wicking feed mechanism formed or configured by collector 1313 through collector 1313 are illustrated, according to one or more embodiments. As shown in fig. 26D, at least one wicking feed 1368 path in collector 1313 may be shaped as a faceted cross-shaped diameter hollow tube. For example, the hollow cross-section of the wick supply 1368 pathway may be in the shape of a plus sign (e.g., a hollow cross-shaped wick supply if viewed in top cross-section) such that the arms of the cross have a narrower width relative to the diameter of the central intersection of the cross from which they extend.

Referring to fig. 26E, a catheter or tube having a cross-shaped diameter formed through the wicking portion supply 1368 pathway may overcome the clogging problem, indicating that because the tube having a cross-shaped diameter may be considered to include five separate pathways (e.g., a central pathway formed at the hollow center of the cross and four additional pathways formed in the hollow arms of the cross). In such an embodiment, a blockage in the supply tube via a bubble (e.g., air bubble) would likely form at the central portion of the cruciform tube, as shown in fig. 26E. This central positioning of the bubble will eventually keep the sub-paths (i.e., the paths through the arms of the cross-shaped tube) open to the flow of vaporizable material 1302 even when the central path is blocked by the bubble.

Referring to fig. 26F, other embodiments are possible for the wicking section supply 1368 pathway structure that achieve the same or similar objectives as disclosed above with respect to trapping bubbles or avoiding trapped bubbles from completely blocking the wicking section supply 1368 pathway. As shown in the example illustration of fig. 26F, one or more drop-like protrusions 1368a/1368b (e.g., shaped like one or more separate joints between which the wick feed 1368 pathway is located) can be formed at the end of the wick feed 1368 pathway through which the vaporizable material 1302 flows from the storage chamber 1342 into the collector 1313 to help direct the vaporizable material 1302 through the wick feed 1368 pathway with air bubbles trapped in a central region of the wick feed 1368 pathway. In this way, a reasonably controlled and consistent flow of vaporizable material 1302 can flow to the wicking portion, preventing situations where the wicking portion is not sufficiently saturated with vaporizable material 1302.

Heating element embodiments

Referring to fig. 18A-18D, the evaporator magazine 1800 can also include heating elements 1850 (e.g., flat heating elements), as described above. The heating element 1850 includes a first portion 1850A positioned substantially parallel to the air flow passage 1838 and a second portion 1850B positioned substantially perpendicular to the air flow passage 1838. As shown, a first portion 1850A of heating element 1850 may be positioned between opposing portions of collector 1813. When heating element 1850 is activated, heat is generated, for example, due to current flowing through heating element 1850, thereby causing an increase in temperature.

Heat may be transferred to the quantity of vaporizable material 1302 by conductive, convective, and/or radiative heat transfer such that at least a portion of vaporizable material 1302 is vaporized. Heat transfer can occur to vaporizable material 1302 in the reservoir, to vaporizable material 1302 being drawn from collector 1813, and/or to vaporizable material 1302 being drawn into a wicking portion held by heating element 1850. Air passing into the vaporizer apparatus flows along an air path across heating element 1850, peeling vaporized vaporizable material 1302 from heating element 1850 and/or the wicking portion. The vaporized vaporizable material 1302 can condense as a result of cooling, pressure changes, etc., such that it exits the mouthpiece 1830 through at least one of the airflow channels 1838 as an aerosol for inhalation by a user. Referring to fig. 19A-19C, evaporator magazine 1900 can include a folding heating element 1950 and two air flow channels 1938. As described above, heating element 1950 may be crimped or pre-formed around wick 1962 to receive wick 1962. Heating element 1950 may include one or more rake wings 1950A. The rake wings 1950A can be located in the heating portion of the heating element 1950 and designed such that the resistance of the rake wings 1950A matches an amount of resistance to affect localized heating in the heating element 1950, thereby more efficiently and effectively heating the vaporizable material 1302 from the wicking portion 1962.

The rake wings 1950A form fine path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular geometry of rake 1950A may be selected as desired to create a particular localized resistance for heating element 1950. For example, rake wings 1950A may include one or more of the various rake wing configuration configurations and features described and discussed in more detail below.

When heating element 1950 is activated, heat is generated due to the flow of current through heating element 1950, thereby causing an increase in temperature. Heat is transferred to the quantity of vaporizable material 1302 by conductive, convective, and/or radiative heat transfer such that at least a portion of vaporizable material 1302 is vaporized. Heat transfer may occur to vaporizable material 1302 in a reservoir, to vaporizable material 1302 drawn from collector 1913, and/or to vaporizable material 1302 drawn into wicks 1962 held by heating elements 1950. In some embodiments, the vaporizable material 1302 can vaporize along one or more edges of the rake wing 1950A.

Air passing into the vaporizer apparatus flows along an air path across heating element 1950, peeling vaporized vaporizable material 1302 from heating element 1950 and/or wicking portion 1962. The vaporized vaporizable material 1302 can condense as a result of cooling, pressure changes, etc., such that it exits the mouthpiece through at least one of the airflow channels 1938 as an aerosol for inhalation by a user. Referring to fig. 20A-20C, the evaporator cartridge 2000 can include a folded heating element 2050 and a single (e.g., central) airflow channel 2038. As described above, heating element 2050 may be crimped or pre-shaped around wicking portion 2062 to receive wicking portion 2062. Heating element 2050 may include one or more rake wings 2050A. The fins 2050A may be located in the heating portion of the heating element 2050 and designed such that the resistance of the fins 2050A is matched to an appropriate amount of resistance to affect localized heating in the heating element 2050 to more efficiently and effectively heat the vaporizable material from the wicking portion 2062.

The rake wings 2050A form fine path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular geometry of the rake wings 2050A may be selected as desired to create a particular localized resistance for heating the heating elements 2050. For example, rake wings 2050A may comprise one or more of a variety of rake wing configuration configurations described in more detail below.

When the heating element 2050 is activated, heat is generated due to the flow of current through the heating element 2050, thereby causing an increase in temperature. Heat is transferred to the quantity of vaporizable material 1302 by conductive, convective, and/or radiative heat transfer such that at least a portion of vaporizable material 1302 is vaporized. Heat transfer can occur to vaporizable material 1302 in a reservoir, to vaporizable material 1302 drawn from collector 2013, and/or to vaporizable material 1302 drawn into a wicking portion 2062 held by heating element 2050.

In some embodiments, the vaporizable material 1302 can be vaporized along one or more edges of the rake wing 2050A. Air passing through the evaporator apparatus flows along an air path that traverses heating element 2050, peeling vaporized vaporizable material 1302 from heating element 2050 and/or wicking portion 2062. The vaporized vaporizable material 1302 can condense as a result of cooling, pressure changes, etc., such that it exits the mouthpiece through at least one airflow channel as an aerosol for inhalation by a user.

Referring to fig. 10C, 11B, and 21A, in some embodiments, the collector 1313 can be configured to include flat ribs 2102 that extend out at a lower periphery of the collector 1313 to create a suitable surface for welding the collector 1313 to the inner wall of the storage chamber 1342 after the collector 1313 has been inserted into a receiving cavity or receptacle in the storage chamber 1342.

Depending on the implementation, a full perimeter weld or tack weld option may be employed to securely fix the collector 1313 within a receiving cavity or receptacle in the storage chamber 1342. In some embodiments, a friction-light (friction-light) and leak-proof coupling may be established without the use of welding techniques. In certain embodiments, adhesive materials may be used instead of or in addition to the above-described coupling techniques.

Referring to fig. 11B and 21B, in accordance with one or more aspects, the seal bead profile 2104 is swaged (fanhon) at the periphery of the helical ribs of the collector 1313 defining the overflow channel 1104 so that the seal bead profile 2104 can support a rapid rotational injection molding process. The geometry of the sealing bead profile 2104 can be designed in various ways so that the collector 1313 can be inserted in a tight friction manner into a receiving cavity or receptacle in the storage chamber 1342, wherein the vaporizable material 1302 can flow through the overflow channel 1104 without any leakage along the sealing bead profile 2104.

Referring to fig. 22A, 22B, and 82-86, the evaporator cartridge 2200 can include a folded heating element (e.g., heating element 500) and two airflow channels 2238. As described above, the heating element 500 may be crimped or pre-shaped around the wick 2262 to receive the wick 2262. Heating element 500 may include one or more rake wings 502. The wings 502 may be located in the heating portion of the heating element 500 and designed such that the electrical resistance of the wings 502 matches an appropriate amount of electrical resistance to affect localized heating in the heating element 500 to more efficiently and effectively heat the vaporizable material 1302 from the wicking portion 2262.

Rake wings 502 form fine path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular geometry of rake wings 502 may be selected as desired to create a particular localized resistance for heating element 500. For example, rake wings 502 and heating element 500 may include one or more of the various rake wing configuration configurations and features described in more detail below.

In some embodiments, rake wings 502 include a platform rake wing 524 and a side rake wing 526. Platform rake wings 524 are configured to contact one end of wicking 2262, and side rake wings 526 are configured to contact the opposite side of wicking 2262. Platform rake wings 524 and side rake wings 526 form pockets shaped to receive wicking 2262 and/or conform to the shape of at least a portion of wicking 2262. The bag allows the wicking 2262 to be secured and held within the bag by the heating element 500. In some embodiments, side rake wings 526 and platform rake wings 524 retain wicking 2262 via compression. Platform rake wings 524 and side rake wing portions 526 contact wicks 2262 to provide multi-dimensional contact between heating element 500 and wicks 2262. The multi-dimensional contact between the heating element 500 and the wicking portion 2262 provides for more efficient and/or faster transfer of the vaporizable material 1302 from the reservoir of the vaporizer cartridge to the heated portion (via the wicking portion 2262) to be vaporized. The heating element 500 may include one or more legs 506 extending from the rake wings 502 and a cartridge contact 124 formed at an end of the one or more legs 506 and/or as part of at least one of the one or more legs. By way of example, the heating element 500 shown in fig. 22A-22B and fig. 82-86 is four legs 506. At least one of the legs 506 may include and/or define one of the cartridge contacts 124 that is configured to contact a corresponding one of the receptacle contacts 125 of the evaporator. In some embodiments, a pair of legs 506 (and cartridge contacts 124) may contact a single one of the receptacle contacts 125.

The legs 506 may be spring loaded to allow the legs 506 to maintain contact with the receptacle contacts 125. The legs 506 may include curved portions to help maintain contact with the receptacle contacts 125. Spring loading of legs 506 and/or bending of legs 506 may help increase and/or maintain consistent pressure between legs 506 and receptacle contacts 125. In some embodiments, legs 506 are coupled with supports 176 that help increase and/or maintain consistent pressure between legs 506 and receptacle contacts 125. The support 176 may comprise plastic, rubber, or other material that helps maintain contact between the legs 506 and the receptacle contacts 125. In some embodiments, the support 176 is formed as part of the leg 506.

The legs 506 may contact one or more wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or the power source 112. For example, a wiping contact will include at least two parallel but offset bosses that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

In some embodiments, leg 506 includes retainer portion 180, retainer portion 180 being configured to be folded around at least a portion of wicking housing 178 surrounding at least a portion of wicking 2262. The retainer portion 180 forms the end of the leg 506. The retainer portion 180 helps secure the heating element 500 and wick 2262 to the wick housing 178 (and evaporator cartridge).

When the heating element 500 is activated, a temperature increase results due to the current flowing through the heating element 500 to generate heat. Heat is transferred to the quantity of vaporizable material 1302 by conductive, convective, and/or radiative heat transfer such that at least a portion of vaporizable material 1302 is vaporized. Heat transfer may occur to vaporizable material 1302 in a reservoir, to vaporizable material 1302 drawn from collector 2213, and/or to vaporizable material 1302 drawn into a wicking portion 2262 held by heating element 500.

In some embodiments, vaporizable material 1302 can be vaporized along one or more edges of rake wings 502. Air passing into the vaporizer apparatus flows along an air path across the heating element 500, peeling the vaporized vaporizable material 1302 away from the heating element 500 and/or the wicking 2262. The vaporized vaporizable material 1302 can condense as a result of cooling, pressure changes, etc., such that it exits the mouthpiece through at least one of the airflow channels 2238 as an aerosol for inhalation by the user. Fig. 23 illustrates a cross-sectional view of a wicking housing 178 consistent with embodiments of the present subject matter. The wick housing 178 may include a wick support rib 2296 extending from the housing of the wick housing 178 toward the wick 2262 when assembled. The wick support ribs 2296 help prevent the wick 2262 from deforming during assembly.

Fig. 24 illustrates an example of a wicking housing 178 including an identification chip 2295. The identification chip 2295 may be at least partially retained by the wick housing 178. The identification chip 2295 can be configured to communicate with a corresponding chip reader located on the vaporizer.

Fig. 25 illustrates perspective, front, side, and exploded views of an exemplary embodiment of a cartridge 1320 having press-fit components. As shown, the cartridge 1320 may include a mouthpiece-reservoir combination formed in a sleeve through which the airflow passage 1338 is defined. An area in cartridge 1320 houses collector 1313, wicking element 1362, heating element 1350, and wick housing 1315. The opening at the first end of the collector 1313 opens into an airflow channel 1338 in the mouthpiece and provides a route for the vaporized vaporizable material 1302 to travel from the region of the heating element 1350 to the mouthpiece from which the user inhales.

Additional and/or alternative fluid vent embodiments

Referring to fig. 27A-27B, front close-up plan views of an example flow management mechanism in a collector 1313 configuration are shown. Similar to the flow management mechanisms discussed with reference to fig. 11M and 11N, the flow

management ventilation mechanisms

2701 or 2702 may be implemented in various shapes in different embodiments. In the example of fig. 27A, the channel or overflow channel 1104 in the collector 1313 may be connected to the storage chamber via, for example, a fluid vent 2701, such that the vent 2701 comprises at least two openings connected to the storage chamber of the cartridge.

As previously described, the liquid seal may be maintained at the vent 2701 independently of the positioning of the cartridge. On one side, a vent path may be maintained between the overflow channel and the vent 2701. On the other side, a high drive channel may be implemented to promote polycondensation to maintain the liquid seal.

Fig. 27B illustrates an alternative vent 2702 structure with three openings connected to the storage chambers of the cartridge with a polycondensation path that prevents the liquid seal between the vent 2701 and the storage chambers from being broken.

Fig. 28 illustrates a snapshot in time when managing the flow of vaporizable material collected in the example collector of fig. 27A or 27B to accommodate proper ventilation in the cartridge storage chamber, according to one embodiment. As shown, the structure of the vent 2701 in fig. 27A may be distinguished from the vent 2702 in fig. 27B in the following respects: the structure of the latter vent 2702 is provided as an open area on one side, instead of the wall structure shown in fig. 27A. This more open embodiment provides for enhanced microfluidic interaction between vaporizable material 1302 and the open side of vent 2702.

Referring to fig. 29A-29C, perspective, front and side views of an example embodiment of a cartridge are illustrated. The cartridge as shown may be assembled from a number of components including a collector, a heating element and a wick housing for holding the cartridge components in place when these components are inserted into the body of the cartridge. In one embodiment, a laser weld may be achieved at a circumferential joint located approximately at the point/location where one end of the collector structure meets the wick housing. The laser weld prevents the liquid vaporizable material 1302 from flowing from the collector into the heating chamber in which the atomizer is placed.

Referring to fig. 30A-30F, perspective views of an example cartridge at different fill volumes are illustrated. As previously mentioned, the volume size of the overflow volume may be configured to be equal to, approximately equal to, or greater than the increase in volume of the contents contained in the storage chamber. When the volume of the contents in the storage chamber expands due to one or more environmental factors, if the volume of the contents contained in the storage chamber is X, then the Z amount of vaporizable material 1302 can be displaced from the storage chamber into the overflow volume when the pressure within the storage chamber increases to Y. As such, in one or more embodiments, the overflow volume is configured to be at least large enough to contain Z amount of vaporizable material 1302.

Fig. 30A illustrates a perspective view of an example cartridge body having a reservoir that, when filled, accommodates storage of a vaporizable material 1302, e.g., having a volume of about 1.20 mL. Fig. 30B illustrates a perspective view of the example cartridge in a fully assembled state, where the storage chamber and collector overflow channel, when both are filled, accommodate a combined volume of vaporizable material 1302 of, for example, about 1.20 mL. Fig. 30C illustrates a perspective view of an example cartridge in a fully assembled state when the collector overflow channel is filled to a volume of, for example, about 0.173 mL. Fig. 30D illustrates a perspective view of the example cartridge in a fully assembled state when the storage chamber is filled to a volume of, for example, about 0.934 mL. Fig. 30E illustrates a perspective view of an example cartridge in a fully assembled state, with the wick supply channel having a volume of, for example, about 0.094mL, and the air flow channel in the mouthpiece shown in cutaway. Fig. 30F illustrates a perspective view of the example cartridge in a fully assembled state, with the overflow air channel incorporated into the portion of the collector that faces the bottom rib, the airflow air channel having a volume of, for example, about 0.043 mL. Fig. 31A to 31C illustrate a front view of an example cartridge according to an embodiment, wherein a two-needle filling application is carried out to fill the reservoir of the cartridge (fig. 31A) before the collector and closing plug are inserted into the body of the cartridge (fig. 31B) to form a fully assembled cartridge (fig. 31C). Fig. 34A and 34B illustrate front and side views of an example cartridge body with an external airflow path. In some embodiments, one or more shutters (also referred to as air inlet apertures) may be provided on the evaporator body 110. The inlet holes may be located within the air inlet channel, having a width, height and depth sized to prevent a user from inadvertently blocking each individual air inlet hole while he is holding the evaporator 100. In one aspect, the air inlet channel structure may be sufficiently long so as not to significantly obstruct or restrict the flow of air through the air inlet channel when, for example, a user's finger blocks an area of the air inlet channel.

In some configurations, the geometry of the air inlet channel may provide for at least one of a minimum length, a minimum depth, or a maximum width, for example, to ensure that a user cannot completely cover or block the air inlet aperture in the air inlet channel with a hand or other body part. For example, the length of the air inlet channel may be longer than the width of an ordinary human finger, and the width and depth of the air inlet channel may be such that when a user's finger is pressed on top of the channel, the resulting skin fold does not contact the air inlet aperture within the air inlet channel.

The air inlet passage may be configured or formed with rounded edges or shaped to wrap around one or more corners or areas of the evaporator body 110 so that the air inlet passage is not easily covered by a user's fingers or body parts. In some embodiments, an optional cover may be provided to protect the air inlet passage so that a user's fingers do not block or completely restrict the flow of air into the air inlet passage. In one example embodiment, an air inlet channel may be formed at the interface between the evaporator cartridge 120 and the evaporator body 110 (e.g., at the receptacle area — see fig. 1). In this embodiment, the air inlet channel can be protected from being blocked, since it is formed in the region of the receptacle. Such an embodiment may also allow for a configuration in which the air inlet passage is hidden from view.

Fig. 32A-32C illustrate front, top, and bottom views, respectively, of an example cartridge body having a condensate collector 3201 incorporated within an air path.

Referring to fig. 33A, air or steam may flow into the airflow path in the cartridge. The airflow path may extend longitudinally along the body of the cartridge internally from an aperture or opening in the mouthpiece so that the vaporisable material 1302 drawn through the mouthpiece passes through the condensate trap 3201. As shown in fig. 33B, in addition to the condensate trap 3201, a condensate recycler channel 3204 (e.g., a microfluidic channel) may be formed to travel from an opening in the mouthpiece to the wicking, for example.

The condensate catcher 3201 acts on the evaporated vaporizable material 1302 in the mouthpiece that cools and becomes droplets to catch and direct the condensed droplets to the condensate recirculator channel 3204. The condensate recycler channel 3204 collects and returns condensate and large vapor droplets to the wicking portion and prevents liquid vaporizable material formed in the mouthpiece from being deposited into the user's mouth during user suction or inhalation from the mouthpiece. The condensate recycler channel 3204 may be implemented as a microfluidic channel to capture any droplet condensate and thereby eliminate direct inhalation of the vaporizable material in liquid form and avoid undesirable sensations or tastes within the user's mouth. Additional and/or alternative embodiments of the condensate recycler channel and/or one or more other features for controlling, collecting, and/or recycling condensate in the evaporator apparatus are described and illustrated with respect to fig. 117-119C. The condensate recycler channel (and/or one or more other features described and illustrated with respect to fig. 117-119C) may assist, alone or in combination with one or more features of the evaporator cartridge, in controlling, collecting, and/or recycling condensate in the evaporator apparatus referring to fig. 35 and 36, illustrating a perspective view of a portion of an exemplary cartridge, wherein the collector structure 1313 includes an air gap 3501 at a bottom rib of the collector structure. The positioning of the air gap 3501 may coincide with the location where the air exchange port is located in the collector structure 1313. As previously described, the collector structure 1313 may be configured with a central opening through which airflow access to the mouthpiece is achieved. The airflow channel may be connected to the air exchange port such that the volume within the overflow channel of the collector 1313 is connected to the ambient air via the air exchange port and also to the volume in the storage chamber via the vent.

According to one or more embodiments, the vent may act as a control valve to primarily control the flow of liquid between the overflow channel and the storage chamber. For example, the air exchange port may be used to primarily control air flow between the overflow passage and the air path leading to, for example, the mouthpiece. The combination of the interaction between the vent, the collector channels of the overflow channels, and the air exchange ports provides for proper wicking saturation, and proper venting of air bubbles that may be introduced into the cartridge due to various environmental factors, and controlled flow of vaporizable material 1302 into and out of the collector channels. The presence of the air gap 3501 at the air exchange port allows for a more robust venting process, as the air gap prevents the liquid vaporizable material 1302 stored in the collector from seeping into the wick housing region.

Fig. 37A-37C illustrate top views of various example wick supply shapes and configurations for cartridges according to one or more embodiments. As shown, fig. 37A illustrates a cross-shaped wick supply cross-section in accordance with an exemplary embodiment. Fig. 37B illustrates a wick supply having an approximately rectangular cross-section. Fig. 37C illustrates a wick supply having an approximately square cross-section. As previously described, according to embodiments, one or more wick feeds 3701 can be configured to travel through a conduit, channel, tube, or cavity of the collector structure 1313 as a path to feed the wick with the vaporizable material 1302 stored in the storage chamber. In some configuration configurations, the wick feed 3701 may extend substantially parallel to the central channel 3700 in the collector 1313.

According to embodiments, the core feed section feed path may be shaped as a tube having a generally rectangular or square cross-sectional shape as shown, for example, in fig. 37B and 37C. A conduit or tube formed into a variable width cross-sectional shape through the wick supply path can overcome the clogging problem, provided that such shape is provided in a multi-path configuration that allows the vaporizable material 1302 to travel through the wick supply even with the formation of air bubbles in a certain area of the wick supply. In such embodiments, a blockage in the wick supply tube would likely form at a portion of the wick supply tube, leaving the sub-channel (e.g., alternate channel) open to flow. In accordance with one or more aspects, the wick supply path can be wide enough to allow the vaporizable material 1302 to travel freely through the supply path and toward the wick. In some embodiments, flow through the wick supply can be enhanced or regulated by designing the relative diameters of certain portions of the wick supply to enhance the capillary pull or pressure on the vaporizable material 1302 traveling through the wick supply path. In other words, depending on shape and other structural or material factors, some wick supply paths may rely on gravity or capillary forces to cause movement of the vaporizable material 1302 toward the wick housing portion.

Fig. 37D and 37E illustrate an example embodiment of a collector 1313 with a dual wick feed 3701 embodiment. At least one of the wick feeds 3701 can be formed to include a partial partition. The partial separation wall may be configured to divide the volume inside the wick supply 3701 into two separate volumes (i.e., body cavities), as illustrated in perspective cut-away views in fig. 37D and 37E. Partial wall embodiments will allow the liquid vaporizable material 1302 to flow easily from the reservoir toward the wick housing area to saturate the wick.

In certain embodiments, the partial walls in the single wick supply form substantially two body lumens in the single wick supply. The body cavity in the wick supply can be separated via a partial wall and used separately to allow the vaporizable material 1302 to flow toward the wick housing. In such embodiments, if the air bubbles travel in one body lumen in the wick supply, the other body lumen may remain open. The body cavity may be so voluminous as to provide sufficient flow of vaporizable material 1302 toward the wicking portion for sufficient saturation.

Thus, in embodiments using two wick feeds 3701, four body cavities are actually available for carrying the flow of vaporizable material 1302 towards the wicks. Thus, in the event that air bubbles form in one, two, or even three body lumens, at least a fourth body lumen will be available to direct the flow of vaporizable material 1302 toward the wicking portion, reducing the chance of dehydration of the wicking portion.

Referring to fig. 38, a close-up view of the wick supply at an end adjacent the wick (e.g., at an end configured to at least partially receive the wick), wherein optionally at least a portion of the wick is sandwiched between two or more prongs extending from the end of the wick supply.

Fig. 39 illustrates a perspective view of an example collector structure with a wicking supply of square design combined with an air gap at one end of the overflow channel.

Referring to fig. 40A-40E, rear, side, top, front and bottom views, respectively, of an example collector structure are illustrated. Fig. 40A illustrates a rear view of a collector structure having, for example, four different ejection locations. Fig. 40B illustrates a side view of the collector structure, particularly showing, for example, clip-shaped end portions 4002 of the wick supply that can securely hold the wick in the path of the wick supply. As shown in fig. 40C, the portion of the cartridge body extending internally from the mouthpiece to the cartridge body may be received through a central channel 3700 in the collector structure that forms an air passage for evaporated vaporizable material 1302 to escape from the atomizer towards the mouthpiece.

Fig. 40C illustrates a top view of a collector structure with a wick supply channel 4001 for receiving the vaporizable material from the storage chamber of the cartridge and holding the vaporizable material toward the wick at a position at the end of the wick supply channel 4001 toward the protruding end of the wick supply channel 4001 that forms the clip-shaped end portion 4002.

Fig. 40D illustrates a front plan view of the collector structure. As shown, an air-gap cavity may be formed at the lower portion of the collector structure at the end of the lower rib of the collector structure where the overflow channel of the collector opens into the air control vent 3902 that is in communication with ambient air. The cartridge body portion extending from the mouthpiece may be received through a central channel 3700 in the collector structure that forms an air passage for the evaporated vaporizable material 1302 to escape from the atomizer towards the mouthpiece.

Fig. 40E illustrates a bottom view of the collector 1313 structure, where the two wick feed channel ends in two clip-shaped end portions 4022 are configured to hold the wicks in place at the bottom end of the collector 1313. As shown, optionally, a segmented ridge, flange or lip 4003 can be formed on the surface of the bottom end of the collector 1313, wherein the collector 1313 is attached to the upper portion of the plug 760 when assembled. The lip 4003 provides a pressure-tight engagement between the upper portion of the plug 760 and the lower portion of the collector 1313 that functions in a manner similar to a flexible O-ring so that a proper seal can be established during assembly. In one embodiment, the bottom end of the collector 1313 may be laser welded to the upper portion of the plug 760.

Fig. 41A and 41B illustrate top plan and side views of an alternative embodiment of a collector structure having two clip-shaped end portions 4002 and two corresponding wicking portion feeds. As shown, the height of this alternative embodiment is shorter than the embodiment illustrated in fig. 40A. This reduced height provides improved functionality by structurally changing the shape of the collector 1313 and the length of the channels in the collector 1313 through which the vaporizable material 1302 flows. As such, depending on the implementation, in certain embodiments, the length of the passage of vaporizable material 1302 through collector 1313 may be shorter to provide more efficient capillary pressure and better management of the flow of vaporizable material 1302 into the passage of collector 1313.

Fig. 42A and 42B illustrate various perspective, top, bottom, and side views of an example collector 1313 with different structural embodiments. For example, the embodiment shown in fig. 42A includes a narrowing point that includes a vertically positioned C-shaped wall. In contrast, in the embodiment shown in fig. 42B, the C-shaped walls are positioned diagonally to promote more controlled flow of vaporizable material 1302 along the collector 1313 pathway. As shown in the example embodiment of fig. 42B, the C-shaped wall is positioned diagonally relative to the bottom vanes of the collector and vertically relative to the downwardly sloping vane portion of the collector.

As previously described, the flow rate into and out of the collector 1313 is controlled via manipulation of the hydraulic diameter of the overflow channel 1104 in the collector 1313 by introducing one or more pinch points, which effectively reduces the overall volume of the overflow channel 1104. As shown, the introduction of multiple pinch points in the overflow channel 1104 divides the overflow channel into multiple sections, where the vaporizable material 1302 can flow in a first direction or a second direction, e.g., toward or away from the air control vent 3902, respectively.

The introduction of a pinch point helps to establish or control the capillary pressure state in the overflow channel 1104 so that the hydraulic flow of the vaporizable material 1302 towards the air control vent 3902 is minimized at pressure states when the pressure in the cartridge reservoir is equal to or less than ambient air. In a pressure state where the pressure in the reservoir is below ambient pressure (e.g., above a first threshold), the constriction point is configured to control the capillary pressure or hydraulic flow of the vaporizable material 1302 in the overflow channel 1104 such that ambient air can enter the overflow channel 1104 through the air control vent 3904 and travel up into the reservoir towards the controlled flow gate 1102 to vent the cartridge (i.e., establish an equilibrium pressure state in the cartridge).

In certain embodiments or situations, the venting process described above may not involve or require ambient air to enter through the air control vent 3904. In some example cases, instead of or in addition to air entering through the air control vent 3904, any air bubbles or gas trapped within the overflow channel 1104 may also travel upward toward the controlled flow gate 1102 to help establish an equilibrium pressure state in the cartridge via venting the reservoir as air bubbles are introduced into the reservoir from the overflow channel 1104 through the controlled flow gate 1102, as provided in further detail herein with reference to, for example, fig. 11M and 11N. The narrowing point and the design of the C-shaped wall formed in the path of overflow channel 1104 (as shown in fig. 42A and 42B) facilitate more controlled flow of vaporizable material 1302 through overflow channel 1104 by better managing capillary pressure throughout the path of overflow control channel 1104.

Fig. 43A illustrates various perspective, top, bottom, and side views of an example wicking portion housing 1315 in accordance with one or more embodiments. As shown, one or more perforations or holes may be formed in the lower portion of the wick housing 1315 to regulate airflow through the wick located in the wick housing 760 of the wick housing 1315. A sufficient number of holes will promote adequate airflow through the wick housing 760 and will provide for proper and timely evaporation of the vaporizable material 1302 absorbed into the wick in response to heat generated by a heating element located near or around the wick.

Fig. 43B illustrates the collector 1313 and wick housing 760 components of an example cartridge 1320 in accordance with one or more embodiments. As shown, the wick housing 1315 (which includes the wick housing portion of the cartridge) may be implemented to include a protruding member or projection 4390. Projections 4390 may be configured to extend from an upper end of wick housing 1315 that mates with a receiving end of collector 1313 during assembly. The projections 4390 can include one or more faces that correspond to or mate with one or more faces in a receiving recess or receiving cavity 1390 in, for example, a bottom portion of the collector 1313. The receiving cavity 1390 may be configured to removably receive the tab 4390, for example, for a snap-fit engagement. The snap-fit arrangement can assist in holding the collector 1313 and wick housing 1315 together during or after assembly.

In certain embodiments, projections 4390 can be used to guide the orientation of wick housing 1315 during assembly. For example, in one embodiment, one or more vibrating mechanisms (e.g., a vibrating bowl) may be used to temporarily store or organize/place (stage) various components of the cartridge 1320. According to some embodiments, projections 4390 can help orient the upper portion of wicking housing 1315 as a mechanical grip for ease of engagement and proper automated assembly purposes.

Additional and/or alternative heating element embodiments

As described above, an evaporator cartridge according to embodiments of the invention can include one or more heating elements. Fig. 44A-116 illustrate examples of heating elements according to embodiments of the invention. While the features described and illustrated in fig. 44A-116 can be included in and/or can include one or more features of the various embodiments of the evaporator cartridge described above, the features of the heating element described and illustrated in fig. 44A-116 can additionally and/or alternatively be included in one or more other example embodiments of an evaporator cartridge, such as those described below.

A heating element consistent with embodiments of the present subject matter may desirably be shaped to receive the wicking element and/or be crimped or squeezed at least partially around the wicking element. The heating element may be bent such that the heating element is configured to secure the wicking element between at least two or three portions of the heating element. The heating element may be bent to conform to the shape of at least a portion of the wicking element. The heating element may be easier to manufacture than typical heating elements. Heating elements consistent with embodiments of the present subject matter may also be made of an electrically conductive metal suitable for resistive heating, and in some embodiments, the heating element may include another material that is selectively plated to allow the heating element (and thus, the vaporizable material) to be heated more efficiently.

FIG. 44A shows an exploded view of an embodiment of the evaporator cartridge 120, FIG. 44B shows a perspective view of an embodiment of the evaporator cartridge 120, and FIG. 44C shows a bottom perspective view of an embodiment of the evaporator cartridge 120. As shown in fig. 44A-44C, the evaporator cartridge 120 includes a housing 160 and an atomizer assembly (or atomizer) 141.

Atomizer assembly 141 (see fig. 99-101) may include a wicking element 162, a heating element 500, and a wicking housing 178. As explained in more detail below, at least a portion of the heating element 500 is positioned between the housing 160 and the wick housing 178 and is exposed to couple with a portion of the evaporator body 110 (e.g., electrically coupled with the receptacle contact 125). Wicking housing 178 may include four sides. For example, the wicking housing 178 may include two opposing short sides and two opposing long sides. The two opposing long sides may each include at least one (two or more) recessed portion 166 (see fig. 99, 111A). Recesses 166 may be located along the long sides of wick housing 178 and adjacent to respective intersections between the long sides and the short sides of wick housing 178. The recesses 166 may be shaped to releasably couple with corresponding features (e.g., springs) on the evaporator body 110 to secure the evaporator cartridge 120 to the evaporator body 110 within the cartridge receptacle 118. The recessed portion 166 provides a mechanically stable fixture for the evaporator cartridge 120 to couple to the evaporator body 110.

In some embodiments, wick housing 178 also includes an identification chip 174 that may be configured to communicate with a corresponding chip reader located on the vaporizer. The identification chip 174 may be glued and/or otherwise adhered to the wick housing 178, such as on a short side of the wick housing 178. Additionally or alternatively, the wick housing 178 may include a chip recess 164 (see fig. 100), the chip recess 164 configured to receive the identification chip 174. The chip recess 164 may be surrounded by two, four, or more walls. Chip recess 164 may be shaped to secure identification chip 174 to wicking portion housing 178.

As described above, the vaporizer cartridge 120 may generally include a reservoir, an air path, and an atomizer assembly 141. In some configurations, the heating elements and/or atomizers described according to embodiments of the present subject matter can be implemented directly into the evaporator body and/or can be non-removable from the evaporator body. In some embodiments, the evaporator body may not include a removable cartridge.

Various advantages and benefits of the present subject matter may relate to improvements over current evaporator arrangement configurations, manufacturing methods, and the like. For example, a heating element of an evaporator device consistent with embodiments of the present subject matter can desirably be made from a sheet of material (e.g., stamped) and crimped or bent around at least a portion of the wicking element to provide a preformed element configured to receive the wicking element (e.g., the wicking element is pressed into the heating element, and/or the heating element is held in tension and pulled over the wicking element). The heating element may be bendable such that the heating element secures the wicking element between at least two or three portions of the heating element. The heating element may be bent into a shape conforming to at least a portion of the wicking element. The configured configuration of the heating element allows for more consistent and improved quality manufacturing of the heating element. Manufacturing quality consistency of heating elements can be particularly important in scaled and/or automated manufacturing processes. For example, a heating element consistent with embodiments of the present subject matter helps to reduce tolerance issues that may arise during a manufacturing process when assembling a heating element having multiple components.

In some embodiments, the accuracy of measurements made by the heating element (e.g., resistance, current, temperature, etc.) is improved due at least in part to improved consistency in manufacturability of the heating element with reduced tolerance issues. When using the evaporator device, higher measurement accuracy may provide an enhanced user experience. For example, as described above, vaporizer 100 may receive a signal to activate the heating element to a full operating temperature to generate an inhalable dose of vapor/aerosol or to a lower temperature to begin heating the heating element. As noted above, the temperature of the heating element of the evaporator may depend on many factors, and several of these factors may be more predictable due to the elimination of potential variations in atomizer component manufacture and assembly. A heating element made from a sheet of material (e.g., stamped) and crimped or bent around at least a portion of the wicking element to provide a preformed element desirably helps to minimize heat loss and helps to ensure that the heating element predictably behaves as heated to a suitable temperature.

Additionally, as described above, the heating element may be plated entirely and/or selectively with one or more materials to enhance the heating performance of the heating element. Plating all or a portion of the heating element can help minimize heat loss. Plating may also help to concentrate the heated portion of the heating element in a proper location, providing a more efficiently heated heating element and further reducing heat loss. Selective plating can help direct the current provided to the heating element to the correct location. Selective plating may also help reduce the amount of plating material and/or the costs associated with manufacturing the heating element.

After the heating element is formed into a suitable shape via one or more processes discussed below, the heating element may be crimped and/or bent around the wicking element into a suitable orientation to receive the wicking element. In some embodiments, the wicking element may be a fibrous wicking portion formed into an at least approximately flat mat or having other cross-sectional shapes such as circular, oval, and the like. A flat pad may allow for more precise and/or accurate control of the rate at which the vaporizable material is drawn into the wicking element. For example, the length, width, and/or thickness may be adjusted for optimal performance. The wicking element forming a flat pad may also provide a greater transfer surface area, which may allow for faster flow of the vaporizable material from the reservoir into the wicking element for vaporization by the heating element (in other words, greater mass transfer of the vaporizable material) and from the wicking element to the air flowing therethrough. In such a configuration, the heating element may contact the wicking element in multiple directions (e.g., on at least two sides of the wicking element) to increase the efficiency of the process of drawing the vaporizable material into the wicking element and vaporizing the vaporizable material. The flat mat may also be easier to form and/or cut and thus the flat mat may be easier to assemble with the heating element. In some embodiments, as discussed in more detail below, the heating element may be configured to contact the wicking element on only one side of the wicking element.

The wicking element may include one or more rigid or compressible materials, such as cotton, silica, ceramic, and/or the like. The cotton wicking element may allow for an increased and/or more controllable flow rate of vaporizable material from the reservoir of the vaporizer cartridge into the wicking element to be vaporized relative to some other material. In some embodiments, the wicking element forms an at least approximately flat pad configured to contact the heating element and/or be secured between at least two portions of the heating element. For example, an at least approximately flat pad may have at least a first pair of opposing sides that are approximately parallel to each other. In some embodiments, the at least approximately flat pad may further have at least a second pair of opposing sides approximately parallel to each other and approximately perpendicular to the first pair of opposing sides.

Fig. 45-48 illustrate schematic views of a heating element 500 consistent with embodiments of the present subject matter. For example, fig. 2 illustrates a schematic view of the heating element 500 in an expanded orientation. As shown, in the deployed orientation, the heating element 500 forms a flat heating element. The heating element 500 may be initially formed from a substrate material. The substrate material is then cut and/or stamped into the appropriate shape via various mechanical processes including, but not limited to, stamping, laser cutting, photo etching, chemical etching, and the like.

The substrate material may be made of a conductive metal suitable for resistive heating. In some embodiments, heating element 500 comprises nichrome, nickel alloy, stainless steel, and/or the like. As described below, the heating element 500 may be coated in one or more locations on the surface of the substrate material to enhance, limit, or otherwise alter the resistivity of the heating element in one or more locations of the substrate material (which may be all or a portion of the heating element 500).

Heating element 500 includes one or more rake wings 502 (e.g., heating segments) located in a heating portion 504, one or more legs or connections 506 (e.g., one, two, or more) located in a transition region 508, and cartridge contacts 124 located in an electrical contact region 510 and formed at an end portion of each of the one or more legs 506. Rake wings 502, legs 506, and cartridge contacts 124 may be integrally formed. For example, rake wings 502, legs 506, and cartridge contacts 124 form part of heating element 500 that is stamped and/or cut from the substrate material. In some embodiments, heating element 500 further includes a thermal barrier 518 that extends from one or more of legs 506 and may also be integrally formed with rake wings 502, legs 506, and cartridge contacts 124.

In some embodiments, at least a portion of the heated portion 504 of the heating element 500 is configured to contact vaporizable material that is drawn into the wicking element from the reservoir 140 of the evaporator cartridge 120. The heating portion 504 of the heating element 500 may be shaped, sized, and/or otherwise treated to produce a desired electrical resistance. For example, the rake wings 502 located in the heating section 504 may be designed such that the electrical resistance of the rake wings 502 matches a suitable amount of electrical resistance to affect localized heating in the heating section 504 to more efficiently and effectively heat the vaporizable material from the wicking element. The rake wings 502 form heating segments or heating traces of fine paths in series and/or parallel to provide the desired amount of resistance.

The rake wings 502 (e.g., traces) may include various shapes, sizes, and configuration configurations. In some configuration configurations, one or more of the wings 502 can be spaced to allow vaporizable material to be wicked out of the wicking element and vaporized from the wicking element away from the side edges of each of the wings 502. Other properties of shape, length, width, composition, etc. of rake wings 502 may be optimized to maximize the efficiency of aerosol generation by evaporation of vaporizable material from within the heated portion of heating element 500 and to maximize electrical efficiency. Additionally or alternatively, other properties of shape, length, width, composition, etc. of wing 502 may be optimized to evenly distribute heat throughout the length of wing 502 (or a portion of wing 502, such as at heating portion 504). For example, the width of rake wings 502 may be uniform or variable along the length of rake wings 502 to control the temperature distribution throughout at least heating portion 504 of heating element 500. In some examples, the length of rake wings 502 may be controlled to achieve a desired electrical resistance along at least a portion of heating element 500, such as at heating portion 504. As shown in fig. 45-48, rake wings 502 each have the same size and shape. For example, rake wings 502 include outer edges 503 that are generally aligned and have a generally rectangular shape with flat or square outer edges 503 (see also fig. 49-53, and) or rounded outer edges 503 (see fig. 54 and 55). In some embodiments, one or more of wings 502 may include a non-aligned outer edge 503 and/or one or more of wings 502 may have a different size or shape (see fig. 57-62). In some embodiments, wings 502 may be evenly spaced, or adjacent wings 502 may have a variable spacing therebetween (see fig. 87-92). The particular geometry of rake wings 502 may be selected as desired to create a particular localized electrical resistance for heating portion 504 and to maximize the ability of heating element 500 to heat the vaporizable material and generate an aerosol.

Heating element 500 may include portions having wider and/or thicker geometries and/or include different compositions relative to rake wings 502. These portions may form electrical contact areas and/or more conductive portions, and/or these portions may include features for mounting the heating element 500 within an evaporator cartridge. A leg 506 of the heating element 500 extends from the end of each outermost rake wing 502A. Legs 506 form a portion of heating element 500 having a width and/or thickness that is generally wider than the width of each rake 502. However, in some embodiments, legs 506 have a width and/or thickness that is the same as or narrower than the width of each rake wing 502. The legs 506 couple the heating element 500 to the wick housing 178 or another portion of the cartridge 120 such that the heating element 500 is at least partially or completely enclosed by the housing 160. Legs 506 provide rigidity to facilitate mechanical stabilization of heating element 500 during and after manufacturing. Legs 506 also connect cartridge contacts 124 with rake wings 502 located in heating portion 504. The legs 506 are shaped and sized to allow the heating element 500 to maintain the electrical requirements of the heating portion 504. As shown in fig. 5, the legs 506 space the heating portion 504 from an end of the evaporator magazine 120 when the heating element 500 is assembled with the evaporator magazine 120. As discussed in more detail below with respect to at least fig. 82-98 and 103-104, the legs 506 may also include capillary features 598 that restrict or prevent fluid from flowing out of the heating portion 504 to other portions of the heating element 500.

In some embodiments, one or more of the legs 506 include one or more locating features 516. The locating features 516 may be used for relative positioning of the heating element 500 or portions thereof during and/or after assembly by interfacing with other (e.g., adjacent) components of the evaporator cartridge 120. In some embodiments, the locating features 516 may be used during or after manufacturing to properly locate the substrate material for cutting and/or stamping the substrate material to form the heating element 500 or for post-processing of the heating element 500. The locating features 516 may be sheared and/or cut away prior to crimping or otherwise bending the heating element 500.

In some embodiments, the heating element 500 includes one or more thermal barriers 518. The thermal barrier 518 forms a portion of the heating element 500 that extends laterally from the leg 506. When folded and/or curled, thermal barrier 518 is positioned offset in the same plane from rake wings 502 in a first direction and/or in a second direction opposite the first direction. When the heating element 500 is assembled in the evaporator cartridge 120, the thermal barrier 518 is configured to be positioned between the rake wings 502 (and heating portion 504) and the body (e.g., plastic body) of the evaporator cartridge 120. The thermal barrier 518 may help isolate the heating portion 504 from the body of the evaporator cartridge 120. The thermal barrier 518 may help minimize the impact of heat dissipated from the heating portion 504 on the body of the evaporator cartridge 120 to protect the structural integrity of the body of the evaporator cartridge 120 and prevent the evaporator cartridge 120 from melting or otherwise deforming. The thermal barrier 518 may also help to maintain a consistent temperature at the heating portion 504 due to the retention of heat within the heating portion 504, thereby preventing or limiting heat loss when evaporation occurs. In some embodiments, the cartridge 120 may also or alternatively include a thermal barrier 518A (see fig. 102) separate from the heating element 500.

As described above, the heating element 500 comprises at least two cartridge contacts 124 forming an end portion of each leg 506. For example, as shown in fig. 45-48, the cartridge contacts 124 may form portions of the legs 506 that fold along fold lines 507. The cartridge contacts 124 may fold at an angle of about 90 degrees relative to the legs 506. In some embodiments, the cartridge contacts 124 may be folded at other angles relative to the legs 506, such as at angles of about 15 degrees, 25 degrees, 35 degrees, 45 degrees, 55 degrees, 65 degrees, 75 degrees, or other ranges therebetween. The cartridge contacts 124 may fold toward or away from the heating portion 504, depending on the implementation. The cartridge contacts 124 may also be formed on another portion of the heating element 500, such as along the length of at least one of the legs 506. The cartridge contacts 124 are configured to be exposed to the environment when assembled in the evaporator cartridge 120 (see fig. 53).

The cartridge contacts 124 may form conductive pins, tabs, posts, receiving holes or surfaces for pins or posts or other contact arrangement configurations. Certain types of cartridge contacts 124 may include springs or other biasing features to promote better physical and electrical contact between the cartridge contacts 124 on the evaporator cartridge and the receptacle contacts 125 on the evaporator body 110. In some embodiments, the cartridge contacts 124 include wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or a power source. For example, the wiping contact may include two parallel but offset bosses that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

The cartridge contacts 124 are configured to interface with receptacle contacts 125 disposed near the base of the cartridge receptacle of the evaporator 100 such that when the evaporator cartridge 120 is inserted into and coupled with the cartridge receptacle 118, the cartridge contacts 124 and the receptacle contacts 125 form an electrical connection. The cartridge contacts 124 may be in electrical communication with the power source 8 of the vaporizer apparatus (e.g., via receptacle contacts 125, etc.). Completing/completing the electrical circuit through these electrical connections may allow for current to be delivered to the resistive heating element to heat at least a portion of the heating element 500, and may also be used for additional functions, such as, for example, for measuring the resistance of the resistive heating element for use in determining and/or controlling the temperature of the resistive heating element based on the temperature coefficient of resistivity of the resistive heating element, for identifying the cartridge based on one or more electrical characteristics of the resistive heating element or other electrical circuits of the vaporizer cartridge, and so forth. As described in more detail below, the cartridge contacts 124 may be processed to provide improved electrical performance (e.g., contact resistance) using, for example, conductive plating, surface treatment, and/or deposition of materials.

In some embodiments, the heating element 500 may be formed into a desired three-dimensional shape by a series of crimping and/or bending operations processes to form the heating element 500. For example, the heating element 500 may be preformed to receive the wicking element or crimped around the wicking element 162 to secure the wicking element between at least two portions (e.g., generally parallel portions) of the heating element 500 (e.g., between opposing portions of the heating portion 504). To crimp the heating element 500, the heating elements 500 may be bent toward each other along fold lines 520. Folding heating element 500 along fold line 520 forms a platform rake wing 524 defined by the area between fold lines 520 and a side rake wing 526 defined by the area between fold lines 520 and the outer edge 503 of rake wing 502. Platform rake wings 524 are configured to contact one end of wicking element 162. Side rake wings 526 are configured to contact opposite sides of wicking element 162. Platform rake wings 524 and side rake wings 526 form pockets shaped to receive wicking element 162 and/or the platform rake wings and side rake wings conform to the shape of at least a portion of wicking element 162. The pocket allows the wicking element 162 to be held and retained within the pocket by the heating element 500. Platform rake wings 524 and side rake wings 526 contact wicking element 162 to provide multi-dimensional contact between heating element 500 and wicking element 162. The multi-dimensional contact between heating element 500 and wicking element 162 provides for more efficient and/or faster transfer of vaporizable material from reservoir 140 to heating portion 504 (via wicking element 162) of vaporizer cartridge 120 to be vaporized.

In some embodiments, portions of the legs 506 of the heating element 500 may also be bent away from each other along the fold lines 522. Folding of portions of legs 506 of heating element 500 away from each other along fold lines 522 positions legs 506 at locations spaced apart from heating portions 504 (and rake wings 502) of heating element 500 in a first direction and/or a second direction opposite the first direction (e.g., on the same plane). Thus, the folding of the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522 separates the heating portion 504 from the body of the evaporator cartridge 120. Fig. 46 illustrates a schematic view of the heating element 500 that has been folded about the wicking element 162 along fold line 520 and fold line 522. As shown in fig. 3, the wicking element is positioned within the pocket formed by folding the heating element 500 along

fold lines

520 and 522.

In some embodiments, the heating element 500 may also be bent along the fold line 523. For example, the cartridge contacts 124 may be bent toward each other (into and out of the page shown in fig. 47) along fold line 523. The cartridge contacts 124 may be exposed to the environment to contact the receptacle contacts while the remainder of the heating element 500 is positioned within the evaporator cartridge 120 (see fig. 48 and 53).

In use, when a user draws on the mouthpiece 130 of the evaporator cartridge 120 when the heating element 500 is assembled into the evaporator cartridge 120, air flows into the evaporator cartridge and along the air path. The heating element 500 may be activated in association with a user's puff, such as by automatic detection of the puff via a pressure sensor, by detection of a user pressing a button, by a signal generated by a motion sensor, a flow sensor, a capacitive lip sensor, and/or otherwise capable of detecting that a user is or is about to puff or otherwise inhale to cause air to enter the evaporator 100 and travel at least along the air path. When the heating element 500 is activated, power may be supplied to the heating element 500 from the evaporator device at the cartridge contacts 124.

When the heating element 500 is activated, heat is generated due to the flow of current through the heating element 500, thereby causing an increase in temperature. Heat is transferred to the quantity of vaporizable material by conductive, convective, and/or radiative heat transfer such that at least a portion of the vaporizable material is vaporized. Heat transfer may occur from the vaporizable material in the reservoir and/or the vaporizable material drawn into wicking element 162 held by heating element 500. In some embodiments, the vaporizable material can be vaporized along one or more edges of rake wings 502, as mentioned above. The air delivered into the vaporizer apparatus flows along an air path through the heating element 500, causing the vaporized vaporizable material to peel away from the heating element 500. The vaporized vaporizable material may condense as a result of cooling, pressure changes, etc., such that it exits the mouthpiece 130 as an aerosol for inhalation by the user.

As described above, the heating element 500 may be made of various materials, such as nichrome, stainless steel, or other resistive heater materials. Combinations of two or more materials may be included in the heating element 500, and such combinations may include homogeneous distribution of the two or more materials throughout the heating element, or other configurations in which the relative amounts of the two or more materials are spatially non-homogeneous. For example, rake wings 502 may have portions that are more resistive and therefore designed to fade to be hotter than the rake wings or other sections of heating element 500. In some embodiments, at least the rake wings 502 (e.g., within the heating portions 504) may comprise a material having high conductivity and heat resistance.

The heating element 500 may be plated entirely or selectively with one or more materials. Since the heating element 500 is made of a thermally and/or electrically conductive material, such as stainless steel, nichrome, or other thermally and/or electrically conductive alloys, the heating element 500 may suffer electrical or heating losses in the path between the cartridge contact 124 and the rake wings 502 in the heating portion 504 of the heating element 500. To help reduce heating and/or electrical losses, at least a portion of heating element 500 may be plated with one or more materials to reduce the resistance of the electrical path to heating portion 504. In some embodiments consistent with the present subject matter, it may also be beneficial for heating portion 504 (e.g., rake wings 502) to remain unplated with at least a portion of legs 506 and/or cartridge contacts 124 being plated with a plating material that reduces electrical resistance (e.g., either or both of body and contact resistance) in those portions.

For example, the heating element 500 may include different portions plated with different materials. In another example, the heating element 500 may be plated with a layered material. Plating at least a portion of the heating element 500 helps to concentrate the current flowing to the heated portion 504 to reduce electrical and/or heat loss in other portions of the heating element 500. In some embodiments, it is desirable to maintain a low resistance of the electrical path between the cartridge contacts 124 and the rake 502 of the heating element 500 to reduce electrical and/or heat losses in the electrical path and compensate for the voltage drop concentrated across the heating portion 504.

In some embodiments, the cartridge contacts 124 may be selectively plated. Selectively plating the cartridge contacts 124 with certain materials may minimize or eliminate contact resistance at the point where the measurement is taken and form electrical contact between the cartridge contacts 124 and the receptacle contacts. Providing a low electrical resistance at the cartridge contacts 124 may provide more accurate voltage, current, and/or resistance measurements and readings, which may be beneficial for accurately determining the current actual temperature of the heating portion 504 of the heating element 500.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 may be plated with one or more outer plating materials 150. For example, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 may be plated with at least gold or another material that provides low contact resistance such as platinum, palladium, silver, copper, or the like.

In some embodiments, to secure the low resistance outer plating material to the heating element 500, the surface of the heating element 500 may be plated with an adhesive plating material. In such a configuration, an adhesive plating material may be deposited onto the surface of the heating element 500, and an outer plating material may be deposited onto the adhesive plating material, defining a first plating layer and a second plating layer, respectively. The adherent plating material includes a material having adhesive properties when the outer plating material is deposited onto the adherent plating material. For example, the adherent plating material may include nickel, zinc, aluminum, iron, alloys thereof, and the like. Fig. 79-81 illustrate examples of heating elements 500 in which cartridge contacts 124 are selectively plated with an adhesive plating material and/or an outer plating material.

In some embodiments, the surface of the heating element 500 may be primed to deposit an outer plating material onto the heating element 500 with a non-plating primer rather than by plating the surface of the heating element 500 with an adhesive plating material. For example, the surface of the heating element 500 may be primed/primed using etching rather than by depositing an adherent plating material.

In some embodiments, all or a portion of the legs 506 and the cartridge contacts 124 may be plated with an adhesive plating material and/or an outer plating material. In some examples, the cartridge contacts 124 may include at least a portion having an outer plating material with a greater thickness relative to the remainder of the cartridge contacts 124 and/or the legs 506 of the heating element 500. In some embodiments, cartridge contacts 124 and/or legs 506 may have a greater thickness relative to rake wings 502 and/or heating portion 504.

In some embodiments, rather than forming the heating element 500 from a single substrate material and plating the substrate material, the heating element 500 may be formed from various materials that are coupled together (e.g., via laser welding, a diffusion process, etc.). The material of each portion of the heating element 500 that is coupled together may be selected to provide low or no electrical resistance at the cartridge contacts 124 and high electrical resistance at the rake 502 of the heating portion 504 relative to the other portions of the heating element.

In some embodiments, the heating element 500 may be plated with silver ink and/or sprayed with one or more plating materials such as an adhesive plating material and an outer plating material.

As described above, the heating element 500 may include various shapes, sizes, and geometries to more efficiently heat the heating portion 504 of the heating element 500 and to more efficiently vaporize the vaporizable material.

Fig. 49-53 illustrate an example of a heating element 500 consistent with embodiments of the present subject matter. As shown, heating element 500 includes one or more rake wings 502 positioned in heating portion 504, one or more legs 506 extending from rake wings 502, cartridge contacts 124 formed at an end portion of each of the one or more legs, and a thermal barrier 518 extending from the one or more legs 506. In this example, each rake wing 502 has the same or similar shape and size. Rake wings 502 have a square and/or flat outer edge 503. In fig. 49-52, rake wings 502 are crimped around wicking element 162 (e.g., a flat pad) to secure wicking element 162 within pockets of rake wings 502.

Fig. 54-55 illustrate another example of a heating element 500 consistent with embodiments of the present subject matter, in an unfolded orientation (fig. 54) and in a folded orientation (fig. 55). As shown, heating element 500 includes one or more rake wings 502 positioned in heating portion 504, one or more legs 506 extending from rake wings 502, cartridge contacts 124 formed at an end portion of each of the one or more legs 506, and a thermal barrier 518 extending from the one or more legs 506. In this example, each wing 502 has the same or similar shape and size, and wings 502 have rounded and/or semi-circular outer edges 503.

Fig. 56 illustrates another example of a heating element 500 in a bent position consistent with embodiments of the present subject matter, which is similar to the example heating element 500 shown in fig. 54-55, but in this example each rake wing 502 has the same or similar shape and size, and the rake wings 502 have a square and/or flat outer edge 503.

Fig. 57-62 illustrate other examples of heating element 500 in which at least one of rake wings 502 has a different size, shape, or position than the remaining rake wings 502. For example, as shown in fig. 57-58, heating element 500 includes one or more rake wings 502 positioned in a heating portion 504, one or more legs 506 extending from rake wings 502, and cartridge contacts 124 formed at an end portion of each of the one or more legs 506. In this example, rake wings 502 include a first set of rake wings 505A and a second set of rake wings 505B. First set of rake wings 505A and second set of rake wings 505B are offset from each other. For example, outer edges 503 of first set of wings 505A and second set of wings 505B are not aligned with each other. As shown in fig. 58, when heating portion 504 is in the bend position, first set of rake wings 505A appear shorter than second set of rake wings 505B in a first portion of heating element 500, and first set of rake wings 505A appear longer than second set of rake wings 505B in a second portion of heating element 500.

As shown in fig. 59-60, heating element 500 includes one or more rake wings 502 positioned in a heating portion 504, one or more legs 506 extending from rake wings 502, and a cartridge contact 124 formed at an end portion of each of the one or more legs 506. In this example, rake wings 502 include a first set of rake wings 509A and a second set of rake wings 509B. The first set of rake wings 509A and the second set of rake wings 509B are offset from each other. For example, the outer edges 503 of the first set of rake wings 509A and the second set of rake wings 509B are not aligned with each other. Here, second set of rake wings 509B comprises a single outermost rake wing 502A. As shown in fig. 59-60, when the heating section 504 is in the bend position, the first set of rake wings 509A appear longer than the second set of rake wings 509B. In addition, in fig. 59-60, rake wings 502 are not bent. Rather, rake wings 502 are positioned on a first portion and a second portion of heating element 500, the second portion being positioned substantially parallel to and opposite the first portion. The first set of rake wings positioned on the first portion of the heating element 500 is separated from the second set of rake wings positioned on the second portion of the heating element 500 by a platform 130, the platform 130 being positioned between the first set of rake wings and the second set of rake wings and spaced apart from both the first and second sets of rake wings. Platform portion 130 is configured to contact an end of wicking element 162. The platform portion 130 includes a cutout portion 532. Cutout 532 may provide additional edges along which vaporizable material may be vaporized when heating element 500 is activated.

As shown in fig. 61-62, heating element 500 includes one or more rake wings 502 positioned in a heating portion 504, one or more legs 506 extending from rake wings 502, and a cartridge contact 124 formed at an end portion of each of the one or more legs 506. In this example, rake wings 502 include a first set of rake wings 509A and a second set of rake wings 509B. The first set of rake wings 509A and the second set of rake wings 509B are offset from each other. For example, outer edges 503 of first set of wings 509A and second set of wings 509B are not aligned with each other. Here, each of first set of rake wings 509A and second set of rake wings 509B includes two rake wings 502. As shown in fig. 18-19, when heating section 504 is in the bend position, first set of rake wings 509A appear shorter than second set of rake wings 509B. In addition, in fig. 61-62, rake wings 502 are not bent. Rather, rake wings 502 are positioned on a first portion and a second portion (parallel and opposite to the first portion) of heating element 500. The first set of rake wings positioned on the first portion is separated from the second set of rake wings positioned on the second portion by a platform positioned between the first set of rake wings and the second set of rake wings and spaced apart from both the first and second sets of rake wings. The platform portion is configured to contact an end of the wicking element 162. The platform portion includes a cutout portion. The cut-out portion may provide an additional edge along which the vaporizable material may be vaporized from when the heating element 500 is activated.

Fig. 63-68 illustrate another example of a heating element 500 consistent with embodiments of the present subject matter, in an unfolded orientation (fig. 63) and a folded orientation (fig. 64-68). As shown, heating element 500 includes one or more rake wings 502 positioned in heating portion 504, one or more legs 506 extending from rake wings 502, cartridge contacts 124 formed at an end portion of each of the one or more legs 506, and a thermal barrier 518 extending from the one or more legs 506. In this example, heating element 500 is configured to be crimped and/or bent around cylindrical wicking element 162 or wicking element 162 having a circular cross-section to receive the wicking element. Each rake wing 502 includes an aperture 540. The apertures 540 may provide additional edges along which the vaporizable material may vaporize from when the heating element 500 is activated. The apertures 540 also reduce the amount of material used to form the heating element 500, reducing the weight of the heating element 500 and the amount of material used for the heating element 500, thereby reducing material costs.

Fig. 69-78 illustrate a heating element 500 consistent with embodiments of the present subject matter, wherein the heating element 500 is pressed against one side of the wicking element 162. As shown, heating element 500 includes one or more rake wings 502 positioned in a heating portion 504, one or more legs 506 extending from rake wings 502, and cartridge contacts 124 formed at an end portion of each of the one or more legs 506. In these examples, the legs 506 and the cartridge contacts 124 are configured to bend in a third direction, rather than in a first-second direction perpendicular to the third direction. In such a configuration, rake wings 502 of heating portion 504 form a flat platform facing outward from heating element 500, and the platform is configured to be pressed against wicking element 162 (e.g., on one side of wicking element 162).

Fig. 71-74 illustrate several examples of heating elements 500, including rake wings 502 configured in various geometries, consistent with embodiments of the present subject matter. As noted above, rake wings 502 form a flat platform that, in use, presses against one side of wicking element 162. Leg 506, rather than rake wings 502, is bent into a bent orientation.

Fig. 75 illustrates the example of the heating element 500 shown in fig. 71 assembled with a component of the evaporator cartridge 120, such as a wicking portion housing (e.g., wicking portion housing 178) that houses the wicking element 162 and the heating element 500, and fig. 76 illustrates the heating element 500 in accordance with an embodiment of the present subject matter, assembled with the example evaporator cartridge 120. As shown, the cartridge contacts 124 are bent toward each other in the transverse direction.

Fig. 77 and 78 illustrate another example of a heating element 500, wherein rake wings 502 form a platform configured to press against wicking element 162. Here, legs 506 may form a spring-like structure that forces rake wings 502 against wicking element 162 when a laterally inward force is applied to each leg 506. For example, fig. 35 illustrates an example of rake wings 502 being pressed against the wicking element 162 when electrical power (e.g., electrical current) is supplied to the heating element 500, such as via the cartridge contacts 124.

Fig. 82-86 illustrate another example of a heating element 500 consistent with embodiments of the present subject matter. As shown, the heating element 500 includes one or more rake wings 502 positioned in a heating portion 504, one or more legs 506 extending from the rake wings 502, and a cartridge contact 124 formed at an end portion of and/or as part of each of the one or more legs 506. In this example, each rake wing 502 has the same or similar shape and size, and each rake wing is spaced apart from each other by an equal distance. Rake wings 502 have rounded outer edges 503.

As shown in fig. 85, rake wings 502 are crimped around wicking element 162 (e.g., a flat pad) to secure wicking element 162 within the pocket formed by rake wings 502. For example, rake wings 502 may be folded and/or rolled to define a pocket in which wicking element 162 is placed. Rake wings 502 include platform rake wings 524 and side rake wings 526. Platform rake wings 524 are configured to contact one side of wicking element 162 and side rake wings 526 are configured to contact the other opposite side of wicking element 162. Platform rake wings 524 and side rake wings 526 form pockets shaped to receive wicking element 162 and/or shaped to conform to the shape of at least a portion of wicking element 162. The pocket allows the wicking element 162 to be held and retained in the pocket by the heating element 500.

In some embodiments, side rake wings 526 and platform rake wings 524 retain wicking element 162 via compression (e.g., at least a portion of wicking element 162 is compressed between opposing side forks 126 and/or platform rake wings 524). Platform rake wings 524 and side rake wings 526 contact wicking element 162 to provide multi-dimensional contact between heating element 500 and wicking element 162. The multi-dimensional contact between heating element 500 and wicking element 162 provides for more efficient and/or faster transfer of vaporizable material from reservoir 140 to heating portion 504 (via wicking element 162) of vaporizer cartridge 120 to be vaporized.

The one or more legs 506 of the example heating element 500 shown in fig. 82-86 are four legs 506. Each leg 506 may include and/or define a cartridge contact 124, the cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the evaporator 100. In some embodiments, each pair of legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125. The legs 506 may be spring loaded to allow the legs 506 to maintain contact with the receptacle contacts 125. The legs 506 may include portions that extend along the curved length of the legs 506 to help maintain contact with the receptacle contacts 125. The spring-loaded legs 506 and/or the curvature of the legs 506 may help increase and/or maintain consistent pressure between the legs 506 and the receptacle contacts 125. In some embodiments, legs 506 are coupled with support 176, which helps to increase and/or maintain consistent pressure between legs 506 and receptacle contacts 125. The support 176 may comprise plastic, rubber, or other material that helps maintain contact between the legs 506 and the receptacle contacts 125. In some embodiments, the support 176 is formed as part of the leg 506.

The legs 506 may contact one or more wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or a power source. For example, the wiping contact will include at least two parallel but offset bosses that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

As shown in fig. 82-98, the one or more legs 506 of the heating element 500 are four legs 506. Fig. 91-92, 97A-98B, and 109-110 illustrate examples of heating elements 500 in an unbent orientation. As shown, heating element 500 has an H-shape defined by four legs 506 and rake wings 502. This configuration allows for more accurate measurement of the resistance across the heater and reduces variability in the resistance measurements, allowing for more efficient aerosol generation and higher quality aerosol generation. The heating element 500 includes two pairs of opposing legs 506. Rake wings 502 couple (e.g., interface) with each pair of opposing legs 506 at or near the center of each pair of opposing legs 506. Heating portion 504 is positioned between a pair of opposing legs 506.

Fig. 109 illustrates an example of the heating element 500 before the heating element 500 is stamped and/or otherwise formed from the substrate material 577. Excess substrate material 577A may be coupled with heating element 500 at one, two, or more coupling locations 577B. For example, as shown, the excess substrate material 577A may be coupled with the heating element 500 at two coupling locations 577B proximate to the platform portion of the heating element and/or the (two) opposing lateral end portions 173 of the heating portion 504 of the heating element 500. In some embodiments, the heating element 500 can be first stamped from the substrate material 577 and then removed from the excess substrate material 577A at the coupling location 577B (e.g., by twisting the heating element 500, pulling the heating element, stamping the heating element, cutting the heating element, etc.).

As described above, to crimp the heating element 500, the heating element 500 may be bent or otherwise folded toward or away from each other along

fold lines

523, 522A, 522B, 520 (see, e.g., fig. 98A). Although a fold line is illustrated in fig. 98A, the example heating element 500 described and illustrated in fig. 44A-115C may also be crimped, folded, or otherwise bent along the fold line. Folding heating element 500 along fold line 520 forms a platform rake wing 524 defined by the area between fold lines 520 and/or a side rake wing 526 defined by the area between fold lines 520 and the outer edge 503 of rake wing 502. Platform rake wings 524 may contact one end of wicking element 162 and/or support one end of wicking element 162. Side rake wings 526 can contact opposite sides of wicking element 162. Platform wing 524 and side wings 526 define an inner volume of the heating element that forms a pocket shaped to receive wicking element 162 and/or conform to the shape of at least a portion of wicking element 162. The internal volume allows wicking element 162 to be held and retained within the pouch by heating element 500. Platform rake wings 524 and side rake wings 526 contact wicking element 162 to provide multi-dimensional contact between heating element 500 and wicking element 162. The multi-dimensional contact between heating element 500 and wicking element 162 provides for more efficient and/or faster transfer of vaporizable material from reservoir 140 to heating portion 504 (via wicking element 162) of vaporizer cartridge 120 to be vaporized.

In some embodiments, portions of the legs 506 of the heating element 500 may also be bent along the

fold lines

522A, 522B. Folding of portions of legs 506 of heating element 500 away from each other along fold lines 522 positions legs 506 at locations that are spaced apart from heating portion 504 (and rake wings 502) of heating element 500 in a first direction and/or a second direction (e.g., on the same plane) that is opposite the first direction. Thus, the folding of the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522 separates the heating portion 504 from the body of the evaporator cartridge 120. The folding of the portions of the legs 506 along the

fold lines

522A, 522B forms a bridge 585. In some embodiments, bridging 585 helps reduce or eliminate overflow of vaporizable material from heating portion 504, such as by capillary action. The bridge 585 also helps to isolate the heating portion 504 from the legs 506 so that heat generated at the heating portion 504 does not extend to the legs 506. This also helps to localize heating of the heating element 500 into the heating portion 504.

In some embodiments, the heating element 500 may also be bent along a fold line 523 to define the cartridge contacts 124. The cartridge contacts 124 may be exposed to the environment or may be otherwise accessible (and may be positioned inside a portion of the cartridge such as a housing) to contact the receptacle contacts, while other portions, such as the heating portion 504 of the heating element 500, are positioned within an inaccessible portion of the evaporator cartridge 120, such as a wicking housing.

In some embodiments, leg 506 includes retainer portion 180 configured to be bent around at least a portion of wicking housing 178, wicking housing 178 surrounding wicking element 162 and at least a portion of heating element 500 (e.g., heating portion 504). The retainer portion 180 forms the end of the leg 506. Retainer portion 180 helps secure heating element 500 and wicking element 162 to wick housing 178 (and evaporator cartridge 120). Retainer portion 180 may alternatively be bent away from at least a portion of wick housing 178.

Fig. 87-92 illustrate another example of a heating element 500 consistent with embodiments of the present subject matter. As shown, heating element 500 includes one or more rake wings 502 positioned in heating portion 504, one or more legs 506 extending from rake wings 502, and magazine contacts 124 formed at an end portion of and/or as part of each of the one or more legs 506.

Rake wings 502 may be folded and/or rolled to define a pocket in which wicking element 162 (e.g., a flat pad) is placed. Rake wings 502 include platform rake wings 524 and side rake wings 526. Platform rake wings 524 are configured to contact one side of wicking element 162 and side rake wings 526 are configured to contact the other, opposite side of wicking element 162. Platform rake wings 524 and side rake wings 526 form pockets shaped to receive wicking element 162 and/or conform to the shape of at least a portion of wicking element 162. The pocket allows the wicking element 162 to be held and retained within the pocket by the heating element 500.

In this example, rake wings 502 are of various shapes and sizes, and the rake wings are spaced apart from each other by the same or varying distances. For example, as shown, each side rake wing portion 526 includes at least four rake wings 502. In first pair 170 of adjacent rake wings 502, each of adjacent rake wings 502 is spaced an equal distance from an inner region 576 located near platform rake wing 524 to an outer region 578 located near outer edge 503. In the second pair 572 of adjacent rake wings 502, adjacent rake wings 502 are spaced at varying distances from the inner region 576 to the outer region 578. For example, adjacent rake wings 502 of the second pair 572 are spaced apart by a width that is: the width is greater at inner region 576 than at outer region 578. These configuration configurations may help maintain a constant and uniform temperature along the length of rake 502 of heating section 504. Maintaining a constant temperature along the length of rake wings 502 may provide a higher quality aerosol because the maximum temperature may be maintained more uniformly throughout heating portion 504.

As described above, each leg 506 may include and/or define a cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the evaporator 100. In some embodiments, each pair of legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125. In some embodiments, legs 506 include retainer portions 180 configured to bend and extend generally away from heating portion 504. Retainer portion 180 is configured to be positioned within a corresponding recess in wicking portion housing 178. The retainer portion 180 forms the end of the leg 506. The retainer portion 180 helps secure the heating element 500 and wicking element 162 to the wick housing 178 (and evaporator cartridge 120). The holder portion 180 may have a tip portion 180A that extends from an end of the holder portion 180 toward the heating portion 504 of the heating element 500. This arrangement configuration reduces the likelihood that the retainer portion will contact another portion of the evaporator cartridge 120 or a cleaning device used to clean the evaporator cartridge 120.

Outer edge 503 of rake 502 in heating section 504 may include a protrusion 580. The protrusion 580 may be one, two, three, four, or more protrusions 580. The protrusion 580 may extend outward from the outer edge 503 and away from the center of the heating element 500. For example, protrusion 580 may be positioned along an edge of heating element 500 that encompasses an internal volume defined by at least side rake wings 526 for receiving wicking element 162. Projections 580 may extend outwardly away from the inner volume of wicking element 162. The tabs 580 may also extend away in the opposite direction from the platform rake wings 524. In some embodiments, projections 580 positioned on opposite sides of the inner volume of wicking element 162 may extend away from each other. This configuration helps widen the opening to the inner volume of wicking element 162, thereby helping to reduce the likelihood that wicking element 162 will seize, tear, and/or become damaged when assembled with heating element 500. Due to the material of the wicking element 162, the wicking element 162 may easily get caught, torn, and/or otherwise become damaged when assembled with (e.g., positioned within or inserted into) the heating element 500. Contact between wicking element 162 and outer edge 503 of rake wings 502 can also result in damage to the heating element. The shape and/or positioning of projections 580 may allow wicking element 162 to be more easily positioned within or into the pocket formed by rake wings 502 (e.g., the inner volume of heating element 500), thereby preventing or reducing the likelihood that wicking element 162 and/or the heating element will be damaged. Thus, the projections 580 help reduce or prevent damage to the heating element 500 and/or the wicking element 162 when the wicking element 162 comes into thermal contact with the heating element 500. The shape of the projections 580 also helps to minimize the effect on the resistance of the heater portion 504.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 may be plated with one or more outer plating materials 150 to reduce the contact resistance at the point where the heating element 500 contacts the receptacle contacts 125.

Fig. 93A-98B illustrate another example of a heating element 500 consistent with embodiments of the present subject matter. As shown, heating element 500 includes one or more rake wings 502 in a localized heating portion 504, one or more legs 506 extending from rake wings 502, and cartridge contacts 124 formed at an end portion of and/or as part of each of the one or more legs 506.

Rake wings 502 may be folded and/or rolled to define a pocket in which wicking element 162 (e.g., a flat pad) is placed. Rake wing 502 includes a platform rake wing 524 and a side rake wing 526. Platform rake wings 524 are configured to contact one side of wicking element 162 and side rake wings 526 are configured to contact the other, opposite sides of wicking element 162. Platform rake wings 524 and side rake wings 526 form pockets shaped to receive wicking element 162 and/or conform to the shape of at least a portion of wicking element 162. The pocket allows the wicking element 162 to be secured and held within the pocket by the heating element 500.

In this example, the rake wings 502 have the same shape and size, and the rake wings are spaced apart from each other by an equal distance. Here, rake wing 502 includes a first side rake wing 526A and a second side rake wing 526B spaced apart by a platform rake wing 524. Each of first side rake wing 526A and second side rake wing 526B includes an inner region 576 positioned proximate to platform rake wing 524 and an outer region 578 positioned proximate to outer edge 503. At outer region 578, first side rake wing 526A is positioned substantially parallel to second side rake wing 526B. At inner region 576, first side rake wing 526A is positioned offset from second side rake wing 526B and first side rake wing 526A and second side rake wing 526B are not parallel. This configuration may help maintain a constant and uniform temperature along the length of rake 502 of heating section 504. Maintaining a constant temperature along the length of rake wings 502 may provide a higher quality aerosol because the maximum temperature may be maintained more uniformly throughout heating portion 504.

As described above, each leg 506 may include and/or define a cartridge contact 124, the cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the evaporator 100. In some embodiments, each pair of legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125. In some embodiments, legs 506 include retainer portions 180, and retainer portions 180 are configured to bend and extend generally away from heating portion 504. Retainer portion 180 is configured to be positioned within a corresponding recess in wicking portion housing 178. The retainer portion 180 forms the end of the leg 506. The retainer portion 180 helps secure the heating element 500 and wicking element 162 to the wick housing 178 (and evaporator cartridge 120). The holder portion 180 may have a tip portion 180A that extends from an end of the holder portion 180 toward the heating portion 504 of the heating element 500. This configuration reduces the likelihood that the retainer portion will contact another portion of the evaporator cartridge 120 or a cleaning device used to clean the evaporator cartridge 120.

The outer edge 503 of the rake wings 502 in the heater section 504 may include a protrusion 580. The protrusion 580 may extend outward from the outer edge 503 and away from the center of the heating element 500. Projections 580 may be shaped to allow wicking element 162 to be more easily positioned within the pocket formed by rake wings 502, thereby preventing or reducing the likelihood that wicking element 162 will be caught by outer rim 503. The shape of the projections 580 helps minimize the effect on the resistance of the heating portion 504.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 may be plated with one or more outer plating materials 150 to reduce contact resistance at the point where the heating element 500 contacts the receptacle contacts 125.

Fig. 99-100 illustrate an example of the atomizer assembly 141 with the heating element 500 assembled with the wick housing 178, and fig. 101 illustrates an exploded view of the atomizer assembly 141 consistent with embodiments of the present subject matter. Wicking housing 178 may be made of plastic, polypropylene, or the like. The wicking housing 178 includes four recesses 192 in which at least a portion of each of the legs 506 of the heating element 500 can be positioned and secured. As shown, wicking housing 178 also includes an opening 193 that provides access to an inner volume 594 in which at least heating portion 504 of heating element 500 and wicking element 162 are positioned.

Wicking housing 178 may also include a separate thermal barrier 518A, which is shown in fig. 102. Thermal barrier 518A is positioned within wicking housing 178 within inner volume 594, between the walls of wicking housing 178 and heating element 500. The thermal barrier 518A is shaped to at least partially surround the heating portion 504 of the heating element 500 and is shaped to space the heating element 500 from the sidewall of the wicking housing 178. The thermal barrier 518A may help isolate the heating portion 504 from the evaporator cartridge 120 and/or the body of the wicking housing 178. The thermal barrier 518A helps minimize the impact of heat emanating from the heating portion 504 on the body of the evaporator cartridge 120 and/or the wick housing 178 to protect the structural integrity of the body of the evaporator cartridge 120 and/or the wick housing 178 and prevent melting or other deformation of the evaporator cartridge 120 and/or the wick housing 178. The thermal barrier 518A may also help maintain a consistent temperature at the heating portion 504 by retaining heat within the heating portion 504, thereby preventing or limiting heat loss.

Thermal barrier 518A includes one or more slots 590 (e.g., three slots) at one end, which one or more slots 590 are aligned with one or more slots (e.g., one, two, three, four, five, six, or seven or more slots) formed in a portion of wicking housing 178 opposite opening 193, such as a base of wicking housing 178 (see fig. 57 and 69). One or more grooves 590, 196 allow pressure escape caused by the flow of liquid vaporizable material and vaporization of vaporizable material within heater portion 504 without affecting the liquid flow of vaporizable material.

In some embodiments, a diffuse flow may occur between the heating element 500 (e.g., legs 506) and the outer wall of the wick housing 178 (or between portions of the heating element 500). For example, liquid vaporizable material may accumulate due to capillary pressure between legs 506 of heating element 500 and the outer wall of wick housing 178, as indicated by liquid path 599. In this case, there may be sufficient capillary pressure to draw the liquid vaporizable material out of the reservoir and/or heated portion 504. To help limit and/or prevent liquid vaporizable material from escaping the internal volume of the wicking portion housing 178 (or heating portion 504), the wicking portion housing 178 and/or heating element 500 can include a capillary feature that causes an abrupt change in capillary pressure, thereby forming a liquid barrier that prevents liquid vaporizable material from passing through the feature without the use of an additional seal (e.g., an air-tight seal). The wicking features may define capillary breaks formed by sharp points, bends, curved surfaces, or other surfaces in the wick housing 178 and/or the heating element 500. The wicking feature allows the conductive element (e.g., heating element 500) to be positioned in the wet and dry region.

The wicking feature may be positioned on and/or formed in a portion of the heating element 500 and/or the wicking housing 178 and cause an abrupt change in capillary pressure. For example, the capillary features may include bends, sharp points, curved surfaces, angled surfaces, or other surface features along the length of the heating element or another component of the evaporator cartridge that cause an abrupt change in capillary pressure between the heating element and the wick housing. The capillary features can also include projections or other portions of the heating element and/or wick housing that widen the capillary channel (e.g., formed between portions of the heating element, between the heating element and the wick housing, etc.) sufficiently to reduce capillary pressure within the capillary channel (e.g., the capillary features space the heating element from the wick housing) such that the capillary channel does not draw liquid into the capillary channel. Thus, the capillary feature prevents or limits liquid flow along a liquid path beyond the capillary feature due, at least in part, to sudden changes and/or decreases in capillary pressure. The size and/or shape of the capillary features (e.g., bends, cusps, curved surfaces, angled surfaces, protrusions, etc.) may be a function of the wetting angle formed between materials (e.g., the heating element and the wick housing or other walls of a capillary channel formed between the components), may be a function of the material of the heating element and/or wick housing or other components, and/or may be a function of the size of a gap formed between two components (e.g., the heating element and/or wick housing defining a capillary channel), among other characteristics.

As an example, fig. 103A and 103B illustrate a wicking housing 178 having a capillary feature 598 that causes an abrupt change in capillary pressure. The capillary features 598 prevent or limit liquid from flowing along the liquid path 599 beyond the capillary features 598 and help prevent liquid from collecting between the legs 506 and the wick housing 178. Capillary features 598 on the wick housing 178 space the heating element 500 (e.g., a component made of metal or the like) from the wick housing 178 (e.g., a component made of plastic or the like), thereby reducing the capillary strength between the two components. The capillary features 598 shown in fig. 103A and 103B also include sharp edges at the ends of the beveled surfaces of the wick housing that limit or prevent liquid flow beyond the capillary features 598.

As shown in fig. 103B, legs 506 of heating element 500 can also be angled inward toward the inner volume of heating element 500 and/or wick housing 178. The beveled legs 506 may form capillary features that help limit or prevent liquid from spilling over the outer surface of the heating element and flowing along the legs 506 of the heating element 500.

As another example, heating element 500 may include a capillary feature (e.g., bridge 585) formed with one or more legs 506 and spacing legs 506 from heating portion 504 (see fig. 82-98). The bridge 585 may be formed by folding the heating element 500 along

fold lines

520, 522. In some embodiments, bridging 585 helps reduce or eliminate overflow of vaporizable material from heating portion 504, such as by capillary action. In some examples, such as the example heating element 500 shown in fig. 93A-98B, the bridge portions 585 are beveled and/or include bends to help restrict fluid flow out of the heating portion 504.

As another example, the heating element 500 may include a capillary feature 598 that defines a sharp point to cause an abrupt change in capillary pressure to prevent the liquid vaporizable material from flowing beyond the capillary feature 598. Fig. 104 illustrates an example of a heating element 500 having a capillary feature 598 consistent with an embodiment of the present subject matter. As shown in fig. 104, capillary features 598 may form ends of bridge portions 585 that extend outwardly away from heating portion by a distance greater than the distance between legs 506 and heating portion 504. The ends of bridge 585 may be sharp edges to further help prevent liquid vaporizable material from passing to legs 506 and/or out of heating portion 504, thereby reducing leakage and increasing the amount of vaporizable material remaining in heating portion 504.

Fig. 105-106 illustrate a variation of the heating element 500 shown in fig. 87-92. In this variation of the heating element 500, the legs 506 of the heating element 500 include a bend at the inflection region 511. The bend in the leg 506 may form a capillary feature 598 that helps prevent the liquid vaporizable material from flowing beyond the capillary feature 598. For example, a bend may cause an abrupt change in capillary pressure, which may also help limit or prevent liquid vaporizable material from flowing beyond the bend and/or collecting between legs 506 and wicking portion housing 178, and which may help limit or prevent liquid vaporizable material from flowing out of heating portion 504.

Fig. 107-108 illustrate a variation of the heating element 500 shown in fig. 93A-98B. In this variation of the heating element 500, the legs 506 of the heating element 500 include a bend at the inflection region 511. The bend in the leg 506 may form a capillary feature 598 that helps prevent the liquid vaporizable material from flowing beyond the capillary feature 598. For example, a bend may cause an abrupt change in capillary pressure, which also helps to limit or prevent liquid vaporizable material from flowing beyond the bend and/or collecting between legs 506 and wicking portion housing 178, and which may help to limit or prevent liquid vaporizable material from flowing out of heating portion 504.

Fig. 111A-112 illustrate another example of an atomizer assembly 141 with a heating element 500 assembled with a wicking portion housing 178 and a thermal barrier 518A, and fig. 113 illustrates an exploded view of atomizer assembly 141 consistent with embodiments of the present subject matter. Wicking housing 178 may be made of plastic, polypropylene, or the like. The wicking housing 178 includes four recesses 192 in which at least a portion of each of the legs 506 of the heating element 500 can be positioned and secured. Within recess 192, wick housing 178 can include one or more wick housing retention features 172 (see fig. 115A) that help secure heating element 500 to wick housing 178, such as, for example, by a snap-fit arrangement between at least a portion of legs 506 of heating element 500 and wick housing retention features 172. Wick housing retention feature 172 may also help space heating element 500 from the surface of wick housing 178 to help prevent heat from acting on the wick housing and melting a portion of wick housing 178.

As shown, wicking housing 178 also includes an opening 193 that provides access to an inner volume 594 in which at least heating portion 504 of heating element 500 and wicking element 162 are positioned.

Wicking housing 178 may also include one or more other cutouts that help space heating element 500 from the surface of wicking housing 178 to reduce the amount of heat contacting the surface of wicking housing 178. For example, the wick housing 178 may include a cutout 170. Cut-outs 170 may be formed along the outer surface of wicking portion housing 178 adjacent opening 193. The cutout 170 may further include a capillary feature, such as capillary feature 598. The capillary feature of the cut-out 170 can define a surface (e.g., a curved surface) that disrupts a tangent point between adjacent (or intersecting) walls (e.g., walls of the wick housing). The curved surface may have a radius sufficient to reduce or eliminate capillary action formed between adjacent outer walls of the wick housing.

Referring to fig. 111A-112, wicking housing 178 can include projections 168. The projections 168 may help properly position and/or orient the wick housing relative to one or more other components of the evaporator cartridge during assembly of the evaporator cartridge. For example, the additional material forming the projections 168 offsets the centroid of the wicking housing 178. Because of the offset center of mass, the wick housing 178 can rotate or slide in a particular orientation during assembly to align with a corresponding feature of another component of the evaporator cartridge.

114A-114C illustrate an example method of forming an atomizer assembly 141 of an evaporator cartridge 120 including a wicking portion housing 178, a wicking element 162, and a heating element 500, consistent with embodiments of the present subject matter. As shown in fig. 114A, wicking element 162 can be inserted into a pocket formed in heating element 500 (e.g., formed by side rake wings 526 and platform rake wings 524). In some embodiments, the wicking element 162 expands after being secured to the heating element 500 when the vaporizable material is introduced to the wicking element 162.

Fig. 114B shows wicking element 162 and heating element 500 coupled to wicking portion housing 178, and fig. 114C shows an example of wicking element 162 and heating element 500 assembled with wicking portion housing 178. At least a portion of the heating element 500, such as the heating portion 504, may be positioned within the internal volume of the wicking portion housing 178. Legs 506 of heating element 500 (e.g., retainer portion 180) may be coupled with the outer wall of wick housing 178 via, for example, a snap-fit arrangement. In particular, retainer portions 180 of legs 506 may be coupled with and at least partially positioned within recesses in wick housing 178.

Fig. 115A-115C illustrate a method of forming an atomizer assembly 141 of an evaporator cartridge 120 including a wick housing 178, a wick element 162, and a heating element 500, consistent with an embodiment of the present subject matter. As shown in fig. 115A, heating element 500 may be coupled to wicking portion housing 178, for example, by inserting or otherwise positioning at least a portion of heating element 500 (such as heating portion 504) within the internal volume of wicking portion housing 178. Legs 506 of heating element 500 (e.g., retainer portion 180) may be coupled with the outer wall of wick housing 178 via, for example, a snap-fit arrangement. In particular, retainer portion 180 or another portion of leg 506 may be coupled with and at least partially positioned within a recess in wick housing 178, such as by coupling with wick housing retention feature 172.

As shown in fig. 115B, wicking element 162 can be inserted into a pocket formed in heating element 500 (e.g., formed by side rake wings 526 and platform rake wings 524). In some embodiments, the wicking element 162 is compressed when the wicking element 162 is coupled with the heating element 500. In some embodiments, the wicking element 162 fits within the heating element 500 and expands after being secured to the heating element when the vaporizable material is introduced to the wicking element 162.

Fig. 115C shows an example of the wicking element 162 and heating element 500 assembled with the wicking housing 178 to form the atomizer assembly 141.

Fig. 116 illustrates an exemplary process 3600 for assembling a heating element 500 consistent with embodiments of the present subject matter. Process flow diagram 3600 illustrates features of a method that may optionally include some or all of the following. At block 3610, a flat substrate having resistive heating characteristics is provided. At block 3612, the flat substrate may be cut and/or stamped into a desired geometry. At block 3614, at least a portion of the heating element 500 may be plated. For example, as described above, one or more layers of plating material (e.g., an adhesive plating material and/or an outer plating material) may be deposited onto at least a portion of the outer surface of the heating element 500. At block 3616, heating portion 504 (e.g., rake wings 502) may be bent and/or otherwise crimped around the wicking element to match the shape of the wicking element and secure the wicking element to the heating element. At block 3618, the cartridge contacts 124, which in some embodiments form end portions of the legs 506 of the heating element 500, may be bent in the first or second direction along a plane perpendicular to the first or second direction or a third direction. At block 3620, the heating element 500 may be assembled into the evaporator cartridge 120 and may facilitate fluid communication between the wicking element 162 and the reservoir of vaporizable material. At block 3622, the vaporizable material may be drawn into the wicking element 162, which may be positioned in contact with at least two surfaces of the heated portion 504 of the heating element 500. At block 3624, a heating fixture may be provided to the cartridge contacts 124 of the heating element to heat the heating element 500 at least the heating portion 504. The heating causes evaporation of the vaporizable material. At block 3626, the vaporized vaporizable material is entrained in the air flow to the mouthpiece of the vaporization cartridge where the heating element is located.

Condensate control, collection and recycle embodiments

117-119C illustrate an embodiment of an evaporator pod including one or more features for controlling, collecting, and/or recycling condensate in an evaporator device. While the features described and illustrated with reference to fig. 117-119C may be included in and/or may include one or more features of the various embodiments of evaporator cartridges described above, the features of the evaporator cartridges described and illustrated with reference to fig. 117-119C may additionally and/or alternatively be included in one or more other exemplary embodiments of evaporator cartridges, such as those described below.

A typical method of a vaporizer device for generating an inhalable aerosol from a vaporizable material includes heating the vaporizable material in a vaporization chamber (or heater chamber) to convert the vaporizable material to a gas phase (or vapor). A vaporization chamber generally refers to an area or volume in a vaporizer device within which a heat source (e.g., conductive, convective, and/or radiant) causes heating of a vaporizable material to produce a mixture of air and vaporized vaporizable material to form a vapor for inhalation by a user of the vaporizer device.

As evaporator devices are introduced into the market, evaporator cartridges containing free liquid (i.e., liquid held in a reservoir rather than by a porous material) have gained popularity. The products on the market may have a cotton pad or no feature at all to collect the condensate generated by the steam generated in the evaporator device.

The liquid resulting from condensation may form a film on the walls of the airway and may travel up the mouthpiece, with the potential for leakage into the mouth of the user, which may cause an unpleasant experience. Even if the wall membrane does not leak out of the mouthpiece, it is entrained by the airflow, creating large droplets that are inhaled into the mouth and throat of the user, resulting in an unpleasant experience for the user. The problems with using a cotton pad to absorb such condensate include inefficiency and additional manufacturing and assembly costs of integrating the cotton pad into a portion of the evaporator device. Furthermore, the accumulation and loss of condensate and/or unevaporated vaporizable material eventually results in the inability to draw all of the vaporizable material into the vaporization chamber, thereby wasting the vaporizable material. Accordingly, there is a need for an improved evaporator device and/or evaporator cartridge.

As described in more detail below, evaporation of the vaporizable material into an aerosol can result in collection of the condensate along one or more internal passages and outlets (e.g., along a mouthpiece) of some vaporizers. For example, such condensate may include vaporizable material that is withdrawn from the reservoir, formed into an aerosol, and condensed into condensate prior to exiting the vaporizer. In addition, vaporizable material that has circumvented the vaporization process can also accumulate along one or more internal passages and/or air outlets. This may result in condensation and/or non-evaporated vaporizable material exiting the mouthpiece outlet and being deposited into the user's mouth, thereby creating an unpleasant user experience and reducing the amount of inhalable aerosol that would otherwise be available. In addition, the accumulation and loss of condensate eventually results in the inability to draw all of the vaporizable material from the reservoir into the vaporization chamber, thereby wasting the vaporizable material. For example, as particles of vaporizable material accumulate in the internal passageway of the air tube downstream of the vaporization chamber, the effective cross-sectional area of the air flow passageway narrows, thereby increasing the flow rate of the air and thereby imparting a drag force on the accumulated fluid, thereby increasing the likelihood of entrainment of fluid from the internal passageway and through the mouthpiece outlet. Various features and devices are described below that ameliorate or overcome these problems.

As described above, the drawing of the vaporizable material from the reservoir and vaporizing the vaporizable material into an aerosol can cause a condensation of the vaporizable material to collect near and/or within one or more outlets formed in the mouthpiece. This can result in condensate exiting the outlet and depositing into the user's mouth, creating an unpleasant user experience and reducing the amount of consumable vapor that would otherwise be available. Various evaporator device features that ameliorate or overcome these problems are described below. For example, various features are described herein for controlling condensate in an evaporator apparatus that may provide advantages and improvements over existing methods while also introducing additional benefits as described herein. For example, evaporator device features are described that are configured to collect and contain condensate that forms or collects near an outlet of a mouthpiece, thereby preventing the condensate from exiting the outlet.

Alternatively or additionally, drawing the vaporizable material 102 from the reservoir 140 and vaporizing the vaporizable material into an aerosol can cause condensation to accumulate within one or more tubes or internal passages (e.g., air tubes) of the evaporator device. As will be described in greater detail below, evaporator device features are described that are configured to capture condensate and prevent particles of vaporizable material from exiting the air outlet of the evaporator cartridge.

Fig. 117 illustrates an embodiment of the evaporator sump 120 that includes a finned condensate collector 352, the finned condensate collector 352 configured to collect and contain condensate that forms or collects near an outlet of a mouthpiece or other region of the evaporator sump 120, thereby preventing condensate from exiting the outlet. As shown in fig. 117, a finned condensate collector 352 may be provided in the mouthpiece 130 in a chamber adjacent the outlet 136 such that the aerosol passes through the finned condensate collector 352 before exiting through the outlet 136.

Fig. 118 illustrates an embodiment of a mouthpiece 330 that includes an embodiment of a finned condensate collector 352 having a plurality of microfluidic fins 354. The mouthpiece 330 may be configured for use with an evaporator pod (e.g., evaporator pod 120) and/or an evaporator apparatus (e.g., evaporator 100) in which the microfluidic fins 354 are housed in the fin condensate collector 352 to improve condensate collection and housing in the evaporator pod. As shown in fig. 118, the microfluidic fin 354 includes a set of walls 355 or other protrusions and narrow grooves 353 having microfluidic properties. In an exemplary embodiment, each wall in the set of walls 355 may be positioned parallel or substantially parallel to each other such that the space between each wall creates a recess 353 that defines a capillary passage. The walls 355 define or otherwise form one or more capillary channels or grooves configured to collect fluid or other condensate.

The mouthpiece 330 shown in fig. 118 may improve or otherwise alter the collection and containment of condensate within the reservoir such that condensate flowing from the air tube outlet 332 (e.g., the air tube or cannula 128 shown in fig. 117) may be trapped or otherwise collected between the microfluidic fins 354 when a user inhales on the evaporator device. As described above, the microfluidic fins define one or more capillary channels, and fluid is collected by capillary forces created when the fluid is located within the capillary channels. To keep the fluid captured by the finned condensate collector 352 from being drawn by the drag force of the airflow, the capillary force of the microfluidic heat sink can be greater than the airflow drag force by providing narrow grooves or channels in which the fluid is positioned. For example, the effective groove width may be 0.3mm, and/or range from about 0.1mm to about 0.8 mm.

One advantage of this configuration is that no additional components need to be manufactured, thereby reducing the number of components without loss of functionality. In one embodiment, the finned condensate collector and mouthpiece may be manufactured as a single body using one mold (e.g., a plastic mold). Additionally, the finned condensate collector and mouthpiece may be separate structures welded together that together form the finned condensate collector. Other manufacturing methods and materials are also within the scope of the present disclosure.

In other embodiments, the microfluidic fin may be formed as a separate component and fitted into the mouthpiece. For example, the microfluidic fins may be formed in any portion of the evaporator device or evaporator cartridge that is used to collect and contain condensate. The microfluidic fin may be formed with the mouthpiece or may be formed as a second plastic component and fitted into the mouthpiece.

In addition to collecting in the mouthpiece, vaporizable material condensate may accumulate in one or more airflow channels or internal passages of the vaporizer device. Various features and devices that ameliorate or overcome these problems are described below. For example, various features are described herein for recirculating condensate in an evaporator apparatus, such as embodiments of a condensate recycler system, as will be described in more detail below.

Fig. 119A-119C illustrate an embodiment of a condensate recirculator system 360 of an evaporator cartridge (e.g., evaporator cartridge 120) and/or an evaporator apparatus (e.g., evaporator 100). The condensate recycler system 360 may be configured to collect the vaporizable material condensate and direct the condensate back to the core for reuse.

The condensate recirculator system 360 may include an internally grooved air tube 334 that forms an air flow channel 338 extending from the mouthpiece toward the evaporation chamber 342, and may be configured to collect any vaporizable material condensate and direct it (via capillary action) back to the wicking portion for reuse.

One function of the grooves may include evaporative material condensate being trapped or otherwise positioned within the grooves. Once the condensate is within the groove, the condensate drains downwardly to the wicking portion due to capillary action created by the wicking element. Drainage of condensate within the grooves may be achieved at least in part by capillary action. If there is any condensate within the air tube, the particles of vaporizable material fill the grooves rather than forming or establishing condensation walls within the air tube in the absence of grooves. When the grooves are filled sufficiently to establish fluid communication with the wicking portion, condensate passes through and drains from the grooves and may be reused as vaporizable material. In some embodiments, the grooves may be tapered such that the grooves are narrower toward the wicking portion and wider toward the mouthpiece. This constriction may promote the movement of the fluid towards the evaporation chamber, as more condensate is collected in the grooves by higher capillary action at the narrower points.

Fig. 119A shows a cross-sectional view of the air tube 334. The air tube 334 includes an air flow passage 338 and one or more internal grooves having a decreasing hydraulic diameter toward the evaporation chamber 342. The grooves are sized and shaped such that a fluid (e.g., condensate) disposed within the grooves may be transported from a first location to a second location via capillary action. The internal grooves include an air tube groove 364 and a chamber groove 365. The air tube recess 364 may be disposed inside the air tube 334 and may narrow such that a cross-section of the air tube recess 364 at the air tube first end 362 may be greater than a cross-section of the air tube recess 364 at the air tube second end 363. The chamber recess 365 may be disposed proximate the air tube second end 363 and coupled with the air tube recess 364. The internal groove may be in fluid communication with the wicking portion and configured to allow the wicking portion to continuously drain the vaporizable material condensate from the internal groove, thereby preventing a thin film of condensate from forming in the air flow channel 338. Condensate may preferentially enter the inner trough due to capillary actuation of the inner trough. The capillary driven gradient in the interior grooves directs the migration of fluid toward the wick housing 346 where the vaporizable material condensate is recirculated by re-saturating the wicking portion.

Fig. 119B and 119C illustrate internal views of the condensate recirculator system 360 from the air tube first end 362 and the air tube second end 363, respectively. The air tube first end 362 may be disposed proximate the mouthpiece and/or the air outlet. The air tube second end 363 may be disposed proximate to the evaporation chamber 342 and/or the wicking housing 346, and may be in fluid communication with the chamber recess 365 and/or the wicking. The air tube recess 364 may have a first diameter 366 and a second diameter 368. The second diameter 368 may be narrower than the first diameter 366.

As described above, as the effective cross-section of the air flow channel narrows (either due to accumulation of condensate in the air flow channel or due to design as described herein), the flow rate of air moving through the air tube increases, thereby exerting a drag force on the accumulated fluid (e.g., condensate). When the drag force pulling the fluid out toward the user (e.g., in response to a suction on the vaporizer) is greater than the capillary force pulling the fluid toward the wicking portion, the fluid exits the air outlet.

To overcome this problem and encourage condensate to move away from the mouthpiece outlet and back towards the evaporation chamber 342 and/or the wicking portion, a constricted airflow path is provided such that the cross-section of the air duct groove 364 adjacent the evaporation chamber 342 is narrower than the cross-section of the air duct groove 364 adjacent the mouthpiece. Further, each interior groove narrows such that the width of the interior groove proximate the air tube first end 362 may be wider than the width of the interior groove proximate the air tube second end 363. As such, the narrowed channel increases the capillary drive of the air tube groove 364 and promotes fluid movement of condensate toward the chamber groove 365. Further, the chamber recess 365 near the air tube second end 363 may be wider than the width of the chamber recess 365 near the wicking portion. That is, each of the groove channels gradually narrows near the wick, except for the gas flow channel itself which narrows toward the wick end.

To maximize the effectiveness of the capillary action provided by the condensate recirculator system design, air tube cross-sectional dimensions relative to groove dimensions may be considered. While capillary drive may increase as the slot width narrows, smaller slot sizes may cause condensation to overflow the slots and clog the air tubes. Thus, the groove width may range from about 0.1mm to about 0.8 mm.

In some embodiments, the geometry or number of grooves may vary. For example, the grooves may not necessarily have a hydraulic diameter that decreases towards the wicking portion. In some embodiments, the reduced hydraulic diameter toward the wicking portion may improve the performance of capillary drive, although other embodiments are contemplated. For example, the internal grooves and channels may have a substantially straight configuration, a narrowed configuration, a spiral configuration, and/or other arrangements.

In some embodiments, the features required to generate capillary drive may be integrated with a housing structure of the aerosol-generating unit (e.g., the evaporation chamber), a mouthpiece, and/or a portion of a separate plastic component (e.g., the finned condensate collector discussed herein).

Term(s) for

When a feature or element is referred to herein as being "on" another feature or element, the feature or element may be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements present. It will also be understood that when a feature or element is referred to as being "connected," "attached," or "coupled" to another feature or element, it can be directly connected, attached, or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being "directly connected," "directly attached," or "directly coupled" to another feature or element, there are no intervening features or elements present.

Although described or illustrated with respect to one embodiment, the features and elements so described or illustrated may be applicable to other embodiments. One skilled in the art will also appreciate that references to a structure or feature that is disposed "adjacent" another feature may have portions that overlap or underlay the adjacent feature.

The terminology used herein is for the purpose of describing particular embodiments and implementations only and is not intended to be limiting. For example, as used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items and may be abbreviated as "/".

In the description above and in the claims, phrases such as "at least one of … …" or "one or more of … …" may appear after a consecutive listing of elements or features. The term "and/or" may also be present in a list of two or more elements or features. Such phrases are intended to mean any of the recited elements or features individually or in any combination with any of the other recited elements or features, unless otherwise implicitly or explicitly contradicted by context in which such phrase is used. For example, the phrases "at least one of a and B", "one or more of a and B", and "a and/or B" are each intended to mean "a alone, B alone, or a and B together". Similar interpretations are also intended to include more than three items. For example, the phrases "at least one of A, B and C", "one or more of A, B and C", and "A, B and/or C" are each intended to mean "a alone, B alone, C alone, a and B together, a and C together, B and C together, or a and B and C together". The use of the term "based on" above and in the claims is intended to mean "based at least in part on" such that non-recited features or elements are also permitted.

Spatially relative terms, such as "forward," "rearward," "below … …," "below … …," "below," "over … …," "over," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device is turned over in the drawings, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below … …" can include both an orientation of "above … …" and an orientation of "below … …". The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted correspondingly. Similarly, the terms "upward," "downward," "vertical," "horizontal," and the like are used herein for the purpose of illustration only, unless explicitly indicated otherwise.

Although the terms "first" and "second" may be used herein to describe different features/elements (including steps), these features/elements should not be limited by these terms unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed below could be termed a second feature/element, and similarly, a second feature/element discussed below could be termed a first feature/element, without departing from the teachings provided herein.

As used in this specification and the claims, including as used in the examples, and unless otherwise expressly specified, all numbers may be read as if prefaced by the word "about" or "approximately", even if the term does not expressly appear. When describing sizes and/or locations, the phrase "about" or "approximately" may be used to indicate that the described values and/or locations are within a reasonably expected range of values and/or locations. For example, a numerical value may have a value (or range of values) that is +/-0.1% of the stated value, a value (or range of values) that is +/-1% of the stated value, a value (or range of values) that is +/-2% of the stated value, a value (or range of values) that is +/-5% of the stated value, a value (or range of values) that is +/-10% of the stated value, and the like. Any numerical value given herein is also to be understood as including about that value or about that value unless the context indicates otherwise. For example, if the value "10" is disclosed, then "about 10" is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when values are disclosed that "less than or equal to" the recited value, "greater than or equal to" the recited value, and possible ranges between values are also disclosed, as is well understood by those of skill in the art. For example, if the value "X" is disclosed, "less than or equal to X" and "greater than or equal to X" (e.g., where X is a numerical value) are also disclosed. It is also understood that throughout this application, data is provided in a number of different forms, and that the data represents endpoints and starting points and ranges for any combination of data points. For example, if a particular data point "10" and a particular data point "15" are disclosed, it is understood that greater than, greater than or equal to, less than or equal to, and equal to 10 and 15 are also considered disclosed, along with between 10 and 15. It is also understood that each unit between two particular units is also disclosed. For example, if 10 and 15 are disclosed, 11, 12, 13 and 14 are also disclosed.

Although various illustrative embodiments have been described above, any number of variations may be made in the various embodiments without departing from the teachings herein. For example, the order in which the different described method steps are performed may often be varied in alternative embodiments, and in other alternative embodiments one or more method steps may be skipped entirely. Optional features in different device and system embodiments may be included in some embodiments and not in others. Accordingly, the foregoing description is provided primarily for the purpose of illustration and should not be construed to limit the scope of the claims.

One or more aspects or features of the subject matter described herein may be implemented as follows: digital electronic circuitry, integrated circuitry, specially designed Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs) computer hardware, firmware, software, and/or combinations thereof. These various aspects or features may include embodiments that employ one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device. A programmable or computing system may include clients and servers. A client and server are conventionally remote from each other and typically interact through a communication network. The association of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

These computer programs, which may also be referred to as "programs," "software applications," "components," or "code," include machine instructions for a programmable processor, and may be implemented in a high-level programming language, an object-oriented programming language, a functional programming language, a logical programming language, and/or in assembly/machine language. As used herein, the term "machine-readable medium" refers to any computer program product, apparatus and/or device for providing machine instructions and/or data to a programmable processor, such as, for example, magnetic disks, optical disks, memory, and Programmable Logic Devices (PLDs), including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal used to provide machine instructions and/or data to a programmable processor. A machine-readable medium may store such machine instructions non-transitory, such as, for example, non-transitory solid state memory or a magnetic hard drive or any equivalent storage medium. A machine-readable medium may alternatively or additionally store such machine instructions in a transitory manner, such as, for example, a processor cache or other random access memory associated with one or more physical processor memories.

The examples and illustrations contained herein show by way of illustration, and not limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and derived from the specific embodiments, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.

The disclosed subject matter has been provided herein with reference to one or more features or embodiments. Those skilled in the art will recognize and appreciate that while the detailed nature of the exemplary embodiments are provided herein, variations and modifications may be made to the described embodiments without limiting or departing from the generally intended scope. These and various other modifications and combinations of the embodiments provided herein are within the scope of the disclosed subject matter as defined by the disclosed elements and features, and their full equivalents.

A portion of the disclosure of this patent document may contain material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the patent and trademark office patent file or records, but otherwise reserves all copyright rights whatsoever. Some of the indicia referenced herein may be a common legal or registered trademark of the applicant, assignee, or a third party with whom the applicant or assignee may or may not be affiliated. The use of these indicia is intended to provide an enabling disclosure by way of example and should not be construed to limit the scope of the disclosed subject matter exclusively to the materials associated with these indicia.

Claims

1. A microfluidic shutter for controlling a flow of liquid vaporizable material between a storage chamber and an adjacent overflow volume in a vaporizer, comprising:

a plurality of openings connecting the reservoir and collector, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel; and

a condensation point located between the plurality of openings.

2. The microfluidic gate of claim 1, comprising an edge of the orifice between the reservoir chamber and the collector that is flatter on a first side facing the reservoir chamber than on a second, more radiused side facing the collector.

3. The microfluidic shutter of claim 2, wherein the microfluidic shutter is configured to allow efficient bubble release into a storage chamber while maintaining a barrier to outflow of liquid from the storage chamber into the microfluidic shutter.

4. The microfluidic gate of claim 1, wherein the collector comprises a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with the storage chamber, the capillary structure comprising a microfluidic feature configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

5. The microfluidic shutter of claim 4, wherein the collector further comprises a primary channel providing fluid connection between the reservoir chamber and an atomizer configured to convert the liquid vaporizable material to a vapor phase state, wherein the primary channel is formed by a structure of the collector.

6. The microfluidic shutter of claim 4, wherein the capillary structure comprises a secondary channel, and wherein the microfluidic feature is configured to allow the liquid vaporizable material to flow along a length of the secondary channel only in which the meniscus completely covers a cross-sectional area of the secondary channel.

7. The microfluidic gate of claim 6, wherein the cross-sectional area is sufficiently small that the liquid vaporizable material preferentially wets the secondary channel around its entire perimeter for the material forming the walls of the secondary channel and the composition of the liquid vaporizable material.

8. The microfluidic gate of claim 6, wherein the secondary channel comprises a plurality of spaced constriction points having a smaller cross-sectional area than the portion of the secondary channel between the constriction points.

9. The microfluidic gate of claim 8, wherein the constriction point has a flatter surface oriented along the secondary channel toward the reservoir chamber and a rounded surface oriented along the secondary channel away from the reservoir chamber.