CN220326832U

CN220326832U - Collector element for a vaporizer for use with a liquid vaporizable material

Info

Publication number: CN220326832U
Application number: CN202321659203.2U
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: 2024-01-12
Anticipated expiration: 2029-10-17
Also published as: BE1026673A1; GB2587742A; MX2021004364A; GB2608918B; NL2024037A; CN111134366A; PL3664631T3; CN212629857U; WO2020081849A3; CN219330724U; ES2913163T3; HUE058137T2; GB202112638D0; WO2020081849A2; BE1026673B1; AU2019361098A1; PT3664631T; TW202103589A; GB2580214B; JP6963037B2

Abstract

The present application discloses a collector component for a vaporizer for use with a liquid vaporizable material, comprising: a reservoir configured to contain a liquid vaporizable material, the reservoir being at least partially defined by at least one wall, the reservoir comprising a storage chamber and an overflow volume; a collector disposed within the overflow volume, the collector formed with an overflow channel, a plurality of constriction points formed along a length of the overflow channel; and a microfluidic gate for controlling the flow of liquid vaporizable material between the reservoir and the overflow volume.

Description

Collector element for a vaporizer for use with a liquid vaporizable material

The present application is a divisional application of chinese utility model patent application No.202123367329.6 submitted on 10 months 17 in 2019, which is a divisional application of chinese utility model patent application No.202120392208.8 submitted on 10 months 17 in 2019, which is a divisional application of chinese utility model patent application No.201921746466.0 submitted on 10 months 17 in 2019.

Cross Reference to Related Applications

The priority of U.S. provisional application No. 62/915,005, entitled "CARTRIDGE FOR A VAPORIZER DEVICE", U.S. provisional application No. 62/812,161, entitled "CARTRIDGE FOR A VAPORIZER DEVICE", U.S. provisional application No. 62/747,099, entitled "WICK FEED AND HEATING ELEMENTS IN A v apizer DEVICE", U.S. provisional application No. 62/812,148, entitled "RESERVOIR OVERFLOW CONTROL WITH CONSTRICTION POINTS", U.S. provisional application No. 62/812,148, entitled "RESERVOIR OVERFLOW CONTROL", U.S. provisional application No. 62/747,055, entitled "VAPORIZER CONDENSATE COLLECTION AND RECYCLING", filed "2018, 10, 17, and U.S. provisional application No. 16/653,455, entitled" HEATING ELEMENT ", filed" 2019, 10, 28, and each of which is incorporated herein by reference in its entirety.

Technical Field

The disclosed subject matter relates generally to features of a cartridge for a vaporizer, and in some examples to the management of leakage of liquid vaporizable material, control of air flow within and near the cartridge, heating of vaporizable material to cause formation of an aerosol, and/or other assembly features of the cartridge and a device to which it may be detachably connected.

Background

A vaporizer device, which is generally referred to herein as a vaporizer, includes a device that heats a vaporizable material (e.g., liquid, plant material, some other solid, wax, etc.) to a temperature sufficient to release one or more components from the vaporizable material into a form (e.g., gas, aerosol, etc.) that can be inhaled by a user of the vaporizer. Some evaporators, such as those in which at least one of the components released from the vaporizable material is nicotine, can be used as smoking substitutes for combustible cigarettes.

Disclosure of Invention

For purposes of summarizing, certain aspects, advantages, and novel features are described herein. It is to be understood that not all of these advantages may be realized 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 or separated except where not feasible based on the present disclosure and as would be appreciated by those skilled in the art.

In one aspect, a vaporizer includes a reservoir configured to hold a liquid vaporizable material. The reservoir is at least partially defined by at least one wall, and the reservoir includes a storage chamber and an overflow volume. The evaporator further comprises 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. Alternatively, the microfluidic gate may comprise a rim of the aperture between the reservoir and the collector, the rim of the aperture being flatter on a first side facing the reservoir than on a second more rounded side facing the collector.

In another related aspect, which may be combined with the other aspects, the collector configured for insertion into the evaporator cartridge includes a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with the reservoir chamber of the evaporator 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 alternative variations, 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 a nebulizer configured to convert the liquid vaporizable material into a vapor phase state. The primary channel may be formed through the structure of the collector.

The primary channel may include a first channel configured to allow liquid vaporizable material to flow from the reservoir to a 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 along a length only in which the meniscus completely covers the cross-sectional area of the secondary channel. The cross-sectional area may be small enough such that the liquid vaporizable material preferentially wets the secondary channel around the entire perimeter of the secondary channel for the material forming the walls of the secondary channel and the composition of the liquid vaporizable material.

The reservoir and the collector may be configured to maintain a 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 results in the continuous column of liquid vaporizable material in the collector being at least partially pulled back into the reservoir. The secondary channel may include a plurality of spaced apart pinch points having a cross-sectional area that is smaller than the portion of the secondary channel between the pinch points. The pinch point may have a flatter surface oriented along the secondary channel toward the reservoir and a more rounded surface oriented along the secondary channel away from the reservoir.

The microfluidic gate may be located between the collector and the reservoir. The microfluidic gate may comprise a rim of the aperture between the reservoir and the collector, the rim 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 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. The meniscus of liquid vaporizable material reaching the condensation point can be directed to the second channel due to the higher capillary drive in the first channel, thereby forming bubbles to escape the liquid vaporizable material into the reservoir.

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

The collector may include a primary channel providing a fluid connection between the reservoir and the atomizer configured to convert the liquid vaporizable material to a vapor phase state, wherein the primary channel is formed through a structure of the collector. In an alternative variation, the capillary structure may comprise an auxiliary channel having microfluidic features, and the microfluidic features may be configured to allow the liquid vaporizable material to move along the secondary channel along a length only in which the meniscus completely covers the cross-sectional area of the secondary channel. The cross-sectional area of the secondary channel may be small enough such that the liquid vaporizable material preferentially wets the secondary channel around the entire perimeter of the secondary channel for the material forming the walls of the secondary channel and the composition of the liquid vaporizable material. 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 results in the continuous column of liquid vaporizable material in the continuous collector being at least partially lifted 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 secondary channel toward the reservoir and a more rounded surface oriented along the secondary channel away from the reservoir.

In yet another related aspect, an evaporator cartridge includes: a cartridge housing, a reservoir disposed within the cartridge housing and configured to hold 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 in the above aspect.

In alternative variations, such an evaporator cartridge may include one or more features as described herein, such as, for example, a wicking element located within the interior airflow path and in fluid communication with the reservoir. The wicking element may be configured to wick liquid vaporizable material from the reservoir. The heating element may be positioned to cause heating of the wicking element to cause at least some of the liquid vaporizable material withdrawn 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 monolithic hollow structure.

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

The channels in the overflow volume may lead to ports connected to ambient air. The reservoir or pocket may also comprise a first wick supply and an optional second wick supply, which are realized in the form of a first and a second cavity, respectively, through a collector placed in the cartridge. The collector may comprise one or more support structures forming channels in the overflow volume. The first and second chambers may control the flow of vaporizable material toward a wick housing configured to house a wicking element.

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

The collector may have a first end and a second end. The first end may be connected to an opening in the mouthpiece and a second end opposite the first end may be configured to receive a wick or wicking element. The wick housing according to some embodiments may include a set of prongs projecting outwardly from the second end to at least partially receive the wick element, and one or more compression ribs positioned adjacent the first or second wick supply and extending from the second end of the collector to compress the wick 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/gush out of the wick housing. The equilibrium pressure state may be maintained by establishing a liquid seal at the opening of the vent portion, which is positioned at a point where the reservoir chamber communicates with the passage in the overflow volume in the cartridge. By maintaining a sufficient capillary pressure for the vaporizable material meniscus to form at a portion of the vent to the channel in 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, a vent structure forming a primary channel and a secondary channel, which effectively configure a fluid valve to control a condensation point at least one of the primary channel or the secondary channel. According to an embodiment, the primary channel and the secondary channel 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 progressive reduction of 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 as the capillary drive of the primary and secondary channels gradually decreases 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 relief 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 state within the storage chamber, the vaporizable material flows into the channel (i.e., overflow volume) of the collector through the vent, wherein the vent is configured to maintain a liquid seal at the polycondensation point, desirably at all times. In certain embodiments, the vent is configured to facilitate a liquid seal at an opening from which vaporizable material flows between a reservoir of a reservoir and a passageway of a collector in an overflow volume.

In another related aspect, one or more wick supply channels may be implemented to control the direct flow of vaporizable material toward the wick. The first wick supply passage may be formed through a collector located in the overflow volume and independently of the primary and secondary passages of the control valve described above. The collector may comprise a support structure forming a 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 an embodiment, the first channel may have a cross-shaped cross-section or have partial dividing walls. The shape of the first channel may provide one or more non-primary sub-channels and one or more primary sub-channels that are larger in 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 may travel through the alternate sub-channels or primary channels. In a cross-shaped wick supply, the main subchannel may extend through the center of the cross-shaped wick supply. When the main sub-channel is restricted due to the formation of bubbles in a portion of the main sub-channel, the vaporizable material flows through at least one non-main sub-channel.

In some embodiments, the collector may have a first end facing the storage chamber and a second end facing away from the storage chamber and configured to include a wick housing. The second wick 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 while the vaporizable material flows through the first wick supply. The second wick supply portion may have a cross-shaped cross-section.

According to one or more aspects, a reservoir for a cartridge usable with an evaporator device may include a reservoir configured to hold an evaporable material. The reservoir may be in operative relationship with a nebulizer 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 in the reservoir, for example, when one or more factors cause the vaporizable material to enter the overflow volume in the cartridge.

One or more factors may include exposure of the cartridge to a pressure state that is different from the 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 include a channel connected to an opening or air control port that leads to the exterior 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 serve 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 may be drawn from the reservoir to the atomizer and converted to a vapor or aerosol phase, thereby reducing the volume of vaporizable material remaining in the reservoir of the reservoir.

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

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

The heating element may comprise a heating portion and at least two legs. The heating portion 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. Power is configured to be supplied from a power source to the heating portion to generate heat to evaporate 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 include 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 portions 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 portion, the second side rake portion, and the platform rake 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 heating 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 include 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 uniformly 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 rake wing is greater than the width of the heating element at an outer region adjacent an outer edge of the first side rake wing 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 the body of the evaporator device. 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 past the capillary feature. In some embodiments, the capillary feature comprises one or more bends in at least two legs. In some embodiments, the at least two legs extend at an angle toward the interior volume of the heating portion, the angled at least two legs defining the capillary feature.

In some embodiments, the evaporator device includes a reservoir containing an evaporable 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 portion 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. Power is configured to be supplied from a power source to the heating portion to generate heat to evaporate the vaporizable material stored within the wicking element.

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

In some embodiments, an evaporator device includes: 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 the evaporator device; a connection portion configured to receive electric power from a power source and 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 utility model, challenges associated with collecting condensate along one or more internal channels and outlets of some evaporator devices (e.g., along a mouthpiece) may be addressed by including one or more features described herein or equivalent methods as would be understood by one of ordinary skill in the art. Aspects of the present utility model relate to systems and methods for capturing condensate of vaporizable material 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 contain the 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 vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may include an airflow passage extending through the evaporation chamber. The cartridge may include at least one capillary channel adjacent the airflow channel. Each capillary channel of the at least one capillary channel may be configured to receive a fluid and to direct the fluid from the first location to the second location by capillary action.

In one aspect consistent with the present utility model, each capillary channel of the at least one capillary channel is narrowed in size. Narrowing in size may result in an increase in capillary drive through each of the at least one capillary channel. Each capillary channel 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 wick. The first location may be adjacent the end of the airflow channel and the mouthpiece. The at least one capillary channel may collect fluid condensate.

In a related aspect, an evaporator device can include an evaporator body including a heating element configured to heat an evaporable material. The evaporator device can include a cartridge configured to be releasably connected to the evaporator body. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to contain the 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 vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may include an airflow passage extending through the evaporation chamber. The cartridge may include at least one capillary channel adjacent the airflow channel. Each capillary channel of the at least one capillary channel may be configured to receive a fluid and to direct the fluid from the first location to the second location by capillary action.

Each of the at least one capillary channel may be narrowed in size. Narrowing in size may result in an increase in capillary drive through each of the at least one capillary channel. Each capillary channel 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 wick. The first location may be adjacent the end of the airflow channel 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 may 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 to wick the fluid from the first location to the second location. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to contain the 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 vaporizable material from the reservoir chamber to the evaporation chamber for evaporation by the heating element. The cartridge may include an airflow passage extending through the evaporation chamber. The at least one capillary channel may be adjacent to the air 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 capillary channel 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 wick. The first location may be adjacent the end of the airflow channel and the mouthpiece.

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

a reservoir configured to contain a liquid vaporizable material, the reservoir being at least partially defined by at least one wall, the reservoir 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 microfluidic features 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 storage chamber and a nebulizer configured to transition the liquid vaporizable material to a vapor phase state.

Optionally, the primary channel is formed by the 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 atomizer, the first channel comprising a cross-sectional shape having at least one irregularity configured to allow fluid within the first channel to bypass 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 the liquid vaporizable material to move along the secondary channel for a length only in which the meniscus completely covers the cross-sectional area of the secondary channel.

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

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

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.

Optionally, the pinch 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 between the collector and the storage compartment, the microfluidic gate comprising a rim of an aperture between the storage compartment 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 with 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 between the plurality of openings.

Alternatively, the meniscus of air-liquid vaporizable material reaching the condensation point is directed to the second channel due to the higher capillary drive in the first channel, such that bubbles are formed to escape into the liquid vaporizable material within the reservoir.

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 gate for controlling flow of liquid vaporizable material between a reservoir in a vaporizer and an adjacent overflow volume, the microfluidic gate comprising:

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

a polycondensation point located between the plurality of openings.

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

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 reservoir chamber of the evaporator cartridge, the capillary structure comprising microfluidic features 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 gate.

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

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

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; a nebulizer configured to cause at least some of the liquid vaporizable material to transition to an inhalable state; and

according to the aforementioned collector.

Optionally, the atomizer comprises:

a wicking element in the interior airflow path and in fluid communication with the reservoir, the wicking element configured to wick the liquid vaporizable material from the reservoir under capillary action; and

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

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

Optionally, the cartridge housing comprises a unitary 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 foregoing, wherein the evaporator body and the evaporator cartridge are detachably attachable to 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 interior 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 evaporate the vaporizable material stored within the wicking element.

Optionally, the at least two legs comprise 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 include:

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 with 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 heating portion by a bridge.

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 disposed at an oblique angle and extending away from the heating portion.

Optionally, the at least two rake wings include 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 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 the platform rake wing, the outer region being adjacent an outer edge of the first side rake wing, opposite the inner region.

Optionally, 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.

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

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

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

Optionally, the at least two legs include capillary features that cause abrupt changes in capillary pressure, thereby preventing the vaporizable material from flowing past the capillary features.

Optionally, the capillary feature comprises one or more bends in the at least two legs. Optionally, the at least two legs extend at an angle towards the interior volume of the heating portion, the at least two legs of the bevel 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 electric power from a power source and guide the electric power to the heating portion; and

a plating layer having a plating material different from the heating portion material, 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 includes one or more layers deposited onto the connection.

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

Optionally, the plating layer includes 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 adhesive coating is deposited onto the heating element to adhere the outer coating to the heating element.

Optionally, the material of the heating portion comprises nichrome.

Optionally, the plating layer comprises gold.

Optionally, further comprising a wick housing comprising:

an outer wall; and

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

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

Optionally, the base comprises one or more slots, wherein air pressure caused by flow of 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 includes 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 opposite long sides;

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

an opening opposite the base.

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

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

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

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

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

Optionally, a cutout in the outer wall is also included, the cutout configured to space the 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 a vaporizer for use with a liquid vaporizable material, the collector component comprising:

a fluid channel;

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

a control vent disposed at a second end of the fluid channel remote 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 fluid resistance when air is in the fluid passage adjacent the control vent and the void volume within the reservoir is at a lower pressure than ambient air outside the evaporator to condense air bubbles into the reservoir; and

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

at least one first wick supply 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 to prevent the pressure in the reservoir 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 communicates with the channel in the overflow volume.

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

Alternatively, the capillary pressure for the meniscus of vaporizable material is controlled by a V-shaped structure forming a primary channel and a secondary channel, the primary channel and the 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 channel and the secondary channel have a narrowing geometry such that as the meniscus continues to recede, capillary drive of the primary channel decreases at a greater rate than capillary drive of the secondary channel.

Optionally, the gradual decrease in capillary drive of the primary channel and the secondary channel reduces a partial headspace vacuum maintained in the reservoir.

Optionally, the discharge pressure of the primary channel is reduced below the discharge pressure of the secondary channel as a result of the capillary drive of the primary channel and the secondary channel being progressively reduced relative to each other.

Alternatively, 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 back contact angle of the primary channel may be reduced below the flooding pressure related to the front contact angle of the secondary channel, thereby filling the primary and secondary channels with vaporizable material.

Optionally, in response to increased pressure within the reservoir, 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 reservoir comprising a reservoir chamber defined by a reservoir barrier, the reservoir configured to contain a vaporizable material in the reservoir chamber;

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;

An airflow passage extending through the evaporation chamber; and

at least one capillary channel adjacent the airflow channel, each capillary channel of the at least one capillary channel configured to receive a fluid and to wick the 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 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 wick.

Optionally, the first location is adjacent to an end of the airflow channel 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 apparatus including:

an evaporator body including a heating element configured to heat the vaporizable material; and

a cartridge configured to be releasably coupled to the evaporator body, the cartridge comprising: a reservoir comprising a reservoir chamber defined by a reservoir barrier, the reservoir configured to hold a vaporizable material in the reservoir chamber;

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 airflow passage extending through the evaporation chamber; and

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 capillary channel of the at least one capillary channel configured to receive a fluid and to direct the fluid from a first location to a second location by capillary action, 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

an airflow channel extending through the evaporation chamber, the at least one capillary channel being adjacent to the airflow channel; and

the collected condensate is directed toward 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 become 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 principles associated with the disclosed implementations provided below.

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

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

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

FIG. 2C illustrates a perspective view of the cartridge of FIG. 2A in accordance with one or more embodiments;

FIG. 2D illustrates another perspective view of the cartridge of FIG. 2C in accordance with one or more embodiments;

FIG. 2E illustrates a schematic diagram of a reservoir system configured for an evaporator cartridge and/or an evaporator device for improving airflow within the evaporator device, in accordance with one or more embodiments;

FIG. 2F illustrates a schematic diagram of a reservoir system configured for use with an evaporator cartridge or evaporator device for improving airflow within the evaporator device, according to another embodiment;

FIGS. 3A and 3B illustrate exemplary plan cross-sectional views of a cartridge having a storage chamber and an overflow volume in accordance with one or more embodiments;

FIG. 4 illustrates an exploded perspective view of an exemplary embodiment of the cartridge of FIGS. 3A and 3B in accordance with one or more embodiments;

FIG. 5 illustrates a plan cross-sectional side view of selected separated portions of a cartridge in accordance with one or more embodiments;

FIG. 6A illustrates a cross-sectional top view of an exemplary cartridge structure in accordance with one or more embodiments;

FIG. 6B illustrates a perspective side view of the exemplary cartridge of FIG. 6A in accordance with one or more embodiments;

7A-7D illustrate an exemplary embodiment of a cartridge connection port having a male or female configuration in accordance with one or more embodiments;

FIG. 8 illustrates a top plan view of a cartridge having an exemplary pattern or logo in accordance with one or more embodiments;

FIGS. 9A and 9B illustrate perspective and plan cross-sectional views of separate portions of an exemplary cartridge in accordance with one or more embodiments;

FIGS. 10A and 10B illustrate closed and exploded perspective views of an exemplary cartridge embodiment having a separable structure for receiving a collector mechanism in accordance with one or more embodiments;

FIGS. 10C-10E illustrate perspective front and side views of an exemplary cartridge structural component having a flow management collector with 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 housing 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 constrictor is built into a flow channel in accordance with one or more embodiments;

FIGS. 11F and 11G illustrate front and side views of an exemplary collector structure in which a flow management constriction is built into the flow channel of the collector, in accordance with 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 reservoir in a cartridge and an overflow volume in accordance with one or more embodiments;

FIGS. 11I through 11K illustrate perspective views of an example collector structure 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 a snapshot of the flow of vaporizable material collected in the example collector of FIGS. 11L-11N as managed to accommodate proper draining as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to an embodiment;

FIGS. 12A and 12B illustrate examples of a single plenum multichannel collector structure in accordance with one or more embodiments;

FIG. 13 illustrates an exemplary dual plenum multichannel collector structure in accordance with one or more embodiments;

FIGS. 14A and 14B illustrate perspective and cross-sectional plan side views of an example collector structure for a cartridge with a dual wick supply 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 illustrate 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 having a collector structure, respectively, in accordance with one or more embodiments;

17A and 17B illustrate a perspective view of a first side of a cartridge and a cross-sectional view of a second side of the cartridge with a wicking element protruding into a storage chamber in accordance with one or more embodiments;

18A-18D illustrate examples of heating elements and airflow channels in an evaporator cartridge in accordance with one or more embodiments;

19A-19C illustrate examples of heating elements and airflow channels in an evaporator cartridge in accordance with one or more embodiments;

FIGS. 20A-20C illustrate examples of heating elements and airflow channels in an evaporator cartridge in accordance with one or more embodiments;

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

22A-22B illustrate examples of heating elements in accordance with one or more embodiments;

FIG. 23 illustrates an example of a portion of a wick housing in accordance with one or more embodiments;

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

FIG. 25 shows a perspective, front, side and exploded view 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 illustrate perspective and cross-sectional views of an example collector structure from different perspectives, focusing on structural details for securing placement of a wicking element and a wicking section housing relative to a nebulizer toward one end of a cartridge, in accordance with one or more embodiments;

26D-26F illustrate top plan views of exemplary wick supply mechanisms formed or constructed by a collector in accordance with one or more embodiments;

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

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

29A-29C illustrate perspective, front and side views, respectively, of an exemplary embodiment of a cartridge;

FIGS. 30A-30F illustrate perspective views of an exemplary cartridge at different fill levels in accordance with one or more embodiments;

31A-31C illustrate front views of an exemplary cartridge as filled and assembled according to one embodiment;

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

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

34A and 34B illustrate front and side views of an exemplary cartridge body having an external airflow path;

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

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

FIGS. 37D and 37E are example embodiments of a collector with a dual wick supply arrangement;

FIG. 38 shows an enlarged view of an end of a wick supply positioned adjacent to a wick and configured to at least partially receive the wick;

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

FIG. 40A shows a rear view of a collector structure with, for example, four different spray sites;

FIG. 40B illustrates a side view of a collector structure, particularly showing the clip-shaped end of the wick supply portion, for example, that can securely hold the wick in the path of the wick supply portion;

FIG. 40C shows a top view of a collector structure with a wick feed channel for receiving vaporizable material from a reservoir of a cartridge and directing the vaporizable material toward a wick that is held in place at the end of the wick feed channel by a protruding end of the wick feed 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;

FIG. 40E shows a bottom view of the collector structure in which the wick supply channel terminates in a clip-like projection configured to hold the wick in place on each end; 41A and 41B show top plan and side views of a collector structure with two respective wick feeds having two clip-like ends;

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

FIG. 43A illustrates various perspective, top, and side views of an example wick housing in accordance with one or more embodiments;

FIG. 43B illustrates a collector and wick housing component of an exemplary cartridge wherein protruding tabs are configured in the structure of the wick housing so as to be insertably received in receiving recesses or cavities in a corresponding bottom portion of the collector;

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

FIG. 44B illustrates a top perspective view of an example of a cartridge according to an embodiment of the present subject matter;

FIG. 44C illustrates a bottom perspective view of an example of a cartridge according to an embodiment of the present subject matter;

FIG. 45 illustrates a schematic diagram of a heating element for an evaporator device consistent with an embodiment of the present subject matter;

FIG. 46 illustrates a schematic diagram of a heating element for an evaporator device consistent with an embodiment of the present subject matter;

FIG. 47 shows a schematic view of a heating element for an evaporator device consistent with an embodiment 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 an embodiment of the present subject matter;

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

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

FIG. 51 illustrates a heating element and a wicking element within an evaporator cartridge consistent with an embodiment of the utility model;

FIG. 52 illustrates a heating element and a wicking element within an evaporator cartridge consistent with an embodiment of the utility model;

FIG. 53 illustrates a heating element within an evaporator cartridge consistent with an embodiment of the present utility model;

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 embodiments of the present subject matter;

FIG. 56 illustrates a heating element in a bent position consistent with embodiments of the present subject matter; FIG. 57 illustrates a heating element in an unbent position consistent with embodiments of the present subject matter;

FIG. 58 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

FIG. 59 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

FIG. 60 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

FIG. 61 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

FIG. 62 illustrates a heating element in a partially folded position consistent with an embodiment 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 an embodiment of the present subject matter;

FIG. 65 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

FIG. 66 illustrates a heating element in a partially folded position consistent with an embodiment of the present subject matter;

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

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

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

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

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

FIG. 77 illustrates a heating element in a partially folded position consistent with an embodiment of the present utility model;

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

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

FIG. 80 illustrates a heating element having a plated portion in a bent position consistent with an embodiment of the present subject matter;

FIG. 81 illustrates a heating element having an electroplated portion within an evaporator magazine consistent with an embodiment 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 an embodiment of the present subject matter;

FIG. 84 illustrates a front view of a heating element in a bent position consistent with an embodiment of the present subject matter;

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

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

FIG. 87 illustrates a perspective view of a heating element in a bent position consistent with an embodiment of the present subject matter;

FIG. 88 illustrates a side view of a heating element in a bent position consistent with an embodiment 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 an embodiment of the present subject matter;

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

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

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

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

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 an embodiment 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, according to embodiments of the 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 an embodiment of the present subject matter;

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

FIG. 107 illustrates a perspective view of a heating element in a bent position consistent with an embodiment of the present subject matter;

FIG. 108 illustrates a side view of a heating element in a bent position consistent with an embodiment of the present subject matter;

FIG. 109 illustrates a top view of a substrate material having a heating element in accordance with 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 wick housing of a nebulizer assembly, consistent with an embodiment of the utility model;

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 an embodiment of the present subject matter;

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

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

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

FIG. 117 illustrates one embodiment of an evaporator magazine;

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

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

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

Fig. 119C shows a second perspective view of the condensate recirculation system of fig. 119A.

In practice, the same or similar reference numerals designate the same, similar or equivalent structures, features, aspects or elements in accordance with one or more embodiments.

Detailed Description

An evaporator configured to convert a liquid vaporizable material to a vapor phase and/or an aerosol phase (e.g., a suspension of vapor phase and particulate phase material in air, which is in relatively local equilibrium between the phases) may generally include a reservoir or reservoir (also referred to herein as a reservoir, reservoir compartment, or reservoir volume) containing a volume of liquid vaporizable material, an atomizer (which may also be referred to as an atomizer assembly), a heating element (e.g., a resistive element through which an electrical current is passed to cause the electrical current to be converted to thermal energy) that heats the liquid vaporizable material to cause at least some of the liquid vaporizable material to be converted 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 applies capillary forces to draw the liquid vaporizable material from the reservoir to a heated position thereof by the action of the heating element). In some cases (depending on a variety 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 through, over, near, around the atomizer, etc.

As the liquid vaporizable material in the wicking element is heated and converted to a vapor phase (and subsequently optionally to an aerosol), the volume of liquid vaporizable material in the reservoir decreases. The reduced pressure state (e.g., at least a partial vacuum) is created within the reservoir without a mechanism for allowing air or some other substance to enter a void space created within the reservoir (e.g., a portion of the reservoir volume not occupied by the liquid vaporizable material) when the volume of the liquid vaporizable material in the reservoir is reduced by transitioning to a gas/aerosol phase. This reduced pressure condition may adversely affect the efficacy of the wicking element for drawing the vaporizable material from the storage compartment or reservoir into the vicinity of the heating element to be vaporized into the vapor phase, as the partial vacuum pressure acts in opposition to the capillary pressure generated within the wicking element.

More particularly, the reduced pressure condition in the reservoir can result in insufficient saturation of the wick and ultimately in a lack of sufficient vaporizable material being delivered to the atomizer for reliable operation of the evaporator. To counteract the depressurized state, ambient air may be allowed to enter the reservoir to equalize the pressure between the interior of the reservoir and the ambient pressure. Allowing air backfill to occur in the reservoir created by the vaporized liquid vaporizable material can occur in some evaporators by air entering the reservoir through the wicking element. However, this process typically requires that the wicking element be at least partially dried. Another typical approach is to provide a vent to allow pressure equalization between ambient conditions and the inside of the container, as dry wicking elements may not be easily achieved and/or may not be desirable for reliable operation of the evaporator.

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 equilibrated (or at least near equilibrated) with the ambient pressure, and especially as the volume of the void space filled with air 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 liquid vaporizable material to leak out of the reservoir, such as through a wick, through any ventilation provided, etc. The negative pressure differential between the air within the reservoir and the current ambient pressure may be created by one or more of several factors, such as 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 over a portion of the evaporator, causing deformation of the reservoir volume, etc.), rapid drop in ambient pressure (e.g., such as may occur in an aircraft cabin during an air ride, when a car or train enters or exits a tunnel, when a window is opened or closed while the vehicle is traveling at a high speed, etc.), and so forth.

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 create undesirable mess (e.g., due to soiling clothing or other items proximate the vaporizer), can enter the inhalation path of the vaporizer and thereby be inhaled by a user, can interfere with the functioning of the vaporizer (e.g., due to soiling of pressure sensors, affecting operability of circuitry and/or switches, soiling of connections between charging ports and/or cartridges and the vaporizer body, etc.), and so forth. Thus, leakage of the liquid vaporizable material can interfere with the function and cleaning of the evaporator.

Examples of a vaporizer include, but are not limited to, an electronic vaporizer, an electronic nicotine delivery system (end), or a device and system 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 can include an evaporator body 110 and an evaporator magazine 120 (also referred to simply as an evaporator magazine 120). The vaporizer body 110 may include a power source 112 (e.g., may be a rechargeable battery) and a controller 104 (e.g., a programmable logic device, a processor, or circuitry capable of executing logic code), the controller 104 for controlling the delivery of heat to the vaporizer 141 to cause a transition of vaporizable material (not shown) from a condensed form (e.g., solid, liquid, solution, suspension, at least partially untreated plant material, etc.) to a vapor phase, or more generally, to cause a transition of vaporizable material to a precursor (pre-or) in an inhalable form or inhalable form. In this regard, and inhalable form may be a gas or aerosol, or some other airborne form. The precursor in inhalable form may comprise a vapor phase state of the vaporizable material that at least partially condenses to form an aerosol some time after formation of the vapor phase state (optionally immediately or nearly immediately or alternatively with some delay or after some amount of cooling). The controller 104 may be part of one or more Printed Circuit Boards (PCBs) consistent with certain embodiments and may be used to control certain 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, an evaporator body contact 125, a seal 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, a positive or negative receptacle configuration, or some combination thereof, may be employed to couple the evaporator cartridge 120 with the evaporator body 110. 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 portions of the outer surface of the evaporator body 110 that form the structure of the cartridge receptacle 118. Such an arrangement for coupling the evaporator magazine 120 to the evaporator body 110 may allow for a convenient, easy to use bonding method that also provides sufficient mechanical coupling strength to avoid unwanted separation of the evaporator magazine 120 and the evaporator body 110. Such a configuration may also provide a desired resistance to deflection of the evaporator formed by coupling the evaporator pan 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 corresponding cartridge contacts 124 (discussed below) are located on a portion of the evaporator cartridge 120 that is inserted into a receptacle or receptacle-like structure on the evaporator body 110. However, the terms "evaporator body contact 125" and/or "receptacle contact 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 the system other than those therein) that the electrical coupling between the evaporator cartridge 120 and the evaporator body 110 occurs between contacts within the cartridge receptacle 118 on the evaporator body 110 and over a portion of the evaporator cartridge 120 that is 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 vaporizable material in an inhalable form. The mouthpiece may alternatively be a separate component from the structure forming the reservoir 140, or alternatively it may be formed from the same portion or component forming at least a portion of one or more walls of the reservoir 140. The liquid vaporizable material in reservoir 140 may be a carrier solution in which the active or inactive ingredient may be suspended, dissolved or maintained in solution or in pure liquid form in the vaporizable material itself.

According to one embodiment, the evaporator cartridge 120 can include an atomizer 141, which atomizer 141 can 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 absorption through the wick by capillary pressure to deliver a quantity of liquid vaporizable material to a portion of atomizer 141 comprising a heating element. The wick 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 wick liquid vaporizable material from a reservoir 140 configured to hold liquid vaporizable material such that liquid vaporizable material can be vaporized (i.e., converted to a vapor phase state) by heat transferred from the heating element to the wicking element and to the liquid vaporizable material being wicked into the wicking element. In some embodiments, in response to removal of 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 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 to the controller 104 (e.g., electrically, electronically, physically, or via a wireless connection). The controller 104 may be a printed circuit board assembly or other type of circuit board. In order to accurately measure and maintain the durability of the evaporator 100, it may be beneficial to provide a resilient seal 115 to separate the airflow path from other portions 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 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 the vaporizer 100 can be disposed within a vaporizer cartridge 120, which vaporizer cartridge 120 can be refilled when empty, or disposable to facilitate a new cartridge containing the same or a different type of additional vaporizable material. The evaporator may be an evaporator using a cartridge or a multipurpose evaporator that can be used with or without a cartridge. For example, the multipurpose vaporizer may include a heating chamber (e.g., an oven) configured to receive the vaporizable material directly within the heating chamber, and also to receive a cartridge or other replaceable device having a receptacle, volume, or other functional or structural equivalent for at least partially containing the vaporizable material.

In the example of a cartridge-based evaporator, 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 may help mitigate potentially damaging effects on evaporator components due to interactions with one or more environmental factors (e.g., condensed water, leaked from a reservoir, and/or vaporizable material condensed after evaporation) to reduce escape of air from a designed airflow path in the evaporator, etc.

Undesired air, liquid, or other fluids passing through or contacting the circuitry of the evaporator 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 evaporator 100 where the undesired materials may cause poor pressure signals, degradation of pressure sensors or other electrical or electronic components, and/or shorter life of the evaporator. Leakage of the seal 115 may also cause the user to inhale air that has passed through a portion of the evaporator 100 containing or consisting of a material that is not suitable for inhalation. Evaporators configured to produce at least a partially inhalable dose of 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 may contain a mass of plant material or other non-liquid material (e.g., a solid form of the vaporizable material itself, such as "wax") that is treated and formed in direct contact with (or radiated and/or convectively heated by) at least a portion of one or more resistive heating elements, which may 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 likewise be completely vaporized or can comprise some portion of the liquid material remaining after all of the material suitable for inhalation has been consumed.

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

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

In some embodiments of the present subject matter, the connection feature 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 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 the pressure of the corresponding 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 the mating portion of the evaporator magazine. 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 sidewalls of the cartridge receptacle 118 against cartridge contacts 124 on a portion of the side of the evaporator cartridge 120 that is located 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 the 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 use in determining or controlling the temperature of the resistive heating element based on the thermal resistivity of the resistive heating element for identifying the evaporator magazine 120 based on one or more electrical characteristics of the resistive heating element or other electrical circuits of the evaporator magazine 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 either of at least two orientations. In other words, one or more circuits configured for operation of the evaporator 100 may be completed by inserting (or otherwise bonding) at least a portion of the evaporator cartridge 120 into the cartridge receptacle 118 in a first rotational orientation (e.g., about an axis along which an end of the evaporator cartridge having the evaporator cartridge 120 is inserted into the cartridge receptacle 118 of the evaporator body 110) such that a first one of the at least two cartridge contacts 124 is electrically connected to a first one of the at least two receptacle contacts 125 and a second one of the at least two cartridge contacts 124 is electrically connected to a second one of the at least two receptacle contacts 125.

Further, by inserting (or otherwise coupling) the evaporator 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, one or more circuits configured for operation of the evaporator 100 may be completed. The evaporator cartridge 120 can be reversibly inserted 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 a stop (e.g., indentation, protrusion, etc.) protruding inwardly from an inner surface of the cartridge receptacle 118. One or more outer surfaces of the evaporator cartridge 120 may include corresponding recesses (not shown in fig. 1) that may mate 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 within and/or otherwise be held within a recess of the evaporator magazine 120 to hold the evaporator magazine 120 in place when assembled. Such a detent-recess assembly may provide sufficient support to hold the evaporator cartridge 120 in place, thereby ensuring 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 discussion above 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 a second order (order two) of rotational symmetry. In other words, the mechanical mating features and 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 circuitry of the evaporator 100 can support the same operation regardless of the symmetrical orientation of the evaporator magazine 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, an evaporator cartridge 120 having rotationally symmetrical mechanical features for co-operating engagement with corresponding features on the inside or outside of the cartridge receptacle 118, shaped and sized to fit within the cartridge receptacle 118 of the evaporator body 110, and likewise having rotationally symmetrical cartridge electrical contacts 124 and internal circuitry compatible by reversing the electrical contacts (which may optionally be located in one or both of the evaporator cartridge 120 and the evaporator body 110), is consistent with the present utility model even if the overall shape and appearance of the insertable end of the evaporator cartridge 120 is not rotationally symmetrical.

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 the 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 having two sets of parallel or approximately parallel opposing sides (e.g., having a parallelogram shape), or other shape having rotational symmetry of at least a second order. In this context, it is apparent that the approximation has a substantial similarity of shape indications to the described shape, 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, it is contemplated that a certain amount of rounding is performed on either or both of the edges or vertices of the cross-sectional shape.

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 evaporator cartridge and the contacts on the evaporator body. The electrical contacts may be gold plated and/or may include other materials.

The evaporator 100 consistent with embodiments of the disclosed subject matter may be configured to connect (e.g., wirelessly or through 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 may establish a wireless communication channel with the communication hardware 105 of the vaporizer 100.

The computing device used as part of the evaporator system may include a general purpose computing device (e.g., a smart phone, tablet, 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 evaporator 100. In other embodiments, the device used as part of the evaporator 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 button, etc.). The evaporator 100 may also include one or more outputs 117 or means for providing information to a user.

The computing device as part of the vaporizer system as defined above may be used for any of one or more functions such as controlling the dose (e.g., dose monitoring, dose setting, dose limiting, user tracking, etc.), controlling the interaction (e.g., interaction monitoring, interaction setting, interaction limiting, user tracking, etc.), controlling the nicotine delivery (e.g., switching between nicotine and non-nicotine vaporizable materials, adjusting the amount of nicotine delivered, etc.), obtaining location information (e.g., location of other users, retailer/business location, electronic cigarette inhalation 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.), engaging in social activities with other users (e.g., social media communication, interacting with one or more groups, etc.), etc. The terms "interactivity", "interaction", "evaporator interaction" or "vapor interaction" may be used to refer to a cycle specific to the use of an evaporator. 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 signals related to activation of the resistive heating element, or in other examples where the computing device is coupled to the evaporator 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 of user interaction with one or more user interface elements by the computing device may cause the computing device to send a signal to the evaporator 100 to activate the heating element, or to a full operating temperature for generating an inhalable dose of vapor/aerosol. Other functions of the evaporator 100 can be controlled through user interaction with a user interface on a computing device that is in communication with the evaporator 100.

In some embodiments, the evaporator cartridge 120 that may be used with the evaporator body 110 may include an atomizer 141 having a wick element and a heating element. Alternatively, one or both of the wicking element and the heating element may be part of the evaporator body 110. In embodiments in which any portion of the atomizer 141 (e.g., a heating element or a 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 an evaporator cartridge to a wick and other atomizer components, such as, for example, a wicking element, a heating element, and the like. Those skilled in the art will appreciate that a capillary structure comprising 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 automatically detecting suction based on one or more signals generated by one or more sensors 113, such as one or more pressure sensors configured to detect pressure (or changes in absolute pressure may be measured) relative to ambient pressure along the airflow path, one or more motion sensors of the evaporator 100, one or more flow sensors of the evaporator 100, a capacitive lip sensor of the evaporator 100; in response to detecting a 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 means for determining that a lifting is occurring or is about to occur.

The heating element may be or include one or more of a conductive 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 contain 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 including a resistive coil or other heating element wrapped around, positioned within, integrated into the overall shape of, extruded in thermal contact with, positioned adjacent to, configured to heat air to cause convective heating of the wicking element, or otherwise arranged to transfer heat to the wicking element to cause liquid vaporizable material lifted by the wicking element from the reservoir 140 to be vaporized for subsequent inhalation by a user with gas and/or condensation (e.g., aerosol particles or droplets). Other wick, heating, or atomizer assembly configurations are also possible, as discussed further below.

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

It will be appreciated that the interaction between the gas phase and the condensed phase in the aerosol produced by the vaporizer may be complex and dynamic in that factors such as ambient temperature, relative humidity, chemistry (e.g., acid-base interactions, protonation or lack of compounds released from the vaporizable material by heating, etc.), flow conditions in the gas flow path (inside the vaporizer and in the airways of a human or other animal), 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 evaporators, and particularly in evaporators for delivering more volatile vaporizable materials, the inhalable dose may exist predominantly in the vapor phase (i.e., the formation of condensed phase particles may be very limited).

As described elsewhere herein, the particular vaporizer may also (or alternatively) be configured to produce an inhalable dose of 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., wax, etc.) or plant material (e.g., tobacco leaf or tobacco leaf portion) comprising a vaporizable material. In such a vaporizer, the resistive heating element may be part of, or otherwise incorporated into or in thermal contact with, the 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 past 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 provided in intimate contact with the plant material such that direct conduction heating of the plant material occurs from within the mass of plant material (e.g., as opposed to conduction inwardly from the walls of the oven).

The heating element may be activated by the controller 104, and the controller 104 may be part of the evaporator body 110. The controller 104 may cause current to flow from the power source 112 through a 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 (e.g., pulling, inhaling, etc.) the mouthpiece 130 of the vaporizer 100, which may cause air to flow from the air inlet along an airflow path through the atomizer 141. The atomizer 141 may include a wick, for example, in combination with a heating element.

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

The temperature of the resistive heating element of the evaporator 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 the duty cycle of the electrical power delivered, conductive and/or radiative heat transfer to other portions of the evaporator 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 the vaporizable material)), loss of latent heat due to the vaporization of the vaporizable material as a whole from the wicking portion and/or atomizer 141, convective heat loss due to airflow (e.g., air moving as a whole across the heating element or atomizer 141 when a user inhales on the evaporator 100), and the like.

As described above, to reliably activate the heating element or heat the heating element to a desired temperature, in some embodiments, the evaporator 100 may utilize a signal from a pressure sensor to determine when a user inhales. The pressure sensor may be located in the airflow path or may be connected (e.g. by a channel or other path) to the airflow path connecting an inlet and an outlet for air into the device, via which outlet the user inhales the generated vapour and/or aerosol such that the pressure sensor experiences a pressure change simultaneously with air passing through the evaporator 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, such as by automatic detection of the puff, such as by a pressure sensor that detects a pressure change in the airflow path.

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

Air flow path embodiment

Referring to fig. 2C and 2D, an exemplary evaporator magazine 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 a user through a mouthpiece 130 that may also be part of the evaporator cartridge 120. The vaporization chamber 150 may include and/or at least partially enclose a nebulizer 141 consistent with the remainder of the 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. Air may then be drawn into the insertable end 122 of the cartridge, through the evaporation chamber 150, which includes or houses 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 shows additional features that may be included in the evaporator magazine 120 consistent with the present subject matter. For example, the evaporator cartridge 120 can 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 structure can optionally form opposite sides of the heating chamber and can optionally act as a heat shield and/or heat sink to reduce heat transfer to the outer wall of the evaporator magazine 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 magazine 120 that defines a portion of the airflow path 134 passing between a heating chamber (also referred to herein as an atomizer chamber, evaporation chamber, etc.) that may be at least partially formed by the conductive structure 126 and the mouthpiece 130. This configuration allows air to flow downwardly into the cartridge receptacle 118 around the insertable end 122 of the evaporator cartridge 120 and then back in the opposite direction after passing around the insertable end 122 of the evaporator cartridge 120 (e.g., the end opposite the end that includes the mouthpiece 130) as it enters the cartridge body toward the evaporation chamber 150. The airflow path 134 then travels through the interior of the evaporator magazine 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 ventilation part

As described above, removal of the vaporizable material 102 from the reservoir 140 (e.g., by capillary lifting of the wicking element) may create a vacuum in the reservoir 140 that is at least partially relative to ambient air pressure (e.g., a reduced pressure created in a portion of the reservoir that has been emptied by consumption of liquid vaporizable material), and such 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 gradients to reduce the efficiency of the wicking element to draw the vaporizable material 102 into the vaporization chamber 150, thereby reducing the efficiency of the amount of vaporizable material 102 required for vaporization of the vaporizer 100, such as when a user draws on the vaporizer 100. In extreme cases, the vacuum created in the reservoir 140 may result in the inability to draw all of the vaporizable material 102 into the vaporization chamber 150, resulting in incomplete use of the 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 equilibrate (optionally fully equilibrate) the pressure in the reservoir 140 with ambient pressure (e.g., the pressure in the ambient air outside of the reservoir 140) to alleviate this problem.

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

Various features and means are described below that improve or overcome these problems. For example, various features for controlling the airflow and flow of vaporizable materials are described herein, which may provide advantages and improvements over existing methods, while also introducing additional benefits as described herein. The evaporator devices and/or cartridges described herein include one or more features that control and improve the flow of air in the evaporator device and/or cartridge, thereby increasing the efficiency and effectiveness of the evaporator device in evaporating the liquid vaporizable material without introducing additional features that may cause 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) in order to improve pressure balance and airflow in the evaporator. More specifically, the reservoir systems 200A, 200B shown in FIGS. 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 liquid vaporizable material through the vent structure. This allows the capillary action of the porous material (e.g., wicking element) associated with the reservoir 240 and the evaporation chamber 242 to continue to efficiently draw the vaporizable material 202 from the reservoir 240 into the evaporation chamber 242 after each puff.

As shown in fig. 2E and 2F, the reservoir systems 200A, 200B include a reservoir 240 configured to hold the liquid vaporizable material 202. The reservoir 240 is sealed by the reservoir wall 232 on all sides except through the wick housing area extending between the reservoir 240 and the evaporation chamber 242. A heating element or heater may be contained within the evaporation chamber 242 and coupled to the wicking element. The wicking element is configured to provide capillary action that draws the vaporizable material 202 from the reservoir 240 to the vaporization chamber 242 for vaporization into an aerosol through the heater. The aerosol is then combined with the airflow 234 traveling along the airflow path 238 of the evaporator for inhalation by the user. The reservoir system 200A, 200B also includes an airflow restrictor 244 that restricts the passage of the airflow 234 along the airflow passage 238 of the evaporator, such as when a user draws on the evaporator. The restriction of the air flow 234 caused by the air flow restrictor 244 may allow a vacuum to be formed along a portion of the air flow channel 238 downstream of the air flow restrictor 244. The vacuum created along the airflow channel 238 may help to draw the aerosol formed in the evaporation chamber 242 (e.g., the chamber containing at least a portion of the atomizer 141) along the airflow channel 238 for inhalation by the user. At least one airflow restrictor 244 may be included in each reservoir system 200A, 200B, and the airflow restrictor 244 may include any number of features for restricting the airflow 234 along the airflow channel 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 negative pressure (vacuum) as described above with respect to the ambient pressure created by the vaporizable material 202 being pulled out of the reservoir 240. At least one vent 246 may be associated with the reservoir 240. The vent 246 may be an active or passive valve, and the vent 246 may include any number of features that allow air to enter the reservoir 240 to relieve the negative pressure created in the reservoir 240.

For example, an embodiment of vent 246 may include a vent passage extending between reservoir 240 and air flow passage 238, and the diameter (or more generally, the cross-sectional area) of the vent passage 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 air flow passage 238), the fluid tension (also referred to as surface tension) of vaporizable material 202 prevents vaporizable material 202 from passing through the passage. 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 generated in the reservoir 240 is able to 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 pressure within the reservoir 240 that is sufficiently low 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 the reservoir 240, the pressure again balances more closely across the vent 246, allowing the surface tension of the vaporizable material 202 to prevent air from entering the reservoir 240 and vaporizable material from leaking from the reservoir 240 through the vent channel.

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

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

The positioning of the vent 246 (e.g., passive vent) and the airflow restrictor 244 relative to the evaporation chamber 242 facilitates efficient operation of the reservoir systems 200A, 200B. For example, improper positioning of the vent 246 or the airflow restrictor 244 may result in undesired leakage of the vaporizable material 202 from the 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 wick may result in an effective reservoir system for releasing the vacuum pressure in the reservoir and resulting in effective capillary action of the wick while preventing leakage. The configuration of a reservoir system having a vent 246 and an airflow restrictor 244 that are operatively positioned relative to the evaporation chamber 242 will be described in more detail below.

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

In this way, during suction (e.g., when a user lifts or draws air from the evaporation device), an amount of pressure differential is created between the vent 246 and the evaporation chamber 242 that is as small as not present. However, after aspiration, capillary action of the wick will cause the vaporizable material 202 to be lifted from the reservoir 240 to the vaporization chamber 242 to replenish the vaporizable material 202 that was vaporized and inhaled as a result of the prior aspiration. As a result, a vacuum or negative pressure will be created in the reservoir 240. A pressure differential will then be created between reservoir 240 and air flow channel 238. As described above, the vent 246 may be configured such that a pressure differential (e.g., a threshold pressure differential) between the reservoir 240 and the air flow channel 238 allows a volume of air from the air flow channel 238 into the reservoir 240, thereby releasing the vacuum in the reservoir 240 and returning to the balanced pressure and stable reservoir system 200A across the vent 246.

In another embodiment, as shown in fig. 2F, the airflow restrictor 244 may be located downstream of the evaporation chamber 242 along the airflow channel 238, while the vent 246 may be positioned along the reservoir 240 such that it provides fluid communication between the reservoir 240 and a portion of the airflow channel 238 upstream of the evaporation chamber 242. Thus, when the user draws on the evaporator, the evaporation chamber 242 and the vent 246 experience little or no suction or negative pressure due to the draw, resulting in little or no pressure differential between the evaporation chamber 242 and the vent 246. Similar to the case in fig. 2E, after aspiration, the pressure differential created across vent 246 will be the result of capillary action of the wick that lifts vaporizable material 202 into vaporization chamber 242. As a result, a vacuum or negative pressure will be created in the reservoir 240. Thus, a pressure differential will be created across the vent 246.

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

Similarly, as described above, a vent 246 placed adjacent to or forming a part of the evaporation chamber 242 or wick housing may allow air to enter the reservoir 240 from inside the evaporation chamber 242 via the vent 246 to increase the pressure inside the reservoir 240, thereby effectively releasing the vacuum pressure created by the vaporizable material 202 being lifted into the evaporation chamber 242. In this way, release of the vacuum pressure allows the vaporizable material 202 to continuously effectively and efficiently wick into the vaporization chamber 242 via the wick to produce an inhalable vapor during subsequent puffs of the vaporizer by a user. Various exemplary embodiments of a vented vaporization chamber element (e.g., a nebulizer assembly) comprising a wick housing 1315, 178 (which houses the vaporization chamber) and at least one vent 596, the at least one vent 596 being coupled to the wick housing 1315, 178 or forming part of the wick housing 1315, 178, to achieve the effective venting of the reservoir 140 described above are provided below.

Open-faced cartridge assembly embodiment

Referring to fig. 3A and 3B, an exemplary plan cross-sectional view of an alternative cartridge embodiment 1320 is shown, wherein the cartridge 1320 includes a mouthpiece or mouthpiece region 1330, a reservoir 1340, and a nebulizer (not separately shown). The atomizer may include a heating element 1350 and a wicking element 1362, 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 evaporating the vaporizable material 1302 lifted from or stored in the wicking element 1362.

In one embodiment, a plate 1326 may be included to provide an electrical connection between the heating element 1350 and the power source 112 (see FIG. 1). An air flow channel 1338 defined through or on the side of the reservoir 1340 may connect a 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 material 1302 to travel from the heating element 1350 region to the mouthpiece region 1330.

As described above, the wicking element 1362 may be coupled to a nebulizer or heating element 1350 (e.g., a resistive heating element or coil) that is connected to one or more electrical contacts (e.g., a plate 1326). The heating element 1350 (and other heating elements described herein in accordance with one or more embodiments) may have various shapes and/or configurations and may 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 sheet material (e.g., stamped) and rolled 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 may 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. Uniformity of manufacturing quality of the heating element 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 occur during the manufacturing process of assembling 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 due, at least in part, to reduced tolerance issues due to improvements in the consistency of manufacturability of the heating element 1350. The heating element 1350, which is made of sheet material (e.g., stamped) and crimped or bent around at least a portion of the wicking element 1362 to provide a preformed element, desirably helps to minimize heat loss and helps to ensure that the heating element 1350 is predictably heated to the proper temperature.

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

In addition to or in combination with the exemplary heating elements described and/or discussed below, the heating elements may include flat heating elements 1850 (see fig. 18A-18D) located within the evaporator magazine 1800 including two airflow channels 1838, folded heating elements 1950 (see fig. 19A-19C, 22A-22B, and 44A-116) located within the evaporator magazine 1900 including two airflow channels 1938, and folded heating elements 2050 (see fig. 20A-20C) located within the evaporator magazine 2000 including a single airflow 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 near or next to plate 1326 and through a resistive heating element in contact with plate 1326. The wick housing may surround at least a portion of the heating element 1350 and connect the heating element 1350 directly or indirectly to the airflow passage 1338. The vaporizable material 1302 may be pulled by the wicking element 1362 through one or more channels connected to the reservoir 1340. In one embodiment, one or both of the primary channel 1382 or the secondary channel 1384 may be used to help direct or transport the vaporizable material 1302 to one or both ends of the wicking element 1362 or in a radial direction along the length of the wicking element 1362.

Overflow collector embodiment

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

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

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

Depending on the change in ambient pressure or temperature or other factors, the cartridge 1320 may experience 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 ambient pressure and a second relative pressure differential between the interior of the reservoir and ambient pressure). 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 collection in the cartridge 1320 and at least temporarily hold and optionally reversibly return liquid vaporizable material that may move out of the storage chamber in response to a change in pressure differential between the storage chamber and ambient air. The vaporizable material 1302 can be lifted from the reservoir 1342 to the atomizer and converted to a vapor or aerosol phase, thereby reducing the volume of vaporizable material remaining in the reservoir 1342 and, absent some mechanism for returning air to the reservoir to equalize the pressure in the reservoir with the ambient pressure, causing at least a portion of the vacuum conditions discussed previously herein.

With continued reference to fig. 3A and 3B, the receptacle 1340 may be implemented to include first and second separable regions such that the volume of the receptacle 1340 is divided into a receptacle storage chamber 1342 and a receptacle overflow volume 1344. The storage chamber 1342 may be configured to store the vaporizable material 1302 and may further be coupled to the wicking element 1362 via one or more primary channels 1382. In some examples, the main channel 1382 may be very short in length (e.g., a through hole from a space housing the 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, the overflow volume 1344 may be configured to store and contain a portion of the vaporizable material 1302 that may overflow from the reservoir chamber 1342 in a second pressure state where the pressure in the reservoir chamber 1342 is greater than ambient pressure.

In the first pressure state, the vaporizable material 1302 may 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 the primary and secondary channels 1382, 1384 are such that the vaporizable material 1302 can flow from the reservoir 1342 toward the wicking element 1362 through the primary channel 1382, such as under capillary action of the wicking element that draws liquid into the vicinity along with a heating element that acts to convert the liquid vaporizable material into a vapor phase. In one embodiment, in the first pressure state, no or a limited amount of vaporizable material 1302 flows into secondary channel 1384. In the second pressure state, the vaporizable material 1302 can flow from the reservoir 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, a second pressure state may exist or be caused when the bubble expands in the reservoir chamber 1342 (e.g., as the ambient pressure becomes 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 vaporizable material from reservoir 1342 to an overflow volume by an increase in pressure. The collector 1313 within 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 pushed into the collector 1313 by excessive pressure in the reservoir 1342 relative to ambient pressure to be reversibly pulled back into the reservoir 1342 when the pressure in the reservoir 1342 relative to ambient pressure is equalized or otherwise reduced. In other words, the secondary channel 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, the microfluidic features may be used to manage the flow of vaporizable material 1302 into and out of collector 1313 (i.e., provide a flow reversing feature) to prevent or reduce leakage or entrapment of bubbles of vaporizable material 1302 into reservoir 1342 or overflow volume 1344.

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

In one 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 to the wicking element 1362 during the first pressure state.

The wicking element 1362 may provide a capillary path for the vaporizable material 1302 stored in the reservoir 1340 through or into the wicking element 1362. The capillary path (e.g., the primary channel 1382) may be sufficiently large to allow wicking or capillary action to displace the vaporized vaporizable material 1302 in the wicking element 1362 and may be sufficiently small to prevent the vaporizable material 1302 from leaking out of the cartridge 1320 during a negative pressure event. The wicking housing or 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, thermally vaporizable coatings (e.g., waxes or other materials).

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 signals 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 the heating element 1350 is activated, the heating element 1350 may have an increase in temperature as a result of current flowing through the plate 1326. Or some other resistive portion through the action of a 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 conduction, convection, or radiant heat transfer such that at least a portion of the vaporizable material 1302 being pulled into the wicking element 1362 is vaporized. According to an embodiment, air entering the cartridge 1320 flows over (or bypasses, is in proximity to, etc.) the heated elements in the wicking element 1362 and the heating element 1350 and breaks the vaporized vaporizable material 1302 off into the air flow channel 1338 where the vapor may optionally be condensed and delivered in the form of an aerosol, for example, through openings in the mouthpiece region 1330.

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

Returning to the example, the air admitted to the reservoir 1342 may expand due to a pressure differential relative to ambient air. This expansion of air in the void space of the reservoir 1342 may cause the liquid vaporizable material to travel through at least some portions of the secondary channel 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, wherein the meniscus completely covers a cross-sectional area of the secondary channel 1384 transverse to the flow direction along the length for only that 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 channel and the composition of the liquid vaporizable material, which preferably wets the secondary channel 1384 around the entire perimeter of the secondary channel 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 way, when the sign (e.g., positive, negative, or equal) and magnitude of the pressure difference between the reservoir 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 channel 1384 of the collector 1313 may be pumped into the reservoir 1342 sufficiently so that the meniscus of liquid-air is directed to a gate or port between the secondary channel 1384 of the collector 1313 and the reservoir 1342. At this point, if the pressure differential in the reservoir 1342 relative to ambient pressure is sufficiently negative to overcome the surface tension holding the meniscus at the gate or port, the meniscus becomes detached from the gate or port wall and one or more bubbles are formed that are released into the reservoir 1342 in sufficient volume to equalize the reservoir pressure relative to the environment. The above process may be reversed when the air admitted to the storage chamber 1340 (or otherwise present therein) experiences an elevated pressure condition relative to the surrounding environment as described above (e.g., due to a drop in ambient pressure that may occur, for example, in an aircraft cabin or other high altitude location, when a window of a moving vehicle is opened, when a train or vehicle leaves a tunnel, etc., or due to an increase in internal pressure in the storage chamber 1340 that may occur, for example, due to localized heating, mechanical pressure that deforms the shape and thereby reduces the volume of the storage chamber 1340, etc.). Liquid enters the secondary channel 1384 of the collector 1313 through a gate or port and forms a meniscus at the front of the column of liquid entering the secondary channel 1384 to prevent air from bypassing and flowing counter to the advancing liquid. By maintaining the meniscus due to the presence of the aforementioned microfluidic properties, when the elevated pressure in the reservoir 1340 is subsequently reduced, the liquid column is drawn back into the reservoir, optionally until the meniscus reaches a gate or port. If the pressure difference is sufficient to favor the ambient pressure relative to the pressure in the reservoir, the bubble formation process described above occurs until the pressure is equalized. In this way, the collector acts as a reversible overflow volume that receives liquid vaporizable material pushed out of the reservoir under transient conditions of greater reservoir pressure relative to ambient, and allows at least some (and desirably all or most) of that overflow volume to return to the reservoir compartment for later delivery to the atomizer for conversion to an inhalable form.

Depending on the embodiment, the reservoir 1342 may be connected to the wicking element 1362 with or without a secondary channel 1384. In embodiments in which the second end of the secondary channel 1384 opens into the wicking element 1362, any vaporizable material 1302 that may leave the secondary channel 1384 at the second end (opposite the first end defining the connection point to the reservoir chamber 1342) may further saturate the wicking element 1362.

The reservoir 1342 may optionally be positioned closer to an end of the reservoir 1340 near the mouthpiece region 1330. The overflow volume 1344 may be located near an end of the reservoir 1340 closer to the heating element 1350, e.g., between the reservoir 1342 and the heating element 1350. The exemplary embodiments shown in the drawings should not be construed as limiting the scope of the claimed subject matter to the location 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 position and location of the reservoir 1342 can be adjusted relative to the location of the overflow volume 1344 such that the reservoir 1342 can be located at the top, middle, or bottom of the cartridge 1320.

In one embodiment, when the evaporator magazine 1320 is full, the volume of liquid vaporizable material can be equal to the interior volume of the reservoir chamber 1342 plus the overflow volume 1344 (which in some examples can be the volume of the secondary channel 1384 between a gate or port connecting the secondary channel 1384 to the reservoir chamber 1340 and the outlet of the secondary channel 1384). In other words, an evaporator cartridge consistent with embodiments 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 an example, the liquid vaporizable material is delivered to the atomizer for delivery to a user as needed. The delivered liquid vaporizable material can be pulled from reservoir 1340, thereby causing liquid in secondary channel 1384 of collector 1313 to be pulled back into reservoir 1340 because the meniscus maintained by the microfluidic nature of secondary channel 1384 prevents air from flowing through the liquid vaporizable material in secondary channel 1384, which cannot enter through secondary channel 1384. After enough liquid vaporizable material has been delivered from reservoir 1340 to the atomizer (e.g., for vaporization and user inhalation) such that the original volume of collector 1313 is drawn into reservoir 1340, the above-described behavior occurs and the bubbles can be released from the gate or port between secondary channel 1384 and the reservoir to equalize the pressure in the reservoir chamber as more liquid vaporizable material is used. When the air that has entered the storage compartment experiences an elevated pressure relative to the surrounding environment, the liquid vaporizable material moves out of the storage chamber 1340 through a 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 the percentage of the vaporizable material 1302 stored in the reservoir 1342, optionally up to about 100%. In one embodiment, the collector 1313 is configured to hold at least 6% to 25% of the volume of the vaporizable material 1302 storable in the reservoir 1342. Other ranges are also possible.

The structure of the collector 1313 may be configured, constructed, molded, manufactured, or positioned in the overflow volume 1344 in different shapes and different characteristics to allow an overflow portion of the vaporizable material 1302 to be at least temporarily received, contained, or stored in the overflow volume 1314 in a controlled manner (e.g., by capillary pressure) to prevent the vaporizable material 1302 from leaking from the cartridge 1320 or oversaturating the wicking element 1362. It should be appreciated that the above description of sub-channels is not intended to be limited to a single such sub-channel 1384. One or alternatively more than one secondary channel may be connected to the reservoir 1340 via one or more than one gate or port. In some implementations 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 divided into more than one secondary channel to provide additional overflow volumes or other advantages.

In some embodiments of the present subject matter, air vent 1318 may connect overflow volume 1344 to airflow channel 1338, which ultimately leads to the ambient air environment outside of cartridge 1320. The air vent 1318 may allow air or bubbles that have formed or trapped in the collector 1313 to escape through the path of the air vent 1318, such as during a second pressure state, when the secondary channel 1384 is filled with an overflow of vaporizable material 1302.

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

In one or more embodiments, the secondary channel 1384 in 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) located at an interface point between reservoir chamber 1342 and overflow volume 1344. As a result, air in the secondary channel 1384 is displaced and may be exhausted through the air vent 1318. In some embodiments, the air vent 1318 may function as or include a control valve (e.g., permselective membrane, microfluidic gate, etc.) that allows air to exit the overflow volume 1344, but prevents the vaporizable material 1302 from exiting the secondary channel 1384 into the airflow passageway 1338. As previously described, the air vent 1318 may function 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 a specified equilibrium is met) or until the vaporizable material 1302 is removed from the overflow volume 1344 (e.g., by evaporation in an atomizer). Thus, the level of vaporizable material 1302 in overflow volume 1344 can be controlled by managing the flow of vaporizable material 1302 into and out of collector 1313 as ambient pressure changes. In one or more embodiments, the overflow of vaporizable material 1302 from reservoir 1342 to overflow volume 1344 can be reversed or can be reversible depending on the detected environmental change (e.g., when a pressure event that caused overflow of vaporizable material 1302 subsides or ends).

As described above, in some embodiments of the present subject matter, in a state in which the pressure within cartridge 1320 becomes relatively lower than ambient pressure (e.g., when returning from the previously mentioned second pressure state to the first pressure state), the flow of vaporizable material 1302 can be reversed in a direction that causes vaporizable material 1302 to flow from overflow volume 1344 back into reservoir chamber 1342 of receptacle 1340. Thus, depending on the implementation, the overflow volume 1344 may be configured to temporarily contain the overflow portion of the 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 reservoir 1342 during or after reversing back to the first pressure state.

To control the flow of vaporizable material 1302 in cartridge 1320, in other embodiments of the present subject matter, collector 1313 may optionally comprise an absorbent or semi-absorbent material (e.g., a material having a spongy nature) for permanently or semi-permanently collecting or containing overflow of vaporizable material 1302 traveling through secondary channel 1384. In the exemplary embodiment in which absorbent material is included in the collector 1313, the reverse flow of vaporizable material 1302 from overflow volume 1344 to reservoir 1342 may not be practical or possible as compared to an embodiment implemented without (or as much as) absorbent material in 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 reversible or reversible rate of the vaporizable material 1302 to the reservoir 1342 can be controlled, wherein such characteristics result in a higher or lower absorption rate immediately or over a longer period of time.

Fig. 4 is an exploded perspective view of an exemplary embodiment of a cartridge 1320. As shown, the body of the cartridge 1320 may be made of two connectable (or separable) components, such as a first portion 1422 (e.g., an upper housing) and a second portion 1424 (e.g., a lower housing), which may be assembled together according to a building implementation model or assembly process on top of each other. Such a separable structure simplifies the assembly and manufacturing process and may not involve assembling or constructing multiple smaller components to construct larger components. Instead, 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, an outer cartridge feature (e.g., side) and a smaller inner cartridge component (e.g., opposing rib-like elements forming one or more of the collector 1313, reservoir 1340, reservoir 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 portion 1422 and the second portion 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 traveling through the airflow channel 1438 (e.g., as formed by condensation of vaporized material and/or water vapor to form larger droplets that create an unpleasant sensation when ingested during inhalation). 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, there is no need for a large number of machines or assembly automation components to construct the cartridge 1320 from a small set of components into a unitary separable two-piece housing.

The separable two-piece structures described herein may provide one or more of the following exemplary advantages or improvements over alternative embodiments: fewer parts count, 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 pitch tooling cores, relatively shallow rib structures. According to an embodiment, ultrasonic or laser welding techniques may be used to form a solid state weld between the first portion 1422 and the second portion 1424 of the cartridge 1420.

Ultrasonic welding is a process commonly used for plastics in which high frequency ultrasonic acoustic vibrations are applied locally to the 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 using a laser beam that provides a concentrated source of heat (e.g., a laser beam) to allow narrow, deep welds at high welding rates.

Referring to fig. 5, a plan cross-sectional side view of selected portions of the cartridge 1320 is shown. Referring to fig. 4 and 5, the first portion 1422 (not shown in fig. 5) and the second portion 1424 of the cartridge 1420 may be molded from plastic components by injection molding (e.g., in an implementation model on top of each other). In one exemplary embodiment, a wire of a pattern drawing technique may be used to allow separation of mold halves (e.g., first portion 1422 and second portion 1424 as shown in fig. 4), allowing each portion to be ejected without any obstruction 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 cartridge 1320 are shown, respectively. As shown, the fill port 610 may be implemented in one or more embodiments of the cartridge 1320 to allow for filling of the reservoir storage chamber 1342, for example, through the fill needle 622. As shown, according to an embodiment, the fill needle 622 may be easily and conveniently inserted into the fill port 610 through, for example, a fill channel 630 leading to a reservoir 1342 (or overflow volume 1344). Thus, for example, using the fill needle 622, the vaporizable material 1302 can be injected into the reservoir 1340 through the fill channel 630. In some embodiments, the fill channel 630 may be configured or positioned on a side of the cartridge 1320, e.g., opposite a side where the air flow channel 1338 is positioned.

Fig. 7A to 7D show design alternatives for cartridge connection ports. Fig. 7A and 7B are perspective views of alternative connection port embodiments, 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, the cartridge 1320 may take different configurations at the end of the cartridge 1320 that engages the 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 by corresponding receptacle contacts 125 in the cartridge receptacle 118, e.g., in a snap-fit manner. The opposing structure may be used for 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 cartridge 1320 is shown. In one example, the cartridge 1320 may be implemented using a separable two-piece structure, wherein a relief (e.g., owner's trademark, serial number, patent number, etc.) or an optional decoration or ornamental feature may be imprinted on the outer wall of the cartridge 1320 by a molding process. The molding process allows flexibility in designing an external shape or externally displayable logo or ornamental design without affecting the positioning or formation of internal features (e.g., reservoir 1340, reservoir 1342, or overflow volume 1344).

Notably, the marks as shown in FIG. 8Is a registered trademark of Juul LABS Inc. Delaware corporation, calif. of headquarters, san Francisco. All rights are reserved by the owner or assignee of the tag. The use of example marks in fig. 8 should not be construed as limiting the scope of the disclosed subject matter to include such exclusive designs or marks. Some embodiments may be label-free or contain no decorative or external design features whatsoever. Thus, fig. 8 provides an illustration of a molded relief, which may be presented as a mark or design on one or more sides of the cartridge 1320, without limitation.

Referring to fig. 9A and 9B, perspective and plan cross-sectional views of an exemplary cartridge 1320 are shown, wherein a first portion 1422 of the cartridge 1320 is separated 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 part split. That is, according to an embodiment, a plurality of split sections of the component are connected together to form the entire component, as shown by way of example in fig. 4.

Referring to fig. 9A, for electrical contacts and heating elements to remain in the core-shell region 910 of the cartridge 1320, the component split may allow for molded compatibility/plasticity. As shown in more detail in fig. 9B, one or more vent holes 920 may be drilled or positioned by injection molding or other suitable method in the body of cartridge 1320 in an area proximate to wick housing area 910 to allow for precise venting or air flow to be directed to the wick, for example, to help control condensation within cartridge 1320 or to affect capillary forces therein.

Referring to fig. 10A and 10B, an assembled and exploded perspective view, respectively, of an alternative exemplary embodiment of a cartridge 1320 is shown. As previously described, 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, the first portion 1422 (e.g., upper housing) and the second portion 1424 (e.g., lower housing) may provide a two-piece structure having one or more internal cavities that may be used to house at least one of the heating element 1350, the wicking element 1362, or the plate 1326. It should be appreciated that alternative assembly methods may be used to create 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., reservoir 1340 in fig. 3A), some features, such as secondary channel 1384 (see fig. 3A) may be implemented in removable or attachable collector 1313, which collector 1313 may be separately constructed as a separate component and may then be enclosed between first portion 1422 and second portion 1424 (see fig. 10A and 10B), or alternatively inserted into an optional unitary hollow cartridge body adapted to receive collector 1313 from an open end (see fig. 10C, 10D, 11B, 13, 16C, 17A, 22B).

Referring to fig. 10A-43B, various embodiments are disclosed that may utilize a collector 1313 that is fully or partially constructed, designed, manufactured, assembled, or otherwise configured independent of the cartridge 1320 housing. Notably, the disclosed implementations are provided as examples. In alternative implementations or embodiments, the collector 1313 may be formed as shown in fig. 10A-14B, having a structure that is at least 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 packaged in, for example, a standardized cartridge 1320 housing. As provided in further detail herein, because some of the primary functions for controlling the flow of vaporizable material 1302 in cartridge 1320 can be accomplished by manipulating the structure of collector 1313 or its material properties, cost savings and other efficiencies and advantages can be obtained from configurations having interchangeable collector 1313 models that allow, for example, for adaptation to different cartridge shells.

For example, referring to fig. 10C and 10D, in some embodiments, the 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 is also referred to as the receiving end of the cartridge housing) may be configured for insertably receiving at least one collector 1313. In one embodiment, the second end of the cartridge housing may serve as a mouthpiece with 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 air flow channel 1338 extending through the body of the cartridge 1320 and the collector 1313. As in other cartridge embodiments according to the present disclosure, a nebulizer, e.g., one containing a wicking element and a heating element as discussed elsewhere herein, may be positioned adjacent to or at least partially in the airflow channel 1338 such that an inhalable form of liquid vaporizable material, or alternatively a precursor of an inhalable form, may be released from the nebulizer into air passing through the airflow channel 1338 toward the orifice or opening.

Air exchange port embodiment

Referring to fig. 11A and 11B, an illustrative plan side view of a single gate, single channel collector 1313 is shown. In these exemplary embodiments, the gate 1102 may 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 with or in communication with the reservoir chamber 1342 of the reservoir (see also fig. 3A and 3B discussed previously). The gate 1102 may dynamically connect the reservoir 1342 to an overflow volume 1344 formed by a second portion (e.g., a middle portion) of the collector 1313.

In one embodiment, the second portion of the collector 1313 may have a ribbed or multi-finned structure forming overflow channels 1104, as shown in fig. 11A, which overflow channels 1104 spiral, narrow or slope in a direction away from the gate 1102 and toward the air exchange port 1106 to direct or cause movement of the vaporizable material 1302 toward the air exchange port 1106 after the vaporizable material 1302 passes through the gate 1102 into the overflow volume 1344. The air exchange port 1106 may be connected to ambient air through an air path or air flow channel connected to the mouthpiece. This air path or air flow channel is not explicitly shown in fig. 11A.

In some embodiments, the collector 1313 is configured with a central opening or channel through which an airflow passage to the mouthpiece is achieved, as provided in further detail below (e.g., see the opening denoted by reference numeral 1100 in fig. 11D). The airflow passage may be connected to the air exchange port 1106 such that the volume within the overflow passage of the collector 1313 is connected to ambient air via the air exchange port 1106 and also to the volume in the reservoir 1342 via the gate 1102. Thus, according to one or more embodiments, the gate 1102 may be used as a control fluid valve to primarily control the flow of liquid and air between the overflow volume 1344 and the reservoir 1342. For example, the air exchange port 1106 may be used to primarily control the flow of air (and sometimes liquid flow) between the overflow volume 1344 and the air path to the mouthpiece. The overflow channel 1104 may be inclined, vertical or horizontal relative to the elongate body of the cartridge 1320.

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

The equilibrium state refers to a state in which the vaporizable material 1302 is neither flowing into nor out of the overflow volume 1344, or 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 equilibrium is maintained when cartridge 1320 is in the first pressure state, when the pressure within reservoir 1342 is approximately equal to ambient pressure.

By adapting or adjusting the volumetric dimensions of the overflow channel 1104 along the channel length, an equilibrium state and further capillary interactions between the vaporizable material 1302 and the walls of the overflow channel 1104 can be established or configured. As provided in further detail herein, the diameter of the overflow channel 1104 (used generally herein to refer to a measure of the size of the cross-sectional area of the overflow channel 1104, including embodiments of the current 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 the vaporizable material 1302 into and out of the collector 1313 as a function of pressure variations, and further allow for a large volume of the overflow channel while still maintaining a gate point for meniscus formation to prevent air from flowing through the liquid in the overflow channel 1104.

As provided in further detail herein, the diameter of overflow channel 1104 may be small or narrow enough that the 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 can 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 should be appreciated that the meniscus has an inherent curvature, and thus reference to a dimension transverse to the flow direction is not intended to imply that the air-liquid interface is planar in that dimension or any other dimension.

The wicking element 1362 may be thermally or thermodynamically coupled with the heating element 1350 (e.g., see fig. 3B and 11B) to cause the generation of vapor by heating the vaporizable material 1302, as discussed in detail previously with reference to fig. 3A and 3B. Alternatively, the air exchange port 1106 may 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, by implementing suitable structures (e.g., microchannel configurations) to introduce or utilize capillary properties that may exist between the vaporizable material 1302 and the retaining walls of overflow channel 1104, direct or reverse flow of vaporizable material 1302 in collector 1313 can be controlled (e.g., enhanced or reduced). For example, factors related to length, diameter, internal surface texture (e.g., rough vs. smooth), protrusions, directional narrowing of channel structures, shrinkage or material used to construct or coat the surfaces 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 influencing forces acting on the cartridge 1320.

Depending on the implementation, 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. Thus, in some embodiments, the flow of vaporizable material 1302 into collector 1313 can be fully reversible or semi-reversible by selectively controlling the various factors described above and depending on the change in pressure conditions inside or outside of 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 structure. In such embodiments, the overflow channel 1104 may be a continuous passageway, tube, channel, or other structure for connecting the gate 1102 to the air exchange port 1106, optionally positioned adjacent to the wicking element 1362 (e.g., see also fig. 3A and 3B, showing a single elongated overflow channel 1104 in the overflow volume 1344). Thus, in such embodiments, the vaporizable material 1302 can enter or exit the collector 1313 from the gate 1102 and pass through a separately configured channel, wherein the vaporizable material 1302 flows in a first direction when the collector 1313 is filled and the vaporizable material flows in a second direction when the collector 1313 is emptied.

To help maintain equilibrium, 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 may be adapted or modified to balance the rate of flow of vaporizable material 1302 in overflow channel 1104 under different pressure conditions. In one example, the overflow channel 1104 may be narrowed such that a narrowed end (i.e., an end having a smaller opening or diameter) opens into the gate 1102.

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

Depending on the implementation, the narrowing channel structure may reduce or increase the restriction of flow into the collector 1313. For example, in embodiments where overflow channel 1104 narrows toward gate 1102, capillary pressure is induced in overflow channel 1104 that is dominant toward reverse flow, such that when the pressure state changes (e.g., when a negative pressure event is eliminated or subsided), the flow of vaporizable material 1302 is directed away from collector 1313 and into reservoir 1342. In particular, implementing overflow channel 1104 with a smaller opening prevents vaporizable material 1302 from freely flowing into collector 1313. The non-narrowed configuration of the overflow channel 1101 in the direction toward 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 in a manner that enters the larger volume section of the overflow channel 1104 from the narrower section of the overflow channel 1104.

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

Mouthpiece embodiment

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

A first end of the air flow channel 1338 may be connected to an opening at a first "mouthpiece" end of the storage chamber 1342 from which a user may inhale the 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 passage 1338 may extend completely or partially through a receiving cavity that passes through the collector 1313 and connects to the wick housing where the wicking element 1362 may be housed.

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

Without limitation, a variety of different structural configurations may be used to connect the mouthpiece (and the air flow 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 cartridge 1320, which may also serve as a storage chamber 1342. In some embodiments, the airflow channel 1338 may be configured as an internal sleeve that is 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 airflow channel 1338.

18A-18D, certain embodiments may include an evaporator cartridge 1800 that includes a dual barrel nozzle 1830 connected to two airflow channels 1838. In such embodiments, a higher dose of vaporized vaporizable material 1302 may 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 embodiments

Referring to fig. 10A-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, according to an embodiment. Some of these factors may include capillary drive configuring the fluid vent (referred to herein as the gate 1102). The capillary drive of the shutter 1102 may be, for example, less than the capillary drive of the wicking element 1362. Furthermore, the flow resistance of the collector 1313 may 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. The overflow channel 1104 may be formed with a narrowed bend to provide an appropriate capillary interaction and force that limits the flow rate through the gate 1102 and into the overflow volume 1344 during a first pressure state to promote a reverse flow rate through the gate 1102 and out of the overflow volume 1344 during a second pressure state.

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

Notably, regardless of the various structural elements and implementations discussed in this disclosure, certain features and functions (e.g., capillary action between the 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, a single channel structure, (2) a single vent, a multi-channel structure, or (3) a multi-vent, multi-channel structure.

Referring to fig. 10E, 11A, 11C, 11D, and 11E, an exemplary structural configuration for the collector 1313 is given according to certain 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 is free to flow 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 opposite ends.

At a first end, a central shaft or central channel 1100 through the collector structure 1313 may interact with or be connected to a housing region in which the wicking element 1362 or atomizer may be positioned. At the second end, the central channel 1100 may interact with, connect to, or receive an end of a conduit or tube that forms an airflow passage 1338 in the mouthpiece portion of the cartridge 1320. A first end of the air flow 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.

According to 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 passageway 1338. The vaporized vaporizable material 1302 can then travel through the airflow passageway 1338 and exit through a mouthpiece opening formed at the 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 spiral inclined surface. In other words, when the collector 1313 is inserted into the body of the cartridge 1320, 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 may be located at one end of overflow channel 1104, toward where reservoir 1342 is located, to control and provide for the ingress and egress of vaporizable material 1302 in overflow channel 1104 in collector 1313. The air exchange port 1106 may be positioned toward the other end of the overflow channel 1104, preferably opposite the end where the gate 1102 is positioned.

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

In particular embodiments, the air exchange port 1106 may be configured to route the vaporizable material 1302 away toward a region in which the wicking element 1362 is housed. Such an embodiment may help to avoid leakage of vaporizable material 1302 into the airflow passageway (e.g., central channel 1100) leading to the mouthpiece, for example, during a negative pressure event. In some embodiments, the air exchange port 1106 may have a membrane that allows gaseous material (e.g., 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 through gate 1102 into or out of collector 1313 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/hydraulic diameter of the overflow channel 1104 such that a decrease in the total volume of the overflow channel 1104 (e.g., uniformly or by introducing multiple constriction points) may result in an increase in pressure in the overflow channel 1104 and adjust the flow rate into the collector 1313. Thus, in at least one embodiment, the hydraulic/hydraulic diameter of the overflow channel 1104 may be reduced uniformly along the length of the spiral path of the overflow channel 1104 or by introducing one or more constriction points 1111a (e.g., narrowing, constriction, or restriction).

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

The constriction point 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 claimed subject matter to any particular configuration or shape.

Referring to fig. 11C, in one exemplary embodiment, the pinch point 1111a may be formed by a bump, raised edge, protrusion, or protrusion (hereinafter "protrusion") extending from the top or bottom or sidewall (or any or all of these) surfaces of the overflow channel 1104 (i.e., the vanes of the collector 1313). The shape of the protrusion may be defined as a ridge, a finger, a prong, a fin, an edge, or any other shape that constrains a 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, e.g. shaped like a shark fin, is shown, wherein the distal end of the protrusion narrows towards the edge.

As shown in fig. 11C, the sharp or cantilevered edges of the shark fin shape may be rounded. However, in other embodiments, the cantilever edge may taper to a tip. The sharpness, size, relative position, and placement frequency of the protrusions in the overflow channel 1104 may be controlled to further fine tune the tendency of the meniscus separating 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) outward of the vaporizable material 1302 (i.e., the flow exiting the collector 1313 and entering the reservoir 1342), while the flat faces of the protrusions may face inward of the vaporizable material 1302 through the gate 1102 (i.e., the flow entering the collector 1313 and exiting the reservoir 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 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 overflow channel 1104 higher than the rate of the outgoing flow, the protrusions may 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 impedes the outward flow of liquid (e.g., away from reservoir 1340) while making it easier for the meniscus to break away from the side of the protrusions facing back toward reservoir 1340. In this way, a series of such protrusions may be used as a "hydraulic ratchet" system, in which the backflow of liquid into the reservoir is promoted by microfluidic means relative 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 one exemplary embodiment, some protrusions may extend from the inner wall of isopipe 1104 in addition to (or in lieu of) protrusions extending from the bottom or top of isopipe 1104. As shown more clearly in fig. 11F, protrusions may extend from the inner wall of isopipe 1104 at the same pinch point 1111a, with two additional protrusions extending from the bottom and top of isopipe 1104 forming a C-shaped pinch point 1111a. 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, because 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 protrusions formed along the overflow channels 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 in 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 be similar to the shape of 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, the overflow channel 1104 may have a protrusion extending from a top of the overflow channel 1104 at a first height, and at a second height, the protrusion may extend from a bottom of the overflow channel 1104. At a third height, for example, the protrusion may extend from the inner wall. Alternatives to the above embodiments are possible by adjusting or varying the number of protrusions and the shape of the protrusions or the positioning of the protrusions in different sequences or heights to help control the microfluidic flow effects in both directions within the overflow channel 1104. In one example, pinch point 1111a may be implemented, for example, on one or more (or all) of the height, sides, or width of collector 1313.

Referring to fig. 11E and 11G, in addition to defining a constriction point 1111a along the longer length of overflow channel 1104 or the wider side of collector 1313, one or more additional constriction points 1111b may be defined along the narrower side of collector 1313. In this way, the exemplary embodiments shown in fig. 11E and 11G may improve the adjustment of resistance in the overflow channel 1104 or facilitate separation of the meniscus in a desired direction as compared to the embodiment in fig. 11D, because the overall hydraulic diameter (or flow rate) of the overflow channel 1104 is more contracted due to the addition of the additional contraction point 1111b.

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, for example, in addition to two or more pinch points 1111 b. Thus, collector 1313 of fig. 11D may include a total of 18 pinch points, while 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) as capillary pressure is enhanced at the plurality of pinch points 1111a and 1111 b.

Referring to fig. 11H, in some embodiments, the gate 1102 may be configured to include an orifice 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, the microfluidic force that encourages backflow toward reservoir 1340 to exceed flow away from reservoir 1340 may be enhanced because meniscus separation on the less rounded side is easier relative to the more rounded side.

Accordingly, depending on the implementation and variation of the pinch point and the structure or configuration of the gate 1102, the flow resistance of the vaporizable material 1302 out of the collector 1313 may be higher than the flow resistance of the vaporizable material 1302 into the collector 1313 and toward the reservoir 1340. In a particular embodiment, the gate 1102 is configured to maintain a liquid seal such that a layer of vaporizable material 1302 is present in the reservoir chamber 1342 at a medium in communication with the overflow channel 1104 in the overflow volume 1344. The presence of a hydraulic seal may help maintain a pressure balance between the reservoir chamber 1342 and the overflow volume 1344 to facilitate a sufficient level of vacuum (e.g., partial vacuum) in the reservoir chamber 1342 to prevent the vaporizable material 1302 from being completely expelled into the overflow volume 1344 and to avoid the wicking element 1362 from losing sufficient saturation.

In one or more exemplary embodiments, a single vent or channel in the collector 1313 may be connected to the reservoir 1342 by two vents such that the two vents remain liquid tight regardless of the positioning of the cartridge 1320. Forming 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 downward. This is because if air bubbles from the collector 1313 enter the reservoir, the pressure within the reservoir 1342 will be equal to ambient pressure. That is, if ambient air flows into the reservoir 1342, a partial vacuum within the reservoir 1342 (e.g., created by the expulsion of the vaporizable material 1302 through the wick supply 1368) will be counteracted.

Referring to fig. 11I-11K, perspective views of an alternative gate 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 the empty space in the storage chamber 1342 (i.e., the headspace above the vaporizable material 1302) contacts the gate 1102, the headspace vacuum may not be maintained. As a result, the fluid seal established at the 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 when the collector 1313 is emptied and the headspace is in contact with the gate 1102, resulting in loss of a partial headspace vacuum.

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

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

Controlled fluid gate embodiments

Fig. 11L-11N illustrate plan and close-up views of a controlled fluid gate 1102 in a collector 1313 configuration in accordance with one or more embodiments. As shown, the passageway or overflow channel 1104 in the collector 1313 may be connected to the reservoir 1342 by, for example, a V-shaped or trumpet-shaped controlled fluid gate 1102 such that the V-shaped gate 1102 includes at least two (and desirably three) openings connected 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 reservoir may be implemented to promote polycondensation at polycondensation point 1122 to maintain a liquid seal that prevents air bubbles from prematurely exiting overflow channel 1104 into the reservoir and prevents air or vaporizable material 1302 from undesirably entering overflow channel 1104 from the reservoir.

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 channels formed on the opposite side (i.e., shown on the left side in fig. 11L) may be configured to have a relatively low capillary drive compared to the high drive channels, but still have sufficient capillary drive such that in the first pressure state, a liquid seal is maintained in both the high and low drive channels.

Accordingly, in a 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 drive channel and the high drive channel, 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), 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, may travel upward and toward the controlled fluidic gate 1102. When the meniscus reaches the condensation point 1122 between the low and high drive channels of the vent 1104, air is preferentially directed through one or more of the low drive channels due to the higher capillary resistance present in the high drive channels.

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. In this way, the air exchange port 1106 in combination with the controlled fluid gate 1102 allows ambient air entering through the overflow channel 1104 to enter the reservoir until an equilibrium pressure condition is established between the reservoir and the ambient air. As previously mentioned, 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 polycondensation point 1122 due to the presence of liquid in both the high drive channel and the low drive channel fed by the liquid vaporizable material 1302 stored in the reservoir.

Fig. 11O-11X illustrate a snapshot of when the air flow collected in the example collector 1313 of fig. 11L-11N is managed to accommodate proper drainage as the meniscus of vaporizable material 1302 continues to recede.

Fig. 11O shows a receding meniscus where the strength of the partial headspace vacuum increases as vaporizable material 1302 is removed from the reservoir into the wick. This is sufficient to overcome the reverse capillary drive of the meniscus, causing the meniscus to move back through the collector toward the pinch 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 the gate 1102 as the meniscus approaches the gate 1102. At this first juncture, the headspace partial vacuum is maximized because it corresponds to the smallest geometry in the gate 1102 structure, and the partial vacuum in the reservoir continues to grow up to that point.

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

Fig. 11R shows how the secondary meniscus begins to fill the capillary channel. The constrictions in the channel geometry 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 decrease in capillary drive will reduce the partial headspace vacuum 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 channel, may drop below the relief pressure, which relates to the advancing contact angle of the secondary channel, causing them to be refilled as shown in the figure.

Fig. 11S shows how a secondary meniscus from one of the two menisci in each secondary channel reaches the point of tangency 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 primary meniscus may cause the system to react instantaneously by making the primary meniscus the advancing meniscus. Subsequently, with the secondary meniscus held in this position, a back-off of the first meniscus will likely occur.

Fig. 11T shows how the secondary meniscus moves towards the collector. In the case of a reservoir filled with liquid, the primary 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 be stable until the bubble breaks, connecting the headspace to the ambient environment.

Fig. 11U shows how the secondary meniscus closes the junction at gate 1102. This geometry is designed to encourage the secondary meniscus to separate to fill both the gate 1102 and collector 1313 channels, as the secondary meniscus will advance until it encounters the apex of the corner in the primary channel. 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, ensuring relief of leakage through the liquid supply channel. Since the newly formed meniscus has a smaller curvature than before splitting, the newly formed meniscus will continue into the channel due to the increased capillary drive.

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

In some embodiments, the constricted passage may be designed to increase the drive towards the controlled vent. In view of the polycondensation of the two advancing menisci, the vessel walls and channel bottoms of the receptacles may be configured to continue to provide drive while the side walls provide polycondensation sites for the menisci. In one configuration, the net drive of the advancing meniscus does not exceed the net drive of the retracting meniscus, thereby keeping the system stationary.

Multi-gate multi-channel collector embodiment

Referring to fig. 12A and 12B, an exemplary perspective side view and an exemplary plan side view of an embodiment of a single-vent multichannel 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 may be positioned, for example, at the 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 gradually expand to and through additional channels 1204 (b) through 1204 (j).

Depending on the embodiment, the position of gate 1202 may be modified to be located in the middle, side or corner or any other location along the length or width of collector 1313. The single-vent multichannel collector 1200 construction may have the additional advantage of allowing the vaporizable material 1302 to enter through a single gate 1202 at a first flow rate and diffuse through 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 multichannel collector 1200 structure allows for a controlled flow (e.g., restricted flow) of the vaporizable material 1302 from the reservoir chamber 1342 into the overflow volume 1344 (see fig. 3A), and further allows for a less controlled (e.g., less restricted) flow once the vaporizable material 1302 is in the overflow volume 1344. In particular 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 first set of channels 1204 (a) through 1204 (f) is at a second rate, and the flow of vaporizable material 1302 in 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 may 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 configuration may help to increase the flow rate through the collector 1200, but maintain a controlled restriction to rapid flow of the vaporizable material 1302 toward the wicking element 1362 once the vaporizable material 1302 enters the collector 1200.

In the dual layer embodiment shown in fig. 12B, the first set of channels 1204 (a) through 1204 (f) (e.g., layer 1) may have a reversible configuration such that the vaporizable material 1302 collected in the first set of channels may flow back into the reservoir 1340. In contrast, the second set of channels 1204 (g) to 1204 (k) (e.g., layer 2) may not have a reversible configuration. In such embodiments, as the second set of channels is proximate to the wicking element 1362, the vaporizable material 1302 is predominantly extracted from the second set of channels and then from the first set of channels (e.g., layer 1, which acts as a retention chamber). As noted above, having reversible and irreversible configurations can help provide additional improvements to 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 under-fed, as 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. Further, in a multi-layer embodiment, the opportunity for the vaporizable material 1302 to flow strongly into the wick housing during a negative pressure event may be prevented, as the second set of channels 1204 (g) through 1204 (k) may be configured to have a more restricted flow than the first set of channels 1204 (a) through 1204 (f), as previously described. 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) through 1204 (f) or the second set of channels 1204 (g) through 1204 (k), an absorbent material (e.g., a sponge) may 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 in accordance with one or more embodiments is shown. As shown, the collector 1300 may be positioned within the cartridge such that the collector 1300 has a dual vent 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 section supply embodiment

Referring back to fig. 10C, 10D, 11B, in some 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 may be configured to receive the wicking element 1362. For example, fork-shaped protrusions may be formed to securely receive the wicking element 1362. The wick housing 1315 may be used to further secure the wick element 1362 in a fixed position between the protrusions. This configuration may also help prevent the wicking element 1362 from expanding and weakening significantly due to oversaturation. Referring to fig. 11C, 11D, and 11E, according to an embodiment, one or more additional conduits, channels, tubes, or cavities traveling through the collector 1313 may be constructed or configured to supply the wicking element 1362 with a path of 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 substantially parallel to the central channel 1100. In at least one configuration, there may be multiple wick feeds extending diagonally along the length of the collector 1313, for example, independently or in relation to a wick exchange including one or more other wick feeds.

In some embodiments, multiple wick feeds may be interactively connected in a multi-linked configuration such that exchanges of feed paths that may cross each other may lead to a wick housing area. Such a configuration may help prevent complete blockage of the wick feed mechanism in the event that one or more of the feed paths in the wick feed exchange are blocked, for example, via formation of bubbles or other types of blockage. Advantageously, the means of multiple feed paths 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 area even if some paths or routes in the wick feed exchange are completely or partially blocked or obstructed.

According to embodiments, the wick feed-path may be shaped as a tube having a cross-shape diameter, 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 periphery of the wick supply may be hollow cross-shaped, e.g., such that the arms of the cross have a narrower width related to the diameter of the central intersection portion of the cross from which the arms extend. More generally, the wick supply passage (also referred to herein as the "first passage") may be of a cross-sectional shape having at least one irregularity (e.g., a protrusion, a side passage, 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 cross-shaped cross-section of the present example is one example of such a structure, but those skilled in the art will appreciate that other shapes are also contemplated and possible consistent with the present disclosure.

A cross-shaped catheter or tube embodiment formed by a wick feed-path may overcome the blockage problem because a cross-shaped tube may be considered to include substantially 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 feed tube via a bubble, for example, would likely form at the central portion of the cross-shaped tube, leaving the sub-path (i.e., the path through the arms of the cross-shaped tube) open to convection.

According to one or more aspects, the wick feed passage may be wide enough to allow the vaporizable material 1302 to pass through the feed passage and freely travel toward the wick. In some embodiments, the flow through the wick supply may be enhanced or regulated via designing the relative diameters of certain portions of the wick supply to enhance capillary traction 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 feed paths may rely on gravity or capillary forces to cause movement of vaporizable material 1302 toward the wick housing portion.

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

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

The wick feed mechanism may be formed through the collector 1313 such that at least one wick feed path in the collector 1313 may be shaped as a multi-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 the arms extend.

A conduit or tube having a cross-shaped diameter formed through the capillary feed path may overcome the clogging problem because a tube having a cross-shaped 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, a 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-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. Other embodiments are possible for the wick supply passage structure that achieve the same or similar purposes as disclosed above with respect to trapping air bubbles or avoiding complete blockage of the wick supply passage by 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 aggregate volume of vaporizable material 1302 may be displaced when additional vents are available. Thus, even though not explicitly shown, examples having more than two vents (e.g., three-vent embodiments, four-vent embodiments, etc.) are within the scope of the disclosed subject matter.

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 section may have a higher saturation level and less chance of starvation than embodiments that provide a single supply.

Referring to fig. 15A, 15B and 15C, perspective and plan sectional side views of an example collector structure for a dual feed wick 1562 are provided. As shown, a wick 1562 may be provided or housed in the cartridge 1500 so as to provide at least two separate wick supplies 1566 and 1568, thereby allowing the vaporizable material 1302 to travel toward the region of the cartridge 1500 where the wick 1562 is housed.

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 a single wick supply alternative. Advantageously, the dual wick supply embodiment provides sufficient supply to the wicks 1562 and helps prevent the wicks 1562 from drying out if, for example, one of the wick supplies is blocked. As shown, a lower portion of the wicking portion 1562 may extend downward into the cartridge 1500 in the area where the heating chamber or atomizer is formed.

Referring to fig. 16A, a side view in plan section of an exemplary cartridge is provided in which a dual horn or dual feed wick 1562 is located within the collector structure. Fig. 16B is a side view in plan section 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 the wicking portion 1562 may have two or more feeds, horns, or flanged ends for at least partially engaging two or more wicking openings in the partition 1513 such that at least one of the flanged ends engages a volume in the storage chamber 1542, e.g., tangentially, or extends at least partially into a volume in the storage chamber 1542, e.g., as shown.

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

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

Referring 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 is provided, the cartridge having a wick 1562 protruding into a storage chamber 1542. The wicking portion 1562 may include at least a first end 1592 and a second end 1594, the first end 1592 being proximate the partition 1513 and the second end extending distally in a direction opposite the first end 1592.

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

Fig. 26A illustrates perspective, front, side, bottom and top views of an example embodiment of a collector 1313 with a V-gate 1102. As shown in fig. 25 and 26A-26D, the collector 1313 may fit within a cavity in the cartridge 1320 along with additional components (e.g., the wick element 1362, the heating element 1350, and the wick housing 1315). 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 being inserted 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 other mentioned components, to hold the components in place in a pressure-tight or press-fit manner. The sealing or fitting 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 wick housing 1315 and collector 1313 and the inner wall of the receiving sleeve of the cartridge 1320 is also tight enough to prevent manual removal of the components by the user.

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

Referring to fig. 26B, in one embodiment, the wicking element 1362 may be constrained 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 that is positioned directly below the wicking supply 1368) to help prevent leakage by, for example, maintaining a larger saturated region of vaporizable material 1302 toward the ends of the wicking element 1362 such that the central portion of the wicking element 1362 remains drier and less prone to leakage. Furthermore, the use of compression ribs 1110 may further force the wicking element 1362 into the atomizer housing to prevent leakage into the atomizer.

26D-26F, top plan views of an example wick feed mechanism formed by collector 1313 or configured to pass through collector 1313 are illustrated in accordance with one or more embodiments. As shown in fig. 26D, at least one wick feed 1368 path in collector 1313 may be shaped as a multi-faceted cross-diameter hollow tube. For example, the hollow cross-section of the wick supply 1368 path 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 the arms extend.

Referring to fig. 26E, a catheter or tube having a cross-shaped diameter formed through the wick supply 1368 pathway may overcome the blockage problem, indicating that because a 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., an air bubble) would likely form at the central portion of the cross-shaped tube, as shown in fig. 26E. This central positioning of the bubble will eventually leave 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 wick supply 1368 path structure that achieve the same or similar purposes as disclosed above with respect to trapping bubbles or avoiding the trapped bubbles from completely blocking the wick supply 1368 path. As shown in the example illustration of fig. 26F, one or more droplet-shaped protrusions 1368a/1368b (e.g., shaped like one or more separate junctions between which the wick supply 1368 path is located) may be formed in the wick supply 1368 path at an end 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 supply 1368 path in the event that a bubble is trapped in a central region of the wick supply 1368 path. In this way, a reasonably controllable and consistent flow of vaporizable material 1302 can flow to the wicking portion, preventing the wicking portion from being insufficiently saturated with vaporizable material 1302.

Heating element embodiments

18A-18D, the evaporator cartridge 1800 can also include a heating element 1850 (e.g., a flat heating element), as described above. The heating element 1850 includes a first portion 1850A positioned generally parallel to the airflow channel 1838 and a second portion 1850B positioned generally perpendicular to the airflow channel 1838. As shown, a first portion 1850A of the heating element 1850 may be positioned between opposing portions of the collector 1813. When the heating element 1850 is activated, heat is generated, for example, due to a current flowing through the heating element 1850, thus causing a temperature increase.

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 may occur to the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 being lifted from the collector 1813, and/or to the vaporizable material 1302 being lifted into the wick held by the heating element 1850. The air introduced into the evaporator apparatus flows along an air path across the heating element 1850, causing the vaporized vaporizable material 1302 to be stripped from the heating element 1850 and/or wick. The vaporized vaporizable material 1302 can condense due to cooling, pressure changes, etc., such that it exits the mouthpiece 1830 as an aerosol for inhalation by a user through at least one of the airflow channels 1838. Referring to fig. 19A-19C, evaporator cartridge 1900 may include a folding heating element 1950 and two air flow channels 1938. As described above, the heating element 1950 may be curled around the wick 1962 or preformed to receive the wick 1962. The heating element 1950 may include one or more rake wings 1950A. The rake wings 1950A can be positioned in the heating portion of the heating element 1950 and designed such that the resistance of the rake wings 1950A matches an appropriate amount of resistance to affect localized heating in the heating element 1950, thereby more efficiently and effectively heating the vaporizable material 1302 from the wick 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 the rake wings 1950A may be selected as desired to create a particular localized resistance for heating the heating element 1950. For example, the 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 the heating element 1950 is activated, heat is generated by the flow of current through the 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 the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 pulled from the collector 1913, and/or to the vaporizable material 1302 pulled into the wick 1962 held by the heating element 1950. In some embodiments, vaporizable material 1302 can evaporate along one or more edges of rake wings 1950A.

Air introduced into the evaporator apparatus flows along an air path across the heating element 1950, stripping the vaporized vaporizable material 1302 from the heating element 1950 and/or wick 1962. The vaporized vaporizable material 1302 can condense due to cooling, pressure changes, etc., such that it exits the mouthpiece through at least one of the air flow passages 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, the heating element 2050 may be crimped around the wick 2062 or preformed to receive the wick 2062. The 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 matches 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 wick 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 element 2050. For example, the rake wings 2050A may include one or more of a variety of rake wing configuration configurations described in more detail below.

When heating element 2050 is activated, heat is generated due to the flow of current through heating element 2050, thereby causing a temperature increase. 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 the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 pulled from the collector 2013, and/or to the vaporizable material 1302 pulled into the wick 2062 held by the heating element 2050.

In some embodiments, the vaporizable material 1302 may be vaporized along one or more edges of the rake wings 2050A. The air passing through the evaporator device flows along an air path across the heating element 2050, causing the evaporated vaporizable material 1302 to be peeled off of the heating element 2050 and/or wick 2062. The vaporized vaporizable material 1302 can condense due to cooling, pressure changes, etc., such that it exits the mouthpiece through at least one air flow channel as an aerosol for inhalation by a user.

Referring to fig. 10C, 11B, and 21A, in some embodiments, the collector 1313 may be configured to include a flat rib 2102 extending at a lower periphery of the collector 1313 to create a suitable surface for welding the collector 1313 to an 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 embodiment, full perimeter welding or tack welding options may be employed to securely fix collector 1313 within a receiving cavity or receptacle in storage chamber 1342. In some embodiments, a friction-tight coupling may be established without employing welding techniques. In certain embodiments, adhesive materials may be used in place of or in addition to the coupling techniques described above.

Referring to fig. 11B and 21B, according to one or more aspects, a sealing bead profile 2104 is plastic molded (fashion) at the periphery of the spiral rib of the collector 1313 defining the overflow channel 1104 such that the sealing bead profile 2104 can support a rapid rotational injection molding process. The geometry of the sealing bead profile 2104 may be designed in various ways such that the collector 1313 may be inserted in a friction-tight manner into a receiving cavity or receptacle in the storage chamber 1342, wherein the vaporizable material 1302 may 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 folding heating element (e.g., heating element 500) and two airflow channels 2238. As described above, the heating element 500 may be crimped around the wicking portion 2262 or preformed to receive the wicking portion 2262. The heating element 500 may include one or more rake wings 502. The rake wings 502 may be located in the heating portion of the heating element 500 and designed such that the resistance of the rake wings 502 matches the appropriate amount of 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.

The 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 the rake wings 502 may be selected as desired to create a particular localized resistance for heating the heating element 500. For example, the rake wings 502 and the 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 platform rake wings 524 and side rake wings 526. Platform rake wings 524 are configured to contact one end of wicking portion 2262 and side rake wings 526 are configured to contact the opposite side of wicking portion 2262. The platform rake wings 524 and the side rake wings 526 form a pocket that is shaped to receive the wicking portion 2262 and/or conform to the shape of at least a portion of the wicking portion 2262. The pouch allows the wicking portion 2262 to be secured and held within the pouch by the heating element 500. In some embodiments, side rake wings 526 and platform rake wings 524 retain wicking portion 2262 via compression. Platform rake wings 524 and side rake wings 526 contact wicking 2262 to provide multi-dimensional contact between heating element 500 and wicking 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 evaporator cartridge to the heating portion (via the wicking portion 2262) to be vaporized. The heating element 500 may include one or more legs 506 extending from the rake wing 502 and cartridge contacts 124 formed at ends 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 FIGS. 22A-22B and 82-86 is four legs 506. At least one of the legs 506 may include and/or define one of the cartridge contacts 124 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 the legs 506 and/or bending of the legs 506 may help to increase and/or maintain a consistent pressure between the legs 506 and the receptacle contacts 125. In some embodiments, the legs 506 are coupled with supports 176 that help increase and/or maintain a consistent pressure between the legs 506 and the receptacle contacts 125. The support 176 may include 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 contact 124 and other contacts or the power source 112. For example, the wiping contact will comprise at least two parallel but offset bosses which frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

In some embodiments, the leg 506 includes a retainer portion 180, the retainer portion 180 being configured to bend around at least a portion of the wick housing 178 surrounding at least a portion of the wick 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 rise results as a current flows 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 the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 pulled from the collector 2213, and/or to the vaporizable material 1302 pulled into the wick 2262 held by the heating element 500.

In some embodiments, the vaporizable material 1302 can be vaporized along one or more edges of the rake wings 502. Air introduced into the evaporator apparatus flows along an air path across the heating element 500, causing the vaporized vaporizable material 1302 to be stripped from the heating element 500 and/or wick 2262. The vaporized vaporizable material 1302 can condense due to cooling, pressure changes, etc., such that it exits the mouthpiece through at least one of the air flow passages 2238 as an aerosol for inhalation by a user. Fig. 23 illustrates a cross-sectional view of a wick housing 178 consistent with an embodiment of the present subject matter. The wick housing 178 may include a wick support rib 2296 that extends from the outer shell 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 wick housing 178 that includes an identification chip 2295. The identification chip 2295 may be at least partially retained by the wick housing 178. The identification chip 2295 may be configured to communicate with a corresponding chip reader located on the evaporator.

Fig. 25 illustrates perspective, front, side and exploded views of an exemplary embodiment of a cartridge 1320 having press-fit features. As shown, the cartridge 1320 may include a mouthpiece-reservoir combination shaped in the form of a sleeve through which the air flow passage 1338 is defined. A region in the cartridge 1320 houses the collector 1313, wicking element 1362, heating element 1350, and wick housing 1315. An opening at the first end of the collector 1313 opens into an airflow passage 1338 in the mouthpiece and provides a route for the vaporized vaporizable material 1302 to travel from the heating element 1350 region 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 the collector 1313 structure are shown. Similar to the flow management mechanisms discussed with reference to fig. 11M and 11N, in different embodiments, the flow management plenum 2701 or 2702 can be implemented in various shapes. 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 includes 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 independent 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 a liquid seal.

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

Fig. 28 illustrates an instant snapshot when the flow of vaporizable material collected in the example collector of fig. 27A or 27B is managed to adjust for proper ventilation in the cartridge storage chamber, according to one embodiment. As shown, the structure of the ventilation portion 2701 in fig. 27A can be distinguished from the ventilation portion 2702 in fig. 27B in the following manner: the latter configuration of the vent 2702 is provided as an open area on one side, rather than the wall structure shown in fig. 27A. This more open embodiment provides for enhanced microfluidic interaction between the vaporizable material 1302 and the open side of the vent portion 2702.

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, the laser weld may be achieved at a circumferential joint approximately at the point/location where one end of the collector structure meets the wick housing. The laser welds prevent liquid vaporizable material 1302 from flowing from the collector into the heating chamber in which the atomizer is disposed.

Referring to fig. 30A-30F, perspective views of example cartridges at different fill capacities are illustrated. As previously mentioned, the volume dimension of the overflow volume may be configured to be equal to, substantially equal to, or greater than the increase in volume of the contents contained in the storage chamber. If the volume of the contents contained in the storage chamber is X when the volume of the contents in the storage chamber expands due to one or more environmental factors, then a 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. Thus, in one or more embodiments, the overflow volume is configured to be at least large enough to contain a Z amount of vaporizable material 1302.

Fig. 30A illustrates a perspective view of an example cartridge body having a reservoir that adjusts to accommodate storage of vaporizable material 1302, for example, having a volume of about 1.20mL, when filled. Fig. 30B illustrates a perspective view of an example cartridge in a fully assembled state, wherein the storage chamber and the collector overflow channel, when both are filled, contain 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 an 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 passage and the airflow passage in the mouthpiece shown in cut-away view, the wick supply passage having a volume of, for example, about 0.094 mL. Fig. 30F illustrates a perspective view of an example cartridge in a fully assembled state, wherein the overflow air channel is incorporated into the bottom rib-facing portion of the collector, the airflow air channel having a volume of, for example, about 0.043 mL. Fig. 31A-31C illustrate front views of an example cartridge according to one embodiment, wherein a two-needle filling application is implemented to fill the receptacle of the cartridge (fig. 31A) prior to insertion of the collector and closure plug 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 external airflow paths. In some embodiments, one or more gates (also referred to as air inlet holes) may be provided on the evaporator body 110. The inlet holes may be located within the air inlet channel with a width, height, and depth sized to prevent a user from inadvertently blocking individual air inlet holes when he holds the evaporator 100. In one aspect, the air inlet channel structure may be sufficiently long so as not to significantly block or restrict air flow through the air inlet channel when, for example, a user's finger blocks an area of the air inlet channel.

In some configuration configurations, the geometry of the air inlet channel may be provided 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 his or her hands or other body parts. For example, the length of the air inlet channel may be longer than the width of an average 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 folds do not contact the air inlet holes within the air inlet channel.

The air inlet channel 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 channel is not easily covered by a user's finger or body part. In some embodiments, an optional cover may be provided to protect the air inlet passage so that the user's finger does not block or completely restrict air flow into the air inlet passage. In one example embodiment, the air inlet channel may be formed at an interface between the evaporator magazine 120 and the evaporator body 110 (e.g., at a receptacle area—see fig. 1). In this embodiment, since the air inlet passage is formed in the receptacle area, the air inlet passage can be protected from being blocked. 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 the air path.

Referring to fig. 33A, air or vapor 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 such that vaporizable material 1302 drawn through the mouthpiece passes through condensate collector 3201. As shown in fig. 33B, in addition to the condensate collector 3201, a condensate recycler channel 3204 (e.g., a microfluidic channel) may be formed to run, for example, from an opening in the mouthpiece to the wick.

Condensate collector 3201 acts on vaporized vaporizable material 1302 cooled in the mouthpiece and becoming droplets to collect and direct the condensed droplets to condensate recycler channel 3204. Condensate recycler channel 3204 collects and returns condensate and large vapor droplets to the wick and prevents liquid vaporizable material formed in the mouthpiece from depositing into the user's mouth during suction or inhalation from the mouthpiece. The condensate recycler channel 3204 may be implemented as a microfluidic channel to trap any droplet condensate and thereby eliminate direct inhalation of vaporizable material in liquid form and avoid undesirable sensations or tastes in the user's mouth. Additional and/or alternative embodiments of condensate recycler channels and/or one or more other features for controlling, collecting, and/or recycling condensate in an evaporator device 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 in controlling, collecting, and/or recycling condensate in the evaporator device, alone or in combination with one or more features of the evaporator cartridge

Referring to fig. 35 and 36, perspective views of a portion of an exemplary cartridge are illustrated, wherein the collector structure 1313 includes an air gap 3501 at the bottom rib of the collector structure. The location of the air gap 3501 may be consistent with the location of the air exchange port in the collector structure 1313. As previously described, the collector structure 1313 may be configured with a central opening through which an airflow passage to the mouthpiece is achieved. The airflow channel may be connected to an air exchange port such that the volume within the overflow channel of the collector 1313 is connected to 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 serve as a control valve to primarily control the flow of liquid between the overflow channel and the storage chamber. For example, an air exchange port may be used to primarily control the air flow between the overflow channel and the air path leading to, for example, a mouthpiece. The combination of interactions between the vent, collector channel of the overflow channel, and the air exchange port 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 channel. The presence of the air gap 3501 at the air exchange port allows for a more robust venting process because the air gap prevents the liquid vaporizable material 1302 stored in the collector from penetrating into the wick housing area.

Fig. 37A-37C illustrate top views of various example wick supply shapes and configurations for a cartridge in accordance with one or more embodiments. As shown, fig. 37A illustrates a cross-shaped wick supply cross-section according to 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 supply portions 3701 may be configured to travel through a conduit, channel, tube, or lumen of the collector structure 1313 as a path to supply the vaporizable material 1302 stored in the storage chamber to the wick. In certain configuration configurations, the wick supply 3701 may extend substantially parallel to the central channel 3700 in the collector 1313. According to an embodiment, the core supply path may be shaped as a tube having a generally rectangular or square cross-sectional shape, such as shown in fig. 37B and 37C. A conduit or tube formed in a variable width cross-sectional shape through the wick feed path can overcome the blockage problem, provided that such shape is provided in a multi-path configuration that allows the vaporizable material 1302 to travel through the wick feed even with air bubbles formed in a region of the wick feed. In such an embodiment, a blockage in the wick supply pipe would likely form at a portion of the wick supply pipe, leaving the sub-channels (e.g., alternate channels) open to flow. According to one or more aspects, the wick feed path may be wide enough to allow the vaporizable material 1302 to freely travel through the feed path and toward the wick. In some embodiments, the flow through the wick supply may be enhanced or regulated by designing the relative diameters of certain portions of the wick supply to enhance the capillary traction 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 feed paths may rely on gravity or capillary forces to cause movement of vaporizable material 1302 toward the wick housing portion.

Fig. 37D and 37E illustrate an example embodiment of a collector 1313 with a dual wick supply 3701 implementation. At least one of the wick supply portions 3701 may be formed to include a partition wall. The partial dividing wall may be configured to divide the volume of the interior of the wick supply 3701 into two separate volumes (i.e., body cavities), as illustrated in perspective cutaway views in fig. 37D and 37E. An embodiment of a partial wall would allow the liquid vaporizable material 1302 to easily flow from the reservoir toward the wick housing area to saturate the wick.

In some embodiments, a portion of the wall in the single-suction portion supply forms substantially two body cavities in the single-suction portion supply. The body cavities in the wick supply may be separated via a portion of the wall and used separately to allow the vaporizable material 1302 to flow toward the wick housing. In such an embodiment, if the air bubble travels in one of the body cavities in the wick supply, the other body cavity may remain open. The body cavity may be so voluminous as to provide sufficient flow of vaporizable material 1302 toward the wick so as to be sufficiently saturated.

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

Referring to fig. 38, a close-up view of the end of the wick supply that is located adjacent to the wick (e.g., at the 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 square design wick supply combined with an air gap at one end of the overflow channel.

Referring to fig. 40A-40E, a back view, a side view, a top view, a front view, and a bottom view, respectively, of an example collector structure are illustrated. Fig. 40A illustrates a rear view of a collector structure with, for example, four different spray sites. Fig. 40B illustrates a side view of the collector structure, particularly showing, for example, a clip-shaped end portion 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 from the mouthpiece internally to the cartridge body may be received through a central channel 3700 in the collector structure, the central channel forming an airway channel for evaporated vaporizable material 1302 to escape from the atomizer towards the mouthpiece.

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

Fig. 40D illustrates a front plan view of the collector structure. As shown, the 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 leads to the air control vent 3902 which 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 airway channel for the vaporized vaporizable material 1302 to escape from the atomizer toward the mouthpiece.

Fig. 40E illustrates a bottom view of the structure of the collector 1313, wherein the two wick feed channel ends in the two clip-shaped end portions 4022 are configured to hold the wick in place at the bottom end of the collector 1313. As shown, optionally, a segmented ridge, flange or lip 4003 may be formed on the surface of the bottom end of collector 1313, wherein collector 1313 is connected to the upper portion of plug 760 when assembled. Lip 4003 provides a pressure-tight engagement between the upper portion of plug 760 and the lower portion of collector 1313 that acts 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 collector 1313 may be laser welded to the upper portion of plug 760.

Fig. 41A and 41B illustrate top plan and side views of an alternative embodiment of a collector structure having two clamp-shaped end portions 4002 and two corresponding wick supplies. As shown, the height of this alternative embodiment is shorter than the embodiment illustrated in fig. 40A. This reduced height provides improved functionality due to 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. Thus, in accordance with an embodiment, the length of the channels through the vaporizable material 1302 of the collector 1313 may be shorter, to provide more efficient capillary pressure and better management of the flow of vaporizable material 1302 into the channels of the collector 1313.

Fig. 42A and 42B illustrate various perspective, top, bottom, and side views of an example collector 1313 having different structural embodiments. For example, the embodiment shown in fig. 42A includes a pinch point that includes a vertically oriented 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 channel of collector 1313. As shown in the example embodiment of fig. 42B, the C-shaped wall is positioned diagonally with respect to the bottom blade of the collector and vertically with respect to the downward sloping blade portion in the collector.

As previously described, the flow rate into and out of the collector 1313 is controlled by manipulating the hydraulic diameter of the overflow channel 1104 in the collector 1313 by introducing one or more pinch points, which effectively reduces the total 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, wherein 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 the pinch point helps to establish or control capillary pressure conditions in the overflow channel 1104 such that hydraulic flow of the vaporizable material 1302 toward the air control vent 3902 is minimized in pressure conditions 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., exceeds 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 toward 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 above-described ventilation process may not involve or require the ingress of ambient air through the air control ventilation 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 pinch point and the design of the C-shaped walls formed in the path of the overflow channel 1104 (as shown in fig. 42A and 42B) facilitate more controlled flow of the vaporizable material 1302 through the overflow channel 1104 via better management of capillary pressure throughout the path of the overflow control channel 1104.

Fig. 43A illustrates various perspective, top, bottom, and side views of an example wick housing 1315 in accordance with one or more embodiments. As shown, one or more perforations or holes may be formed in a 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 a sufficient airflow through the wick housing 760 and will provide for the 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 a collector 1313 and wick housing 760 component 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 protrusion 4390. The projections 4390 may be configured to extend from an upper end of the wick housing 1315 that mates with a receiving end of the collector 1313 during assembly. The projection 4390 may comprise one or more faces corresponding to or matching 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 protrusion 4390, for example, for a snap-fit engagement. The snap fit arrangement may assist in holding the collector 1313 and the wick housing 1315 together during or after assembly.

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

Additional ofAnd/or alternative heating element embodiments

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

Heating elements consistent with embodiments of the present subject matter may desirably be shaped to receive the wicking element and/or to be crimped or pressed 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. Heating elements may be easier to manufacture than typical heating elements. Heating elements consistent with embodiments of the present subject matter may also be made of conductive metals suitable for resistive heating, and in some embodiments, the heating elements 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 one embodiment of the evaporator magazine 120, fig. 44B shows a perspective view of one embodiment of the evaporator magazine 120, and fig. 44C shows a bottom perspective view of one embodiment of the evaporator magazine 120. As shown in fig. 44A-44C, the evaporator cartridge 120 includes a housing 160 and an atomizer assembly (or atomizer) 141.

The atomizer assembly 141 (see fig. 99-101) may include a wick element 162, a heating element 500, and a wick housing 178. As described 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 exposed to couple with a portion of the evaporator body 110 (e.g., electrically couple with the receptacle contacts 125). The wick housing 178 may include four sides. For example, the wick 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) recess 166 (see fig. 99, 111A). The recess 166 may be positioned along the long side of the wick housing 178 and adjacent to a corresponding interface between the long side and the short side of the wick housing 178. The recess 166 may be shaped to releasably couple with a corresponding feature (e.g., a spring) on the evaporator body 110 to secure the evaporator cartridge 120 to the evaporator body 110 within the cartridge receptacle 118. The recess 166 provides a mechanically stable securing means for the evaporator magazine 120 to be coupled to the evaporator body 110.

In some embodiments, the wick housing 178 further includes an identification chip 174 that is configurable to communicate with a corresponding chip reader located on the evaporator. 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. The chip recess 164 may be shaped to secure the identification chip 174 to the wick housing 178.

As described above, the evaporator cartridge 120 can generally include a reservoir, an air path, and an atomizer assembly 141. In some configuration constructions, the heating element and/or atomizer described in accordance with embodiments of the present subject matter may be implemented directly into the evaporator body and/or may not be 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 can relate to improvements over current evaporator configuration constructions, manufacturing methods, and the like. For example, a heating element of an evaporator device consistent with embodiments of the present subject matter may desirably be made (e.g., stamped) from a sheet of material and rolled 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 folded to conform to the shape of at least a portion of the wicking element. The configuration of the heating element allows for a more consistent and improved quality of manufacture of the heating element. The consistency of the quality of manufacture of the heating elements can be particularly important in a large-scale and/or automated manufacturing process. For example, heating elements consistent with embodiments of the present subject matter help reduce tolerance issues that may occur during a manufacturing process when assembling heating elements having multiple components.

In some embodiments, the accuracy of measurements made by the heating element (e.g., resistance, current, temperature, etc.) is improved at least in part due to improved consistency in manufacturability of the heating element with reduced tolerance issues. Higher measurement accuracy may provide an enhanced user experience when using the evaporator device. For example, as described above, the vaporizer 100 may receive a signal to activate the heating element to a full operating temperature to produce an inhalable dose of vapor/aerosol or to a lower temperature to begin heating the heating element. As mentioned above, the temperature of the heating element of the evaporator may depend on many factors, and several of these factors may become more predictable due to the elimination of potential variations in atomizer part 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 minimize heat loss and helps ensure that the heating element predictably behaves as being heated to a suitable temperature.

In addition, as described above, the heating element may be entirely and/or selectively plated with one or more materials to enhance the heating performance of the heating element. Plating all or a portion of the heating element may help minimize heat loss. Plating may also help concentrate the heated portion of the heating element in place, providing a more efficiently heated heating element and further reducing heat loss. Selective plating may 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 costs associated with manufacturing the heating element.

After the heating element is formed into a suitable shape via one or more of the processes discussed below, the heating element may be curled and/or bent into a suitable position around the wicking element to receive the wicking element. In some embodiments, the wicking element may be a fibrous wick formed as an at least approximately flat pad or having other cross-sectional shapes such as circular, oval, etc. The flat pad may allow for more precise and/or accurate control of the rate at which the vaporizable material is pulled into the wicking element. For example, the length, width, and/or thickness may be adjusted to obtain optimal performance. The wicking element forming a flat pad may also provide a greater transfer surface area, which may allow for increased flow of vaporizable material from the reservoir into the wicking element for vaporization by the heating element (in other words, greater mass transfer of vaporizable material) and from the wicking element to 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 evaporating the vaporizable material. The flat pad may also be easier to shape and/or cut, and thus the flat pad may be more easily assembled 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 comprise 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 controlled flow rate of vaporizable material from the reservoir of the evaporator cartridge into the wicking element 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 opposite sides approximately parallel to each other. In some embodiments, the at least approximately flat pad may further have at least a second pair of opposite sides approximately parallel to each other and approximately perpendicular to the first pair of opposite sides.

Fig. 45-48 illustrate schematic diagrams of heating elements 500 consistent with embodiments of the present subject matter. For example, fig. 2 illustrates a schematic view of a heating element 500 in an extended position. As shown, in the deployed position, 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, the 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).

The 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. The rake wings 502, legs 506, and cartridge contacts 124 may be integrally formed. For example, the rake wings 502, legs 506, and cartridge contacts 124 form part of the heating element 500 that is stamped and/or cut from the substrate material. In some embodiments, the heating element 500 further includes a thermal barrier 518 extending from one or more of the legs 506 and may also be integrally formed with the rake wings 502, the legs 506, and the cartridge contacts 124.

In some embodiments, at least a portion of the heating portion 504 of the heating element 500 is configured to contact the vaporizable material that is lifted 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 processed to produce a desired electrical resistance. For example, the rake wings 502 located in the heating portion 504 may be designed such that the resistance of the rake wings 502 matches a suitable amount of resistance to affect localized heating in the heating portion 504, thereby more efficiently and effectively heating the vaporizable material from the wicking element. The rake wings 502 form heating segments or traces of fine paths in series and/or parallel to provide a desired amount of resistance.

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

The heating element 500 may include portions having wider and/or thicker geometries and/or include different compositions relative to the 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 the evaporator cartridge. Legs 506 of the heating element 500 extend from the ends of each outermost rake wing 502A. The legs 506 form a portion of the heating element 500 having a width and/or thickness that is generally wider than the width of each rake wing 502. However, in some embodiments, the legs 506 have a width and/or thickness that is the same as or narrower than the width of each rake wing 502. 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 manufacture. Legs 506 also connect cartridge contacts 124 with rake wings 502 located in heating portion 504. Legs 506 are shaped and dimensioned to allow heating element 500 to maintain the electrical requirements of heating portion 504. As shown in fig. 5, the legs 506 space the heating portion 504 from the 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 leg 506 may also include a capillary feature 598 that restricts or prevents fluid from flowing out of the heating portion 504 to other portions of the heating element 500.

In some implementations, one or more of the legs 506 include one or more locating features 516. The locating feature 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 magazine 120. In some embodiments, the locating features 516 may be used during or after manufacture to properly position 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 feature 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 extending laterally from the legs 506. When folded and/or rolled, the thermal barrier 518 is positioned offset in the same plane from the 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 magazine 120, the thermal barrier 518 is configured to be positioned between the rake 502 (and the heating portion 504) and the body (e.g., plastic body) of the evaporator magazine 120. The thermal barrier 518 may help isolate the heating portion 504 from the body of the evaporator magazine 120. The thermal barrier 518 may help minimize the impact of heat emanating 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 melting or other deformation of the evaporator cartridge 120. The thermal barrier 518 may also help to maintain a consistent temperature at the heating portion 504 by maintaining 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 includes at least two cartridge contacts 124 forming an end portion of each leg 506. For example, as shown in fig. 45-48, the cartridge contact 124 may form a portion of the leg 506 that is folded along the fold line 507. The cartridge contact 124 may be folded at an angle of about 90 degrees relative to the leg 506. In some embodiments, the cartridge contact 124 may be folded at other angles with respect to the leg 506, such as at about 15 degrees, 25 degrees, 35 degrees, 45 degrees, 55 degrees, 65 degrees, 75 degrees, or other ranges therebetween. The cartridge contacts 124 may be folded toward or away from the heating portion 504, depending on the implementation. The cartridge contact 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 contact 124 includes a wiper contact configured to clean the connection between the cartridge contact 124 and other contacts or power source. For example, the wiping contact may comprise two parallel but offset bosses which frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

The cartridge contact 124 is configured to interface with a receptacle contact 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 contact 124 and the receptacle contact 125 form an electrical connection. The cartridge contact 124 may be in electrical communication with the power source 8 of the evaporator device (e.g., via receptacle contact 125, etc.). The electrical circuit completed/completed by these electrical connections may allow 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 circuitry of the evaporator cartridge, and so forth. As described in more detail below, the cartridge contacts 124 may be treated to provide improved electrical properties (e.g., contact resistance) using, for example, conductive plating, surface treatment, and/or deposition materials.

In some embodiments, the heating element 500 may be processed through a series of crimping and/or bending operations to shape the heating element 500 into a desired three-dimensional shape. For example, the heating element 500 may be preformed to receive the wicking element or to curl 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 element 500 may be folded toward each other along the fold line 520. Folding the heating element 500 along fold lines 520 forms a platform rake wing 524 defined by the area between the fold lines 520 and a side rake wing 526 defined by the area between the fold lines 520 and the outer edge 503 of the rake wing 502. The platform rake wing 524 is configured to contact one end of the wicking element 162. Side rake wings 526 are configured to contact opposite sides of wicking element 162. The platform rake wings 524 and side rake wings 526 form pockets shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pouch allows the wicking element 162 to be secured and held within the pouch 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 the heating element 500 and the wicking element 162 provides for more efficient and/or faster transfer of the vaporizable material from the reservoir 140 of the evaporator cartridge 120 to the heating portion 504 (via the wicking element 162) to be vaporized.

In some embodiments, portions of legs 506 of heating element 500 may also be folded away from each other along fold line 522. Folding portions of legs 506 of heating element 500 away from each other along fold lines 522 positions legs 506 at a location spaced apart from heating portion 504 (and rake 502) of heating element 500 in a first direction and/or a second direction (e.g., on the same plane) opposite the first direction. Thus, folding of the portions of the legs 506 of the heating element 500 away from each other along the fold line 522 spaces the heating portion 504 from the body of the evaporator magazine 120. Fig. 46 illustrates a schematic view of a 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 a pouch formed by folding the heating element 500 along fold lines 520 and 522.

In some embodiments, the heating element 500 may also be folded along the fold line 523. For example, the cartridge contacts 124 may be folded toward each other along the fold line 523 (into the page shown in fig. 47 and out of the page shown in fig. 47). 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 a 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 other means 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 an 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, a temperature rise results as heat is generated by the flow of current through the heating element 500. 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 to the vaporizable material in the reservoir and/or the vaporizable material being pulled into the wicking element 162 held by the heating element 500. In some embodiments, the vaporizable material may evaporate along one or more edges of the rake wings 502, as mentioned above. The air delivered to the evaporator apparatus flows along an air path through the heating element 500, causing the evaporated vaporizable material to be stripped from the heating element 500. The vaporized vaporizable material may condense due to cooling, pressure changes, etc., such that it exits the mouthpiece 130 as an aerosol for inhalation by a user.

As described above, the heating element 500 may be made of various materials, such as nichrome, stainless steel, or other resistive heater materials. A combination of two or more materials may be included in the heating element 500, and such a combination may include a homogeneous distribution of the two or more materials throughout the heating element, or other configuration configurations that include a relative amount of the two or more materials that is spatially heterogeneous. For example, the rake wings 502 may have portions that are more resistive and thus are designed to taper to be hotter than the rake wings or other sections of the heating element 500. In some embodiments, at least the rake wings 502 (such as within the heating portion 504) may comprise a material having high conductivity and heat resistance.

The heating element 500 may be entirely or selectively plated 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 alloy, the heating element 500 may suffer electrical or heating losses in the path between the cartridge contacts 124 and the rake wings 502 in the heating portion 504 of the heating element 500. To help reduce heating loss and/or electrical losses, at least a portion of the heating element 500 may be plated with one or more materials to reduce the resistance of the electrical path to the heating portion 504. In some embodiments consistent with the present subject matter, it may also be beneficial for the heating portion 504 (e.g., rake wings 502) to remain unplated in the event that at least a portion of the legs 506 and/or cartridge contacts 124 are plated with a plating material that reduces resistance in those portions (e.g., either or both of the body and contact resistance).

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 concentrate the current flowing to the heating portion 504 to reduce electrical and/or thermal losses 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 wings 502 of the heating element 500 to reduce electrical and/or thermal losses in the electrical path and to 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 measurements are made and form electrical contact between the cartridge contacts 124 and the receptacle contacts. Providing a low 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 contact 124 and/or at least a portion of the leg 506 may be plated with one or more outer plating materials 150. For example, at least a portion of the cartridge contact 124 and/or at least a portion of the leg 506 may be plated with at least gold or another material that provides a low contact resistance, such as platinum, palladium, silver, copper, and 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 adherent plating material may be deposited onto the surface of the heating element 500, and an outer plating material may be deposited onto the adherent plating material, defining a first plating layer and a second plating layer, respectively. The adherent plating material includes a material having adherent 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/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 adhesive plating material.

In some embodiments, all or a portion of the legs 506 and cartridge contacts 124 may be plated with an adhesive plating material and/or an outer plating material. In some examples, the cartridge contact 124 may include at least a portion having an outer plating material that has a greater thickness relative to the remainder of the cartridge contact 124 and/or the legs 506 of the heating element 500. In some embodiments, the cartridge contacts 124 and/or legs 506 may have a greater thickness relative to the rake wings 502 and/or the 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, diffusion processes, etc.). The material of each portion of the heating element 500 that is coupled together may be selected to provide low or no resistance at the cartridge contacts 124 and high resistance at the rake wings 502 of the heating portion 504 relative to the other portions of the heating element.

In some embodiments, the heating element 500 may be electroplated 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 more efficiently evaporate the vaporizable material.

Fig. 49-53 illustrate examples of heating elements 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, 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. The rake wings 502 have square and/or flat outer edges 503. 49-52, the rake wings 502 are crimped around the wicking element 162 (e.g., a flat pad) to secure the wicking element 162 within the pocket of the rake wings 502.

Fig. 54-55 illustrate another example of a heating element 500 in an unbent position (fig. 54) and in a bent position (fig. 55) 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, 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 of the rake wings 502 has the same or similar shape and size, and the rake wings 502 have rounded and/or semi-circular outer edges 503.

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

57-62 illustrate other examples of heating elements 500 in which at least one of the rake wings 502 has a different size, shape, or position than the remaining rake wings 502. For example, as shown in fig. 57-58, 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 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. The first set of rake wings 505A and the second set of rake wings 505B are offset from each other. For example, the outer edges 503 of the first set of rake wings 505A and the second set of rake wings 505B are not aligned with each other. As shown in fig. 58, when heating portion 504 is in the folded-over position, first set of blades 505A appear shorter than second set of blades 505B in a first portion of heating element 500, and first set of blades 505A appear longer than second set of blades 505B in a second portion of heating element 500.

As shown in fig. 59-60, 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 cartridge contacts 124 formed at an end portion of each of the one or more legs 506. In this example, the 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 and second sets of rake wings 509A, 509B are not aligned with each other. Here, the second set of rake wings 509B includes a single outermost rake wing 502A. As shown in fig. 59-60, when the heating portion 504 is in the folded position, the first set of rake wings 509A appear longer than the second set of rake wings 509B. In addition, in FIGS. 59-60, rake wings 502 are not bent. Instead, the rake wings 502 are positioned on a first portion and a second portion of the heating element 500, the second portion being positioned generally 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 the platform portion 130, the platform portion 130 being positioned between and spaced apart from both the first set of rake wings and the second set of rake wings. The platform 130 is configured to contact the end of the wicking element 162. The platform portion 130 includes a cutout portion 532. The cut-out 532 may provide an additional edge along which vaporizable material may evaporate when the heating element 500 is activated.

As shown in fig. 61-62, 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 cartridge contacts 124 formed at an end portion of each of the one or more legs 506. In this example, the 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 and second sets of rake wings 509A, 509B are not aligned with each other. Here, each of the first set of rake wings 509A and the second set of rake wings 509B includes two rake wings 502. As shown in fig. 61-62, when the heating portion 504 is in the folded position, the first set of rake wings 509A appear shorter than the second set of rake wings 509B. In addition, in FIGS. 61-62, rake wings 502 are not bent. Instead, 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 portion positioned between and spaced apart from both the first set of rake wings and the second set of rake wings. The platform portion is configured to contact the end of the wicking element 162. The platform portion includes a cutout portion. The cut-out may provide an additional edge along which the vaporizable material may evaporate when the heating element 500 is activated.

Fig. 63-68 illustrate another example of a heating element 500 consistent with an embodiment of the present subject matter, in an unbent position (fig. 63) and in a bent position (fig. 64-68). 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, 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, the heating element 500 is configured to curl and/or curve around the cylindrical wicking element 162 or the 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 vaporizable material may evaporate when the heating element 500 is activated. The aperture 540 also reduces the amount of material used to form the heating element 500, reduces 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, 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 cartridge contacts 124 formed at an end portion of each of the one or more legs 506. In these examples, the legs 506 and cartridge contacts 124 are configured to bend in a third direction, rather than bending in a first-second direction perpendicular to the third direction. In such a configuration, the rake wings 502 of the heating portion 504 form a flat platform facing outward from the heating element 500, and the platform is configured to be pressed against the wicking element 162 (e.g., on one side of the 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 described above, the rake wings 502 form a flat platform that presses against one side of the wicking element 162 in use. The legs 506, but not the rake wings 502, are bent into a bent position.

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

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

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 cartridge contacts 124 formed at and/or as part of each of the one or more legs 506. In this example, each of the rake wings 502 are of the same or similar shape and size, and each of the rake wings are spaced apart from each other by an equal distance. The rake wings 502 have rounded outer edges 503.

As shown in fig. 85, the rake wings 502 are crimped around the wicking element 162 (e.g., a flat pad) to secure the wicking element 162 within the pocket formed by the rake wings 502. For example, the rake wings 502 may be folded and/or rolled to define a pocket in which the wicking element 162 is disposed. 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. The platform rake wings 524 and the side rake wings 526 form a pocket that is shaped to receive the wicking element 162 and/or to conform to the shape of at least a portion of the wicking element 162. The pouch allows the wicking element 162 to be secured and held in the pouch 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 prongs 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 the heating element 500 and the wicking element 162 provides for more efficient and/or faster transfer of the vaporizable material from the reservoir 140 of the evaporator cartridge 120 to the heating portion 504 (via the wicking element 162) to be vaporized.

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 a consistent pressure between the legs 506 and the receptacle contacts 125. In some embodiments, the legs 506 are coupled with supports 176 that help increase and/or maintain a consistent pressure between the legs 506 and the receptacle contacts 125. The support 176 may include 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 contact 124 and other contacts or power sources. 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.

82-98, 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 element 500 in an unflexed position. As shown, the heating element 500 has an H-shape defined by four legs 506 and rake wings 502. This configuration allows for more accurate measurement of resistance across the heater and reduces variability in resistance measurements, allowing for more efficient aerosol generation and higher quality aerosol generation. The heating element 500 includes two pairs of opposing legs 506. The rake wings 502 are coupled (e.g., interface) with each pair of opposing legs 506 at or near the center of each pair of opposing legs 506. The heating portion 504 is positioned between a pair of opposing legs 506.

Fig. 109 illustrates an example of the heating element 500 prior to the heating element 500 being stamped and/or otherwise formed from the substrate material 577. Excess substrate material 577A may be coupled to the heating element 500 at one, two, or more coupling locations 577B. For example, as shown, 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 ends 173 of the heating portion 504 of the heating element 500. In some embodiments, the heating element 500 may be first stamped from the substrate material 577, and then removed from the excess substrate material 577A at the coupling locations 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 folded or otherwise folded toward or away from each other along the fold lines 523, 522a,522b,520 (see, e.g., fig. 98A). Although fold lines are illustrated in fig. 98A, the example heating element 500 depicted and shown in fig. 44A-115C may also be curled, folded, or otherwise bent along the fold lines. Folding the heating element 500 along fold lines 520 forms a platform rake wing 524 defined by the area between the fold lines 520 and/or a side rake wing 526 defined by the area between the fold lines 520 and the outer edge 503 of the rake wing 502. The platform rake wings 524 may contact one end of the wicking element 162 and/or support one end of the wicking element 162. Side rake wings 526 may contact opposite sides of wicking element 162. The platform rake wings 524 and the side rake wings 526 define an interior volume of the heating element that forms a pocket shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The internal volume allows the wicking element 162 to be secured and held within the pouch 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 the heating element 500 and the wicking element 162 provides for more efficient and/or faster transfer of the vaporizable material from the reservoir 140 of the evaporator cartridge 120 to the heating portion 504 (via the wicking element 162) to be vaporized.

In some embodiments, portions of legs 506 of heating element 500 may also be folded along fold lines 522A, 522B. Folding portions of legs 506 of heating element 500 away from each other along fold lines 522 positions legs 506 at a location that is separated from heating portion 504 (and rake 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, folding of the portions of the legs 506 of the heating element 500 away from each other along the fold line 522 spaces the heating portion 504 from the body of the evaporator magazine 120. The folding of the portions of leg 506 along fold lines 522A, 522B forms bridge 585. In some embodiments, the bridge 585 helps reduce or eliminate overflow of vaporizable material from the heating portion 504, such as caused by capillary action. The bridge 585 also helps 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 folded along the fold line 523 to define the cartridge contact 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 the 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 the wick housing.

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

Fig. 87-92 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 cartridge contacts 124 formed at and/or as part of each of the one or more legs 506.

The rake wings 502 may be folded and/or rolled to define a pocket in which the wicking element 162 (e.g., a flat pad) is disposed. 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. The platform rake wings 524 and the side rake wings 526 form a pocket that is shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pouch allows the wicking element 162 to be secured and held within the pouch by the heating element 500.

In this example, the rake wings 502 have various shapes and sizes, and the rake wings are spaced apart from one another at the same or varying distances. For example, as shown, each side rake wing 526 includes at least four rake wings 502. In the first pair 170 of adjacent rake wings 502, each of the adjacent rake wings 502 are spaced apart an equal distance from an inner region 576 located near the platform rake wing 524 to an outer region 578 located near the outer edge 503. In the second pair 572 of adjacent rake wings 502, the adjacent rake wings 502 are spaced apart 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 the inner region 576 than at the outer region 578. These configuration configurations may help maintain a constant and uniform temperature along the length of the rake wings 502 of the heating portion 504. Maintaining a constant temperature along the length of the rake wings 502 may provide a higher quality aerosol because the maximum temperature may be maintained more uniformly throughout the 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, the leg 506 includes a retainer portion 180 configured to bend and extend generally away from the heating portion 504. The retainer portions 180 are configured to be positioned within corresponding recesses in the wick housing 178. The retainer portion 180 forms the end of the leg 506. The retainer portion 180 helps secure the heating element 500 and the wicking element 162 to the wick housing 178 (and the evaporator cartridge 120). The retainer portion 180 may have a tip portion 180A that extends from an end of the retainer 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 magazine 120 or a cleaning device for cleaning the evaporator magazine 120.

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

In some embodiments, at least a portion of the cartridge contact 124 and/or at least a portion of the leg 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 contact 125.

Fig. 93A-98B 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 cartridge contacts 124 formed at and/or as part of each of the one or more legs 506.

The rake wings 502 may be folded and/or rolled to define a pocket in which the wicking element 162 (e.g., a flat pad) is disposed. 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 sides of wicking element 162. The platform rake wings 524 and the side rake wings 526 form a pocket that is shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pouch allows the wicking element 162 to be secured and held within the pouch by the heating element 500.

In this example, the rake wings 502 are of 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 that are spaced apart by a platform rake wing 524. Each of the first side rake wing 526A and the second side rake wing 526B includes an inner region 576 located proximate to the platform rake wing 524 and an outer region 578 located proximate to the outer edge 503. At the outer region 578, the first side rake wing 526A is positioned substantially parallel to the second side rake wing 526B. At the inner region 576, the first side rake wing 526A is positioned offset from the second side rake wing 526B and the first side rake wing 526A and the second side rake wing 526B are not parallel. This configuration may help maintain a constant and uniform temperature along the length of the rake wings 502 of the heating portion 504. Maintaining a constant temperature along the length of the rake wings 502 may provide a higher quality aerosol because the maximum temperature may be maintained more uniformly throughout the 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 contact 124) may contact a single receptacle contact 125. In some embodiments, the legs 506 include retainer portions 180, the retainer portions 180 configured to bend and extend generally away from the heating portion 504. The retainer portions 180 are configured to be positioned within corresponding recesses in the wick housing 178. The retainer portion 180 forms the end of the leg 506. The retainer portion 180 helps secure the heating element 500 and the wicking element 162 to the wick housing 178 (and the evaporator cartridge 120). The retainer portion 180 may have a tip portion 180A that extends from an end of the retainer 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 magazine 120 or a cleaning device for cleaning the evaporator magazine 120.

The outer edge 503 of the rake wing 502 in the heating portion 504 may include a tab 580. The tab 580 may extend outwardly from the outer edge 503 and away from the center of the heating element 500. The protrusions 580 may be shaped to allow the wicking element 162 to be more easily positioned within the pocket formed by the rake wings 502, thereby preventing or reducing the likelihood that the wicking element 162 will become stuck by the outer edge 503. The shape of the tab 580 helps minimize the effect on the resistance of the heating portion 504.

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. The wick housing 178 may be made of plastic, polypropylene, or the like. The wick housing 178 includes four recesses 192 in which at least a portion of each of the legs 506 of the heating element 500 may be positioned and secured. As shown, the wick housing 178 further includes an opening 193 that provides access to an interior volume 594 in which at least the heating portion 504 of the heating element 500 and the wicking element 162 are positioned.

The wick housing 178 may also include a separate thermal barrier 518A, which is shown in fig. 102. The thermal barrier 518A is positioned within the inner volume 594 within the wick housing 178, between the wall of the wick housing 178 and the heating element 500. The thermal barrier 518A is shaped to at least partially enclose the heating portion 504 of the heating element 500 and is shaped to space the heating element 500 from the side walls of the wick housing 178. The thermal barrier 518A may help isolate the heating portion 504 from the evaporator magazine 120 and/or the body of the wick 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 to 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 maintaining heat within the heating portion 504, thereby preventing or limiting heat loss.

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

In some embodiments, flooding 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 will be sufficient capillary pressure to draw the liquid vaporizable material out of the reservoir and/or heating portion 504. To help limit and/or prevent the escape of liquid vaporizable material from the interior volume of the wick housing 178 (or heating portion 504), the wick housing 178 and/or heating element 500 may include a capillary feature that causes a sudden change in capillary pressure, thereby forming a liquid barrier that prevents the passage of liquid vaporizable material through the feature without the use of an additional seal (e.g., a hermetic seal). The capillary feature may define a capillary break formed by a sharp point, bend, curved surface, or other surface 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 within the wet and dry zone.

The capillary feature may be located on and/or formed in a portion of the heating element 500 and/or the wick housing 178 and cause an abrupt change in capillary pressure. For example, the capillary feature may include a bend, sharp point, curved surface, beveled surface, or other surface feature along the length of the heating element or another component of the evaporator cartridge that causes an abrupt change in capillary pressure between the heating element and the wick housing. The capillary feature may also include protrusions or other portions of the heating element and/or wick housing that widen the capillary channel (e.g., a capillary channel formed between portions of the heating element, between the heating element and wick housing, etc.) sufficiently to reduce capillary pressure within the capillary channel (e.g., the capillary feature separates the heating element from the wick housing) so that the capillary channel does not draw liquid into the capillary channel. Thus, the capillary feature prevents or restricts liquid from flowing along the 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 feature (e.g., bend, sharp point, curved surface, angled surface, protrusion, etc.) may be a function of a wetting angle formed between materials (e.g., heating element and wick housing or other walls of a capillary channel formed between the components), may be a function of a material of the heating element and/or wick housing or other components, and/or may be a function of a size of a gap formed between two components (e.g., heating element and/or wick housing defining a capillary channel), among other characteristics.

As an example, fig. 103A and 103B illustrate a wick housing 178 having a capillary feature 598 that causes an abrupt change in capillary pressure. The capillary feature 598 prevents or restricts liquid from flowing along the liquid path 599 beyond the capillary feature 598 and helps prevent liquid from collecting between the leg 506 and the wick housing 178. The capillary feature 598 on the wick housing 178 spaces the heating element 500 (e.g., a component made of metal, etc.) from the wick housing 178 (e.g., a component made of plastic, etc.), thereby reducing the capillary strength between the two components. The capillary feature 598 shown in fig. 103A and 103B also includes sharp edges at the ends of the beveled surface of the wick housing that limit or prevent liquid flow beyond the capillary feature 598.

As shown in fig. 103B, the legs 506 of the heating element 500 may also be sloped inwardly toward the interior volume of the heating element 500 and/or the 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, the heating element 500 may include a capillary feature (e.g., bridge 585) formed with one or more legs 506 and spacing the legs 506 from the 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, the bridge 585 helps reduce or eliminate overflow of vaporizable material from the heating portion 504, such as caused by capillary action. In some examples, such as the example heating element 500 shown in fig. 93A-98B, the bridge 585 is beveled and/or includes a bend to help limit fluid flow out of the heating portion 504.

As another example, the heating element 500 may include a capillary feature 598 defining 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 capillary features 598 consistent with embodiments of the present subject matter. As shown in fig. 104, the capillary feature 598 may form an end of the bridge 585 that extends outwardly away from the heating portion at a distance greater than the distance between the leg 506 and the heating portion 504. The ends of the bridge 585 may be sharp edges to further help prevent the transfer of liquid vaporizable material to and/or from the legs 506 and/or out of the heating portion 504, thereby reducing leakage and increasing the amount of vaporizable material remaining in the heating portion 504.

Fig. 105-106 illustrate variations 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 bends at the inflection regions 511. The bends in the legs 506 may form capillary features 598 that help prevent the flow of liquid vaporizable material beyond the capillary features 598. For example, the bend may cause an abrupt change in capillary pressure, which may also help limit or prevent the flow of liquid vaporizable material beyond the bend and/or between the leg 506 and the wick housing 178, and which may help limit or prevent the flow of liquid vaporizable material out of the heating portion 504.

Fig. 107-108 illustrate variations 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 bends at the inflection regions 511. The bends in the legs 506 may form capillary features 598 that help prevent the flow of liquid vaporizable material beyond the capillary features 598. For example, the bend may cause an abrupt change in capillary pressure, which may also help limit or prevent the flow of liquid vaporizable material beyond the bend and/or between the leg 506 and the wick housing 178, and which may help limit or prevent the flow of liquid vaporizable material out of the heating portion 504.

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

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

The wick housing 178 may also include one or more other cutouts that help space the heating element 500 from the surface of the wick housing 178 to reduce the amount of heat contacting the surface of the wick housing 178. For example, the wick housing 178 may include a cutout 170. The cut-out 170 may be formed along the outer surface of the wick housing 178 adjacent the opening 193. The cutout 170 may also include capillary features, such as capillary feature 598. The capillary characteristics of the cut 170 may define a surface (e.g., a curved surface) that breaks a tangent point between adjacent (or intersecting) walls (e.g., walls of a 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, the wick housing 178 may include a protrusion 168. The protrusions 168 may help to properly position and/or orient the wick housing with respect to one or more other components of the evaporator cartridge during assembly of the evaporator cartridge. For example, the additional material forming the tab 168 shifts the center of mass of the wick housing 178. Because of the centroid offset, the wick housing 178 may 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 wick housing 178, a wick element 162, and a heating element 500, consistent with embodiments of the present subject matter. As shown in fig. 114A, the wicking element 162 may be inserted into a pocket formed in the heating element 500 (e.g., formed by the side rake wings 526 and the platform rake wings 524). In some embodiments, when the vaporizable material is introduced to the wicking element 162, the wicking element 162 expands after being secured to the heating element 500.

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

Fig. 115A-115C illustrate a method of forming an atomizer assembly 141 of an evaporator cartridge 120, the atomizer assembly 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, the heating element 500 may be coupled to the wick housing 178, for example, by inserting or otherwise positioning at least a portion of the heating element 500 (such as the heating portion 504) within the interior volume of the wick housing 178. The legs 506 (e.g., retainer portion 180) of the heating element 500 may be coupled with the outer wall of the wick housing 178 via, for example, a snap-fit arrangement. In particular, the retainer portion 180 or another portion of the leg 506 may be coupled with and positioned at least partially within a recess in the wick housing 178, such as by being coupled with the wick housing retention feature 172.

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

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

Fig. 116 illustrates an exemplary process 3600 for assembling the heating element 500 consistent with an embodiment of the present subject matter. Process flow chart 3600 illustrates features of a method that may optionally include some or all of the following. At block 3610, a planar substrate having resistive heating characteristics is provided. At block 3612, the flat substrate may be cut and/or stamped to 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., adhesive plating material and/or overplating material) may be deposited onto at least a portion of the outer surface of the heating element 500. At block 3616, the 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 a first or second direction along a plane or third direction perpendicular to the first or second 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 a reservoir of vaporizable material. At block 3622, the vaporizable material may be lifted into the wicking element 162, which may be positioned in contact with at least two surfaces of the heating portion 504 of the heating element 500. At block 3624, a heating appliance may be provided to the cartridge contact 124 of the heating element to heat at least the heating portion 504 of the heating element 500. The heating causes evaporation of the vaporizable material. At block 3626, the vaporized vaporizable material is entrained in an air stream to a mouthpiece of an evaporation cartridge in which the heating element is located.

Condensate control, collection and recycle examples

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

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

As evaporator devices are introduced to the market, evaporator cartridges containing free liquid (i.e., liquid held in a reservoir rather than by a porous material) have become popular. Products on the market may have cotton pads or no feature at all to collect condensate generated by the vapor generated in the evaporator unit.

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

As described in more detail below, evaporating the vaporizable material into an aerosol may cause condensate to collect along one or more internal channels and outlets of some evaporators (e.g., along the mouthpiece). For example, such condensate may include vaporizable material that is drawn from a reservoir, forms an aerosol, and condenses into condensate prior to exiting the evaporator. In addition, vaporizable material that has circumvented the vaporization process may also accumulate along one or more internal channels and/or air outlets. This may cause condensate and/or non-evaporated vaporizable material to leave the mouthpiece outlet and deposit into the mouth of the user, thereby creating an unpleasant user experience and reducing the amount of inhalable aerosol that would otherwise be available. Furthermore, 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 vaporizable material. For example, as particles of vaporizable material accumulate in the interior 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 drag on the accumulated fluid, thereby increasing the likelihood of entrainment of fluid from the interior passageway and through the mouthpiece outlet. Various features and devices that improve or overcome these problems are described below.

As described above, lifting the vaporizable material from the reservoir and evaporating the vaporizable material into an aerosol may cause the vaporizable material condensate 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 improve or overcome these problems are described below. For example, various features for controlling condensate in an evaporator device are described herein 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 the outlet of the mouthpiece, thereby preventing the condensate from exiting the outlet.

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

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

Fig. 118 illustrates an embodiment of a mouthpiece 330 that includes an embodiment of a fin-type condensate collector 352 having a plurality of microfluidic fins 354. The mouthpiece 330 may be configured for use with an evaporator cartridge (e.g., evaporator cartridge 120) and/or an evaporator device (e.g., evaporator 100) in which microfluidic fins 354 are housed in the fin condensate collector 352 to improve condensate collection and containment in the evaporator cartridge. 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 of the set of walls 355 may be positioned parallel or substantially parallel to each other such that the space between each wall creates a groove 353 defining a capillary channel. The wall 355 defines or otherwise forms 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 sleeve 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 fin defines one or more capillary channels, and fluid is collected by capillary forces that are created when fluid is located within the capillary channels. In order to keep the fluid captured by the fin condensate collector 352 from being extracted by the drag force of the airflow, the capillary force of the microfluidic heat sink may be greater than the airflow drag force by providing a narrow groove or channel 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 0.8mm.

One advantage of this construction is that no additional components need to be manufactured, thereby reducing the number of components without losing functionality. In one embodiment, the fin-type condensate collector and mouthpiece may be manufactured as a single piece using one mold (e.g., a plastic mold). In addition, the fin-type condensate collector and the mouthpiece may be separate structures welded together, which together form the fin-type condensate collector. Other methods of manufacture 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 for collecting and containing 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, the vaporizable material condensate may accumulate in one or more airflow channels or internal channels of the evaporator device. Various features and means are described below that improve or overcome these problems. For example, various features for recycling condensate in an evaporator device are described herein, such as embodiments of a condensate recycler system, as will be described in more detail below.

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

The condensate recycler 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 (by capillary action) back to the wick for reuse.

One function of the grooves may include the vaporizable material condensate being captured or otherwise positioned within the grooves. Once the condensate is within the grooves, the condensate drains down to the wick due to capillary action created by the wick element. The draining of condensate within the groove may be at least partially achieved by capillary action. If any condensate is present within the air tube, the vaporizable material particles fill into 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 wick, condensate passes through and out of the grooves and may be reused as an evaporable material. In some embodiments, the groove may be narrowed such that the groove is narrower toward the wick and wider toward the mouthpiece. This constriction may promote fluid movement toward the evaporation chamber, as more condensate collects in the groove by higher capillary action at narrower points.

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

Fig. 119B and 119C show interior views of the condensate recycler 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 to 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 wick housing 346 and may be in fluid communication with the chamber recess 365 and/or the wick. The air tube groove 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 airflow channel narrows (either due to the accumulation of condensate in the airflow channel or due to the 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 toward the user (e.g., in response to inhalation on the evaporator) is greater than the capillary force pulling the fluid toward the wick, the fluid exits the air outlet.

To overcome this problem and encourage condensate to flow away from the mouthpiece exit and back toward the evaporation chamber 342 and/or the wicking section, a constricted air flow path is provided such that the cross-section of the air tube groove 364 adjacent the evaporation chamber 342 is narrower than the cross-section of the air tube groove 364 adjacent the mouthpiece. In addition, each internal groove narrows such that the width of the internal groove near the air tube first end 362 may be wider than the width of the internal groove near the air tube second end 363. In this way, the narrowed channel increases the capillary drive of the air tube groove 364 and promotes fluid movement of condensate toward the chamber groove 365. In addition, 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 section. That is, each fluted passageway narrows near the wick except that the airflow passageway itself narrows toward the end of the wick.

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

In some embodiments, the geometry or number of grooves may vary. For example, the grooves may not necessarily have a hydraulic diameter that decreases toward the wick. In some embodiments, the reduced hydraulic diameter toward the wick 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 portion of the housing structure, mouthpiece, and/or a separate plastic component (e.g., the fin-type condensate collector discussed herein) of the aerosol-generating unit (e.g., the evaporation chamber).

Terminology

When a feature or element is referred to herein as being "on" another feature or element, it can 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 adapted for use with other embodiments. Those skilled in the art will also appreciate that reference to a structure or feature that is disposed "adjacent" another feature may have portions of the adjacent feature overlying or underlying the 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 is abbreviated as "/".

In the description above and in the claims, phrases such as "at least one of … …" or "one or more of … …" may occur after a consecutive enumeration of elements or features. The term "and/or" may also occur in the enumeration of two or more elements or features. Unless implicitly or explicitly contradicted by context in which such phrases are used, such phrases are intended to represent any of the recited elements or features alone or in combination with any of the recited elements or features in addition. 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 together with B". Similar interpretations are also intended to include more than three items of enumeration. 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 together with B, a together with C, B together with C, or a together with B and C. The use of the term "based on" in the foregoing and in the claims is intended to mean "based at least in part on" such that unrecited features or elements are also permitted.

Spatially relative terms, such as "forward", "rearward", "below … …", "below … …", "lower", "above … …", "upper", 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 inverted in the drawings, elements described as "under" or "beneath" other elements or features would then be oriented "over" the other elements or features. Thus, the exemplary term "under … …" may include both an orientation of "over … …" and an orientation of "under … …". The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms "upward," "downward," "vertical," "horizontal," and the like are used herein for illustrative purposes only, unless explicitly indicated otherwise.

Although the terms "first" and "second" may be used herein to describe various features/elements (including steps), these features/elements should not be limited by these terms unless otherwise indicated by the context. 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 indicated, all numerical values should be understood as being prefaced by the word "about" or "about", even if the term does not expressly appear. When describing a size and/or position, the phrase "about" or "approximately" may be used to indicate that the value and/or position being described is within a reasonably expected range of values and/or positions. For example, a numerical value may have a value (or range of values) of +/-0.1% of the stated value, a value (or range of values) of +/-1% of the stated value, a value (or range of values) of +/-2% of the stated value, a value (or range of values) of +/-5% of the stated value, a value (or range of values) of +/-10% of the stated value, and so forth. Any numerical values set forth herein should also be understood to include 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 a value is disclosed, "less than or equal to" the value, "greater than or equal to" the value, and possible ranges between the values are also disclosed, as would be well understood by one of ordinary skill in the art. For example, if the value "X" is disclosed, then "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 the 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.

While the above describes various illustrated embodiments, any number of variations may be made to the various embodiments without departing from the teachings herein. For example, the order in which the various described method steps are performed may often be varied in alternative embodiments, and in other alternative embodiments, one or more of the method steps may be skipped entirely. Optional features in different apparatus and system embodiments may be included in some embodiments and not in others. Accordingly, the foregoing description is provided mainly for the purpose of example and should not be construed as limiting 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 employing 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 system or computing system may include clients and servers. The client and server are conventionally remote from each other and typically interact through a communication network. The association of the client and the server occurs by means 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 procedural, object-oriented, functional, logical, and/or assembly/machine language. As used herein, the term "machine-readable medium" refers to any computer program product, apparatus and/or device, such as, for example, magnetic disks, optical disks, memory, and Programmable Logic Devices (PLDs), used to provide machine instructions and/or data to a programmable processor, 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, as a non-transitory solid state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium may alternatively or additionally store such machine instructions in a transitory manner, such as, for example, as a processor cache or other random access memory associated with one or more physical processor memories.

The examples and descriptions included herein illustrate, by way of illustration and not limitation, particular 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, although detailed description of exemplary embodiments is provided herein, variations and modifications may be made to the described embodiments without limiting or departing from the general 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 all equivalents thereof.

A portion of the disclosure of this patent document may contain material that is subject to copyright protection. The owner is not interested in copying through any of the patent documents or patent publications, as it appears in the patent and trademark office patent files or records, but otherwise reserves all copyrights whatsoever. Some of the indicia referenced herein may be common laws or registered trademarks of the applicant, assignee, or third party affiliated or non-conforming with the applicant or assignee. The use of these indicia is to provide disclosure that can be achieved 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 collector member for a vaporizer for use with a liquid vaporizable material, the collector member comprising:

a fluid channel;

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

2. The collector component of claim 1 wherein the equilibrium state is maintained by establishing a liquid seal at the opening of the control vent where the reservoir communicates with the passage in the overflow volume.

3. The collector component of claim 2 wherein a liquid seal is established and maintained at the vent by maintaining sufficient capillary pressure for a meniscus of vaporizable material to be formed at a portion of a channel leading into the overflow volume of the control vent.

4. A collector member as claimed in claim 3 wherein the capillary pressure for the meniscus of vaporizable material is controlled by a V-shaped structure forming primary and secondary channels, the primary and secondary channels constituting the control vent to control at least one condensation point at one of the primary or secondary channels.

5. The collector member as claimed in claim 4 wherein the primary and secondary channels have a constricted geometry such that capillary drive of the primary channel decreases at a greater rate than capillary drive of the secondary channel as the meniscus continues to recede.

6. The collector member as claimed in claim 5 wherein the capillary driven tapering of the primary and secondary channels reduces the partial headspace vacuum maintained in the reservoir.

7. The collector member as claimed in claim 6 wherein the discharge pressure of the primary channel is reduced below the discharge pressure of the secondary channel as a result of capillary actuation of the primary and secondary channels progressively decreasing relative to one another.

8. The collector member as claimed in claim 7 wherein 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.

9. The collector element of claim 8 wherein the discharge pressure associated with the receding contact angle of the primary channel is capable of being reduced below the flooding pressure associated with the advancing contact angle of the secondary channel to fill the primary and secondary channels with vaporizable material.

10. The collector component of claim 9 wherein vaporizable material flows into the channel of the collector through the vent in response to increased pressure within the reservoir, wherein the vent is configured to maintain a liquid seal at all times.