GB2580214A

GB2580214A - Cartridge for a vaporizer device

Info

Publication number: GB2580214A
Application number: GB1917180.0A
Authority: GB
Inventors: Atkins Ariel; Christensen Steven; M Hoopai Alexander; Joseph Johnson Eric; King Jason; Leon Duque Esteban; Rios Matthew; L Belisle Christopher; James Rosser Christopher; J Stratton Andrew; Thawer Alim; P Westley James; Wesely Norbert
Original assignee: Juul Labs Inc
Current assignee: Juul Labs Inc
Priority date: 2018-10-17
Filing date: 2019-10-17
Publication date: 2020-07-15
Anticipated expiration: 2039-10-17
Also published as: GB2599226B; NL2024037A; GB2587742B; ES2913163T3; GB2580214A8; PT3664631T; GB2587742A; TW202103589A; JP2021510492A; PH12021550818A1; GB2599226A; DE112019005228T5; AU2019361098A1; TWI827707B; WO2020081849A3; GB202214056D0; IE20190173A1; DK3664631T3; KR20210076104A; JP6963037B2

Abstract

A vaporization device includes a cartridge for a vaporizer device. For example, the vaporizer cartridge and/or features thereof may improve management of leaks of vaporizable material from the vaporizer cartridge, control of airflow within and/or near the vaporizer cartridge, heating of vaporizable material in the vaporizer cartridge, management of condensate in the vaporizer cartridge, and/or other assembly features of the vaporizer cartridge. Related systems, methods, and articles of manufacture are also described.

Claims

1. A vaporizer comprising: a reservoir configured to contain a liquid vaporizable material, the reservoir at least partially defined by at least one wall, the reservoir comprising a storage chamber and an overflow volume; and a collector disposed in the overflow volume, the collector comprising a capillary structure configured to retain a volume of the liquid vaporizable material in fluid contact with the storage chamber, the capillary structure comprising a microfluidic feature configured to prevent air and liquid from bypassing each other during filling and emptying of the collector.

2. The vaporizer of claim 1, further comprising a primary passageway providing a fluid connection between the storage chamber and an atomizer configured to convert the liquid vaporizable material to a gas-phase state.

3. The vaporizer of claim 2, wherein the primary passageway is formed through a structure of the collector.

4. The vaporizer of any of claims 2 or 3, wherein the primary passageway comprises a first channel configured to allow for the liquid vaporizable material to flow from the storage chamber toward a wicking element in the atomizer, the first channel having a cross- sectional shape with at least one irregularity configured to allow liquid in the first channel to bypass an air bubble blocking a remainder of the first channel.

5. The vaporizer of claim 4, wherein the cross-sectional shape resembles a cross.

6. The vaporizer of any preceding claim, wherein the capillary structure comprises a secondary passageway comprising the microfluidic feature, and wherein the microfluidic feature is configured to allow the liquid vaporizable material to move along a length of the secondary passageway only with a meniscus fully covering a cross-sectional area of the secondary passageway.

7. The vaporizer of claim 6, wherein the cross-sectional area is sufficiently small that, for a material from which walls of the secondary passageway are formed and a composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary passageway around an entire perimeter of the secondary passageway.

8. The vaporizer of any preceding claim, wherein the storage chamber and the collector are configured to maintain a continuous column of the liquid vaporizable material in the collector in contact with the liquid vaporizable material in the storage chamber such that a reduction in pressure in the storage chamber relative to ambient pressure causes the continuous column of the liquid vaporizable material in the collector to be at least partially drawn back into the storage chamber.

9. The vaporizer of any of claims 6 to 8, wherein the secondary passageway comprises a plurality of spaced-apart constriction points having a smaller cross-sectional area than parts of the secondary passageway between the constriction points.

10. The vaporizer of claim 9, wherein the constriction points have a flatter surface directed along the secondary passageway toward the storage compartment and a rounder surface directed along the secondary passageway away from the storage compartment.

11. The vaporizer of any preceding claim, further comprising a microfluidic gate between the collector and the storage compartment, the microfluidic gate comprising a rim of an aperture between the storage chamber and the collector that is flatter on a first side facing the storage compartment than a second, more rounded, side facing the collector.

12. The vaporizer of claim 11, wherein the microfluidic gate comprises a plurality of openings connecting the storage chamber and the collector and a pinch-off point between the plurality of openings, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel.

13. The vaporizer of claim 12, wherein an air-liquid vaporizable material meniscus reaching the pinch-off point is routed to the second channel due to the higher capillary drive in the first channel such that an air bubble is formed to escape into the liquid vaporizable material in the storage chamber.

14. The vaporizer of any preceding claim, wherein the liquid vaporizable material comprises one or more of propylene glycol and vegetable glycerin.

15. A microfluidic gate for controlling flow of liquid vaporizable material between a storage chamber and an adjoining overflow volume in a vaporizer, the microfluidic gate comprising: a plurality of openings connecting the storage chamber and the collector, the plurality of openings comprising a first channel and a second channel, wherein the first channel has a higher capillary drive than the second channel; and a pinch-off point between the plurality of openings.

16. The microfluidic gate of claim 15, wherein the microfluidic gate comprises a rim of an aperture between the storage chamber and the collector that is flatter on a first side facing the storage compartment than a second, more rounded, side facing the collector.

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

18. The collector of claim 17, further comprising the microfluidic gate of any of claims 15 and 16.

19. The collector of any of claims 17 to 18, further comprising a primary passageway providing a fluid connection between the reservoir and an atomizer configured to convert the liquid vaporizable material to a gas-phase state, wherein the primary passageway is formed through a structure of the collector.

20. The collector of any of claims 17 to 19, wherein the capillary structure comprises a secondary passageway comprising the microfluidic feature, and wherein the microfluidic feature is configured to allow the liquid vaporizable material to move along a length of the secondary passageway only with a meniscus fully covering a cross-sectional area of the secondary passageway.

21. The collector of claim 20, wherein the cross-sectional area is sufficiently small that, for a material from which walls of the secondary passageway are formed and a composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary passageway around an entire perimeter of the secondary passageway.

22. The collector of any of claims 17 to 21, wherein the storage chamber and the collector are configured to maintain a continuous column of the liquid vaporizable material in the collector in contact with the liquid vaporizable material in the storage chamber such that a reduction in pressure in the storage chamber relative to ambient pressure causes the continuous column of the liquid vaporizable material in the collector to be at least partially drawn back into the storage chamber.

23. The collector of any of claims 20 to 22, wherein the secondary passageway comprises a plurality of spaced-apart constriction points having a smaller cross-sectional area than parts of the secondary passageway between the constriction points.

24. The collector of claim 23, wherein the constriction points have a flatter surface directed along the secondary passageway toward the storage compartment and a rounder surface directed along the secondary passageway away from the storage compartment.

25. A vaporizer 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; an atomizer configured to cause conversion of at least some of the liquid vaporizable material to an inhalable state; and a collector as in any of claims 17 to 24.

26. The vaporizer cartridge of claim 25, wherein the atomizer comprises: a wicking element positioned within the internal airflow path and in fluid communication with the reservoir, the wicking element configured to draw the liquid vaporizable material from the storage chamber under capillary action; and a heating element positioned to cause heating of the wicking element to result in conversion of at least some of the liquid vaporizable material drawn from the storage chamber to a gaseous state.

27. The vaporizer cartridge of claim 26, wherein the inhalable state comprises an aerosol formed by condensation of at least some of the liquid vaporizable material from the gaseous state.

28. The vaporizer cartridge of any of claims 25 to 27, wherein the cartridge housing comprises a monolithic hollow structure having a first, open end, and a second end opposite the first end.

29. The vaporizer cartridge of claim 28, wherein the collector is insertably received within the first end of the monolithic hollow structure.

30. A vaporizer comprising a vaporizer body and the vaporizer cartridge of any of claims 25 to 29, wherein the vaporizer body and the vaporizer cartridge are separably attachable to form the vaporizer.

31. The vaporizer cartridge of any of claims 25 to 30, wherein the heating element comprises: a heating portion comprising at least two tines spaced apart from one another, the heating portion being preformed to define an interior volume configured to receive the wi eking element such that the heating portion secures at least a portion of the wicking element to the heating element, the heating portion being configured to contact at least two separate surfaces of the wicking element; and at least two legs coupled to the at least two tines and spaced apart from the heating portion, the at least two legs configured to electrically communicate with a power source, wherein power is configured to be supplied to the heating portion from the power source to generate heat, thereby vaporizing the vaporizable material stored within the wicking element.

32. The vaporizer cartridge of claim 31, wherein the at least two legs includes four legs.

33. The vaporizer cartridge of claim 32, wherein the heating portion is configured to contact at least three separate surfaces of the wicking element.

34. The vaporizer cartridge of any of claims 31 to 33, wherein the at least two tines comprises: a first side tine portion; a second side tine portion opposing the first side tine portion; and a platform tine portion connecting the first side tine portion with the second side tine portion, the platform tine portion being positioned approximately perpendicular to a portion of the first side tine portion and the second side tine portion, wherein the first side tine portion, the second side tine portion, and the platform tine portion define the interior volume in which the wicking element is positioned.

35. The vaporizer cartridge of claim 34, wherein the at least two legs are located away from the heating portion by a bridge.

36. The vaporizer cartridge of any of claims 31 to 35, wherein 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 electrically communicate with the power source, the cartridge contact being angled and extending away from the heating portion.

37. The vaporizer cartridge of any of claims 34 to 36, wherein the at least two tines includes a first pair of tines and a second pair of tines.

38. The vaporizer cartridge of claim 37, wherein the tines of the first pair of tines are evenly spaced from one another.

39. The vaporizer cartridge of claim 37 or claim 38, wherein the tines of the first pair of tines are spaced apart by a width.

40. The vaporizer cartridge of claim 39, wherein the width is greater at an inner region of the heating element adjacent the platform tine portion than the width at an outer region of the heating element adjacent an outer edge of the first side tine portion opposite the inner region.

41. The vaporizer cartridge of any of claims 32 to 40, wherein the vaporizer device is configured to measure a resistance of the heating element at each of the four legs to control a temperature of the heating element.

42. The vaporizer cartridge of any of claims 31 to 41, further comprising a heat shield configured to insulate the heating portion from a body of the vaporizer device.

43. The vaporizer cartridge of any of claims 31 to 42, wherein the vaporizer device further comprises a heat shield configured to surround at least a portion of the heating element and insulate the heating portion from a body of a wick housing configured to surround at least a portion of the wicking element and the heating element.

44. The vaporizer cartridge of any of claims 31 to 43, wherein 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.

45. The vaporizer cartridge of any of claims 31 to 44, wherein the heating portion further comprises at least one tab that extends from a side of the at least two tines to allow for easier entry of the wicking element to the interior volume of the heating portion.

46. The vaporizer cartridge of claim 45, wherein the at least one tab extends away from the interior volume at an angle.

47. The vaporizer cartridge of any of claims 31 to 46, wherein the at least two legs include a capillary feature, the capillary feature causing an abrupt change in capillary pressure to thereby prevent the vaporizable material from flowing beyond the capillary feature.

48. The vaporizer cartridge of claim 47, wherein the capillary feature comprises one or more bends in the at least two legs.

49. The vaporizer cartridge of any of claims 47 to 48, wherein the at least two legs extend at an angle towards the interior volume of the heating portion, the angled at least two legs defining the capillary feature.

50. The vaporizer cartridge of any of claims 25 to 30, wherein 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 the vaporizer device; a connecting portion configured to receive power from a power source and direct the power to the heating portion; and a plating layer having a plating material that is different from a material of the heating portion, the plating layer configured to reduce contact resistance between the heating element and the power source, thereby localizing heating of the heating element to the heating portion.

51. The vaporizer cartridge of claim 50, wherein the plating layer comprises one or more layers deposited onto the connecting portion.

52. The vaporizer cartridge of any of claims 50 to 51, wherein the plating layer is integrally formed with the connecting portion.

53. The vaporizer cartridge of any of claims 50 to 52, wherein the plating layer includes an adhering plating layer and an outer plating layer.

54. The vaporizer cartridge of claim 53, wherein at least the outer plating layer is configured to reduce contact resistance between the heating element and the power source.

55. The vaporizer cartridge of any of claims 53 to 54, wherein the adhering plating layer is deposited onto the heating element to adhere the outer plating layer to the heating element.

56. The vaporizer cartridge of any of claims 50 to 55, wherein the material of the heating portion comprises nichrome.

57. The vaporizer cartridge of any of claims 50 to 56, wherein the plating layer comprises gold.

58. The vaporizer cartridge of any of claims 25 to 57, further comprising a wick housing, the wick housing comprising: an outer wall; and an interior volume defined by the outer wall, the interior volume configured to receive a portion of a heating element and a wicking element of the vaporizer device.

59. The vaporizer cartridge of claim 58, wherein the heating element comprises a heating portion and a connecting portion, the heating portion configured to heat vaporizable material stored in the wicking element to generate an aerosol, the connecting portion configured to electrically communicate with a power source to provide power to the heating portion, and wherein the portion of the heating element is the heating portion.

60. The vaporizer cartridge of any of claims 58 to 59, wherein the outer wall is configured to be positioned between the heating portion and the connecting portion.

61. The vaporizer cartridge of any of claims 58 to 60, wherein the outer wall comprises two opposing short sides and two opposing long sides.

62. The vaporizer cartridge of claim 61, wherein each of the two opposing long sides includes a recess configured to releasably couple the vaporizer cartridge to a corresponding feature of the vaporizer body.

63. The vaporizer cartridge of claim 62, wherein the recess is positioned proximate to an intersection between a long side of the two opposing long sides and a short side of the two opposing short sides.

64. The vaporizer cartridge of claim 63, wherein each of the two opposing long sides includes two recesses.

65. The vaporizer cartridge of any of claims 61 to 64, wherein the outer wall further comprises a base positioned approximately perpendicular to the two opposing short sides and two opposing long sides.

66. The vaporizer cartridge of claim 65, wherein the base comprises one or more slots, wherein air pressure caused by the flow of vaporizable material within the heater portion is configured to escape through the one or more slots.

67. The vaporizer cartridge of claim 61, wherein at least one of the two opposing short sides comprises a chip recess configured to receive an identification chip.

68. The vaporizer cartridge of claim 67, wherein the chip recess comprises at least two walls configured to surround and retain the identification chip.

69. The vaporizer cartridge of claim 68, wherein the at least two walls comprise at least four walls.

70. The vaporizer cartridge of any of claims 58 to 69, wherein the outer wall comprises: two opposing short sides; two opposing long sides; a base positioned approximately perpendicular to the two opposing short sides and the two opposing long sides; and an opening opposite the base.

71. The vaporizer cartridge of claim 70, further comprising an outer rim surrounding the opening and extending away from the opening.

72. The vaporizer cartridge of claim 71, wherein the outer wall comprises a capillary feature, the capillary feature causing an abrupt change in capillary pressure between the heating element and the wick housing to thereby prevent the vaporizable material from flowing beyond the capillary feature.

73. The vaporizer cartridge of claim 72, wherein the capillary feature comprises a curved surface formed at the intersection between at least one of the two opposing long sides and the outer rim.

74. The vaporizer cartridge of claim 73, wherein the curved surface has a radius that is sufficient to break tangency points between the outer surface and the outer rim.

75. The vaporizer cartridge of any of claims 72 to 74, wherein the capillary feature is positioned within a cutout in the outer wall, the cutout configured to space the heating element from the outer wall, thereby preventing excess heat from contacting the outer wall.

76. The vaporizer cartridge of any of claims 58 to 75, further comprising a cutout in the outer wall configured to space the heating element from the outer wall, thereby preventing excess heat from contacting the outer wall.

77. A collector component of a vaporizer for use with a liquid vaporizable material, the collector component comprising: a fluid passage; an outer port disposed at a first end of the fluid passage and configured to be in fluid communication with ambient air external to the vaporizer; a control vent disposed at a second end of the fluid passage distal to the first end and configured to manage flow between the fluid passage and a reservoir of the vaporizer configured to contain the liquid vaporizable material, the control vent configured to provide at least: a first fluidic resistance to pinching off of an air bubble into the reservoir when air is in the fluid passage adjacent to the control vent and a void volume within the reservoir is at a lower pressure than the ambient air external to the vaporizer; and a second fluidic resistance to allowing the liquid vaporizable material to pass the control vent into the fluid passage when the void volume within the reservoir is at a higher pressure than the ambient air external to the vaporizer; and at least a first wick feed implemented in form of a first channel to allow for the vaporizable material stored in a storage chamber to flow toward a wick placed in a wick housing positioned in an overflow volume, the control vent maintaining an equilibrium state in the storage chamber to prevent pressure in the storage chamber to increase to a point that would cause the vaporizable material to flood the wick housing.

78. The collector component of claim 77, wherein the equilibrium state is maintained by way of establishing a liquid seal at the opening of the control vent where the storage chamber communicates with the passageway in the overflow volume.

79. The collector component of claim 78, wherein the liquid seal is established and maintained at the vent by maintaining sufficient capillary pressure for the vaporizable material menisci to be formed at a portion of the control vent leading to the passageway in the overflow volume.

80. The collector component of claim 79, wherein the capillary pressure for the vaporizable material menisci is controlled by V-shaped structures forming a primary channel and a secondary channel constructing the control vent to control at least a pinch-off point at one of the primary channel or the secondary channel.

81. The collector component of claim 80, wherein the primary channel and the secondary channel have tapered geometries such that, as the menisci continue to recede, a capillary drive of the primary channel decreases at a greater rate than the capillary drive of the secondary channel.

82. The collector component of claim 81, wherein a gradual reduction in the capillary drives of the primary and the secondary channels reduces partial headspace vacuum maintained in the storage chamber.

83. The collector component of claim 82, wherein drain pressure of the primary channel drops below the drain pressure of the secondary channel as a result of the gradual reduction in the capillary drives of the primary and the secondary channels in relations to one another.

84. The collector component of claim 83, wherein the meniscus in the primary channel continues to drain when the drain pressure of the primary channel changes, while the meniscus in the secondary channel remains static.

85. The collector component of claim 84, wherein the drain pressure involving receding contact angle of the primary channel may drop below the flooding pressure involving advancing contact angle of the secondary channel, causing the primary and secondary channels to fill with vaporizable material.

86. The collector component of claim 85, wherein, in response to an increased pressure inside the storage chamber, vaporizable material flows into the collectorâ s passageway through the vent, wherein the vent is constructed to maintain the liquid seal at all times.

87. A cartridge for a vaporizer device, the cartridge comprising: a reservoir including a reservoir chamber defined by a reservoir barrier, the reservoir being configured to contain a vaporizable material in the reservoir chamber; a vaporization chamber in communication with the reservoir and including a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporization chamber to be vaporized by a heating element; an airflow passageway that extends through the vaporization chamber; and at least one capillary channel adjacent the airflow passageway, each capillary channel of the at least one capillary channel configured to receive a fluid and direct the fluid from a first location toward a second location via capillary action.

88. The cartridge of claim 87, wherein each capillary channel of the at least one capillary channel tapers in size.

89. The cartridge of claim 88, wherein the taper in size results in an increase in capillary drive through each capillary channel of the at least one capillary channel.

90. The cartridge of any of claims 87 to 89, wherein each capillary channel of the at least one capillary channel is formed by a groove defined between a pair of walls.

91. The cartridge of any of claims 87 to 90, wherein the at least one capillary channel fluidly communicates with a wick.

92. The cartridge of claim 91, wherein the first location is adjacent an end of the airflow passageway and a mouthpiece.

93. The cartridge of any of claims 87 to 92, wherein the at least one capillary channel collects a fluid condensate.

94. A vaporizer device, comprising: a vaporizer body including a heating element configured to heat a vaporizable material; and a cartridge configured to be releasably coupled to the vaporizer body, the cartridge comprising: a reservoir including a reservoir chamber defined by a reservoir barrier, the reservoir being configured to contain the vaporizable material in the reservoir chamber; a vaporization chamber in communication with the reservoir and including a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporization chamber to be vaporized by the heating element; an airflow passageway that extends through the vaporization chamber; and at least one capillary channel adjacent the airflow passageway, each capillary channel of the at least one capillary channel configured to receive a fluid and direct the fluid from a first location toward a second location via capillary action.

95. The vaporizer device of claim 94, wherein each capillary channel of the at least one capillary channel tapers in size.

96. The vaporizer device of claim 95, wherein the taper in size results in an increase in capillary drive through each capillary channel of the at least one capillary channel.

97. The vaporizer device of any of claims 94 to 96, wherein each capillary channel of the at least one capillary channel is formed by a groove defined between a pair of walls.

98. The vaporizer device of any of claims 94 to 97, wherein the at least one capillary channel fluidly communicates with a wick.

99. The vaporizer device of claim 98, wherein the first location is adjacent an end of the airflow passageway and a mouthpiece.

100. The vaporizer device of any of claims 94 to 99, wherein the at least one capillary channel collects a fluid condensate.

101. A method compri sing: collecting a condensate in a first capillary channel of at least one capillary channel of a cartridge of a vaporization device, each of the at least one capillary channel configured to receive a fluid and direct the fluid from a first location toward a second location via capillary action, the cartridge comprising: a reservoir including a reservoir chamber defined by a reservoir barrier, the reservoir being configured to contain a vaporizable material in the reservoir chamber; a vaporization chamber in communication with the reservoir and including a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporization chamber to be vaporized by a heating element; and an airflow passageway that extends through the vaporization chamber, the at least one capillary channel adjacent the airflow passageway; and directing the collected condensate towards the vaporization chamber and along the first capillary channel.

102. The method of claim 101, further comprising vaporizing, at the vaporization chamber, the collected condensate.

103. The method of any of claims 101 to 102, wherein the first capillary channel tapers in size.

104. The method of any of claims 101 to 103, wherein each capillary channel of the at least one capillary channel is formed by a groove defined between a pair of walls.

105. The method of any of claims 101 to 104, wherein the at least one capillary channel fluidly communicates with a wick.

106. The method of claim 105, wherein the first location is adjacent an end of the airflow passageway and a mouthpiece.