RU2779335C2 - Bent heater for electronic vaping device - Google Patents

Abstract

FIELD: tobacco industry.

SUBSTANCE: group of inventions relates to bent heaters of an electronic vaping device, a cartridge of an electronic vaping device, an electronic vaping device, a method for the manufacture of a heating node. The bent heater of the electronic vaping device contains the first set of U-shaped segments located in the first direction and forming the first side of the heater. The bent heater also contains the second set of U-shaped segments located in the first direction and forming the second side of the heater, parallel to the first side. The bent heater includes the first output section and the second output section. The first set of U-shaped segments, the second set of U-shaped segments, the first output section, and the second output section are a single whole element.

EFFECT: increase in the efficiency of heating due to an increase in a surface area of a heating element.

29 cl, 21 dwg

Description

The present invention relates to a bent heater for an electronic vaping or e-vaping device.

An electronic vaping device contains a heating element that vaporizes the pre-vapor compound to generate "vapour".

An electronic vaping device contains a power source, such as a rechargeable battery, located in the device. The battery is electrically connected to the heater such that the heater is heated to a temperature sufficient to convert the pre-flash composition to vapor. Vapor exits the electronic vaping device through a mouthpiece containing at least one outlet.

At least one exemplary embodiment relates to a bent heater of an electronic vaping device.

In at least one exemplary embodiment, the bent heater of an electronic vaping device comprises a first plurality of U-shaped segments located in a first direction and forming a first side of the heater; a second plurality of U-shaped segments located in the first direction and forming the second side of the heater, essentially parallel to the first side; the first output section; and a second outlet. The first set of U-shaped segments, the second set of U-shaped segments, the first lead-out section and the second lead-out section represent one integral element.

In at least one exemplary embodiment, at least one of the first plurality of U-segments is connected to at least one of the second plurality of U-segments via one of the third plurality of U-segments. Each of the third set of U-shaped segments contains a bent section. A third plurality of U-shaped segments extend in the second direction. The second direction is substantially perpendicular to the first direction.

In at least one exemplary embodiment, the folded portion has a width ranging from about 0.5 millimeters to about 2.0 millimeters. Each of the first set of U-shaped segments, each of the second set of U-shaped segments and each of the third set of U-shaped segments contains at least one side and top. The vertices have at least one of the following: a rounded shape, a rectangular shape, a square shape, and a triangular shape. The width of each of the vertices of the first plurality of U-segments, the second plurality of U-segments, and the third plurality of U-segments is greater than the width of each of the sides of at least one of the first plurality of U-segments, the second plurality of U-segments, and the third set of U-shaped segments.

In at least one exemplary embodiment, the width of each of the vertices is in the range of about 0.25 millimeters to about 0.50 millimeters. In at least one exemplary embodiment, the width of each of the sides is in the range of about 0.05 millimeters to about 0.20 millimeters. Each of the first lead-out portion and the second lead-out portion has a width greater than a side width. The width of the first lead-out portion and the second lead-out portion ranges from about 1.0 millimeters to about 3.0 millimeters. The top width of at least one of the first plurality of U-shaped segments is substantially the same as the width of the top of at least one of the second plurality of U-shaped segments. The top of at least one of the first set of U-shaped segments is offset from the top of at least one of the second set of U-shaped segments.

In at least one exemplary embodiment, the first plurality of U-shaped segments are spaced from the second plurality of U-shaped segments by a distance ranging from about 0.5 millimeters to about 2.0 millimeters.

In at least one exemplary embodiment, the bent heater has a resistance in the range of about 0.5 ohms to about 5.0 ohms.

In at least one exemplary embodiment, the bent heater is made from nichrome. In other exemplary embodiments, the bent heater is made of stainless steel (eg, 304, 316, 304L, or 316L). The bent heater has a thickness in the range of about 0.05 millimeters to about 0.50 millimeters.

In at least one exemplary embodiment, the first set of U-shaped segments is in the first plane, and the second set of U-shaped segments is in the second plane. The second plane is different from the first plane.

In at least one exemplary embodiment, each of the first plurality of U-segments and each of the first plurality of U-segments comprises at least one side and a top. The top has at least one of the following: a rounded shape, a rectangular shape, a square shape, and a triangular shape.

At least one exemplary embodiment relates to an electronic vaping device cartridge.

In at least one exemplary embodiment, an electronic vaping device cartridge comprises a reservoir configured to store a pre-vapor formulation; a wick in fluid communication with the reservoir; and a bent heater partially surrounding the wick portion. The bent heater includes a first plurality of U-shaped segments located in the first direction and forming the first side of the heater; and a second plurality of U-shaped segments located in the first direction and forming the second side of the heater, and the second side is essentially parallel to the first side, the first outlet section and the second outlet section. The first set of U-shaped segments, the second set of U-shaped segments, the first lead-out section and the second lead-out section represent one integral element.

In at least one exemplary embodiment, the first plurality of U-shaped segments is in the first plane and the second plurality of U-shaped segments is in the second plane. The second plane is different from the first plane.

In at least one exemplary embodiment, at least one of the first plurality of U-segments is connected to at least one of the second plurality of U-segments via one of the third plurality of U-segments. Each of the third plurality of U-shaped segments contains a bent section.

At least one exemplary embodiment relates to an electronic vaping device.

In at least one exemplary embodiment, the electronic vaping device comprises a reservoir configured to store a pre-vapor formulation; a wick in fluid communication with the reservoir; a curved heater partially surrounding the wick portion; and a power supply configured to be electrically connected to said bent heater. The bent heater includes a first plurality of U-shaped segments located in the first direction and forming the first side of the heater; and a second plurality of U-shaped segments located in the first direction and forming the second side of the heater, and the second side is essentially parallel to the first side, the first outlet section and the second outlet section. The first plurality of U-shaped segments, the second plurality of U-shaped segments, the first outlet section and the second outlet section are one integral element.

At least one exemplary embodiment relates to a bent heater.

In at least one exemplary embodiment, the bent heater comprises a first plurality of U-shaped portions extending in a first direction such that said first plurality of U-shaped portions have U-shaped tops located in different planes, and each of the row from the first of the set of U-shaped sections has a first leg and a second leg, wherein the first leg is connected to the second leg of the previous one of the first set of U-shaped sections using one of the second set of U-shaped sections, and the second leg is connected to the next leg using one of the third sets of U-shaped sections.

In at least one exemplary embodiment, each of the first plurality of U-shaped portions is in a different plane from the others.

In at least one exemplary embodiment, each of the second plurality of segments is in a first plane and each of the third plurality of segments is in a second plane different from the first plane, wherein the first plane and the second plane are substantially perpendicular to each of the first plurality of U-shaped segments .

At least one embodiment relates to a method for manufacturing a connector assembly.

In at least one exemplary embodiment, a method for manufacturing a heating assembly includes the steps of: making a heater from a metal sheet, comprising a first plurality of U-shaped segments arranged in a first direction and forming a first side of the heater, a second plurality of U-shaped segments located in the first direction and forming the second side of the heater, essentially parallel to the first side, the first outlet section and the second outlet section, and the first set of U-shaped segments, the second set of U-shaped segments, the first outlet section and the second outlet section are a single monolithic element ; and bending the heater along straight sections between the first set of U-shaped sections and the second set of U-shaped sections so that the first set of U-shaped segments is essentially parallel to the second set of U-shaped segments and located at a distance from it, with the formation of a bent heater.

In at least one exemplary embodiment, the method may include placing a sheet of wick material within the bent heater.

In at least one exemplary embodiment, the method may include arranging the sheet of wick material along straight sections prior to folding.

The various features and advantages of the non-limiting embodiments described herein may become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are for illustrative purposes only and should not be interpreted as limiting the scope of the claims. The accompanying drawings are not to be taken to scale unless expressly stated. For clarity, various dimensions in the drawings may have been enlarged.

FIG. 1 shows a side view of an electronic vaping device according to at least one exemplary embodiment.

FIG. 2 is a sectional view taken along line II-II of the electronic vaping device of FIG. 1 according to at least one exemplary embodiment.

FIG. 3A is a front view of an evaporator including a bent heating element and a wick according to at least one exemplary embodiment.

FIG. 3B is a side view of the heating element of FIG. 3A according to at least one exemplary embodiment.

FIG. 3C is a perspective view of the heating element of FIG. 3A and 3B according to at least one exemplary embodiment.

FIG. 4 is a plan view of the heating element of FIG. 3 in an unfolded state according to at least one exemplary embodiment.

FIG. 5 is a cross-sectional view of an electronic vaping device cartridge comprising a vaporizer according to at least one exemplary embodiment.

FIG. 6 is an enlarged perspective view of the evaporator and connector of FIG. 5 according to at least one exemplary embodiment.

FIG. 7 is a graph illustrating aerosol output and battery discharge of an electronic vaping device comprising a vaporizer comprising a bent heating element according to at least one exemplary embodiment.

FIG. 8 shows a heating element etched into a sheet of material according to at least one exemplary embodiment.

FIG. 9 shows a heating element in an unbent state according to at least one exemplary embodiment.

FIG. 10 shows a heating element in an unbent state according to at least one exemplary embodiment.

FIG. 11 is a side view of a heating element according to at least one exemplary embodiment.

FIG. 12 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

FIG. 13 is a side view of a heating element according to at least one exemplary embodiment.

FIG. 14 is a front view of a heating element and a wick according to at least one exemplary embodiment.

FIG. 15 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

FIG. 16 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

FIG. 17 is a side view of a heating element according to at least one exemplary embodiment.

FIG. 18 is a perspective view of a heating element and wick according to at least one exemplary embodiment.

FIG. 19 is an exploded view of a cartridge according to at least one exemplary embodiment.

This document discloses some detailed examples of embodiments of the invention. However, the specific structural and functional details disclosed herein are for the purpose of describing exemplary embodiments only. However, the exemplary embodiments may be implemented in many alternative forms and should not be construed as being limited to the exemplary embodiments set forth herein.

Accordingly, since the exemplary embodiments may have various modifications and alternative forms, the corresponding exemplary embodiments are shown as examples in the drawings and will be described in detail herein. However, it should be understood that the exemplary embodiments are not intended to be limited to the specific forms disclosed; on the contrary, they should cover all modifications, equivalents and alternatives within the scope of the exemplary embodiments of the invention. Like numbers refer to like elements throughout the description of the figures.

It should be understood that if an element or layer is referred to as "located on", "connected to", "associated with", or "covering" another element or layer, it may be directly located on, connected to, associated with or cover another element. or layer, or intermediate elements or layers may be present. Conversely, if an element is referred to as "directly located on", "directly connected to", or "directly connected to" another element or layer, then there are no intermediate elements or layers. Like numbers refer to like elements throughout the description. As used herein, the conjunction "and/or" includes any and all combinations of one or more of the related listed elements.

It should be understood that, although the ordinal numbers "first", "second", "third", etc. may be used in this document to describe various elements, components, regions, layers or sections, these elements, components, regions, layers or sections should not be limited to these ordinal numbers. These ordinal numbers are only used to distinguish one element, component, area, layer or section from another area, layer or section. Thus, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section without departing from the ideas of the exemplary embodiments.

The terms of relative spatial location (for example, "below", "under", "bottom", "above", "upper", etc.) can be used in this document to simplify the description to disclose the relationship of one element or feature to another. element or feature as shown in the figures. It should be understood that the terms of relative spatial arrangement are intended to cover various orientations of the device during use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is reversed, then elements described as located "under" or "below" other elements or features will be located "above" other elements or parts. Thus, the word "under" can cover both the location above and the location below. The device may be oriented differently (rotated 90 degrees or positioned in other orientations) and definitions of relative spatial location used herein will be interpreted accordingly.

The terminology used in this document is only intended to describe various embodiments and is not intended to limit exemplary embodiments. In the context of this document, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the terms "comprises", "comprising", "comprises" and/or "comprising" when used in the present description indicate the presence of established features, integers, steps, operations, elements and/or components, but not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.

Exemplary embodiments are described herein with reference to cross-sectional illustrations, which are schematic representations of idealized embodiments (or intermediate structures) of exemplary embodiments. Therefore, changes in the forms of illustrations should be expected due to changes, for example, in manufacturing technologies and / or tolerances. Thus, exemplary embodiments should not be construed as being limited to the shapes of the areas depicted herein, but should include variations in shape that are due to, for example, manufacturing.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meanings as commonly understood by those skilled in the art to which the exemplary embodiments relate. It should also be understood that terms, including those defined in common dictionaries, should be interpreted as having the meaning appropriate to their meaning in the context of the relevant technical field, and should not be interpreted in an idealized or overly formal sense unless explicitly defined. in this document.

FIG. 1 shows a side view of an electronic vaping device according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 1, an electronic vaping device 10 (e-vaping device) may include a replaceable cartridge (or first section) 15 and a refillable battery section (or second section) 20, which may be connected to each other via a threaded connector 25. It should be understood that the connector 25 may be any type of connector, such as a push-fit connector, retainer, clip, bayonet connector, and/or latch. The air inlet 55 passes through the section of the connector 25.

In at least one exemplary embodiment, connector 25 may be the connector described in US Patent Application Serial No. 15/154,439, filed May 13, 2016, the entire contents of which are incorporated herein by reference. As described in US Patent Application Serial No. 15/154,439, filed May 13, 2016, the entire contents of which are incorporated herein by reference, connector 25 may be manufactured using a deep drawing process. As described in US Patent Application Serial No. 15/349,377, filed Nov. 11, 2016, the entire contents of which are incorporated herein by reference, connector 25 may be manufactured using a casting process.

In at least one exemplary embodiment, the first section 15 may comprise a first shroud 30 and the second section 20 may comprise a second shroud 30'. The electronic vaping device 10 includes an insert 35 at the mouth end located at the first end 45.

In at least one exemplary embodiment, the first shroud 30 and the second shroud 30' may have a substantially cylindrical cross section. In other exemplary embodiments, shrouds 30 and 30' may have a generally triangular cross-section along one or more of first section 15 and second section 20. In addition, shrouds 30 and 30' may have the same or different cross-sectional shape, as well as the same or different sizes. As described herein, shrouds 30, 30' may also be referred to as outer or main shrouds.

In at least one exemplary embodiment, the electronic vaping device 10 may include an end cap 40 at the second end 50 of the electronic vaping device 10. The electronic vaping device 10 also includes an indicator light 60 between the end cap 40 and the first end 45 of the electronic vaping device 10.

FIG. 2 is a sectional view taken along line II-II of the electronic vaping device of FIG. one.

In at least one exemplary embodiment shown in FIG. 2, the first section 15 may include a reservoir 95 configured to store the pre-flasher composition and an evaporator 80 which can vaporize the pre-flasher composition. The vaporizer 80 includes a heating element 85 and a wick 90. The wick 90 may draw the pre-vapor composition from the reservoir 95. The electronic vaping device 10 may also contain the features set forth in U.S. Published Application No. 2013/0192623 to Tucker et al., filed January 31, 2013. ., and/or features set forth in Holtz et al., U.S. Published Application Serial No. 15/135,930, filed April 22, 2016, the entire contents of each of which are incorporated herein by reference. In other exemplary embodiments, an electronic vaping device may contain the features set forth in U.S. Published Serial No. 15/135,923, filed April 22, 2016, and U.S. Patent No. 9,289,014, issued March 22, 2016, all of the contents of each which are incorporated herein by reference.

In at least one exemplary embodiment, the pre-vapor composition is a material or combination of materials that can be converted to vapor. For example, the pre-vapor formulation may be a liquid, solid and/or gel formulation including, but not limited to, water, granules, solvents, active ingredients, ethanol, plant extracts, natural or artificial flavors and/or vaporizers such as like glycerin and propylene glycol. The pre-vapor composition may also contain plant material, such as tobacco material or non-tobacco material.

In at least one exemplary embodiment, the first section 15 may include a casing 30 extending in the longitudinal direction and an inner tube (or conduit) 70 located coaxially within the casing 30.

In at least one exemplary embodiment, the first fitting 155 may include a male threaded section for making a connection between the first section 15 and the second section 20.

At the upstream end of the inner tube 70, the protruding portion 245 of the gasket (or seal) 240 can be inserted into the inner tube 70, and the outer perimeter of the gasket 240 can provide a seal with the inner surface of the casing 30. The gasket 240 can also contain a Central longitudinal air channel 235 , which is in fluid communication with the inner tube 70 to form an inner channel (also referred to as a central channel or central inner channel) 120. A transverse channel 230 in the back portion of the gasket 240 may intersect and communicate with an air channel 235 of the gasket 240. This transverse channel 230 provides communication between the air passage 235 and the space 250 formed between the gasket 240 and the first fitting 155.

In at least one exemplary embodiment, the first fitting 155 may include a male threaded section for making a connection between the first section 15 and the second section 20.

In at least one exemplary embodiment, the housing 30 may be provided with at least two air inlets 55. Alternatively, one air inlet 55 may be located in the casing 30. This arrangement allows the air inlet 55 to be positioned adjacent to the connector 25 without blocking due to the first fitting 155. This arrangement also allows the area of the air inlets 55 to be reinforced to assist in the precise drilling of the air inlets 55.

In at least one exemplary embodiment, the air inlets 55 may be provided in the connector 25 rather than in the housing 30. In other exemplary embodiments, the connector 25 may not include threaded portions.

In at least one exemplary embodiment, at least one air inlet 55 may be provided in housing 30 adjacent connector 25 to minimize the likelihood of an adult vaper's fingers blocking one of the holes and to control resistance-to-puff. -draw, RTD) while vaping. In some exemplary embodiments, the air inlets 55 can be machined into the case 30 with a precision tool so that their diameters are precisely controlled and reproducible from one electronic vaping device 10 to the next during the manufacturing process.

In at least one exemplary embodiment, the air inlets 55 may be sized and configured such that the electronic vaping device 10 has a draw resistance in the range of about 60 millimeters of water column to about 150 millimeters of water column (e.g., about 70 mmH2O to about 140 mmH2O, from about 80 mmH2O to about 130 mmH2O, or from about 90 mmH2O to about 120 mmH2O). The size and number of the air inlets 55 can be adjusted to control the draw resistance.

In at least one exemplary embodiment, the protruding portion 110 of the gasket 65 may be inserted into the first end portion 105 of the inner tube 70. The outer perimeter of the gasket 65 may provide a substantially impermeable seal with the inner surface 125 of the casing 30. The gasket 65 may include a central channel 115, located between the inner channel 120 of the inner tube 70 and the interior of the insert 35 at the mouth end and capable of transferring steam from the inner channel 120 to the insert 35 at the mouth end. The mouth end insert 35 includes at least two outlets 100 that may be positioned offset from the longitudinal axis of the electronic vaping device 10. The outlets 100 may be inclined outwardly relative to the longitudinal axis of the electronic vaping device 10. The outlets 100 may be substantially evenly distributed around the perimeter of the insert 35 at the mouth end so that a substantially even distribution of vapor occurs.

In at least one exemplary embodiment, the space formed between gasket 65, gasket 240, casing 30, and inner tube 70 may define the boundaries of reservoir 95. Reservoir 95 may contain a pre-flash composition and, optionally, a storage medium (not shown). ), made with the possibility of storing a pre-evaporator composition in it. The storage medium may include a wrap of cotton gauze or other fibrous material around the inner tube 70.

The inner tube 70 has an outer diameter ranging from about 2.0 millimeters to about 3.5 millimeters. The outside diameter can be chosen to maximize tank size 95.

In at least one exemplary embodiment, the reservoir 95 may at least partially surround the inner channel 120. In this way, the reservoir 95 can at least partially surround the inner channel 120. The heating element 85 can extend transversely through the inner channel 120 between opposite sections reservoir 95. In some exemplary embodiments, the heater 85 may extend parallel to the longitudinal axis of the inner channel 120. In other exemplary embodiments, the heating element 85 may not be located in the inner channel 120 of the inner tube 70.

In at least one exemplary embodiment, the reservoir 95 may be sized and shaped to hold a sufficient amount of pre-vapor composition such that the electronic vaping device 10 is capable of vaping for at least about 200 seconds. In addition, the electronic vaping device 10 may be configured to provide a duration of each puff up to a maximum of about 5 seconds.

In at least one exemplary embodiment, the storage medium may be a fibrous material containing at least one of the following: cotton, polyethylene, polyester, rayon, and combinations thereof. The fibers may have a diameter ranging from about 6 microns to about 15 microns (eg, from about 8 microns to about 12 microns, or from about 9 microns to about 11 microns). The storage carrier may be a sintered, porous or foamed material. In addition, the fibers may be sized to be inhalable and may have a Y-shape, cruciform, clover-shape, or any other suitable cross-sectional shape. In at least one exemplary embodiment, reservoir 95 may comprise a filled container that does not contain any storage media and contains only the pre-vapor composition.

During vaping, the pre-vapor composition may be transferred from the reservoir 95 and/or the storage medium to the vicinity of the heating element 85 due to the capillary action of the wick 90. The wick 90 may include at least a first end portion and a second end portion, which may extend to opposite sides of the reservoir 95. The heating element 85 may at least partially surround the central portion of the wick 90 such that, upon activation of the heating element 85, the pre-flash composition in the central portion of the wick 90 may be vaporized by the heating element 85 to form steam.

In at least one exemplary embodiment, the wick 90 may comprise a sheet of wick material capable of drawing in the pre-flash composition. In at least one exemplary embodiment, the wick 90 may comprise one or more sheets of material, such as a sheet made from borosilicate fibers. The sheet of material may be folded, woven, twisted, glued together, and the like. to form a wick 90. The sheet of material may comprise one or more layers of material. The sheet of material may be folded and/or twisted. If multiple layers of material are included, then each layer may have the same density as the other layers or a different density. The layers may have the same thickness or different thicknesses. The wick 90 may have a thickness in the range of about 0.2 millimeters to about 2.0 millimeters (eg, about 0.5 millimeters to about 1.5 millimeters, or about 0.75 millimeters to about 1.25 millimeters). In at least one exemplary embodiment, wick 90 comprises woven amorphous silica fibers.

A thicker wick 90 can deliver more pre-flash composition to heating element 85 so that more steam will be generated, while a thinner wick 90 can deliver less pre-flash composition to heating element 85 so less steam will be generated.

In at least one exemplary embodiment, the wick 90 may comprise a rigid structural layer and at least one additional less rigid layer. The addition of a rigid structural layer provides the possibility of facilitating automated cartridge manufacturing. The rigid structural layer may be made of ceramic or other substantially heat resistant material.

In other embodiments, wick 90 may be a bundle of glass (or ceramic) fibers, a bundle containing a group of twisted glass filaments, and the like, all of which may be capable of drawing the pre-flash composition through capillary action created by internal voids. between fibers. The fibers may be generally aligned in a direction perpendicular (transverse) to the longitudinal direction of the electronic vaping device 10. In at least one exemplary embodiment, the wick 90 may comprise from one to eight strands of fibers, each containing a plurality of glass fibers twisted together. . The end portions of the wick 90 may be flexible and foldable within the boundaries of the reservoir 95. The cross section of the fibers may be generally cross-shaped, clover-shaped, Y-shaped, or any other suitable shape.

In at least one exemplary embodiment, the wick 90 may comprise any suitable material or combination of materials. Examples of suitable materials may include, but are not limited to, materials based on glass, ceramic or graphite. The wick 90 may have any suitable capillary draw action to accommodate pre-vapor formulations having different physical properties such as density, viscosity, surface tension and vapor pressure. Wick 90 may be non-conductive.

In at least one exemplary embodiment, heating element 85 may comprise a bent metal sheet (described below in connection with FIGS. 3A, 3B, and 4) that at least partially surrounds wick 90. Heating element 85 may extend entirely or partially along the length of the wick. 90. The heating element may also extend wholly or partially around the circumference of the wick 90. In some exemplary embodiments, the heating element 85 may or may not be in contact with the wick 90.

In at least one exemplary embodiment, heating element 85 may be made from any suitable electrically resistive materials. Examples of suitable electrically resistive materials may include, but are not limited to, copper, titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include, but are not limited to, stainless steel, nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium -, manganese- and iron-containing alloys and heat-resistant alloys based on nickel, iron, cobalt and stainless steel. For example, the heating element 85 may be made of nickel aluminide, a material with a layer of alumina on the surface, iron aluminide, and other composite materials, and the electrical resistive material may, if necessary, be embedded in, encapsulated in or coated with the insulating material, or vice versa, in depending on the kinetics of energy transfer and the required external physical and chemical properties. Heating element 85 may comprise at least one material selected from the group consisting of stainless steel, copper, copper alloys, chromium-nickel alloys, superalloys, and combinations thereof. In an exemplary embodiment, the heating element 85 may be made of chromium-nickel alloys or iron-nickel alloys. In another exemplary embodiment, heating element 85 may be a ceramic heater having an electrically resistive layer on its outer surface.

The inner tube 70 may include a pair of opposing slots so that the wick 90 and the first and second electrical leads 225, 225' or ends 260, 260' of the heating element 85 can extend outward from the respective opposing slots. By providing opposing slots in inner tube 70, it is possible to facilitate placement of heater 85 and wick 90 at a location within inner tube 70 without contact with the edges of said slots and bent section of heating element 85. In at least one exemplary embodiment, inner tube 70 may have a diameter of about 4 millimeters, and each of said opposing slots may have a largest and a smaller dimension of from about 2 millimeters to about 4 millimeters.

In at least one exemplary embodiment, the first lead portion 225 is physically and electrically connected to the threaded male connector 155. As shown in the figures, the first male thread fitting 155 is a hollow cylinder with male threads in the outer side surface portion. The connecting piece is conductive and may be made of or covered with a conductive material. The second lead portion 225' is physically and electrically connected to the first conductive pin 130. The first conductive pin 130 may be made of a conductive material (eg, stainless steel, copper, etc.) and may have a T-section as shown. in FIG. 2. The first conductive pin 130 is located within the hollow portion of the first connector 155 and is electrically isolated from the first connector 155 by an insulating sheath 135. The first conductive pin 130 may be hollow, as shown in the figures, and its hollow portion may be in fluid communication with air passage 120. Accordingly, the first connecting piece 155 and the first conductive rod 130 form a respective external electrical connection with the heating element 85.

In at least one exemplary embodiment, the heating element 85 may heat the pre-flash composition in the wick 90 by conduction. Alternatively, the heat from the heating element 85 may be transferred to the pre-vapor composition via a heat conduction element, or the heating element 85 may transfer heat to the incoming ambient air that is drawn in through the electronic vaping device 10 during vaping, which in turn results in heating of the pre-evaporator composition due to convection.

As shown in FIG. 2, the second section 20 includes a power supply 145, a control circuit 185, and a sensor 190. As shown in the figure, the control circuit 185 and the sensor 190 are located in the housing 30'. The control circuit 185 may include a printed circuit board 200. A second female thread connector 160 forms the second end. As shown in the figure, the second connecting part 160 is in the form of a hollow cylinder with threads on the inner side surface. The inner diameter of the second connector 160 corresponds to the outer diameter of the first connector 155, so that the two connectors 155, 160 can be threaded together to form a connection 25. In addition, the second connector 160, or at least another side surface thereof, is conductive. , for example, made of a conductive material or containing it. Thus, when connecting the first and second fittings 155, 160, a physical and electrical connection occurs.

As shown in the figures, the first output section 165 electrically connects the second connecting piece 160 with the control circuit 185. The second terminal section 170 electrically connects the control circuit 185 to the first connector 180 of the power supply 145 . The third output portion 175 electrically connects the second connector 140 of the power supply 145 to the power connector of the control circuit 185 to supply power to the control circuit 185. In addition, the second connector 140 of the power supply 145 is electrically and physically connected to the second conductive pin 150. The second conductive pin 150 may be made of a conductive material (for example, stainless steel, copper, etc.), and it may have a T-shaped section as shown in FIG. 2. The second conductive pin 150 is located within the hollow portion of the second connector 160 and is electrically isolated from the second connector 160 by the second insulating sheath 215. The second conductive pin 150 may also be hollow, as shown in the figures. When connecting the first and second connecting parts 155, 160, the second conductive pin 150 is physically and electrically connected to the first conductive pin 130. In addition, the hollow portion of the second conductive pin 150 may be in fluid communication with the hollow portion of the first conductive pin 130.

Although the first section 15 is shown and described as having a male connector and the second section 20 is shown and described as having a female connector, an alternative embodiment includes a reverse arrangement in which the first section 15 has a female connector and the second section 20 has a male connector. detail.

In at least one exemplary embodiment, power supply 145 comprises a battery located in electronic vaping device 10. Power supply 145 may be a lithium ion battery or one of its variants, such as a lithium ion polymer battery. Alternatively, power supply 145 may be a nickel metal hydride battery, a nickel cadmium battery, a lithium manganese battery, a lithium cobalt battery, or a fuel cell. The electronic vaping device 10 can be used for vaping by an adult vaper until the power supply 145 is depleted or, in the case of a lithium polymer battery, until a minimum voltage cutout level is reached.

In at least one exemplary embodiment, power supply 145 is rechargeable. The second section 20 may include circuitry configured to allow the battery to be recharged using an external charger. To recharge the electronic vaping device 10, a USB (Universal Serial Bus) charger or other suitable charger can be used, as described below.

In at least one exemplary embodiment, the sensor 190 is configured to generate an output signal indicative of the intensity and direction of the airflow in the electronic vaping device 10. The control circuit 185 receives the output from the sensor 190 and determines: (1) whether the direction of the airflow indicates the puffing on insert 8 at the mouth end (opposite of blowing), and (2) whether the puff intensity exceeds a threshold level. When these vaping conditions are met, the control circuit 185 electrically connects the power source 145 to the heating element 85, thereby activating the heating element 85. More specifically, the control circuit 185 electrically connects the first and second terminals 165, 170 (for example, by activating the heater power control transistor forming part of the control circuit 185), so that the heating element 85 becomes electrically connected to the power supply 145. In an alternative embodiment, sensor 190 may indicate a drop in pressure and control circuit 185 activates heating element 85 in response.

In at least one exemplary embodiment, control circuit 185 may also include an indicator light 60 that is activated by control circuit 185 to ignite when heating element 85 is activated and/or when battery 145 is recharged. Indicator light 60 may include one or more LEDs (light-emitting diodes). emitting diodes, LEDs). The LEDs may have one or more colors (eg, white, yellow, red, green, blue, etc.). In addition, the indicator light 60 may be positioned so that it is visible to an adult vaper and may be between the first end 45 and the second end 50 of the electronic vaping device 10. In addition, the indicator light 60 may be used to diagnose an electronic vaping system or to indicate that it is currently recharging. The indicator light 60 may also be configured to enable an adult vaper to activate and/or deactivate the indicator light 60 for privacy purposes.

In at least one exemplary embodiment, the control circuit 185 may include a time period limiter. In another exemplary embodiment, the control circuit 185 may include a manually actuated switch to initiate heating by an adult vaper. The time period for applying electric current to the heating element 85 may be set or preset depending on the amount of pre-evaporator composition required for evaporation.

Next, the operation of the electronic vaping device for generating vapor will be described. For example, air is initially drawn into the first section 15 through at least one air inlet 55 in response to a puff on the insert 35 at the mouth end. Air enters through air inlet 55 into space 250, passes through transverse passage 230, air passage 235 and inner passage 120, and exits through outlet 100 of insert 35 at the mouth end. When circuit 185 detects the above-described vaping conditions, control circuit 185 initiates power to heating element 85 so that heating element 85 heats the pre-vapor composition in wick 90. Vapor and air passing through internal passage 120 mix and exit electronic vaping device 10 through the outlet 100 of the insert 35 at the mouth end.

When the heating element 85 is activated, it can heat the wick portion 90 for less than about 10 seconds, or for less than about 1 second.

In at least one exemplary embodiment, the first section 15 may be replaceable. In other words, after the pre-vapor composition in the cartridge is used up, only the first section 15 can be replaced. An alternative configuration may include an exemplary embodiment in which the entire electronic vaping device 10 can be discarded when the contents of the reservoir 95 are used up. In at least one exemplary embodiment the electronic vaping device 10 may be an integral electronic vaping device.

In at least one exemplary embodiment, the electronic vaping device 10 may be about 80 millimeters to about 110 millimeters long and about 7 millimeters to about 8 millimeters in diameter. For example, in one exemplary embodiment, the electronic vaping device 10 may be approximately 84 millimeters long and approximately 7.8 millimeters in diameter.

FIG. 3A is a front view of an evaporator including a bent heating element and a wick according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 3A, bent heating element 85 is a single piece that is cut and/or laser etched from a sheet of metal and bent around at least a portion of wick 90. Bent heating element 85 contacts wick 90 on three sides.

In at least one exemplary embodiment, the bent heating element 85 includes a first plurality of U-shaped segments 270 located in the first direction and forming the first side 275 of the heating element 85. The bent heating element also includes a second set of U-shaped segments 280 located in the first direction. direction and forming the second side 285 of the heating element 85 (shown in FIG. 3B and 4 and described in detail below). The second side 285 is substantially parallel to the first side 275.

In at least one exemplary embodiment, bent heating element 85 also includes ends that define first outlet portion 260 and second outlet portion 260'. As shown in FIG. 3A, both ends 260, 260' may be located on the second side 285 of the bent heating element 85.

In at least one exemplary embodiment, the first plurality of U-shaped segments 270, the second plurality of U-shaped segments 280, the first lead-out portion 260, and the second lead-out portion 260' are one single piece.

In at least one exemplary embodiment, each of the first set of U-segments 270 is connected to at least one of the second set of U-segments 280 by one of the third set of U-segments 290.

In at least one exemplary embodiment, each of the third plurality of U-shaped segments 290 includes a bent section 295. The third plurality of U-shaped segments 290 extends in the second direction. The second direction is substantially perpendicular to the first direction. Thus, the third set of U-segments 290 extends substantially perpendicular to the first set of U-segments 270 and the second set of U-segments 280.

In at least one exemplary embodiment, each of the first set of U-shaped segments 270 is in the first plane, and each of the second set of U-shaped segments 280 is in the second plane, which is different from the first plane. The first plane is substantially parallel to the second plane. In other exemplary embodiments, the first plane may not be parallel to the second plane.

In at least one exemplary embodiment, each of the third set of U-segments 290 is in a different plane than the other segments of the third set of U-segments 290. Each of the third set of U-segments 290 is in a different plane than the first set of U-shaped segments 270, and in a different plane than the second set of U-shaped segments 280. For example, the third set of U-shaped segments 290 extends perpendicular to the first set of U-shaped segments 270 and is in a different plane than the second set of U- figurative segments 280.

In at least one exemplary embodiment, each of the first plurality of U-shaped segments 270, the second plurality of U-shaped segments 280, and the third plurality of U-shaped segments 290 may comprise from one to twenty U-shaped segments (for example, from two to eighteen U-segments, three to fifteen U-segments, four to twelve U-segments, or five to ten U-segments). The number of U-shaped segments in each of the first plurality of U-shaped segments 270, the second plurality of U-shaped segments 280, and the third plurality of U-shaped segments 290 may be selected depending on the required resistance and/or the required size of the heating element 85.

In at least one exemplary embodiment, each of the first set of U-segments 270 is offset from a corresponding segment of the second set of U-segments 280. The first set of U-segments 270 may comprise the same or a different number of U-segments compared to with a plurality of U-shaped segments 280. In at least one exemplary embodiment, the first plurality of U-shaped segments 270 has more or fewer U-shaped segments than the second plurality of U-shaped segments 280.

Each of the first plurality of U-shaped segments 270 and each of the second plurality of U-shaped segments 280 includes at least one side (or leg) 300 and a top 310. The tops 310 have at least one of the following: a rounded shape, a rectangular shape, oval shape, square shape and triangular shape.

In at least one exemplary embodiment, heating element 85 has a resistance in the range of about 0.5 ohms to about 5.0 ohms (e.g., about 1.0 ohms to about 4.5 ohms, or about 2.0 ohms to about 4.0 ohms or from about 2.5 ohms to about 3.5 ohms). The resistance may be selected based on the desired steam output and/or battery life.

FIG. 3B is a side view of the heating element of FIG. 3A according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 3B, heater 85 is the same as in FIG. 3A but shown from the side. As shown in the figures, the bent section 295 has an internal width W1 ranging from about 0.05 millimeters to about 2.0 millimeters (for example, from about 0.5 millimeters to about 1.75 millimeters or from about 0.75 millimeters to about 1.5 mm). The inner width W1 may vary depending on the resistance of the heating element 85. The heating elements 85 having a lower resistance have an inner width W1 larger than the heating elements 85 having a higher resistance. For example, if the heating element 85 has a resistance of approximately 2.9 ohms, then the internal width W1 of the bent section 295 may be from about 0.25 millimeters to about 0.50 millimeters, while the heating element 285 with a resistance of approximately 3.5 ohms may have an internal width W1 of the bent portion 295 of about 0.5 millimeters to about 1.5 millimeters.

In at least one exemplary embodiment, the bent section 295 does not contain sharp corners (eg, has rounded edges and/or corners). In other exemplary embodiments, the bent portion 295 includes sharp corners. The folded portion 295 may be substantially perpendicular to the sides 300 of the first plurality of U-shaped portions 270 and the second plurality of U-shaped portions 280.

In at least one exemplary embodiment, the bent section 295 is configured such that three sides of the heating element 85 contact the wick 90 to increase the contact surface area between the wick 90 and the heating element 85. In addition, the internal width W1 is chosen such that the wick 90 is tightly held between the first plurality of U-shaped portions 270 and the second plurality of U-shaped portions 280 such that only a certain amount of pre-flash composition reaches the heating element 85 between activations of the heating element 85.

In at least one exemplary embodiment, the width W1 is small enough such that only a set amount of preflash composition can flow into the wick 90, and thus too much preflash composition is prevented from entering the heating element 85 at a given time. The small width W1 also makes it possible to substantially prevent and/or reduce pre-flash composition cooling of the heating element 85, since only a set amount of pre-flash composition can be transferred by capillary effect to the heating element 85 at a time.

In at least one exemplary embodiment shown in FIG. 3B, each of the third plurality of U-shaped segments 290 includes at least one side (or leg) 300 and a top 310. The tops 310 have at least one of the following: rounded shape, rectangular shape, oval shape, square shape, and triangular shape. . Vertices 310 may have an inside corner radius of about 0.10 millimeters to about 0.20 millimeters, and an outside corner radius of about 0.25 millimeters to about 0.30 millimeters. The vertices 310 of the third set of U-segments 290 may have the same or a different shape than the vertices 310 of the first set of U-segments 270 and the second set of U-segments 280.

In at least one exemplary embodiment, heating element 85 may have a thickness T1 (shown in FIG. 3B) in the range of about 0.001 millimeters to about 0.20 millimeters (e.g., about 0.01 millimeters to about 0.15 millimeters, or about 0.05 mm to about 0.10 mm).

FIG. 3C is a perspective view of the heating element of FIG. 3A and 3B according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 3C, heating element 85 is the same as in FIG. 3A and 3B, but shown in perspective. As shown in the figure, the vertices 310 of the first set of U-segments 270 are offset from the vertices 310 of the second set of U-segments 280.

In at least one exemplary embodiment, the leads 260, 260' may be wider and/or thicker than other portions of the heating element 85 to provide rigidity, stability, resistance, and ease of spot welding.

FIG. 4 is a plan view of the heating element of FIG. 3A in an unfolded state according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 4, heating element 85 is formed into a flat planar shape prior to being folded around wick 90. As described above, heating element 85 can be made by cutting (eg, laser cutting), stamping, and/or etching (eg, photoetching) a sheet of metal. The metal may contain any suitable material including 80 Nichrome, 60 Nichrome, 304 Stainless Steel, 316 Stainless Steel, and 30 Nicrotal.

In at least one exemplary embodiment shown in the figure, the unfolded heating element 85 has a length L1 of about 4.0 millimeters to about 15.0 millimeters (e.g., about 4.5 millimeters to about 6.5 millimeters, or from about 5.0 millimeters to about 6.0 millimeters). Lead-out sections 260, 260' extend beyond the second set of U-shaped segments 280.

In at least one exemplary embodiment, the lead-out portions 260, 260' have a width W3 ranging from about 1.0 millimeters to about 3.0 millimeters (for example, from 1.25 millimeters to about 2.75 millimeters, or from about 1. 75 millimeters to about 2.25 millimeters) and a length L2 ranging from about 1.0 millimeters to about 2.5 millimeters (for example, from about 1.25 millimeters to about 2.25 millimeters or from about 1.75 millimeters to about 2.0 millimeters).

In at least one exemplary embodiment, the length L3 is the length of the heating element 85 from the outer surface 320 of the tops 310 of the first set of U-shaped segments 270 to the outer surface 320 of the tops 310 of the second set of U-shaped segments 280. The length of L3 is in the range of approximately 4.5 millimeters to about 6.0 millimeters (eg, about 4.75 millimeters to about 5.75 millimeters, or about 5.0 millimeters to about 5.25 millimeters).

In at least one exemplary embodiment, the length L4 is the length between the inner surface 330 of the vertices 310 of the first set of U-segments 270 and the inner surface 330 of the vertices 310 of the second set of U-segments 280. The length of L4 is in the range of approximately 3.25 millimeters to about 7.0 millimeters (eg, from about 4.0 millimeters to about 6.0 millimeters, or from about 4.5 millimeters to about 5.5 millimeters).

In at least one exemplary embodiment, the width W4 of each of the peaks 310 ranges from about 0.25 millimeters to about 0.50 millimeters.

In at least one exemplary embodiment, the width W5 of each side 300 of the first plurality of U-shaped segments 270 and the second plurality of U-shaped segments 280 ranges from about 0.05 millimeters to about 0.20 millimeters (for example, from about 0. 10 mm to approximately 0.15 mm).

In at least one exemplary embodiment, the width W4 of each of the vertices 310 of the first set of U-segments 270 and the second set of U-segments 280 is greater than the width W5 of each of the sides 300 of the first set of U-segments 270 and the second set of U -shaped segments 280.

In at least one exemplary embodiment, each of the first lead portion 260 and the second lead portion 260' has a width W3 greater than the width W5 of the side 300. The width W4 of the top 300 of each of the first plurality of U-shaped segments 270 is substantially the same as and a width W4 of the top 300 of each of the second plurality of U-shaped segments 280. The top 300 of each of the first plurality of U-shaped segments 270 is offset from the top 300 of each of the second plurality of U-shaped segments 280 when the heating element 85 is in the bent state.

In at least one exemplary embodiment, the dimensions of the heating element 85 can be adjusted to adjust the resistance of the heating element 85. The dimensions of the heating element 85 can also be adjusted to make heaters larger or smaller for use in other vaping devices, including those described in the US patent application. Serial No. 15/135,930, Holtz et al., filed April 22, 2016, U.S. Patent Application Serial No. 15/135,923, Holtz et al., Filed April 22, 2016, U.S. Patent Application Serial No. 15 /224,866, Gavrielov et al., filed August 1, 2016, U.S. Patent Application Serial No. 14/998,020, Hawes et al., Filed April 22, 2015, U.S. Patent Application Serial No. 15/147,454, authors Li et al., filed May 5, 2016, and U.S. Patent Application Serial No. 15/135,932 to Hawes et al., filed April 22, 2016, the entire contents of each of which are incorporated herein. by referring to it.

In at least one exemplary embodiment, the heating element 85 may extend substantially perpendicular to the longitudinal axis of the electronic vaping device. In other exemplary embodiments, heating element 85 may be substantially parallel to the longitudinal axis of the electronic vaping device.

FIG. 5 is a cross-sectional view of an electronic vaping device cartridge comprising a vaporizer according to at least one exemplary embodiment.

In at least one exemplary embodiment, the first section 15 containing the heating element 85 is the same as in FIG. 2, but inner tube 70 does not contain opposing slots, and heating element 85 and wick 90 are not inside inner tube 70, as detailed below.

In at least one exemplary embodiment shown in FIG. 5, instead of a second gasket or seal, disc 340 is located at the second end of tank 95 between inner tube 70 and casing 30. Thus, tank 95 is formed by seal 65, inner tube 70, casing 30, and disc 340. Disc 340 can be made of polymer or metal that is essentially non-porous. Disk 340 may be provided with outlets 360 such that the pre-flasher composition can be discharged from reservoir 95. The size and/or number of outlets 260 provided in disc 340 may be selected based on the desired amount and/or delivery time of the pre-flasher. . The disk 240 defines a central channel 362 in fluid communication with the inner channel 120 of the inner tube 70. The central channel 362 has approximately the same diameter as the inner diameter of the inner channel 120

In at least one exemplary embodiment, carrier material tube 350 abuts disc 340 such that any pre-flash composition exiting reservoir 95 through outlets 360 is transferred into carrier material tube 350. The material used to make the transfer material tube 350 may depend on the material used to make the wick and/or the viscosity, density, and the like. pre-evaporator composition. The transfer material tube 350 may have a density in the range of about 0.08 grams per cubic centimeter to about 0.3 grams per cubic centimeter.

The transfer material tube 350 defines a channel 370 that is in fluid communication with an inner channel 120 of the inner tube 70.

In at least one exemplary embodiment, a heating element 85 is positioned between the first connector 155 and the transfer material tube 350. As steam is generated, this steam passes through channel 370 and moves into the central channel 362 and into the inner channel 120.

FIG. 6 is an enlarged perspective view of the first cartridge connector of FIG. 5 according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 6, the first connector 155 may include an inner pin 430. Both of the connector 155 and the inner pin 430 are made of plastic. Thus, electrical connection to the heater is made through the first connection ring 385 and the second connection ring 395. The first connection ring 385 includes a first tongue 380 that extends substantially perpendicular to the first connection ring 385. The second connection ring 395 includes a second tongue 390 that extends substantially perpendicular to the second connecting ring 395. Each of the first tongue 380 and the second tongue 390 has an internal groove sized and shaped to accommodate one of the tongues 260, 260'.

In at least one exemplary embodiment, the first connection ring 385 and the second connection ring 395 are electrically separated from each other by a spacer disk 500. In FIG. 6 shows only part of the spacer disc 500 to show the first connection ring 385 and the second connection ring 395. The spacer disc 500 has two slots 510, 510' formed therein. Each of the first tongue and second tongue 380, 390 passes through one of the two slots 510, 510' in the spacer disk 500. In addition, the first connecting ring 385 and the second connecting ring 395 have different inner and/or outer diameters, so that one of they are smaller than the other and do not contact him even when they are placed together.

In at least one exemplary embodiment, the first and second connector rings 385, 395 allow an electrical connection to be made with the heating element 85 without the need for crimping and/or soldering. In other exemplary embodiments, the ends 260, 260' may be held in the slots 700, 700' formed by the first and second connecting tabs 380, 390 while being crimped and/or soldered for added strength. The protrusions 380, 390 may have a guide surface that transitions into (eg, dovetailed) slots 700, 700' to facilitate placement of the heating element tabs 260, 260' therein. Thus, the grooves 700, 700' further facilitate the automated manufacturing of the electronic vaping device.

FIG. 7 is a graph illustrating aerosol output and battery discharge of an electronic vaping device comprising a vaporizer comprising a bent heating element according to at least one exemplary embodiment.

The MarkTen XL electronic vaping device was compared with: (1) the first vaping device containing a MarkTen XL battery section, a cartridge such as shown in FIG. 5 and 6 and the heating element of FIG. 3A, 3B and 4 having a resistance of approximately 3.0 ohms; (2) a second vaping device containing a MarkTen XL battery section, a cartridge such as shown in FIG. 5 and 6 and the heating element of FIG. 3A, 3B and 4 having a resistance of approximately 3.5 ohms; and (3) a third vaping device containing a MarkTen XL battery section, a cartridge such as shown in FIG. 5 and 6 and the heating element of FIG. 3A, 3B and 4 having a resistance of approximately 3.5 ohms. The first, second and third vaping devices contained internal tubes with a diameter of 3.0 millimeters and the transfer material was made from an Essentra pad having a density of approximately 0.115 grams per cubic centimeter. The wick of the first vaping device was made of Ahlstrom Grade 181 wick material. The wicks of the second and third vaping devices were made of Sterlitech 934-AH wick material. Each of the four test cartridges was filled with the classic MarkTen XL formulation.

Each vaping device has been tested with a Mettler AE240 Balance weigher (used to weigh pads to determine the amount of aerosol collected), serial number GS9700, PM03715, Fluke 287 RMS Multimeter, Borgwaldt PV 10 RTD Machine to measure resistance to draw and smoking machine Borgwaldt Single Port Smoking Machine. The Single Port Smoking Machine was set to a puff duration of 4 seconds and a puff volume of 55cc. cm and a delay between puffs of 26 seconds. There were 10 puffs per measurement and the cartridges were oriented to ensure complete saturation of the wicks. The batteries of each device were fully charged prior to testing.

As shown in FIG. 7, MarkTen XL provides a substantially stable aerosol mass during initial puffs and a battery life of at least about 150 puffs. By comparison, a vaping device containing a 3.0 ohm heating element delivered higher aerosol mass during initial puffs, but less battery life than the MarkTen XL. Vaping devices containing a heating element with a resistance of approximately 3.5 ohms delivered a higher aerosol mass than the MarkTen XL while still providing a battery life in excess of 150 puffs.

FIG. 8 shows a heating element made by etching in a sheet of material according to at least one exemplary embodiment.

In at least one exemplary embodiment, the heating element may be made by etching using a photochemical etching and cleaning process. The photochemical etching process can be carried out in an electrolytic bath containing a mixture of dilute inorganic acids.

In at least one exemplary embodiment, the photochemical etching and cleaning process may include cleaning the surfaces of the material using alcohol. A dry photoresist film can be applied to the surface of the material by layering at a temperature of approximately 80 degrees Celsius. The dry film coated starting material can be exposed through the vacuum contact plate with UV light. The plate can be developed with a solvent solution in a processor. The plate is then cleaned of material and solvent residues. The raw material plate can then be etched in an etching machine using an acidic solvent containing ferric chloride with other additives. Remove the photoresist material using a basic solvent such as sodium carbonate, wash the plate with water, dry and quality control.

In at least one exemplary embodiment shown in FIG. 8, the heating element 85 is the same as in FIG. 3A, 3B and 4, however, the ends 260, 260' are generally square and extend in such a way that when the heating element 85 is bent, the ends 260, 260' are located along the bent portion 295.

FIG. 9 shows a heating element in an unbent state according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 9, the heating element 85 is the same as the heating element 3A, 3B and 4, however this heating element has ends 260, 260' and additional ends 262, 262'. The addition of ends 262, 262' allows a more reliable electrical connection to the heating element 85.

The cartridge may include additional electrical leads and/or slots (shown in FIG. 6) to accommodate additional ends 262, 262'.

FIG. 10 shows a heating element in an unbent state according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 10, the heating element 85 is the same as the heating element 3A, 3B and 4, however the ends 260, 260' extend from opposite sides of the bent section 295.

The cartridge may be configured to receive ends 260, 260' that are in different planes.

FIG. 11 is a side view of a heating element according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 11, the heating element 85 is the same as in FIG. 3A, 3B and 4, however, the first side 275 is at an angle to the second side 285 and the folded portion 295 contains one fold such that the folded heating element 85 is substantially V-shaped in side view. The first side 275 may be at an angle of from about 5 degrees to about 90 degrees to the second side 285 (for example, from about 10 degrees to about 80 degrees, from about 20 degrees to about 70 degrees, from about 30 degrees to about 60 degrees, or from approximately 40 degrees to approximately 50 degrees).

FIG. 12 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 12, the heating element 85 is the same as in FIG. 3A, 3B and 4, however, the ends 260, 260' extend from the first side 275 and are curved such that the ends 260, 260' are substantially perpendicular to the first side 275. In addition, the wick 90 may include one or more twisted portions that extend beyond the edges of the heating element 85.

FIG. 13 is a side view of a heating element according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 13, the heating element 85 is the same as in FIG. 3A, 3B, and 4, however, the first side 275 and the second side 285 may be inclined and/or bent so that the first side 275 is not parallel to the second side 285. The slanted and/or curved shape of the first side 275 and the second side 285 allows the thicker wick 90.

FIG. 14 is a front view of a heating element and a wick according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 14, the heating element 85 is the same as in FIG. 3A, 3B and 4, except that the wick 90 does not extend beyond the edges of the heating element 85.

FIG. 15 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 15, the heating element 85 is the same as in FIG. 3A, 3B, and 4, except that the wick 90 extends beyond the edges of the heating element 85.

IN FIG. 16 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

In at least one example of the embodiment shown in FIG. 16, the heating element and wick may be the same as in FIG. 3A and 5, except that the wick has an upper portion 1600 having an end surface 1610 that is approximately the same size and shape as the transfer material 350 such that the wick 90 can extend at least partially along the end surface of the transfer material. 350.

IN FIG. 17 is a side view of a heating element according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 17, the heating element 85 is the same as in FIG. 3A, 3B, and 4, except that the second side 285 of the heating element 85 is longer than the first side 275 of the heating element 85. In other exemplary embodiments (not shown), the first side 275 and/or the second side 285 may be concave. and/or convex.

FIG. 18 is a perspective view of a heating element and a wick according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 18, the heating element 85 is essentially the same as in FIG. 6, except that the tabs 260, 260' are adjacent to the bent portion 295, the first set of U-shaped segments 270 and the second set of U-shaped segments 280 extend in the direction of the tank (not shown), and the tabs 260, 260' along substantially parallel to the bent section 295. In addition, each of the tongues 260, 260' includes a through hole 1800. During manufacture, the tongues 260, 260' may be spot-welded to the pins 1820, 1820'. Holes 1800 provide a line of sight to facilitate spot welding during fabrication. Pin 1820 is electrically isolated from pin 1820' as shown and described in connection with FIG. 19.

Since the greatest amount of heat can be generated in the bent section 295, placing the bent section 295 as close as possible to the place where the air enters allows efficient movement of air flow and heat.

FIG. 19 is an exploded view of a cartridge according to at least one exemplary embodiment.

In at least one exemplary embodiment shown in FIG. 19, the cartridge is the same as the cartridge shown in FIG. 5 and 6, except that the tabs 260, 260' contact the pins 1820, 1820' and not the first and second connecting brackets 380, 390. As shown in the figure, the connecting piece 1900 includes a disc of insulating material 1910 , forming an air channel 1920 passing through it. The air channel 1920 is in fluid communication with the channel 370 in the transfer material 350. Two arcuate plates 1840, 1840' are mounted on the disk of insulating material 1920. Each plate 1840, 1840' contains one respective pin 1820, 1820' extending from the top surface of the respective plate 1840, 1840'. The pins 1820, 1820' pass through corresponding pin holes 1930, 1930' made in the disc of insulating material 1920.

In addition, the casing 30 may be integral with the inner tube 70 so that the need for a gasket is eliminated. The casing 30 and the inner tube 70 may be connected at a transverse end wall forming an outlet. An insert 35 at the mouth end may be provided around the end portion of the housing 30 so that the outlet in the end wall is in fluid communication with the outlets in the insert 35 at the mouth end.

While a number of exemplary embodiments are disclosed herein, it should be understood that other variations are possible. Such variations are not to be considered as departing from the spirit and scope of the present invention, and all such modifications, as will be apparent to those skilled in the art, are intended to be included within the scope of the following claims.

Claims (57)

1. A bent heater for an electronic vaping device, comprising: the first set of U-shaped segments located in the first direction and forming the first side of the heater; a second plurality of U-shaped segments located in the first direction and forming the second side of the heater, parallel to the first side; first output section; and the second output section, and the first set of U-shaped segments, the second set of U-shaped segments, the first output section and the second output section represent one integral element. 2. The bent heater according to claim 1, further comprising a third set of U-shaped segments, wherein at least one of the first set of U-shaped segments is connected to at least one of the second set of U-shaped segments using one of the third set U-shaped segments. 3. The bent heater according to claim 2, wherein each of the third plurality of U-shaped segments comprises a bent portion, the third plurality of U-shaped segments extending in a second direction that is perpendicular to the first direction. 4. The bent heater according to claim 3, wherein the bent portion has a width in the range of 0.5 millimeters to 2.0 millimeters. 5. The bent heater according to claim 3 or 4, wherein each of the first plurality of U-shaped segments, each of the second plurality of U-shaped segments, and each of the third plurality of U-shaped segments has at least one side and top. 6. The bent heater according to claim 5, wherein each of the vertices has at least one of the following: a rounded shape, a rectangular shape, a square shape, and a triangular shape. 7. A bent heater according to claim 5 or 6, in which the width of each of the vertices of the first set of U-shaped segments, the second set of U-shaped segments and the third set of U-shaped segments exceeds the width of each of the sides of at least one of the first set of U -shaped segments, a second set of U-shaped segments and a third set of U-shaped segments. 8. Bent heater according to any one of paragraphs. 5-7, in which the width of each of the vertices is in the range from 0.25 millimeters to 0.50 millimeters. 9. A bent heater according to claim 8, wherein the width of each side is in the range of 0.05 mm to 0.20 mm. 10. The bent heater according to claim 9, wherein each of the first outlet portion and the second outlet portion has a width that is greater than the width of a side. 11. The bent heater according to claim 10, wherein the width of the first outlet portion and the second outlet portion is in the range of 1.0 millimeters to 3.0 millimeters. 12. The bent heater according to claim 8, wherein the width of the top of at least one of the first plurality of U-shaped segments is the same as the width of the top of at least one of the second plurality of U-shaped segments. 13. A bent heater according to any one of the preceding claims, wherein the top of at least one of the first plurality of U-shaped segments is offset from the top of at least one of the second plurality of U-shaped segments. 14. A bent heater according to any one of the preceding claims, wherein the first plurality of U-shaped segments are spaced from the second plurality of U-shaped segments by a distance in the range of 0.5 millimeters to 2.0 millimeters. 15. A bent heater according to any one of the preceding claims, having a resistance in the range of 0.5 ohms to 5.0 ohms. 16. Bent heater according to any of the previous paragraphs, made of nichrome. 17. A bent heater according to any one of the preceding claims, having a thickness in the range of 0.05 millimeters to 0.50 millimeters. 18. A bent heater according to any one of the preceding claims, wherein the first plurality of U-shaped segments is in the first plane and the second plurality of U-shaped segments is in the second plane, and the second plane is different from the first plane. 19. A bent heater according to any of the preceding claims, wherein each of the first plurality of U-shaped segments and each of the first plurality of U-shaped segments comprises at least one side and a top, and the top has at least one of the following: a rounded shape , rectangular shape, square shape and triangular shape. 20. An electronic vaping device cartridge, comprising: a reservoir configured to store the pre-evaporator composition; a wick in fluid communication with the reservoir; and a curved heater partly surrounding the wick portion and comprising: - the first set of U-shaped segments located in the first direction and forming the first side of the heater, - a second set of U-shaped segments located in the first direction and forming the second side of the heater, parallel to the first side, - the first output section and - the second output section, and the first set of U-shaped segments, the second set of U-shaped segments, the first output section and the second output section represent one integral element. 21. The cartridge of claim 20, wherein the first plurality of U-shaped segments is in the first plane and the second plurality of U-shaped segments is in the second plane, the second plane being different from the first plane. 22. The cartridge according to claim 20 or 21, wherein at least one of the first plurality of U-shaped segments is connected to at least one of the second plurality of U-shaped segments using one of the third plurality of U-shaped segments, each of the third set of U-shaped segments contains a bent section. 23. An electronic vaping device, comprising: a reservoir configured to store the pre-evaporator composition; a wick in fluid communication with the reservoir; and a curved heater partly surrounding the wick portion and comprising: - the first set of U-shaped segments located in the first direction and forming the first side of the heater, - a second set of U-shaped segments located in the first direction and forming the second side of the heater, parallel to the first side, - the first output section and - the second output section, and the first set of U-shaped segments, the second set of U-shaped segments, the first output section and the second output section represent one integral element; and a power source configured to be electrically connected to the bent heater. 24. Bent heater, containing: a first plurality of U-shaped portions extending in a first direction such that said first plurality of U-shaped portions has U-shaped vertices located in different planes, and each of the row of the first plurality of U-shaped portions has a first leg and a second leg, wherein the first leg is connected to the second leg of the previous of the first set of U-shaped sections through one of the first set of U-shaped sections, and the second leg is connected to the next leg through one of the third set of U-shaped sections. 25. The bent heater according to claim 24, wherein each of the first plurality of U-shaped portions is in a different plane from the others. 26. A bent heater according to claim 24 or 25, in which each of the second set of sections is in the first plane, and each of the third set of sections is in a second plane different from the first plane, and the first plane and the second plane are perpendicular to each of the first set U-shaped sections. 27. A method for manufacturing a heating unit, in which: a heater is made from a sheet of metal, containing: - the first set of U-shaped segments located in the first direction and forming the first side of the heater, - a second set of U-shaped segments located in the first direction and forming the second side of the heater, parallel to the first side, - the first output section and - the second output section, and the first set of U-shaped segments, the second set of U-shaped segments, the first output section and the second output section represent one integral element; and bending the heater along straight sections between the first set of U-shaped segments and the second set of U-shaped segments so that the first set of U-shaped segments is parallel to the second set of U-shaped segments and located at a distance from it, with the formation of a bent heater. 28. The method according to claim 27, wherein additionally: placing a sheet of wick material inside the bent heater. 29. The method according to claim 27, wherein additionally: placing a sheet of wick material along straight sections before folding.

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