WO2023047313A1

WO2023047313A1 - Compressed cartomizer matrix for improved flavor delivery

Info

Publication number: WO2023047313A1
Application number: PCT/IB2022/058940
Authority: WO
Inventors: Timothy Wong
Original assignee: 2792684 Ontario Inc.
Priority date: 2021-09-22
Filing date: 2022-09-21
Publication date: 2023-03-30
Also published as: CA3232745A1

Abstract

During the consumption of an atomizable liquid stored in a cartomizer matrix, in a vaporizer pod, flavor drop off has been noted to occur. To avoid or diminish flavor drop-off, a region of higher cartomizer matrix density is created away from a wick in the pod. The wick is placed in contact with a lower density section of the cartomizer matrix, facilitating delivery of the atomizable liquid to the wick. The higher density segment of the matrix is sized to hold a volume of atomizable liquid and prevent the delivery of this liquid to the wick, so that the liquid associated with flavor drop off is held away from the wick, preventing or diminishing the user experience of flavor drop off.

Description

Compressed Cartomizer Matrix for Improved Flavor

Delivery

Cross Reference to Related Applications

[0001] This application claims the benefit of priority to US Patent Application Serial No. 17/482,243 filed on September 22, 2021 and entitled “Compressed Cartomizer Matrix for Improved Flavor Delivery”, the contents of which are incorporated herein by reference.

Technical Field

[0002] This application relates generally to a matrix for use in a cartomizer, and more particularly to a cartomizer under partial compression for use in conjunction with an electronic cigarette or vaporizer.

Background

[0003] Electronic cigarettes and vaporizers are well regarded tools in smoking cessation. In some instances, these devices are also referred to as an electronic nicotine delivery system (ENDS). A nicotine based liquid solution, commonly referred to as e-liquid, often paired with a flavoring, is atomized in the ENDS for inhalation by a user. In some embodiments, e-liquid is stored in a cartridge or pod, which is a removable assembly having a reservoir from which the e-liquid is drawn towards a heating element by capillary action through a wick. In many such ENDS, the pod is removable, disposable, and is sold pre-filled.

[0004] In some ENDS, a refillable tank is provided, and a user can purchase a vaporizable solution with which to fill the tank. This refillable tank is often not removable, and is not intended for replacement. A fillable tank allows the user to control the fill level as desired. Disposable pods are typically designed to carry a fixed amount of vaporizable liquid, and are intended for disposal after consumption of the e-liquid. The ENDS cartridges, unlike the aforementioned tanks, are not typically designed to be refilled. Each cartridge stores a predefined quantity of e-liquid, often in the range of 0.5 to 3ml. In ENDS systems, the e-liquid is typically composed of a combination of any of vegetable glycerine, propylene glycol, nicotine and flavorings. In systems designed for the delivery of other compounds, different compositions may be used. [0005] In the manufacturing of the disposable cartridge, different techniques are used for different cartridge designs. Typically, the cartridge has a wick that allows e-liquid to be drawn from the e-liquid reservoir to an atomization chamber. In the atomization chamber, a heating element in communication with the wick is heated to encourage aerosolization of the e-liquid. The aerosolized e-liquid can be drawn through a defined air flow passage towards a user’s mouth.

[0006] Figures 1A, IB and 1C provide front, side and bottom views of an exemplary pod 50. Pod 50 is composed of a reservoir 52 having an air flow passage 54, and an end cap assembly 56 that is used to seal an open end of the reservoir 52. End cap assembly has wick feed lines 58 which allow e-liquid stored in reservoir 52 to be provided to a wick (not shown in Figure 1). To ensure that e-liquid stored in reservoir 52 stays in the reservoir and does not seep or leak out, and to ensure that end cap assembly 56 remains in place after assembly, seals 60 can be used to ensure a more secure seating of the end cap assembly 56 in the reservoir 52. In the illustrated embodiment, seals 60 may be implemented through the use of o-rings.

[0007] As noted above, pod 50 includes a wick that is heated to atomize the e-liquid. To provide power to the wick heater, electrical contacts 62 are placed at the bottom of the pod 50. In the illustrated embodiment, the electrical contacts 62 are illustrated as circular. The particular shape of the electrical contacts 62 should be understood to not necessarily germane to the function of the pod 50.

[0008] Because an ENDS device is intended to allow a user to draw or inhale as part of the nicotine delivery path, an air inlet 64 is provided on the bottom of pod 50. Air inlet 64 allows air to flow into a pre-wick air path through end cap assembly 56. The air flow path extends through an atomization chamber and then through post wick air flow passage 54.

[0009] Sitting atop pod 52 is an optional mouthpiece 68, shown in Figures 1 A and IB in cross section to allow a reader to see the structure of pod 50 in better detail. Mouthpiece 68 may attach to the pod 50 through the use of a detente and protrusion, or it may make use of a further seal not shown in the drawing. Within mouthpiece 68 are a pair of apertures that are shown as being off center from a central vertical axis of the pod 50. These apertures allow for an airflow through the pod 50 to both entrain atomized e-liquid, and for delivery of this airflow to the user. Between the mouthpiece 68 and the top of the pod 50, is an absorbent pad 66, typically made of cotton, and often annular in shape. This pad 66 is often referred to as a spitback pad, and is designed to absorb any large droplets of e-liquid that it encounters. This pad 66 may also serve to absorb e-liquid that condenses within the post wick airflow path 54 between uses.

[0010] Figure 2 illustrates a cross section taken along line A in Figure IB. This cross section of the device is shown with a complete (non- sectioned) wick 66 and heater 68. End cap assembly 56 resiliently mounts to an end of air flow passage 54 in a manner that allows air inlet 64 to form a complete air path through pod 50. This connection allows airflow from air inlet 64 to connect to the post air flow path through passage 54 through atomization chamber 70. Within atomization chamber 70 is both wick 66 and heater 68. When power is applied to contacts 62, the temperature of the heater increases and allows for the volatilization of e-liquid that is drawn across wick 66.

[0011] Typically the heater 68 reaches temperatures well in excess of the vaporization temperature of the e-liquid. This allows for the rapid creation of a vapor bubble next to the heater 68. As power continues to be applied the vapor bubble increases in size, and reduces the thickness of the bubble wall. At the point at which the vapor pressure exceeds the surface tension the bubble will burst and release a mix of the vapor and the e-liquid that formed the wall of the bubble. The e-liquid is released in the form of aerosolized particles and droplets of varying sizes. These particles are drawn into the air flow and into post wick air flow passage 54 and towards the user.

[0012] Figure 3 illustrates an alternate design for a pod 50, having a reservoir 52 with a post wick airflow passage 54 and an end cap 56. In place of O-ring style seals, a resilient top cap 78 can be affixed to the end cap 56 to provide a friction fit within reservoir 52. Although no mouthpiece is illustrated, one could be affixed at what is illustrated as the bottom of the pod 50. End Cap 56 and resilient top cap 78 define wick feedlines 58 that allow e-liquid to make contact with the wick 72. Heater 74 is connected to electrical leads 62 to receive power so that e-liquid drawn across the wick 72 can be volatilized. Airflow can pass through pre-wick airflow passage 64 and enter into the atomization chamber 70, where atomized e-liquid can be entrained and carried towards the user through post wick air flow passage 54. Within the post wick airflow passage 54, and provided as a feature within the top silicone 78 is a vortex generator 76. Vortex generator 76 introduces turbulence into the airflow at the start of the post wick airflow passage 54 to encourage droplets above a threshold size to be directed into the wall of the post wick air flow passage 54. [0013] The above described pods make use of a reservoir designed to directly store e-liquid. To aid in the avoidance of leaks, seals are employed in addition to the design of an e-liquid that is sufficiently viscous to prevent leaks. This results in a slowed progression of e-liquid through the wick, which may result in reduced flavor generation during use. A less viscous e-liquid has traditionally been associated with increased flavor generation, but is also associated with increased difficulty in preventing leaks.

[0014] In place of a reservoir that directly stores e-liquid, a cartomizer can be described as a pod where the reservoir contains a matrix which is used to help in the storage and distribution of the e-liquid. There are a variety of different materials that can be used as the cartomizer matrix, each with a different set of benefits and detriments. In common implementations, the matrix can be implemented as a sponge, made of any number of different materials including cellulose, cotton, wool, hemp, linen, polymer-based materials such as nylon and other bulk materials, as a stack of woven sheets, or . In the example of the stack of woven sheets, cotton or other materials can be woven into cloth, the woven cloth can be cut to a desired size and shape, and then rolled, wrapped or otherwise shaped so that it can be placed within the cartomizer reservoir.

[0015] While there are a variety of different cartomizer fill materials, they all serve the same purpose, to provide a matrix to capture, hold and release e-liquid. In many cartomizers, the fill material provides a capillary structure within which the e-liquid is held and transported. [0016] Figure 4A illustrates a perspective view of a cartomizer pod 80 having a reservoir 82, a top 84 and a post wick airflow path 86. Cut line A will be used in a subsequent Figure. Figure 4B illustrates the base of cartomizer pod 80. The end cap 88 of the cartomizer pod 80 has an entrance to pre-wick airflow 90 and a pair of electrical contacts 92.

[0017] Figure 5 is a cross section view of cartomizer pod 80 taken along cut line Bin Figure 4A. Cartomizer pod 80 has a reservoir 82 defined by the sidewalls of the pod, along with the top wall 84. An open base is sealed by an end cap 88 having a pre-wick air flow passage 90 and electrical contacts 92. Within pod 80 is an air flow passage spanning from pre-wick airflow passage 90 to post wick air flow passage 86. Within this structure is situated a wick 96 in contact with a heater 94 that is connected to electrical contacts 92. A matrix 98 fills the reservoir defined within the pod 80. As noted above, this reservoir can be used to store e-liquid. Ends of the wick 96 are in fluid contact with the matrix 98. This allows e-liquid stored within the matrix 98 to be drawn across wick 96 so that it can be atomized through the heating of heater 94. Where in the previously illustrated pod 50, the e-liquid filled the reservoir 52 and was fed to the wick 72 using gravity, a less viscous e-liquid can be stored in matrix 98 and fed into wick 96 by capillary action. It should be understood that the capillary forces within matrix 98 are a function of both the matrix material, and the configuration of the void spaces between the matrix material. By ensuring that wick 96 has stronger capillary forces acting within it than the material within matrix 98, the wick 96 can be fed e-liquid without strict reliance upon a gravity feed system.

[0018] Because the cartomizer matrix 98 holds the e-liquid within pod 80, where the e-liquid was simply filling reservoir 52 in pod 50, a less viscous e-liquid formulation can be employed. This allows for the e-liquid to be more rapidly drawn across the wick, aiding in the generation of atomized e-liquid that can be entrained within an airflow through pod 80. Less viscous e-liquids are typically not relied upon in a pod without a cartomizer due to the propensity for leakage, which is reduced due to the presence of the cartomizer matrix.

[0019] Many cartomizers currently available are not in the format of a pod like cartomizer pod 80, but instead are provided within single-use e-cigarettes that are designed to be disposed of after use. In many of these devices, the limiting factor for the use of the device is the non-rechargeable battery. When the battery is exhausted, the device no longer functions and the user can dispose of it. In a replaceable pod device, such as a device using pod 80, the battery is typically re-chargeable, so the limiting factor in the lifespan of pod 80 is the e-liquid contained within it.

[0020] Figure 6 illustrates an alternate configuration of a cartomizer pod 80 of the existing art. Sidewall 82 and top wall 84, and post wick airflow path 86 define an internal reservoir. The internal reservoir is sealed through the insertion of end cap 88 which includes a pre-wick airflow path 90 and electrical contacts 94. Where the previously illustrated embodiments make use of a wick that is perpendicular to the axial orientation of the post wick airflow path 86, in the embodiment of Figure 6, wick 96 is inline with the pre-wick airflow path 90 and the post wick airflow path 86. In the illustrated embodiment, these features are all co-axial. Wick 96 has a hollow center that creates a vertical path through which an airflow can be drawn. Where in previous designs, the wick was surrounded by a heater, in this embodiment, the heater coil 90 is internal to the wick 96, so that it can help atomize e-liquids into the airflow passing through the middle of the wick 96 from pre-wick airflow passage 90 and on to post wick airflow passage 86. This configuration allows e-liquid to pass from the cartomizer matrix 98 into the wick 96 over a larger surface area. The location of the heater 94 inside the wick allows for the e-liquid to be atomized adjacent to the airflow within which it is to be entrained.

[0021] Many pod designs making use of a cartomizer matrix to store e-liquids are integrated within the vaping device. Because the pod is not replaceable, the device is treated as a disposable device, and in some devices, there is no mechanism to allow for recharging the battery. As such, the device is provided with enough e-liquid to exceed the ability of the battery to atomize e-liquid. One problem that has been observed relates to the delivery of flavor in the use of a vaping device using a cartomizer matrix. E-liquid is stored within the cartomizer matrix and drawn from the matrix across the wick towards the heater where it is atomized. It has been observed that there is a change in the flavor of the vapor produced by a vaping device over the life of the cartomizer. This phenomenon has been referred to as flavor drop off. Many users complain about the changing nature of the flavor in the generated vapor during the lifetime of a vaporizer using a cartomizer matrix. This is now a typical problem with a conventional pod that directly stores liquid within a reservoir. It should be understood by those skilled in the art that the role of a cartomizer matrix is to help store a less viscous e-liquid that would otherwise cause leakage if it were directly stored within a reservoir. [0022] It should be understood that the cartomizer matrix is able to hold the less viscous e-liquid within the reservoir through the use of capillary forces that hold the e-liquid within the interstitial spaces of the cartomizer matrix. However, it should also be understood that the e-liquid is not a homogeneous solution, and instead is a combination of components, as noted above. Some of these components may be dissolved within the e-liquid while others may be in suspension. Although all the mechanics of the flavor drop off are not yet clear, it is understood that it does not appear to be associated with a change in the flavorants (such as a denaturing of the flavorant compounds), and instead is associated with the volatile flavorants being consumed in greater quantities early in the life of the cartomizer. This may be associated with migration of flavorants through the e-liquid stored within the reservoir. Although e-liquid may be referred to as being trapped within pockets within the cartomizer matrix, components within the e-liquid can still migrate within the e-liquid, and the e-liquid itself may migrate but only when replaced by other e-liquid. This migration may allow flavorants to migrate into the wick more rapidly than other components of the e-liquid. This results in the flavorants being consumed more quickly than other e-liquid components. As this continues the flavoring of the e-liquid varies over time, and can result in a drop off in the concentration of flavorants in the e-liquid being atomized. As the amount of e-liquid left within the cartomizer matrix decreases, it becomes less flavored, which results in a bad user experience.

[0023] It would therefore be beneficial to have a mechanism to provide a mechanism for improving the consistency in flavor delivery of e-liquid to the wick within a vaporizing system.

Summary

[0024] It is an object of the aspects of the present invention to obviate or mitigate the problems of the above-discussed prior art.

[0025] In accordance with a first aspect of the present invention, there is provided a pod for storing an atomizable liquid. The pod has an airflow path defining a vertical axis, and a wick located within the pod. The pod comprises a cartomizer matrix having first and second sections. The cartomizer matrix is situated within the pod and stores the atomizable liquid for delivery to the wick. The first section of the cartomizer matrix stores the atomizable liquid with a first capillary force. It is aligned with a location of the wick within the pod. The second section of the cartomizer matrix stores the atomizable liquid with a second capillary force greater than the first capillary force, and is aligned to not overlap with the location of the wick within the pod.

[0026] In an embodiment of the first aspect, the second section of the cartomizer matrix has disjoint first and second parts located on opposite sides of the first section of the cartomizer matrix.

[0027] In another embodiment, the second section of the cartomizer matrix is made from the same material as the first section of the cartomizer matrix. Optionally, the second section of the cartomizer matrix is under greater radial compression than the first section of cartomizer matrix. In another embodiment, a compression member radially compresses the second section of the cartomizer matrix. In a further embodiment, the compression member is integrally formed within a sidewall of the pod. In another embodiment, the compression member is wrapped around the cartomizer matrix and applies a greater radial compression to the second section of the cartomizer matrix than to the first section of the cartomizer matrix. [0028] In another embodiment, the second section of the cartomizer matrix is made from a different material as the first section of the cartomizer matrix.

[0029] In a further embodiment, the ratio of the volume of the first section of the cartomizer matrix to the second section of the cartomizer matrix is a function of the capillary sizes within the first and second sections of the cartomizer matrix. Optionally, the ratio is also a function of the carrying capacity of the first and second sections with respect to the atomizable liquid. In another embodiment, the second section is sized to store a volume of e-liquid determined in accordance with a determined volume of atomizable liquid associated with flavor drop off.

[0030] In some embodiments, the atomizable liquid is an e-liquid comprising at least one of vegetable glycerine, propylene glycol, nicotine and a flavoring. In some embodiments, the atomizable liquid is an e-liquid containing a cannabinoid.

[0031] In an embodiment the cartomizer matrix comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials. Optionally, the cartomizer matrix comprises a woven sheet of at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials. In a further embodiment, the first and section sections of the cartomizer matrix comprise blown nylon filaments with different densities.

[0032] In another embodiment, the first section of the cartomizer matrix is comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials, and the second section of the cartomizer matrix is a different material than the first section of the cartomizer matrix.

Brief Description of the Drawings

[0033] Embodiments of the present invention will now be described in further detail by way of example only with reference to the accompanying figure in which:

Figure 1 A is a front view of a prior art pod for use in an electronic nicotine delivery system;

Figure IB is a side view of the pod of Figure 1A;

Figure 1C is a bottom view of the pod of Figure 1 A;

Figure 2 is a cross section of the pod of Figures 1 A and IB along cut line A in Figure IB;

Figure 3 is a cross section of an alternate pod design; Figure 4A is a perspective view of a cartomizer pod;

Figure 4B is a bottom view of the pod of Figure 4A;

Figure 5 is a cross section view of the cartomizer pod of Figure 4A along cut line B;

Figure 6 is a cross section view of an alternate configuration for the cartomizer pod of Figure 4A cut along cut line B showing the use of a vertical heater coil;;

Figure 7 is a cross section view of a pod according to an embodiment of the present invention;

Figure 8 is a magnification of the cartomizer matrix in sections 126 and 128 of Figure 7;

Figure 9A is a cross section view of a cartomizer matrix according to an alternate embodiment of the present invention;

Figure 9B is a cross section view of a pod with the cartomizer matrix of Figure 9A;

Figure 10 is a cross section view of a cartomizer pod according to an embodiment of the present invention;

Figure 11 is a cross section view of a cartomizer pod according to an embodiment of the present invention; and

Figure 12 is a cross section view of a cartomizer pod according to an embodiment of the present invention.

[0034] In the above described figures like elements have been described with like numbers where possible.

Detailed Description

[0035] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. Disclosure of numerical range should be understood to not be a reference to an absolute value unless otherwise indicated. Use of the terms about or substantively with regard to a number should be understood to be indicative of an acceptable variation of up to ±10% unless otherwise noted.

[0036] Although presented below in the context of use in an electronic nicotine delivery system such as an electronic cigarette (e-cig) or a vaporizer (vape) it should be understood that the scope of protection need not be limited to this space, and instead is delimited by the scope of the claims. Embodiments of the present invention are anticipated to be applicable in areas other than ENDS, including (but not limited to) other vaporizing applications. Furthermore, although discussions below specifically make reference to an e-liquid, it should be understood that other atomizable liquids can be used, including those carrying pharmaceutical compounds. Broadly speaking an e-liquid is typically composed of a combination of any of vegetable glycerine, propylene glycol, nicotine and flavorings. Other atomizable liquids may be used to carry compounds, such as cannabinoids, which may use different carriers. It should also be noted that although discussed in the context of a pod, it should be understood that a pod according to the disclosed embodiments does not necessarily have to be removable from the vaping device that it is associated with. Accordingly, a vaping device comprising a battery for storing electrical charge, a processor for regulating the application of charge to the pod, and the pod itself may be embodied as a single item, or the device and pod may be embodied as separate elements.

[0037] A cartomizer matrix for use in a vaping device is often formed from a material such as woven cotton, woven spun nylon, or a similar fabric structure, that is packed into a reservoir within the pod. In some embodiments, a woven material is rolled to create a cylindrical structure. This rolled cartomizer matrix is typically loaded with a wick assembly that includes a vertical airflow structure that provides both a post-wick airflow passage and an interface to a pre-wick airflow passage in the endcap. The amount of material used in the matrix is generally consistent from top to bottom, and is determined in accordance with an e-liquid storage capacity. The above referenced inconsistencies in the cartomizer matrix may be attributed to non-uniformities in the weave of the fabric among other factors. In other embodiments, a filament or thread, such as a nylon, can be heated and then blown into a mold so that it forms to a desired shape. Irregularities in the placement of filaments within the mold may result in small differences in the density of the cartomizer matrix.

[0038] The e-liquid is stored within interstitial spaces within the matrix, such as the spaces between the threads in the woven matrix, the spaces between adjacent woven sheets, and to a limited extent the spaces between filaments within the threads. In embodiments in which the cartomizer matrix is a result of blowing filament into a mold, the interstitial spaces are a function of the volume of filament blown into the mold. The e-liquid is held within these spaces as a result of capillary forces. As e-liquid is drawn out of the matrix, there is a general equalizing force caused by the capillary forces in other areas of the matrix. It has also been observed that sections of the matrix with smaller capillary sizes (either because of the design of the substrate forming the matrix, or because of compression of the capillary matrix) exert a stronger capillary force on the e-liquid than sections with larger capillary sizes. Thus, although sections of cartomizer matrix with larger capillary sizes can hold more e-liquid, they will effectively surrender this e-liquid to sections of the cartomizer matrix with smaller capillary sizes (assuming that the section with smaller capillary sizes is not at its e-liquid carrying capacity).

[0039] This preferential e-liquid storage phenomenon can be used to address the e-liquid flavor drop off. If, for example, it is believed that flavor drop off, resulting from rapid consumption of the flavorant, becomes a noticeable phenomenon in the last 15% of the life of the cartomizer matrix pod, cartomizer matrix sections with smaller capillary sizes can be employed to act as e-liquid traps to prevent use of the last 15-20% of the e-liquid. A pod containing a cartomizer matrix may be advertised as storing a defined volume of liquid, it can then be filled with more liquid than advertised to ensure that the advertised volume is available for consumption. The retention of the intentional excess e-liquid allows for the flavorless (or flavor-reduced) e-liquid to be retained so that the user is not subjected to the worst effects of the flavor drop off. Embodiments of pods designed to provide this function will now be discussed with reference to the figures.

[0040] Figure 7 is a cross section of a cartomizer based pod 100 which has a reservoir defined by sidewall 102 and top wall 104. Into this reservoir, cartomizer matrix 118 can be inserted, and the cartomizer matrix 118 can be sealed within the pod 100 through the insertion of end cap 108. End cap 108 includes electrical contacts 112 and a pre-wick airflow passage 110. Prior to insertion of cartomizer matrix 118 into the reservoir, an airflow channel and wick structure comprising wick 116, heater 114, ancillary wiring connecting heater 114 to electrodes 112 and an airflow passage linking pre-wick airflow passage 110 to the top of the pod and comprising post-wick airflow passage 106, is inserted into the cartomizer matrix 118. [0041] In the prior art, consistent compression of the matrix 118 in both radial and axial directions results in a matrix that has a generally consistent degree of compression, and thus a generally consistent interstitial spacing between the fibers within the weave of the cartomizer matrix 118. In the illustrated embodiment, controlled compression of the cartomizer matrix 118 is applied to create high compression sections 124 and low compression sections 120. It should be understood that the terms high and low compression are only applied in comparison to the other sections of the cartomizer matrix 118. Compression is controlled through the use of compression members 122 which effectively reduce the radius of the reservoir, causing increased compression of a cartomizer matrix 118 in the high compression sections.

[0042] As noted above, regions 124 in which the cartomizer matrix 118 is compressed demonstrate increased capillary force, and have a greater affinity for e-liquid storage. These compressed regions draw e-liquid to them with greater force than other areas, and are less likely to surrender their stored e-liquid to the regions 120 of the cartomizer matrix 118 that have lower capillary forces.

[0043] In Figure 7, a radially compressed region of the cartomizer matrix is formed through using a compression member implemented as bulge 122 in sidewall 102. By decreasing the radial space within the pod 100, bulge 122 creates a high compression section 124within a consistently sized cartomizer matrix 118. Regions 120 within the cartomizer matrix 118 where the compressive effects of bulge 122 are not present have reduced degree of compression in comparison to the region 124 adjacent to bulge 122. It should be understood that the bulge 122 may take the form of a ridge encircling pod 100, although in some embodiments this may differ. In the illustrated embodiment, a low compression region 120 is provided adjacent the wick 116 to allow for the e-liquid provided to the wick 116 to be preferentially drawn from this region. By ensuring that sufficient e-liquid is inserted into the cartomizer matrix to allow low compression region 120 to store approximately 80-85% of the e-liquid, it is possible to substantially sequester 15-20% of the e-liquid within the high compression sections 124. This allows the low compression section 120 to house enough e-liquid accessible to the wick 116 so that it will be exhausted of usable e-liquid before flavor drop off is observed by the user. Those skilled in the art will appreciate that if a different e-liquid composition, or different cartomizer matrix composition is used, the 15-20% vs 80-85% e-liquid ratios can be varied if flavor drop off occurs at a different point. Most importantly, it should be understood that bulge 122 acts as a compression member to provide radial compression to a region of the cartomizer matrix 118. The radial compression caused by a compression member is illustrated in Figure 8, with respect to two portions of the cartomizer matrix, portion 126 outside the radially compressed region and portion 128 which is inside the radially compression region.

[0044] In Figure 8, a magnification of callout 126 is illustrated to show one of the warp or the weft threads 130 in the first section 120 of cartomizer matrix 118. The interstitial space 132 illustrated in callout 126 is representative of the space between the threads in a given layer, and between the different layers of a woven material in a stackup of the cartomizer matrix 118. The e-liquid is typically carried within the interstitial spacing, and is subjected to capillary forces that are associated with the distance between the threads 130.

[0045] Callout 128, shows a magnification of the second section 124 of the cartomizer matrix 118 which is subject to radial compression as a result of the compression member embodied by bulge 122. The threads 134, and the interstitial space 132 are both subjected to radial compression 136 caused by the narrower diameter of the interior of pod 100 as a result of the bulge 122. This compression reduces both the lateral size of the threads 134 and the spacing 132 between them. This compression causes a reduction in the interstitial spacing 132, both the spacing between the threads 134 and the spacing between filaments within the threads 134. This compression may reduce the quantity of e-liquid held by the second section 122 of the cartomizer matrix 118, but it also increases the capillary forces at play within the cartomizer matrix 118. This increase in the capillary forces will reduce the likelihood of e-liquid being drawn away from the second section 122 by the first section 120 of cartomizer matrix 118. This will create a hydrodynamic system in which e-liquid stored in the first section 120 preferentially flows to the second section 124, where it can be drawn into wick 116

[0046] Figures 9A and 9B illustrate an embodiment of pod 100 that stores a first section 120 of the cartomizer matrix 118 under a lower compressive force than a second section 140 of the matrix 118. Where previous embodiments of the pod 100 used a compression member, in the embodiment of Figure 9B, a different configuration of the cartomizer matrix 118 is used, as illustrated in Figure 9A. Where in other embodiments, and in the prior art, a cartomizer matrix is generally uniform in cross section, the cross section of matrix 118 illustrated in Figure 9A has sections with differing widths. A first section 120 is less wide than each of the second sections 140. First section 120 can be adjusted in location to place it so that it will coincide with the placement of wick 116 within the assembled pod 100 as shown in Figure 9B. Second sections 140 are placed away from alignment with the wick so that they will sequester a quantity of e-liquid away from the wick 116. Because a larger quantity of the cartomizer matrix 118 is stored within the same width, second section 140 will be subject to higher radial compressive forces within pod 100. This greater compression will result in higher capillary forces within second sections 140, as demonstrated by the differences in callouts 126 and 128, which were previously shown in Figure 8. Although pod 100 in Figure 9B is not shown as having a compression member, it is possible for a cartomizer matrix 118 as shown in Figure 9Ato be used in conjunction with a compression member such as a bulge or ridge as previously shown.

[0047] Figure 10 illustrates a further embodiment of pod 100. Although structurally similar to the description of pod 100 in Figure 9, in the embodiment of Figure 10, pod 100 makes use of a cartomizer matrix 150 composed of different materials. To obtain the different capillary sizes required for the first and second sections, instead of a radial compression, pod 100 makes use of a cartomizer 150 that has a first section made of a first material 152 and second sections made of a second material 154. It should be understood that the first and second materials have different capillary sizes, even if made of the same underlying material. In one embodiment, material 152, corresponding to the first section, may be made of an absorbent nylon, while material 154, corresponding to the second section, may be made of a super absorbent nylon (or other super absorbent fiber). The different material structure provides for higher capillary forces in the second section without requiring compression of the matrix. In another embodiment, the two sections could be formed of first and second cellulose sponges, with the first cellulose sponge 152 having a larger pore structure than the second cellulose sponge 154. This will result in more e-liquid being stored in the first section, but the e-liquid stored in the second sections being more tightly held. It should be understood that using different underlying materials for the first and second materials has also been considered, so that a cartomizer matrix 150 made up of a first material 152 such as cotton and a second material 154 such as a cellulose based sponge with smaller capillaries could be used. The smaller capillaries in the second material 154, much like the compressed material in the above described embodiments, results in a greater capillary force that acts to hold the e-liquid. As a result, e-liquid within the first material 152 can be drawn into wick 116, while the e-liquid within the second material 154 may be available for flavorant migration, but will be otherwise substantially sequestered. Second material 154 will preferentially store e-liquid within the cartomizer matrix 150, and will allow the e-liquid within the first material 152 to be exhausted to aid in the pre-emption of flavor drop off.

[0048] In the above illustrations, a horizontally aligned wick is illustrated. Vertically oriented wicks allow for a replacement of some of the airflow path between the pre-wick airflow path and the post wick airflow path. This can provide for a large interface area between the wick and the cartomizer matrix, while minimizing the distance through the wick that the e-liquid has to traverse to before it is atomized so that it can be entrained within the airflow.

Conventional vertical wicks demonstrate some desirable user experience characteristics including a desirable flavor and vapor delivery with a sufficiently high power delivered to the heater, but often have poor wicking characteristics that can result in negative user experiences. The application of high power to the heater to generate the desired flavor can burn the wick if the wick has not been able to draw in enough e-liquid. Although this is a problem also faced by horizontal wicks, it may be more pronounced with vertical wicks due to the higher power required by their heaters.

[0049] Figure 11 illustrates a pod 160 making use of a vertical wick 176. Pod 160 has sidewalls 162 and a top wall 164, and defines a post wick airflow passage 166. The interior of pod 160 forms a reservoir. An end cap 168 having pre-wick airflow passage 170 and electrical contacts 172, is sized to seal the reservoir within pod 160 created by the sidewalls 162 and top wall 164. Connecting the prewick airflow passage 170 to the post wick airflow passage 166 is vertical wick 176. As with conventional vertical wicks, vertical wick 176 is illustrated as a hollow cylinder of wick material, such as cotton, with an open central column. The vertical wick 176 houses a heater 174 that is connected to electrical leads 172. The heater is at the interface of the vertical wick with its open central column. When activated, heater 174 will volatilize e-liquid drawn from cartomizer matrix 178 across wick 176.

[0050] Within pod 160, e-liquid will be preferentially drawn to the second section 180of cartomizer matrix 178, while the first cartomizer section 182 is used to hold a larger quantity of e-liquid under a lower capillary force. E-liquid is drawn from the first section 182 by wick 176 to replenish the wick 176 after each use. As e-liquid is consumed, there may be an exchange of liquid between the first cartomizer matrix section 182 and the second cartomizer matrix section 180. In such an exchange, the second cartomizer section matix 180 will tend to keep the same amount of e-liquid, so this exchange is not typically associated with replenishing e-liquid within the first cartomizer section 182. It should be noted however, that this exchange is typically, at least for the early part of the pod life, an exchange of fully flavored e-liquid from the second cartomizer matrix section for less flavored e-liquid from the first cartomizer section. Additionally, there may be a migration of flavorants within the e-liquid from high density locations within the second cartomizer matrix sections 182 to the less flavorant dense regions of e-liquid within the first cartomizer matrix section 180. As e-liquid is consumed, it is drawn largely from the first section 182 of the cartomizer matrix 178. The higher capillary forces within the second sections 180 will result in e-liquid being substantively sequestered within these sections of the cartomizer matrix 178 to allow for the pre-emption of flavor drop off.

[0051] Although Figure 11 illustrates the use of a compression member 184 to create the radial compression of the second section 182, it should be understood that the substantially similar effect could be accomplished through the use of a cartomizer matrix similar to matrix 118 shown in Figure 9B, with or without the use of the compression member 184 shown in Figure 11.

[0052] It should also be understood that while compression members, such as compression member 184, or bulge 122 are illustrated as features within the pod and attached to the interior of the sidewall, this is one of a number of different possible embodiments. In some other embodiments, an insert into the reservoir may be used to provide a compression member located to create radial compression of the cartomizer matrix in the area surrounding the interface between the wick and the cartomizer matrix. In other embodiments a compression member may take the form of a resilient band wrapped around a cartomizer matrix before insertion into the pod reservoir. This compression member could be made from a resilient material such as silicone, and could be used to create radial compression of the cartomizer matrix to surround the interface between the cartomizer matrix and the wick. In embodiments where the reservoir is not directly accessible to a user, for example, where the vaping device has an integral pod, the compression members may be external to the pod but applying a radial compression to sections of the pod. Other embodiments may use different techniques to create zones with different capillary forces.

[0053] Figure 12 illustrates a cross section of an alternate embodiment of pod 160 in which the cartomizer 186 is formed from sections with different capillary properties. Where the structure of the overall pod 160 is similar to that of the pod illustrated in Figure 11, vertical wick 176 engages with a cartomizer 186 made of a first section 188 surrounded by a second section 190.

[0054] To obtain the different capillary sizes required for the first and second sections, instead of a radial compression, pod 160 makes use of a cartomizer 186 that has a first section made of a first material 188 and a second section made of a second material 190. It should be understood that the first and second materials have different capillary sizes, even if made of the same underlying material. In one embodiment, material 188, corresponding to the first section, may be made of an absorbent nylon, while material 190, corresponding to the second section, may be made of a super absorbent nylon (or other super absorbent fiber). The different material structure provides for higher capillary forces in the second section without requiring compression of the matrix. In another embodiment, the two sections could be formed of first and second cellulose sponges, with the first cellulose sponge 188 having a larger pore structure than the second cellulose sponge 190. It should be understood that using different underlying materials for the first and second materials has also been considered, so that a cartomizer matrix 186 made up of a first material 188 such as cotton and a second material 190 such as a cellulose based sponge with smaller capillaries could be used. The smaller capillaries in the second material 190, much like the compressed material in the above described embodiments, results in a greater capillary force that acts to hold the e-liquid. As a result, e-liquid will be substantially sequestered within the second material 190 so that as e-liquid is drawn from the first material 188 into wick 176 a portion of the e-liquid is effectively sequestered. Second material 190 will preferentially store e-liquid within the cartomizer matrix 186, and will allow for substantial pre-emption of the flavor drop off by preventing the use of a portion of e-liquid stored within cartomizer matrix 186.

[0055] As shown above, the differing capillary forces can be achieved through the use of sections in which different capillary forces may be a result of differing sizes of pores or interstitial spaces. These differing pore sizes or sizing of interstitial spaces can be a result of material selection or it could be the result of a radial compression applied to one of the sections. As shown above, radial compression can be achieved through the use of a compression feature that is built into the internal reservoir of the pod, or it can be achieved through the use of a separate element. Those skilled in the art will appreciate that a cartomizer matrix of a non-uniform width could also be used in a pod either with or without a compression feature. The radial compression allows for defined boundaries between the first and second sections. A cartomizer matrix made of two materials can also make use of radial compression as described above, though it may not be strictly necessary based on the selection of the different cartomizer materials.

[0056] In embodiments using a cartomizer matrix formed through a process of blowing threads, filaments or fibers into a mold, regions of different density may be produced through blowing more or less of the material into the mold in a given time interval, or through the use of differential heating of the material as it is being blown into the mold. This may allow for the creation of a matrix that has smaller interstitial spaces in some areas, and larger interstitial spaces in other areas. In such an embodiment, the pod 160 shown in Figure 12 can be integrally formed with different cartomizer sections having different capillary forces within the sections.

[0057] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. The sizes and dimensions provided in the drawings are provided for exemplary purposes and should not be considered limiting of the scope of the invention, which is defined solely in the claims.

Claims

1. A pod for storing an atomizable liquid, the pod having an airflow path defining a vertical axis, and a wick located within the pod, the pod comprising: a cartomizer matrix within the pod for storing the atomizable liquid for delivery to the wick, the cartomizer matrix comprising: a first section of the cartomizer matrix, for storing the atomizable liquid with a first capillary force, the first section aligned with a location of the wick within the pod; and a second section of the cartomizer matrix, for storing the atomizable liquid with a second capillary force greater than the first capillary force, the second section aligned to not overlap with the location of the wick within the pod.

2. The pod of claim 1 wherein the second section of the cartomizer matrix has disjoint first and second parts located on opposite sides of the first section of the cartomizer matrix.

3. The pod of any one of claims 1 and 2 wherein the second section of the cartomizer matrix is made from the same material as the first section of the cartomizer matrix.

4. The pod of claim 3 wherein the second section of the cartomizer matrix is under greater radial compression than the first section of cartomizer matrix.

5. The pod of claim 4 wherein a compression member radially compresses the second section of the cartomizer matrix.

6. The pod of claim 5 wherein the compression member is integrally formed within a sidewall of the pod.

7. The pod of any one of claims 5 and 6 wherein the compression member is wrapped around the cartomizer matrix and applies a greater radial compression to the second section of the cartomizer matrix than to the first section of the cartomizer matrix.

8. The pod of any one of claims 1 to 7 wherein the second section of the cartomizer matrix is made from a different material as the first section of the cartomizer matrix.

9. The pod of any one of claims 1 to 8 wherein the ratio of the volume of the first section of the cartomizer matrix to the second section of the cartomizer matrix is a function of the capillary sizes within the first and second sections of the cartomizer matrix.

10. The pod of claim 9 wherein the ratio is also a function of the carrying capacity of the first and second sections with respect to the atomizable liquid.

11. The pod of claim 10 wherein the second section is sized to store a volume of atomizable liquid determined in accordance with a determined volume of atomizable liquid associated with flavor drop off.

11. The pod of any one of claims 1 to 10 wherein the atomizable liquid is an e-liquid comprising at least one of vegetable glycerine, propylene glycol, nicotine and a flavoring.

12. The pod of any one of claims 1 to 11 wherein the atomizable liquid is an e-liquid containing a cannabinoid.

13. The pod of any one of claims 1 to 12 wherein the cartomizer matrix comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.

14. The pod of claim 13 wherein the cartomizer matrix comprises a woven sheet of at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials.

15. The pod of any one of claims 1 to 14 wherein the first and section sections of the cartomizer matrix comprise blown nylon filaments with different densities.

16. The pod of any one of claims 1 to 15 wherein the first section of the cartomizer matrix is comprises at least one of cellulose, cotton, wool, hemp, linen, nylon and other polymer based materials, and the second section of the cartomizer matrix is a different material than the first section of the cartomizer matrix.