Patent Application
20220183355
The present invention relates generally to micro-vaporizers and, more particularly, to a vaporizer cartridge having a liquid reservoir and heating element that can be used in conjunction with a reusable vaporizer power and control unit.
Liquid vaporizing devices (referred to herein as vaporizers or micro-vaporizers) are devices in which a vaporizable liquid is drawn from a storage reservoir into a chamber where it is heated to vaporization temperature by a heating element. The vaporized liquid is then drawn or forced from the chamber. In products such as electronic cigarettes (also known as e-cigarettes or personal vaporizers), the vaporized liquid is drawn from the chamber through a mouthpiece and inhaled by the user. In other products the vaporized liquid is dispersed into the atmosphere.
Conventional micro-vaporizers use a wick to draw vaporizable liquid from a reservoir into a vaporization chamber where the liquid is brought into close proximity with the heating element. The heating element itself typically includes a coiled heating wire that may be positioned near a surface of the wick or, in some cases, may be wrapped around a portion of the wick. Many conventional vaporizers provide for refilling of the reservoir upon exhaustion of the vaporizable liquid. Refilling, however, can easily result in spillage or contamination. To avoid this issue, some vaporizers have been designed to accept a disposable liquid cartridge. In such designs, the main vaporizer body retains reusable components such as the mouthpiece, air and vapor product flow ducts, heating element and vaporization chamber, and, typically, the power source, which may be separately replaceable.
An illustrative aspect of the invention provides a vaporizer cartridge comprising a cartridge case having a plurality of cartridge case walls defining a cartridge case interior. The cartridge case is sized and configured for mating with a cartridge receiver. The vaporizer cartridge further comprises a flow passage within the case interior extending from a cartridge air inlet to a mouthpiece exit port. The cartridge air inlet and the exit port are each formed through one of the plurality of cartridge case walls. The vaporizer cartridge also comprises a liquid reservoir configured for receiving a vaporizable liquid therein, a resistive heating element, and a liquid transport structure. The resistive heating element has a central heating portion that is in electrical communication with positive and negative electrical contact tabs and that is positioned within the case interior adjacent a portion of the flow passage. The positive and negative contact tabs each extend outside the cartridge case through one of the plurality of cartridge case walls. The positive and negative contact tabs are configured for engagement by complementary electrical contacts of the cartridge receiver when the cartridge case is mated to the cartridge receiver. The fluid transport structure is disposed within the case interior and has an intake surface in fluid communication with the liquid reservoir and an outflow surface adjacent or in contact with the heating element. The fluid transport structure is configured for transfer of the vaporizable liquid from the reservoir to the outflow surface.
Another illustrative aspect of the invention provides a vaporizer comprising a vaporizer cartridge and a cartridge receiver. The vaporizer cartridge comprises a cartridge case having a plurality of cartridge case walls defining a cartridge case interior. The cartridge case has spaced apart proximal and distal ends. A flow passage within the case interior extends from a cartridge air inlet at or adjacent the distal end and a mouthpiece exit port at or adjacent the proximal end. The vaporizer cartridge further comprises a liquid reservoir having a vaporizable liquid disposed therein, a resistive heating element, and a fluid transport structure. The resistive heating element has a central heating portion in electrical communication with positive and negative electrical contact tabs. The central heating portion is positioned within the case interior adjacent a portion of the flow passage. The positive and negative contact tabs each extend outside the cartridge case through one of the plurality of cartridge case walls. The fluid transport structure is disposed within the case interior and has an intake surface in fluid communication with the liquid reservoir and an outflow surface adjacent or in contact with the heating element. The fluid transport structure is configured for transfer of the vaporizable liquid from the liquid reservoir to the outflow surface. The cartridge receiver comprises a receiver case having a plurality of receiver case walls collectively defining a receiver case interior and a cartridge receiving cavity. the cartridge receiving cavity is separated from the receiver case interior by a cavity base wall and is configured for slidably receiving at least a distal portion of the cartridge case therein. Positive and negative receiver contacts are mounted to the base wall so that when the at least a distal portion of the cartridge case is fully received into the cartridge receiving cavity, the positive and negative receiver contacts each make physical and electrical contact with a respective one of the positive and negative contact tabs. The cartridge receiver also comprises a power source disposed within the receiver case interior and activation control circuitry. The activation control circuitry is in electrical communication with the power source and the receiver contacts and is configured for selectively connecting the power source to the receiver contacts, thereby energizing the resistive heating element when the at least a portion of the cartridge case is fully received into the cartridge receiving cavity.
The invention can be more fully understood by reading the following detailed description together with the accompanying drawing, in which like reference indicators are used to designate like elements, and in which:
Conventional micro-vaporizers have a reservoir from which vaporizable liquid is drawn (typically through the use of a wick) to a vaporization chamber. There the liquid is brought into close proximity with a heating element. The heating element and, generally, a portion of the wick are disposed within the vaporization chamber. When the heating element is activated, the liquid from the wick is vaporized/aerosolized. The resulting vaporization products and unvaporized liquid are mixed with air that is drawn from outside the device into the vaporization chamber. The mixture is then released from or drawn out of the device.
Embodiments of the present invention provide modular vaporizers that make use of disposable cartridges that include, not only a vaporizable liquid reservoir, but a heating element as well. Cartridges according to the invention may also include complete air and vapor product flow passages, including a vaporization/mixing chamber and an integrated mouthpiece. These cartridges are configured for mating with a reusable cartridge receiver that retains a power source and operational circuitry. When joined with a cartridge receiver, a reusable cartridge of the invention establishes electrical contact with the circuitry of the receiver so that the mated vaporizer system operates like a conventional vaporizer. Upon exhaustion of the liquid from the cartridge reservoir, the cartridge can be removed, discarded, and replaced with another cartridge.
As used herein, the terms proximal and distal are used to define relative locations along a longitudinal axis of the vaporizer system 1000, with proximal indicating a direction toward a user during inhalation use of the system 1000 and distal indicating a direction away from the user.
The features of the vaporizer system 1000 and, in particular, the vaporizer cartridge 100, will now be discussed in more detail. With reference to
The cartridge case 110 may be formed as a single integral structure or may be made up of multiple sub-structures. In particular embodiments, the cartridge case 110 may be formed as a single or multiple molded plastic structure or structures. In a particular embodiment, the cartridge case walls 111, 112, 115, 116, 118 are integrally formed as a single molded plastic body with the heating element 150 held within the molded structure.
The mouthpiece section 140 may be formed as an integral part of the main cartridge case 110 or may be formed as a separate structure that is permanently attached to the case structure by bonding or welding. The mouthpiece section defines an exit chamber 144 in fluid communication with an exit port 142 at the cartridge's proximal end 101. The exit chamber 144 is also in fluid communication with the flow passage 170 through the reservoir and heater sections 120, 130 so that inhalation at the exit port 142 produces flow potential across the inlet port 136 and the vaporization window 118.
The reservoir section 120 comprises the vaporization products portion 124 of the flow passage 170 and the reservoir space 122. The upper wall 111 serves to define the upper boundary of the reservoir 122. As best seen in
As best seen in
The liquid reservoir 122 may be configured as a simple tank in which vaporizable liquid may be disposed. In some embodiments, the reservoir 122 may have an adsorptive or absorptive material or structure disposed therein that retains the vaporizable liquid.
The heater section 130 is configured for retaining a thin plate heating element 150 adjacent the vaporization window 118 and for receiving a liquid transport structure 160 configured for transferring vaporizable liquid from the reservoir 122 to an area adjacent the heating element 150. The cartridge case 110 may be configured so that at least a portion of the cartridge heater section 130 is sized to allow it to be received into a receiving cavity of the cartridge receiver 200. In the illustrated embodiment, the upper wall 111 is configured so that the maximum vertical thickness of the heater section 130 is smaller than that of the reservoir section 120.
While any flat plate heating element may be usable in embodiments of the invention, in preferred embodiments, the heating element 150 has a central portion configured for heating vaporizable liquid at or adjacent an outflow surface of the fluid transport structure 160 and a peripheral portion that supports the central heating portion and connects the central heating portion to a power source. Heating elements of this type are disclosed in U.S. application Ser. No. 17/117,373, filed Dec. 10, 2020 and U.S. application Ser. No. 17/117,510, filed Dec. 10, 2020, the complete disclosures of which are incorporated herein by reference. The heating element 150 may be configured so that the only contact between the heating element 150 and the case structure 110 is through the peripheral portion of the heating element. This isolation of the central heating portion allows the use of case materials that would otherwise be unable to withstand the heat generated by the heating element 150.
Thin plate heating elements usable in the present invention may be manufactured from a single thin sheet of conductive material. Features of the heating element may be formed by cutting a pattern of channels through the material to provide a flow path for vaporizable liquid and vaporization products to flow through. This may be accomplished, for example, using any suitable cutting tool (e.g., a laser or water jet) or by punching or chemical etching.
The resulting thin plate heating element body 150 has a peripheral conduction portion made up of a positive support arm 151 and a negative support arm 152 and a central heating portion 153 positioned between the support arms 151, 152. The support arms 151, 152 have interior edges 158 facing inward toward one another and toward the central heating portion 153 and exterior lateral edges 159 facing outward. The interior edges 158 are parallel to one another and to a longitudinal axis 154. The positive support arm 151 includes a positive contact tab 171 and the negative support arm 152 includes a negative contact tab 172 extending in a longitudinal direction away from the central heating portion 153. As will be discussed the positive and negative contact tabs 171, 172 are configured to extend outside the cartridge 100 so as to establish electrical contact with corresponding elements of an electrical power circuit in the cartridge receiver 200.
In particular embodiments, the heating element 150 may have a plurality of peripheral support tabs 156 extending laterally outward from the exterior edges 159 of the support arms 151, 152. These tabs 156 may be sized and configured to engage surfaces or to be engaged by other structures in order to support and/or hold the heating element 150 in place within the case structure 110.
The central heating portion 153 of the heating element 150 is made up of an array of spaced apart but interconnected heating strips 169. These heating strips 169 are parallel to one another and to the longitudinal axis 154. In particular embodiments and as illustrated in
In particular embodiments, the central heating portion 153 includes central support tabs 161 extending longitudinally from the ends of the heating strips 169. As shown in the illustrated embodiment, the central support tabs 161 may extend from the ends 166 of the heating element loops 160. Each central support tab 161 may be T-shaped with a stem 167 and a rectangular head 168. The tabs 161 may be sized and configured to engage surfaces or to be engaged by other structures in order to support and/or hold the central heating portion 153 of the heating element 150 in place within the structure of a micro-vaporizer. While the illustrated embodiment has two tabs 161 for each loop 160, it will be understood that in other embodiments, some loops 160 may have a tab 161 at just one end or may have no tabs 161 at all.
The two lateral bridge strips 155 serve to electrically connect the central heating portion 153 to the positive and negative support arms 151, 152. Aside from the bridge strips 155, the central heating portion 153 is otherwise isolated from the supporting arms 151, 152, thereby minimizing heat conduction from the central heating portion 153 to the supporting arms 151, 152. The array of heating strips 169 of the central heating portion 153 may be sized and configured to produce a heating profile for heating the spaces on both sides of the heating element 150 and vaporizable liquid within these spaces and/or passing through the channels 181, 182, 183. The array of heating strips 169 in combination with the support arms 151, 152 may also be sized to produce a particular flow area for passage of liquid and vaporization products through the heating element 150. The combination may be further configured to provide a desired overall heating element electrical resistance (i.e., the resistance between the positive and negative contact tabs 171, 172). Suitable combinations may provide an overall heating element resistance in a range of 0.0010 ohm to 5.2000 ohms. In certain embodiments, suitable combinations have been structured to provide an overall resistance in a range of 0.0015 ohm to 3.00000 ohms, and in more particular embodiments, in a range of 0.3500 ohm to 0.8000 ohm. It will be understood that the specific configuration of the central heating portion 254 and/or thickness of the heating element 250 may be tailored (in some cases, along with the power source) to the vaporizable liquid. For example, some liquids such as those containing CBD, may need to be vaporized at a lower power to prevent scorching or burning.
As best shown in
It can be seen that the thin plate heating element 150 is positioned so that it is parallel to the direction of air flow into and through the vaporization/mixing section 138 of the flow passage 170 and so that it, in effect, provides a part of the boundary surrounding the vaporization/mixing section 138.
The thin plate heating element 150 is further positioned so that the positive and negative contact tabs 171, 172 extend outward through the distal case wall 114. As shown in
The receiving well 133 is sized and configured to receive a liquid transport structure 160 configured to transfer vaporizable liquid from the reservoir 122 to an area at or adjacent the upper surface of the flat plate heating element 150. As previously discussed, the internal case structure is configured to provide a reservoir passage 135 connecting the reservoir 122 and the receiving well 133. The reservoir passage 135 may be sized and configured to receive a portion of the liquid transport structure 160 so that an intake surface 162 of the liquid transport structure 160 will be in contact with liquid disposed within the reservoir 122. In some embodiments, the liquid transport structure 160 may be sized to extend through the passage 135 into the reservoir 122.
The liquid transport structure 160 is configured for drawing vaporizable liquid from the reservoir 122c through the upstream intake surface 162 into the structure 160 and transporting the liquid to the downstream outflow surface 164 where the liquid may be heated to vaporization by the heating element 150. The liquid transport structure 160 may be or comprise a wick or collection of wicking material. Typical personal vaporizer wicks are formed from organic fiber materials such as cotton, jute, flax, cellulose, or hemp. Some inorganic materials such as silica, carbon, and non-organic polymer fibers, ceramics and steel mesh may also be used. In general, vaporizer wicks can be formed from any material that is thermally stable and that provides sufficient wicking action to transport the vaporizable liquid from the reservoir to the heating element 150. The liquid transport structure 160 may also comprise a composite wick formed from a combination of wicking materials and active materials. The liquid transport structure may, in particular be or include any of the composite wicks disclosed in U.S. patent application Ser. No. 15/639,139, filed Jun. 30, 2017 (the “'139 Application”), the complete disclosure of which is incorporated herein by reference in its entirety. Composite wick materials may include woven or non-woven fibrous wicking materials in combination with embedded, trapped, adhered or alternately layered active additive materials. They are generally configured so that, in transport from the liquid reservoir, the vaporizable liquid must come into contact with the active additive materials. Portions of the active additive materials may be released into the fluid or may otherwise affect or impart desired characteristics to the liquid.
While the liquid transport structure 160 in the illustrated embodiment is configured as a rectangular block, it will be understood that other shapes may be used including cylinders, flat sheets or bent elongate elements. It will also be understood that the receiving well 133 may be shaped to receive and retain various shaped transport structures 160.
As used herein, the term “active material” refers to any material that controllably alters or adds to the vaporization products of the device. Depending on the application, active materials can include, without limitation, plant material, minerals, deodorizing agents, fragrances, insect repellants, medications, and disinfectants and any material or structure containing or incorporating any of the foregoing.
In the specific instance of personal vaporizers, active materials may include flavorant substances that augment the flavorant of the vaporizable liquid. These may include, without limitation, marijuana, hemp, cannabidiol (cbd), citronella, geraniol, mint, thyme, tobacco, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, lemon grass, cedar wood, clove, cinnamon, coumarin, helio, vanilla, menthol, eucalyptus, peppermint, rosemary, lavender, licorice, and cocoa and any material or structure containing or incorporating any of the foregoing.
The configuration of the heater section 130 provides for straight-forward final assembly of the cartridge 100. As shown in
As shown in
The vaporizer cartridge 100 is essentially a self-contained vaporizer device, lacking only the circuitry and power source for energizing the heating element 150. These elements are provided by mating the cartridge 100 with the cartridge receiver 200.
The cartridge receiver 200 has proximal and distal ends 201, 202 and a receiver case 210 having upper and lower receiver case walls 211, 212, side case walls 217, and proximal and distal end walls 218, 219. The receiver case 210 also has a middle case wall 213 and a cavity base wall 224 that, when combined with the outer case walls 211, 212, 217, 218, 219 define a case interior space 230.
The case interior space 230, which may have additional supporting structure disposed therein, is configured for disposition of a power source 250 and a control system circuit board 260 configured for selectively providing power to positive and negative electrodes 262 (only one shown) mounted to and through the cavity base wall 224. The electrodes 262 extend through the base wall 224 and terminate in positive and negative electrode contacts 264, respectively (only one shown). The electrodes 262 are sized and positioned so that the electrode contacts 264 line up with the positioning of the contact tabs 171, 172 of the flat plate heating element 150 when the cartridge 100 is mated with the receiver 200. The power source 250 may be any battery capable of providing the voltage necessary to produce the desired temperatures in the thin plate heating element 150.
A button switch 266 operatively connected to the control system circuit board 260 may be configured to allow the user to selectively energize the electrode power circuit. A spring-loaded and/or elastic button cover 267 may be positioned in line with the button switch 266 within an opening in the lower case wall 212. The button cover 267 may be further configured to seal the case wall opening to prevent contamination of the interior 230. The electrode power circuit may have, in addition to or instead of the button switch 266, an air pressure switch 270 in fluid communication with the cartridge cavity 220 (described below). The air pressure switch 270 may be configured to respond to application of a pressure differential (e.g., due to inhalation of a user at the exit port 142 of the cartridge 100 when mated to the receiver 200) to close the circuit to energize the electrodes 262. The use of this type of switch provides an automatic system that activates the vaporizer upon inhalation without additional action by the user.
The upper wall 211 cooperates with the side walls 217, middle wall 213, and cavity base wall 224 to define a cartridge receiving cavity 220 that is sized and configured to slidably receive some or all of the heater section 130 of the cartridge 100 therein. A receiver air inlet port 215 is formed through the upper case wall 211 into the cavity 220 adjacent the base wall 224. A pair of guide rail extensions 214 extend proximally from the proximal end 226 of the upper wall 211 and laterally inwardly from the side walls 217. The guide rail extensions 214 are configured to slidably engage the slide grooves 117 of the cartridge 100 to guide the cartridge 100 into position as shown in the sequence illustrated in
The cartridge case 110 and the receiver case 210 are configured so that in the fully mated, operational configuration of
In some embodiments, a cartridge retention arrangement may be used to keep the cartridge in the operational configuration shown in
In the fully mated configuration of
It will be understood that there may be many other configurations for the vaporizer components and air passageways. In some configurations, for example, there may be multiple air inlet ports through the receiver case leading into the cartridge receiving cavity. In other configurations, a mating passageway may be used to bypass the receiving cavity, connecting up directly to the cartridge air inlet. There may also be additional liquid flow passages and/or wicking structures to provide communication between the reservoir and the liquid transport structure.
It will be understood that the simplicity of the cartridge construction and internal features (e.g., low cost flat plate heating element and wick structures) make it possible to produce large numbers of cartridges at very low cost. Of particular advantage is use of a low cost flat plate heating element designed for use in conjunction with molded plastic retaining structure. This combination requires few or new additional materials for isolation of the heating element. In addition, the heating element can be configured with a low expected operational life-span that need only exceed the number of uses required to exhaust the liquid from the reservoir. This makes it practical for the cartridges to be removed, discarded, and replaced upon exhaustion of the liquid. Ultimately, the combined life cycle cost of the reusable cartridge receiver and cartridge replacements may be the same or lower than prior art refillable vaporizer systems with the added benefit of never needing to go through the hassle of refilling.
While the foregoing illustrates and describes exemplary embodiments of this invention, it is to be understood that the invention is not limited to the construction disclosed herein. The invention can be embodied in other specific forms without departing from the spirit or essential attributes.
