1. Field
The present disclosure relates to an electronic vaping device and a method of forming an electronic vaping device that produces a vapor having two distinct particle size distributions.
2. Description of Related Art
An electronic vaping device includes a heater element, which vaporizes a pre-vapor formulation to produce a vapor. The heater element may include a resistive heater coil, with a wick extending there through.
At least one example embodiment relates to a cartridge of an electronic vaping device.
In at least one example embodiment, a cartridge of an electronic vaping device includes an outer tube extending in a longitudinal direction, an inner tube within the outer tube, the inner tube including a flow constriction along a portion of a length of the inner tube, a reservoir containing a pre-vapor formulation, a wick in communication with the reservoir, and a heater in communication with the wick. The heater is configured to heat the pre-vapor formulation to a temperature sufficient to form a vapor. The flow constriction is configured to reduce a temperature of the vapor, and the flow constriction positioned about 1 mm to about 5 mm from the heater.
In at least one example embodiment, the flow constriction comprises an insert friction fit in the inner tube. The insert is formed of at least one of a metal, an alloy, a plastic, and a thermoplastic. The material is at least one of polypropylene, polyetheretherketone (PEEK), ceramic, fiberglass, and polyethylene.
In at least one example embodiment, the cartridge also includes a mouth-end insert including four outlets. Each of the four outlets is at an end of an off-axis passage and each off-axis passage extending generally perpendicularly to adjacent off-axis passages. The inner tube has an inner diameter ranging from about 3 mm to about 4 mm. The flow constriction has an inner diameter ranging from about 1 mm to about 2.5 mm. The flow constriction has a length ranging from about 3 mm to about 8 mm.
In at least one example embodiment, a cartridge of an electronic vaping device includes an outer tube extending in a longitudinal direction, an inner tube within the outer tube, a reservoir comprising a pre-vapor formulation, a wick in communication with the reservoir, a heater in communication with the wick, the heater configured to heat the pre-vapor formulation, and a mouth-end insert. The mouth-end insert includes a first outlet at an end of a first off-axis passage, and a second outlet at an end of a second off-axis passage. The first off-axis passage and the second off-axis passage each have a central axis extending from an inlet to the outlet, and the first off-axis passage and the second off-axis passage extend tangentially to a circumference surrounding a central, longitudinally extending axis of the electronic vaping device.
In at least one example embodiment, the mouth-end insert includes four outlets, each of the four outlets being at an end of an off-axis passage.
In at least one example embodiment, A cartridge of an electronic vaping device includes an outer tube extending in a longitudinal direction, an inner tube within the outer tube, the inner tube including a flow constriction along a portion of a length of the inner tube, a reservoir comprising a pre-vapor formulation, a wick in communication with the reservoir, a heater in communication with the wick, the heater configured to heat the pre-vapor formulation to form a vapor, and a mouth-end insert. The mouth-end insert includes four outlets. Each of the four outlets is at an end of one of four off-axis passages. The four off-axis passages each have a central axis extending from an inlet to the outlet, and the four off-axis passages each extend tangentially to a circumference surrounding a central, longitudinally extending axis of the electronic vaping device. The flow constriction is between the mouth-end insert and the heater.
In at least one example embodiment, the flow constriction is an insert friction fit in the inner tube. The insert is formed of at least one of a metal, an alloy, a plastic, and a thermoplastic. The material is at least one of polypropylene, polyetheretherketone (PEEK), ceramic, fiberglass, and polyethylene. The flow constriction is about 1 mm to about 5 mm from the heater. The flow constriction has an inner diameter ranging from about 1 mm to about 2.5 mm. The flow constriction has a length ranging from about 3 mm to about 8 mm.
The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated.
Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.
It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
At least one example embodiment is related to an electronic vaping device, which may include at least one of mouth-end insert and a flow constriction. The flow constriction may be between a heater and the mouth-end insert. The mouth-end insert may include two or more holes that are rotationally and radially angled so as to distribute vapor in a diverging and swirling pattern as the vapor exits the electronic vaping device. Moreover, the diverging and swirling pattern reduces vapor temperature before exiting the electronic vaping device. The flow constriction downstream of the heater may reduce vapor temperature before exiting the electronic vaping device.
In at least one example embodiment, the electronic vaping device produces a vapor upon heating a pre-vapor formulation.
In at least one example embodiment, the pre-vapor formulation may be a material or combination of materials that may be transformed into a vapor. For example, the pre-vapor formulation may be a liquid, solid and/or gel formulation including, but not limited to, water, beads, solvents, active ingredients, ethanol, plant extracts, natural or artificial flavors, and/or vapor formers, such as glycerin and propylene glycol.
As shown in
In at least one example embodiment, as shown in
A nose portion 393 of a second gasket 310 is fitted into a second end portion 381 of the inner tube 362. An outer perimeter 382 of the second gasket 310 provides a seal with an interior surface 397 of the outer housing 22. The second gasket 310 includes a central channel 384 disposed between the central passage 321 of the inner tube 362 and the mouth-end insert 20.
In at least one example embodiment, the reservoir 314 is contained in an annulus between the inner tube 362 and the outer housing 22 and between the first gasket 320 and the second gasket 310. Thus, the reservoir 314 at least partially surrounds the central air passage 321. The reservoir 314 comprises a pre-vapor formulation and optionally a storage medium (not shown) configured to store the pre-vapor formulation therein.
In at least one example embodiment, the heater 319 extends through the central air passage 321 of the inner tube 362. The heater 319 is in contact with the filamentary wick 328, which extends between opposing sections of the reservoir 314 so as to deliver the pre-vapor formulation from the reservoir 314 to the heater 319. The electronic vaping device 60 may include at least one air inlet 440 arranged at the threaded joint 74 and/or between the threaded joint 74 and the heater 319.
In at least one example embodiment, the power supply 12 may include a battery arranged in the electronic vaping device 60. The power supply 12 is configured to apply voltage across the heater 319 associated with the filamentary wick 328. Thus, the heater 319 vaporizes the pre-vapor formulation according to a power cycle of a desired (or, alternatively a predetermined) time period, such as a 2 to 10 second period of time. The battery may be disposable or rechargeable.
In at least one example embodiment, the electronic vaping device 60 may include the control circuit 11, which may be on a printed circuit board. The control circuit 11 may also include a heater activation light 27 that is configured to glow when the heater 319 is activated. An end cap 45 may be positioned at an end or along the housing 22 of the electronic vaping device 60.
In at least one example embodiment, the outer housing 22 of the electronic vaping device 60 may be formed of any suitable material or combination of materials. The outer housing 22 may be generally cylindrical and may be formed at least partially of metal. Although the housing 22 is described herein as cylindrical, other forms and shapes are contemplated.
In at least one example embodiment, as shown in
In at least one example embodiment, the outlets 21 are substantially uniformly distributed about the perimeter of mouth-end insert 20 so as to substantially uniformly distribute vapor during vaping and create a greater perception of fullness in the mouth. Thus, the vapor enters the mouth and moves in different directions so as to provide a full mouth feel.
In contrast, electronic vaping devices having a single, on-axis orifice tend to direct vapor as single jet of greater velocity toward a more concentrated location when exiting the electronic vaping device.
In at least one example embodiment, the off-axis passages 23 are angled at about 5° to about 60° with respect to the central, longitudinal axis of the outer housing 22 so as to more completely distribute vapor during vaping and to remove droplets. In at least one example embodiment, there are four off-axis passages 23, each at an angle of about 40° to about 50° with respect to the central, longitudinal axis of the outer housing 22, or about 40° to about 45°, or about 42°.
In at least one example embodiment, each of the off-axis passages 23, each inlet 3, and each outlet 21 has a diameter ranging from about 0.015 inch to about 0.090 inch (e.g., about 0.020 inch to about 0.040 inch or about 0.028 inch to about 0.038 inch). The size of the off-axis passages 23 and outlets 21 and the number of off-axis passages 23 and outlets 21 may be selected to adjust the resistance to draw (RTD) of the electronic vaping article 60, if desired.
In at least one example embodiment, the mouth-end insert 20 may be integrally affixed within the outer housing 22 of the first section 70. Moreover, the mouth-end insert 20 may be formed of a polymer, such as low-density polyethylene, high-density polyethylene, polypropylene, polyvinylchloride, polyetheretherketone (PEEK), and/or combinations of polymers. The mouth-end insert 20 may also be colored if desired.
In at least one example embodiment, the mouth-end insert 20 disperses and changes the direction of the vapor as it is drawn from the electronic vaping device 60 so as to provide a fuller mouth feel. As vapor is formed, it passes through the central channel 321 in the inner tube 362 and through the central channel 384 in the second gasket 310. In at least one example embodiment, the inner tube 362 has an inner diameter ranging from about 3 mm to about 4 mm, or about 3.5 mm.
In at least one example embodiment, as shown in
In at least one example embodiment, as shown in
In at least one example embodiment, the flow constriction 445 and/or the inner tube 362 may be formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK), ceramic, fiberglass, and polyethylene. The material is light and non-brittle.
In at least one example embodiment, when included, the flow constriction 445 is about 3 mm to about 8 mm in length, or about 3 mm to about 7 mm (e.g., about 4 mm to about 6 mm). The flow constriction 445 may be positioned about 1 mm to about 5 mm from the heater (e.g., about 1 mm to about 3 mm or about 2 mm to about 4 mm).
In at least one example embodiment, the flow constriction 445 may have an inner diameter of about 1 mm to about 2.5 mm, or about 2 mm. The inner diameter of the inner tube 362 adjacent the flow constriction 445 and along the remaining length of the inner tube 362 not including the flow constriction 445 may range from about 3 mm to about 4 mm, or about 3.5 mm.
In at least one example embodiment, the flow constriction 445 is about 1 mm to about 5 mm from the heater 319 (e.g., about 1.5 mm to about 4.5 mm, about 2 mm to about 4 mm, or about 2.5 mm to about 3.5 mm).
In at least one example embodiment, as shown in
In at least one example embodiment, as shown in
In at least one example embodiment, the mouth-end insert may include three holes instead of four, and the same relationships would apply: for each passage 23, the inlet 3 and outlet 21 would be mutually spaced along a tangent along a concentric arc “C” and the passages 23 would be equally spaced about the arc “C”, for example about 120° from one another.
In at least one example embodiment, as shown in
In at least one example embodiment, the off-axis passages 23 are arranged and include interior surfaces 2, such that droplets of unvaporized pre-vapor formulation, if any, that may be entrained in the vapor impact the interior surfaces 2 of the mouth-end insert 20. As a result, such droplets are substantially removed or broken apart so as to enhance the vapor.
In at least one example embodiment, as shown in
In at least one example embodiment, as shown in
In at least one example embodiment, the electronic vaping device 60 may include only the mouth-end insert 20, as described herein, or only the flow constriction 445.
In at least one example embodiment, both the mouth-end insert 20, as described herein, and the flow constriction 445 are effective to reduce the temperature of vapor before exiting the electronic vaping device 60 when included individually in the electronic vaping device 60. Moreover, when used in combination, the mouth-end insert 20 and the flow constriction 445 reduce the temperature of the vapor even more than when only the mouth-end insert 20 or only the flow constriction 445 is included in the electronic vaping device 60.
When the word “about” is used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value. Moreover, when reference is made to percentages in this specification, it is intended that those percentages are based on weight, i.e., weight percentages. The expression “up to” includes amounts of zero to the expressed upper limit and all values therebetween. When ranges are specified, the range includes all values therebetween such as increments of 0.1%.
Moreover, when the words “generally” and “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. When used with geometric terms, the words “generally” and “substantially” are intended to encompass not only features which meet the strict definitions but also features which fairly approximate the strict definitions.
It will now be apparent that a new, improved, and nonobvious electronic vaping device has been described in this specification with sufficient particularity as to be understood by one of ordinary skill in the art. Moreover, it will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for features of the electronic vaping device, which do not materially depart from the spirit and scope of the invention. Accordingly, it is expressly intended that all such modifications, variations, substitutions, and equivalents which fall within the spirit and scope of the invention as defined by the appended claims shall be embraced by the appended claims.
This application is a non-provisional application that claims priority to U.S. provisional app. No. 62/075,417, filed on Nov. 5, 2014, the entire contents of which is incorporated by reference in its entirety.
Number | Date | Country | |
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62075417 | Nov 2014 | US |