Example embodiments relate generally to a flavored mouth-end insert for an e-vaping device or add-on tip for a smokeable device, and/or a manufacturing method thereof.
Electronic vaping devices, or e-vaping devices, are used to vaporize a formulation in order for an adult vapor to draw the vapor through outlet(s) of the e-vaping device. An e-vaping device may typically include several e-vaping elements such as a power supply section and a cartridge. The power supply section includes a power source such as a battery, and the cartridge includes a heater along with a reservoir capable of holding the pre-vapor formulation in liquid form. The cartridge typically includes the heater which is in contact with a pre-vapor formulation via a wick, the pre-vapor formulation being stored in a storage container, the heater being configured to heat the pre-vapor formulation via the wick to produce a vapor. The pre-vapor formulation typically includes an amount of nicotine. The e-vaping device may also include a mouth-end insert designed to facilitate drawing of the vapor through outlet(s) of the e-vaping device by the adult e-vapor. For example, the pre-vapor formulation is a material or combination of materials that may be transformed into a vapor. For example, the pre-vapor formulation may include 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 glycerine and/or propylene glycol.
In other e-vaping devices, adding flavorants or aromas is typically performed by adding the flavorants or aromas to the storage container. However, if one or more flavorants or aromas adversely react with other ingredients of the pre-vapor formulation, degradation of the pre-vapor formulation, or degradation of the flavorants, taste compounds and aromas, may occur as a result.
With respect to smokeable devices such as, for example, cigars, it is typically challenging to add flavorants without adding the flavorants directly to the tobacco included in the cigar.
At least one example embodiment relates to a flavored mouth-end insert of an e-vaping device or of a smokeable device.
At least one example embodiment relates to a flavored add-on tip of a smokeable device.
In example embodiments, flavorants, taste compounds and/or aromas may be included in the fabricating process of a mouth-end insert and/or of an add-on tip. For example, flavorants, taste compounds and/or aromas may be inserted in the material used to form the mouth-end insert and/or the add-on tip. The mouth-end insert and/or the add-on tip may be manufactured by injection molding of a thermoplastic such as, for example, polypropylene (PP) or high density or low density polyethylene (PE). Accordingly, by adding an amount of flavorant and/or aromas to the thermoplastic and mixing the flavorants, taste compounds and/or aromas to the thermoplastic before the injection molding process, the flavorant and/or aromas may be incorporated in the resulting mouth-end insert and/or add-on tip. Thus, during operation of the e-vaping device by an adult e-vapor, the vapor consumed by the adult e-vapor, which passes first through the mouth-end insert and/or the add-on tip, may include an amount of flavorant and/or aroma, the flavorant and/or aroma being those incorporated during the fabricating process of the mouth-end insert or of the add-on tip. As a result, the adult e-vapor may experience an improved sensory experience.
In example embodiments, a temperature of the injection molding process may be, for example, about 150° C. and may typically not exceed, for example, about 350° C. When the temperature of the injection molding process exceeds 350° C., the thermoplastic polymer may undergo degradation, resulting in degraded properties of the thermoplastic polymer.
In example embodiments, the flavorant and/or aroma may be included at a concentration of up to about 2% by weight of the mixture of thermoplastic polymer used to manufacture the mouth-end insert and/or add-on tip, and may be configured to be resistant to the temperature of the injection molding process. For example, the flavorant and/or aroma may be encapsulated, or provided in granulated form in the mixture of thermoplastic polymer, in order to have a higher heat resistance.
Example flavorants may include flavors such as, for example, menthol, and the like. Example taste compounds may include, for example, sweet, sour, and the like. Various aromas providing various smells may also be added to the mixture of thermoplastic polymer.
In example embodiments, the flavorant, taste compounds and/or aromas are substantially homogeneously mixed with the thermoplastic polymer mixture prior to undergoing the injection molding process. Accordingly, as the conclusion of the injection molding process, the flavorant, taste compounds and/or aroma may be substantially homogeneously distributed within the resulting solid matrix of the thermoplastic polymer. With respect to aromas, the aromas may remain substantially homogeneously distributed in the solid thermoplastic polymer, even after multiple operations of the e-vaping device. With respect to the flavorants, although the flavorants are homogeneously distributed in the thermoplastic polymer at the conclusion of the injection molding process, during operation of the e-vaping device, the flavorants may tend to migrate towards the outer surface of the solid thermoplastic polymer.
During operation of the e-vaping device, the heated vapor generated in the chimney of the cartridge transits through the mouth-end insert and/or add-on tip before reaching the mouth of the adult e-vapor. Accordingly, because the mouth-end insert includes flavorant and/or aromas incorporated therein, the heated vapor transiting through the mouth-end insert before reaching the mouth of the adult e-vapor collects the flavors and/or aromas consistent with the flavorant and/or aromas incorporated in the thermoplastic polymer mouth-end insert and/or add-on tip during manufacture of the mouth-end insert and/or the add-on tip.
In example embodiments, if two different flavorants or aromas could not be mixed together in the pre-vapor formulation because of the potential occurrence of an adverse reaction between the different flavorants or aromas, the incorporation of the flavorants or aromas in the mouth-end insert and/or in the add-on tip, homogeneously distributed within the thermoplastic polymer matrix of the mouth-end insert and/or the add-on tip, provides the ability for the adult e-vapor, in the case of an e-vaping device, or to the adult smoker, in the case of a smokeable device, to taste two or more favors or aromas that could otherwise not be stably mixed together.
In example embodiments, the thermoplastic polymer used to form the mouth-end insert may include polypropylene (PP), high density or low density polyethylene (PE), or the like.
In example embodiments, the manufacturing method of a mouth-end insert including flavorants, taste compounds and/or aromas may minimize flavor loss, provide better control of delivery of flavor and/or taste to the adult e-vapor, in the case of an e-vaping device, or to the adult smoker, in the case of a smokeable device, and improve the sensory experience of the adult e-vapor.
The above and other features and advantages of example embodiments will become more apparent by describing in detail, example embodiments with reference to the attached drawings. The accompanying drawings are intended to depict example embodiments and should not be interpreted to limit the intended scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted.
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 embodiments set forth herein.
Accordingly, while example embodiments are capable of various modifications and alternative forms, 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, regions, layers and/or sections, these elements, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section discussed below could be termed a second element, 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 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 and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements 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. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of example embodiments.
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.
When the terms “about” or “substantially” are 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%.
As used herein, the term “vapor former” describes any suitable known compound or mixture of compounds that, in use, facilitates formation of a vapor and that is substantially resistant to thermal degradation at the operating temperature of the e-vaping device. Suitable vapor-formers consist of various compositions of polyhydric alcohols such as propylene glycol and/or glycerol or glycerin. In at least one embodiment, the vapor former is propylene glycol.
In example embodiments, the reservoir 14 may include a wrapping of gauze about an inner tube (not shown). For example, the reservoir 14 may be formed of or include an outer wrapping of gauze surrounding an inner wrapping of gauze. In at least one example embodiment, the reservoir 14 may be formed of or include an alumina ceramic in the form of loose particles, loose fibers, or woven or nonwoven fibers. Alternatively, the reservoir 14 may be formed of or include a cellulosic material such as cotton or gauze material, or a polymer material, such as polyethylene terephthalate, in the form of a bundle of loose fibers. A more detailed description of the reservoir 14 is provided below.
The second section 72 can house a power supply 12 and control circuitry 11 configured to control the power supply 12, and a puff sensor 16. The puff sensor 16 is configured to sense when an adult vapor is drawing on the e-vaping device 60, which triggers operation of the power supply 12 via the control circuitry 11 to heat the pre-vapor formulation housed in the reservoir 14, and thereby form a vapor. A threaded portion 74 of the second section 72 can be connected to a battery charger, when not connected to the first section or cartridge 70, to charge the battery or power supply section 12.
In example embodiments, the capillary tube 18 is formed of or includes a conductive material, and thus may be configured to be its own heater by passing current through the tube 18. The capillary tube 18 may be any electrically conductive material capable of being heated, for example resistively heated, while retaining the necessary structural integrity at the operating temperatures experienced by the capillary tube 18, and which is non-reactive with the pre-vapor formulation. Suitable materials for forming the capillary tube 18 are one or more of stainless steel, copper, copper alloys, porous ceramic materials coated with film resistive material, nickel-chromium alloys, and combinations thereof. For example, the capillary tube 18 is a stainless steel capillary tube 18 and serves as a heater via electrical leads 26 attached thereto for passage of direct or alternating current along a length of the capillary tube 18. Thus, the stainless steel capillary tube 18 is heated by, for example, resistance heating. Alternatively, the capillary tube 18 may be a non-metallic tube such as, for example, a glass tube. In such an embodiment, the capillary tube 18 also includes a conductive material such as, for example, stainless steel, nichrome or platinum wire, arranged along the glass tube and capable of being heated, for example resistively. When the conductive material arranged along the glass tube is heated, pre-vapor formulation present in the capillary tube 18 is heated to a temperature sufficient to at least partially volatilize pre-vapor formulation in the capillary tube 18.
In at least one embodiment, the electrical leads 26 are bonded to the metallic portion of the capillary tube 18. In at least one embodiment, one electrical lead 26 is coupled to a first, upstream portion 101 of the capillary tube 18 and a second electrical lead 26 is coupled to a downstream, end portion 102 of the capillary tube 18.
In operation, when an adult vapor draws on the e-vaping device, the puff sensor 16 detects a pressure gradient caused by the drawing of the adult vapor, and the control circuitry 11 controls heating of the pre-vapor formulation located in the reservoir 14 by providing power to the capillary tube 18. Once the capillary tube 18 is heated, the pre-vapor formulation contained within a heated portion of the capillary tube 18 is volatilized and emitted from the outlet 63, where the pre-vapor formulation expands and mixes with air and forms a vapor in mixing chamber 240.
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The power supply 12 of example embodiments can include a battery arranged in the second section 72 of the e-vaping device 60. The power supply 12 is configured to apply a voltage to volatilize the pre-vapor formulation housed in the reservoir 14.
In at least one embodiment, the electrical connection between the capillary tube 18 and the electrical leads 26 is substantially conductive and temperature resistant while the capillary tube 18 is substantially resistive so that heat generation occurs primarily along the capillary tube 18 and not at the contacts.
The power supply section or battery 12 may be rechargeable and include circuitry allowing the battery to be chargeable by an external charging device. In example embodiments, the circuitry, when charged, provides power for a given number of draws through outlets of the e-vaping device, after which the circuitry may have to be re-connected to an external charging device.
In at least one embodiment, the e-vaping device 60 may include control circuitry 11 which can be, for example, on a printed circuit board. The control circuitry 11 may also include a heater activation light 27 that is configured to glow when the device is activated. In at least one embodiment, the heater activation light 27 comprises at least one LED and is at a distal end 28 of the e-vaping device 60 so that the heater activation light 27 illuminates a cap which takes on the appearance of a burning coal during a puff. Moreover, the heater activation light 27 can be configured to be visible to the adult vapor. The light 27 may also be configured such that the adult vapor can activate and/or deactivate the light 27 when desired, such that the light 27 is not activated during vaping if desired.
In at least one embodiment, the e-vaping device 60 further includes a mouth-end insert 20 having at least two off-axis, diverging outlets 21 that are uniformly distributed around the mouth-end insert 20 so as to substantially uniformly distribute vapor in an adult vapor's mouth during operation of the e-vaping device. In at least one embodiment, the mouth-end insert 20 includes at least two diverging outlets 21 (e.g., 3 to 8 outlets or more). In at least one embodiment, the outlets 21 of the mouth-end insert 20 are located at ends of off-axis passages 23 and are angled outwardly in relation to the longitudinal direction of the e-vaping device 60 (e.g., divergently). As used herein, the term “off-axis” denotes an angle to the longitudinal direction of the e-vaping device.
In at least one embodiment, the e-vaping device 60 is about the same size as a tobacco-based product. In some embodiments, the e-vaping device 60 may be about 80 mm to about 110 mm long, for example about 80 mm to about 100 mm long and about 7 mm to about 10 mm in diameter.
The outer cylindrical housing 22 of the e-vaping device 60 may be formed of or include any suitable material or combination of materials. In at least one embodiment, the outer cylindrical housing 22 is formed at least partially of metal and is part of the electrical circuit connecting the control circuitry 11, the power supply 12 and the puff sensor 16.
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The e-vaping device 60 may include an air flow diverter comprising an impervious plug 30 at a downstream end 82 of the central air passage 24 in seal 15. In at least one example embodiment, the central air passage 24 is an axially extending central passage in seal 15, which seals the upstream end of the annulus between the outer and inner tubes 6, 65. The radial air channel 32 directing air from the central passage 20 outward toward the inner tube 65. In operation, when an adult vapor draws through outlets of the e-vaping device, the puff sensor 16 detects a pressure gradient caused by the drawing of the adult vapor through outlets of the e-vaping device, and as a result the control circuitry 11 controls heating of the pre-vapor formulation located in the reservoir 14 by providing power the heater 19.
In various example embodiments, a mouth-end insert similar to or the same as the mouth-end insert 20 discussed above, may be provided at an end of a smokeable device such as, for example, a cigar. In this case, flavorants present in the mouth-end insert may be transported to the adult smoker, and the adult smoker may taste various flavors when smoking the smokeable device.
In S120, the flavorants, taste compounds and/or aromas are mixed with the thermoplastic polymer prior to the mouth-end insert or add-on tip fabricating process. In example embodiments, the flavorants, taste compounds and/or aromas are homogeneously mixed with the thermoplastic polymer. In example embodiments, the flavorant and/or aroma may be included at a concentration from about 0.05% to about 5%, from about 1.0% to about 3%, or from about 1.0% to about 2%, by weight of the mixture. In example embodiments, the flavorants, taste compounds and/or aromas are provided in liquid form or in the form of particles, granules, or encapsulated, and are configured to withstand the manufacturing temperature of the mouth-end insert without losing substantially any of the flavor, taste and/or aroma. When the flavorants, taste compounds and/or aromas are encapsulated, the capsules including the flavorants, taste compounds and/or aromas are of a material that is also configured to withstand the manufacturing temperatures of the mouth-end insert and/or the add-on tip. For example, the capsules are configured to withstand temperatures of up to about 350° C. without undergoing physical or chemical degradation to a point where the capsules are no longer able to hold the flavorants, taste compounds and/or aromas.
In S130, the mouth-end insert or add-on tip fabricating process is performed. In example embodiments, the fabricating process may be an injection molding process, or may be another process capable of solidifying the mixture of thermoplastic polymer and flavorants, taste compounds and/or aromas. Accordingly, the entirety of the mixture of flavorants, taste compounds and/or aromas with the thermoplastic polymer is subjected to the injection molding process. As a result of the injection molding process, a mouth-end insert and/or add-on tip that includes particles of flavorants, taste compounds and/or aromas homogeneously distributed within the matrix of the mouth-end insert or add-on tip is produced. For example, a flavorant may impart a menthol flavor to the vapor when the vapor passes through the mouth-end insert or the add-on tip on the way to the mouth of the adult e-vapor. In example embodiments, an aroma may impart a sweet or sour taste to the vapor. In example embodiments, fillers may also be added to the mixture prior to undergoing the fabricating process. For example, the fillers may hold the liquid flavors within the polymer matrix after the injection molding process.
In
During operation of the e-vaping device, as the vapor passes through the mixing chamber 240 and the outlets 21 to the mouth of an adult e-vapor, the vapor collects one or more flavors from the flavorants embedded in the solid polymer matrix of the mouth-end insert 20 or add-on tip 25. As a result, if one or more flavorants typically adversely react with each other or with other ingredients of the pre-vapor formulation, degradation of the pre-vapor formulation, or degradation of the flavorants, may be substantially avoided or reduced. As a result, the adult e-vapor is able to taste a combination of flavorants that would otherwise not be available due to the adverse reactions of the various flavorants with each other or with other ingredients of the pre-vapor formulation.
Example embodiments having thus been described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the intended spirit and scope of example embodiments, and all modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.