Abstract:
Handheld vaporizing devices with improved heating element and temperature controls, improved e-liquid reservoir, and capacitive technology to activate the heating element to prime the device to deliver aerosol on demand.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/001,972, entitled “E-Cigarette”, filed on May 22, 2014, fully incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to handheld vaporizing devices with improved heating element and temperature controls, improved e-liquid reservoir, and capacitive technology to activate the heating element to prime the device to deliver aerosol on demand. 
       BACKGROUND 
       [0003]    Traditional handheld vaporizing devices, also known as e-cigarettes, are battery-operated portable devices comprising a battery, an atomizer, and an e-liquid cartridge. Handheld vaporizing devices are designed to deliver nicotine by producing an aerosol as a result of vaporizing a liquid solution known as an e-liquid. E-liquids usually contain a mixture of propylene glycol, vegetable glycerin, nicotine, and flavorings, while others release a flavored vapor without nicotine. 
         [0004]    Traditional handheld vaporizing devices generally use a heating element known as an atomizer that vaporizes e-liquid to produce a nicotine aerosol for inhalation. An atomizer consists of a heating element responsible for vaporizing e-liquid and wicking material that draws the e-liquid from the cartridge. A heating element in the form of a resistance wire is coiled around the wicking material and is connected to a power source. The e-liquid is absorbed into the wicking material by capillary action. When the device is activated, the heating coil heats up and vaporizes the e-liquid that has been absorbed by the wicking material, creating the aerosol for inhalation. 
         [0005]    Some prior art handheld vaporizing devices use a cartomizer, which is a device consisting of an atomizer and a cartridge integrated into a single component that connects to a power source. Prior art atomizer or cartomizer heating elements do not accurately control the heating and vaporization process. Significant variation in the quality and consistency of the wrapping of the heating wire around the wicking material, the differences in the electrical resistance of the wire, and the differences in the efficiency and absorption characteristics of the wicking material greatly affect the quantity or volume of the aerosol and the perceived quality of the aerosol that will be produced by the atomizer. Lack of temperature control may result in uneven heating and overheating of the heating element, which in turn may result in creation of hazardous chemicals in the vapor. For example, overheating of the e-liquid may result in creation of formaldehyde, inhalation of which is hazardous to the user&#39;s health. 
         [0006]    In prior art handheld vaporizing devices, a user needed to inhale air through the device to activate the heating elements of the device in order to vaporize the e-liquid. It may take a user several puffs on the prior art device before it will generate sufficient vapor, resulting in inefficiency and inconvenience to the user. 
         [0007]    The present invention is directed to overcome the drawbacks of the prior art by providing a novel handheld vaporizing devices incorporating an electroconductive textile heating element, e-liquid reservoir made of elastically deformable materials, and improved temperature and heating control system including an auto-on feature to prime the device to deliver aerosol on demand by activating the heating element upon sensing the user&#39;s touch on the device, without waiting for the user to take the first inhale through the device. The electroconductive textile heating element according to the present invention replaces the prior art wick and coils atomization systems and draws e-liquid by capillary action, and allows more even and direct heating of the e-liquid than traditional wicking systems. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a top plan view of a handheld vaporizing device according to an embodiment of the present invention. 
           [0009]      FIG. 2  illustrates the operation of the heating and temperature control system according to an embodiment of the present invention. 
           [0010]      FIG. 3  illustrates the operation of the “auto-on” system according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    A handheld vaporizing device according to an embodiment of the present invention will now be described with reference to  FIGS. 1-3 . 
         [0012]      FIG. 1  illustrates a handheld vaporizing device  10  having a longitudinal axis and comprising a first and second longitudinal ends in oppositely-disposed first and second longitudinal directions. Handheld vaporizing device  10  comprises a mouth piece  200  and a main body  100 . Main body  100  defines an interior cavity  110 . A heating element  240 , a reservoir  250 , a power unit  260  comprising control circuitry  270  and power source  290 , and a power connect element  280  are sequentially provided inside cavity  110 . 
         [0013]    A mouth piece  200 , adapted to be held between the lips of a user, and having a first end  200   a  and a second end  200   b , is connected to the first longitudinal end of body  100 . In a preferred embodiment, mouth piece  200  is annular-shaped and comprises an inner shell of hard material such as, for example, metal or plastic, and an outer shell of soft pliable material such as, for example, foam, silicone or rubber, to mimic the feel of the filter of a conventional cigarette. Mouthpiece  200  may also include an anti-microbial agent coating to inhibit bacterial growth. Commercially available antimicrobial products such as, for example, Microban (http://www.microban.com/), or another comparable supplier, may be used according to methods known in the art. 
         [0014]    Opening  210  is provided at end  200   a  of the mouth piece  200  to allow the aerosol to be drawn out of device  10  and into the user&#39;s lungs when a user applies an inhale portion of the user&#39;s breath to mouth piece  200 . In a preferred embodiment, opening  210  has a generally circular cross section 1 mm to 1.5 cm in diameter. In other embodiments, opening  210  may have a square, triangular or any other geometric cross section shape. 
         [0015]    Opening  230  is provided at the opposite end  200   b  of the mouth piece  200  to allow the aerosol to enter the mouth piece  200  when the user inhales. In a preferred embodiment, opening  230  has a generally circular cross section 1 mm to 1.5 cm in diameter. In other embodiments, opening  230  may have a square, triangular or any other geometric cross section shape. 
         [0016]    Preferably, an air inlet check valve  220  is provided for opening and closing opening  230 . Air inlet check valve  220  may be a commercially available product from, for example, Smart Products, Inc., (http://www.smartproducts.com/check_valves_series — 100_cartridge.php), or another comparable supplier. In a preferred embodiment, a Series 100 Cartridge Check Valve (found at http://www.smartproducts.com/check_valves_series — 100_cartridge.php) may be used. 
         [0017]    Check valve  220  prevents environmental air from entering the interior of body  100  through openings  210  and  230  when device  10  is not in use, in order to prevent evaporation and oxidation of the e-liquid and to maintain e-liquid freshness. In addition, valve  220  prevents leakage of e-liquid out of the device, and keeps dust and dirt out of the device when carried in the user&#39;s pocket, bag, purse, etc. 
         [0018]    A power connect element  280  is disposed in the second, opposite longitudinal end of body  100 . In a preferred embodiment, the power connect element  280  comprises a Universal Serial Bus (USB) interface for insertedly connecting with an external power source, in order to allow the user to utilize universal chargers to charge device  10  without any adapters or chargers made especially for e-cigarettes. In other embodiments, the power connect element  280  may comprise a mini USB interface, a micro USB interface, or any other suitable communications bus known in the art. 
         [0019]    Cavity  110  includes a power element  260  electrically coupled to the power connect element  280 . Power element  260  comprises microprocessor control circuitry  270  and a power source  290 . According to an embodiment of the invention, the power source may be a lithium polymer battery. 
         [0020]    Cavity  110  includes an e-liquid reservoir  250 , which may be either refillable or disposable. Reservoir  250  may be made of elastically deformable materials such as polymers or metal/polymer composites known in the art. According to an embodiment of the invention, reservoir  250  may be made of polyester with aluminum printed exterior and may be at least 5 ml in volume. This material is inert and keeps the external environmental factors from interacting with the liquid contents of the reservoir. An elastically deformable reservoir will allow the user to insert different types of e-liquids into the device, and will also allow the e-liquid to be fully utilized by the device, which provides an advantage over prior art devices with rigid reservoirs where some of the fluid remaining in the reservoir cannot reach the wick to be utilized. 
         [0021]    Cavity  110  further includes a heating element  240  which is fluidly coupled to reservoir  250  and electrically coupled to power element  260 . The heating element  240  according to this invention comprises an electroconductive textile heating element. The electroconductive textile heating element according to present invention include heating elements made of fabric with metalized or electro-conductive coating, fabric incorporating woven metal strands, or any other suitable materials known in the art. According to an embodiment of the invention, ultra thin grade stainless steel wire cloth (found at http://www.saati.com/bopp-wire.php or from another similar supplier may be used) may be used, and may be layered to form a sponge or a multi-ply electro-textile cloth. According to an embodiment of the invention, the finest mesh material Bopp stainless steel wire cloth having a 400 threads/inch may be used to ensure fast and even heating of the e-liquid. 
         [0022]    The e-liquid reaches the electroconductive textile heating element via capillary action and is vaporized by the heating action of the electroconductive textile heating element. By providing an a electroconductive textile heating element coupled with a heating and temperature control system, the e-cigarette according to the invention allows an optimal vaporization state to be consistently maintained constantly so as to minimize or eliminate transformation of the e-liquid into unwanted chemicals such as formaldehyde. 
         [0023]    An air opening  130  is disposed on the outer surface of body  100  between the first longitudinal end of body  100  and a position on the outer surface of body  100  corresponding to the location of the heating element  240  inside cavity  110 . In a preferred embodiment, opening  130  has a generally circular cross section 1 mm to 1.5 cm in diameter. In other embodiments, opening  130  may have a square, triangular or any other geometric cross section shape. Other embodiments may comprise multiple air openings  130 . In order to ensure that the air entering the device is moving at a sufficiently high velocity to allow for air mixing in the area surrounding the electroconductive textile heating element, the total cross-area of opening  130  should be less than the total cross-area of opening  230 . 
         [0024]    Preferably, an air inlet check valve  120  is provided for opening and closing each opening  130 . Air inlet check valve  120  prevents environmental air from entering cavity  110  when e-cigarette  10  is not in use, to prevent evaporation and/or oxidation of the e-liquid. Air inlet check valve  120  may be a commercially available product from, for example, Smart Products, Inc., (http://www.smartproducts.com/check_valves_series — 100_cartridge.php), or another comparable supplier. In a preferred embodiment, a Series 100 Cartridge Check Valve (found at http://www.smartproducts.com/check_valves_series — 100_cartridge.php) may be used. In another embodiment, an elastic soft polymer flap attached to body  100  may be used in place of air inlet check valve  120 . The opening pressure necessary to open either the air inlet check valve  120  or an elastic soft polymer flap should be reduced to a minimum (for example, 0.5 PSI) to allow the user to inhale effortlessly. 
         [0025]    When the user inhales, he or she creates an area of negative pressure in mouth piece  200 . The opening pressure necessary to open either the air inlet check valve  120  or an elastic soft polymer flap should be reduced to a minimum (for example, 0.5 PSI) to allow the user to inhale effortlessly. User&#39;s inhalation causes a pressure sensor switch located at the mouthpiece of the device to turn on the device and activate the heating element  240  by applying an electrical current from power element  260 , thereby vaporizing some of the e-liquid and producing the aerosol mist. The negative pressure created by the user&#39;s inhale causes valves  120  and  220  to open, thereby allowing external air to enter cavity  110  through the opening  130 . The aerosol mist then combines with the external air and passes through the mouth piece  200  to enter the user&#39;s lungs through the opening  210 . 
         [0026]    An LED element  140  (comprising an LED light and an LED driver), and a light channel  150  are disposed on the upper outer surface of body  100 , and are electrically connected to the power element  260 . According to another embodiment of the invention, a commercially available microprocessor with a build-in LED driver from Texas Instruments, Inc. (http://www.ti.com/lsds/ti/power-management/indicator-rgbw-overview.page) or from another similar supplier may be used. 
         [0027]    According to an embodiment of the invention, the LED element  140  channels light via channel  150  along the upper surface of body  100  so as to make the light visible to the user. According to other embodiments, LED element  140  may be incorporated into second longitudinal end of body  100 , opposite to the first end of body  100  which incorporates mouthpiece  200 . LED light  140  may be activated by microprocessor control circuitry  270  when the user inhales from the e-cigarette. The intensity of the LED light is controlled by the microprocessor circuitry and by a pressure sensor located at the mouthpiece, according to methods known in the art. As the pressure sensor switch senses higher negative pressure caused by the user&#39;s inhale, it cause the microprocessor circuitry  270  to send a higher duty cycle to the LED element  140 . A duty cycle is the ratio of time a circuit is ON to the time a circuit is OFF. 
         [0028]    LED light  140  and light channel  150  may display various colors and flashing sequences of lights to denote dosage, battery level or other functional parameters of e-cigarette  10 . The color or the intensity of the light may gradually change during usage of e-cigarette  10  to indicate the equivalent dosage of nicotine relative to a conventional cigarette that the user has inhaled. For example, light sequences may be “green” for full battery charge, “yellow” for about half charge, and “red” when the battery requires re-charge. Similar color schemes may be employed to indicate the amount of e-liquid remaining in the device. 
         [0029]      FIG. 2  illustrates the operation of the “auto-on” system to control the heating element  240  of a handheld vaporizing device  10  according to the present invention. Handheld vaporizing device  10  incorporates a capacitive touch sensor element  190 . Capacitive touch sensor element  190  may be incorporated into body  100  of device  10 , as illustrated in  FIG. 1 . According to other embodiments, capacitive touch sensor element  190  may be incorporated into the mouth piece  200  of device  10 . 
         [0030]    A step  400  of  FIG. 2 , the software and hardware of the microprocessor control circuitry  270  determines, according to the methods known in the art, if the capacitive sensor  190  is active or inactive. When capacitive touch sensor element  190  is active because the user is touching device  10 , heating element  240  is turned on, as illustrated in step  420 , and vapor is created by the vaporizing action of the heating element  240 , thereby allowing the user to enjoy the vapor on demand. When capacitive touch sensor element  190  is inactive because the user is not touching device  10 , heating element  240  is turned off, as illustrated in step  410  of  FIG. 2 . 
         [0031]      FIG. 3  illustrates the operation of the heating and temperature control system to control the heating duty cycles of the heating element  240  according to the present invention. As shown in step  300  of  FIG. 3 , when the capacitive sensor  190  is active because the user is touching device  10 , heating element  240  is activated and its duty cycles are controlled by the microprocessor control circuitry  270 , to heat the e-liquid to an optimal pre set vaporization temperature of the e-liquid. This allows aerosol to be created when the user touches the device, without waiting for the user&#39;s first inhale. Thus, aerosol may be consumed immediately without the user having to take one or more puffs on the device to create the first dose of aerosol, thereby more closely mimicking the experience of smoking a real cigarette or cigar. As illustrated in step  310 , the heating element is controlled by the microprocessor control circuitry  270  by methods known in the art not to significantly exceed or fall below the pre-set optimal vaporization temperature, assuring a supply of vapor and preventing generation of unwanted by-products of over-heating the e-liquid. According to an embodiment of the invention, the heating element should be controlled not to exceed 120° C. to prevent formation of formaldehyde. 
         [0032]    As illustrated in step  320  of  FIG. 3 , if the temperature of the heating element  240  falls above or below the optimal pre set vaporization temperature of the e-liquid, the duty cycles of the heating element  240  are increased or decreased by the microprocessor control circuitry  270  to maintain the temperature of the heating element  240  at optimal pre set vaporization temperature of the e-liquid. 
         [0033]    The above mentioned is only exemplary embodiments of the present invention. It should be noted, for persons of ordinary skill in this art field, improvements and modifications within the spirit of the present invention can be further made, and such improvements and modifications should be seemed to be included in the claimed scope of the present invention.