Abstract:
A power supply section for an e-vaping device includes a sensor housed in a housing, a sensor holder holding the sensor, the sensor holder disposed in the housing to divide the housing into a first portion and a second portion, and the sensor and the sensor holder configured to substantially prevent air flow from the first portion into the second portion, and a power source disposed in the second portion. The construction of this unit insures that gases that may be produced by outgassing of the battery cell will be vented to the environment and that those gases will be isolated from the air that is mixed with the vaporized e-liquid and inhaled by the user.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
       [0001]    Some example embodiments relate generally to a power supply section configuration for an electronic vaping device, and/or an electronic vaping device. 
       Related Art 
       [0002]    Electronic vaping devices are used to vaporize a liquid material into a vapor in order for an adult vaper to inhale the vapor. These electronic vaping devices may be referred to as e-vaping devices. An e-vaping device may typically include several e-vaping elements such as a power supply section and a cartomizer. The power supply section includes a power source such as a battery, and the cartomizer includes a heater along with a reservoir capable of holding the liquid material. The cartomizer typically includes the heater which is in contact with a liquid material via a wick, the heater being configured to heat the liquid material to produce a vapor. The liquid material typically includes an amount of nicotine. An e-vaping device may also include a puff sensor that triggers heating of the liquid material when the user puffs on the e-vaping device in order to produce the vapor inhaled by the adult vaper. 
         [0003]    Conventional e-vaping devices include the puff sensor at a distal end of the device in the power supply section, which is typically at an opposite end of the device from the mouthpiece. Accordingly, during use, air enters at the tip of the device and circulates around the power source and then passes through the cartomizer. The air is then mixed with the vaporized liquid and is inhaled by the adult vaper. The power source may be a lithium ion battery cell which may exhibit outgassing during operation resulting in a potentially harmful gas being released from the battery cell. Because the incoming air must flow over the power source the result may be a mixing of the battery cell outgas with the vaporized Liquid inhaled by the adult vaper. In addition, after constant use the vent hole at the tip may eventually be clogged as a result of dust or other environmental conditions and the resistance to draw (RTD) may be increased which may result in a decreased life for the battery. 
       SUMMARY OF THE INVENTION 
       [0004]    At least one example embodiment relates to a power supply section of an e-vaping device. 
         [0005]    In one example embodiment, the power supply section for an e-vaping device includes a sensor housed in a housing, a sensor holder holding the sensor, the sensor holder disposed in the housing to divide the housing into a first portion and a second portion, and the sensor and the sensor holder configured to substantially prevent air flow from the first portion into the second portion, and a power source disposed in the second portion. The sensor holder section as well as the power source section will each contain separate and independent vent holes respectively. The vent hole in the sensor section allows air to enter into the cartomizer as well as activates the sensor when in use. The vent hole in the power supply section allows the outgassing from the battery cell to exit through the tip of the e-vaping device. As a result of the separation of compartments between the sensor and power supply, the inhaled air may be substantially preventing from passing over the power supply. Thus, the inhaled vapor will not mix with the gases released from the battery cell. If outgassing occurs from the battery cell, the resulting gas may be released through the vent in the tip of the e-vaping device. 
         [0006]    In one embodiment, the sensor holder holds the sensor such that the sensor senses a pressure drop in the first portion, the sensor may be a puff sensor and the power source may be a battery. The sensor holder is a hollow structure having a first dimension section and a second dimension section, the first dimension section defining a first cavity having a least a first dimension, the second dimension section defining a second cavity having a least a second dimension, the second cavity corresponding to a shape of the sensor, and the first dimension being smaller than the second dimension. 
         [0007]    In one embodiment, the sensor holder has a substantially cylindrical shape, and the first and second dimensions are first and second diameters, respectively. The sensor holder may have an annular flange at a transition between the first dimension section and the second dimension section. 
         [0008]    In one embodiment, the sensor holder includes at least one first projection projecting from one end of the sensor holder, the at least one first projection being between the sensor holder and the power source, and the power supply section includes at least one second projection projecting from another end of the sensor holder. 
         [0009]    In one embodiment, the sensor includes a control circuitry configured to control supply of power from the power source. 
         [0010]    Alternatively, the power supply circuit includes a control circuitry that is coupled with the sensor and configured to control supply of power from the power source. 
         [0011]    Example embodiments relate to a power supply section for an e-vaping device that includes a seal between a first portion and a second portion of the power supply section, the seal being configured to substantially prevent air flow from the first portion into the second portion, and a power source in the second portion. 
         [0012]    In one embodiment, the seal includes a sensor and a sensor holder, the sensor being electrically coupled to the power source. 
         [0013]    At least one example embodiment relates to an e-vaping device. 
         [0014]    In one embodiment, the e-vaping device includes a cartomizer including a liquid reservoir holding a liquid, a mouthpiece and a heater configured to heat the liquid, and a power supply section removably connected to the cartomizer via a connector and including a sensor housed in a housing, a sensor holder holding the sensor, the sensor holder disposed in the housing to divide the housing into a first portion and a second portion, and the sensor and the sensor holder are configured to substantially prevent air flow from the first portion into the second portion, and a power source disposed in the second portion and configured to supply power to the heater. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    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. 
           [0016]      FIGS. 1A-1B  are illustrations of an e-vaping device according to at least one example embodiment; 
           [0017]      FIG. 2  is a longitudinal cross-section of a power supply section for an e-vaping device, according to at least one example embodiment; 
           [0018]      FIGS. 3A-3E  are illustrations of a puff sensor and a puff sensor holder, according to at least one example embodiment; and 
           [0019]      FIG. 4  is a cross-sectional view of cartomizer according to at least one example embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    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. 
         [0021]    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. 
         [0022]    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. 
         [0023]    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. 
         [0024]    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&#39;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. 
         [0025]    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, 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. 
         [0026]    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. 
         [0027]    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. 
         [0028]      FIGS. 1A-1B  illustrate an e-vaping device according to at least one example embodiment. In  FIG. 1A , the e-vaping device  100  includes a replaceable cartomizer (or first section)  25  and a power source section (or second section)  75 , which are coupled together at a connector  50 . Both the power source section  75  and the cartomizer  25  are illustrated as having a cylindrical shape of substantially equal diameter. However, it will be appreciated that example embodiments are not limited to a cylindrical shape. For example, the power source section  75  and the cartomizer  25  may have a rectangular or other shape. In one example embodiment, a power source or battery and control circuitry are included in the power source section  75 . Upon completing the connection between the power source section  75  and the cartomizer  25  at the connector  50 , when an adult vaper uses the e-vaping device  100 , the power source included in the power source section  75  is electrically connected with a heater element of the cartomizer  25 . It should be noted that although  FIG. 1A  illustrates the e-vaping device  100  having two releasably coupled sections  25  and  75 , example embodiments may include a unitary e-vaping device where the above-discussed features are housed in a single section. 
         [0029]    In  FIG. 1B , the power source section  75  includes a male connector  50   a  of the connector  50  located at an end thereof. Although a male connector  50   a  is illustrated in  FIG. 1B , the connector  50   a  may instead be a female connector. The power source section  75  may also include an air vent  55  configured to let air flow therein during use of the e-vaping device by an adult vaper. 
         [0030]      FIG. 2  illustrates a cross-section of a power source section for an e-vaping device, according to at least one example embodiment. As shown, a puff sensor holder  35  divides the power source section  75  into a sensing portion  68  and a power source portion  70 . The power source portion  70  includes a power source  64 . The power source  64  may be, for example, a battery. The power source portion  70  also includes a heater activation light or LED  60  configured to glow when power is generated. In one embodiment, the heater activation light  60  is at a proximate end of the power source section  75  so that the heater activation light  60  takes on the appearance of a burning coal during a puff. In one embodiment, the proximate end of the power source section  75  may also include at least one air vent  65  configured to evacuate any gases present in the power source section  75 . 
         [0031]    In one embodiment, the sensing portion  68  includes a chamber  58  configured to receive air via the air vents  55  when the e-vaping device is in use. In an embodiment, the air vents  55  are provided at an angle with respect to a longitudinal direction of the power source section  75 . For example, an acute angle ensures greater efficiency in allowing the airflow to enter the chamber  58  during use of the e-vaping device  100 . The puff sensor holder  35  holds or supports a puff sensor  40  such that the puff sensor  40  may sense when an adult vaper is using the e-vaping device  100 , for example, sensing the receipt of air through the air vents  55  and the chamber  58 , or sensing a pressure drop in the chamber  58  when in use. 
         [0032]    In one embodiment, the sensing portion  68  may also include control circuitry  45  that may be integrated with or connected to the puff sensor  40  to control the supply of power in response to the puff sensor  40  sensing that an adult vaper is using the e-vaping device. The control circuitry  45  may be connected to the heater activation light or LED  60  of the power source portion  70  and a heater in the cartomizer  25  when the cartomizer  25  is connected to the power source section  75 . 
         [0033]    According to at least one example embodiment, the puff sensor  40  is placed in close proximity to the male connector  50   a  and is held in place via the puff sensor holder  35 . The male connector  50   a  may include a suction post  30  configured to allow a path for air entering air vents  55 , during use of the e-vaping device, to flow to the cartomizer  25 . The suction post  30  may be a tubular section at an end of the power source section  75  and is configured to ensure a direct air path between the chamber  58  and the cartomizer  25  when the power source section  75  is connected to the cartomizer  25 . The suction post  30  may be held in place via a gasket ring  32 . 
         [0034]    In one embodiment, the puff sensor holder  35  is held in place and/or substantially prevented from moving inside the sensing portion  68  by one or more projections  56  located against an inside wall of the power source section  75 . Alternatively, the projections  56  may be a thicker portion of the inside wall of the power source section  75 . Accordingly, the puff sensor holder  35  is substantially prevented from sliding towards the male connector  50   a  by the projections  56 . 
         [0035]    During operation of the e-vaping device, the puff sensor  40  is configured to sense an air pressure drop in the chamber  58  and to initiate the application of voltage from the power source via the control circuitry  45 . 
         [0036]    In one embodiment, the combination of the puff sensor holder  35  and the puff sensor  40  form a seal configured to substantially hermetically isolate the power source portion  70  from the sensing portion  68 . Accordingly, when airflow is created in the sensing portion  68  as a result of using the e-vaping device  100  by an adult vaper, which draws outside air from the air vents  55  and create a pressure drop at the puff sensor  40 , little or no airflow enters the power source portion  70  by the puff sensor holder  35 . As a result, degradation of the power supply source  64  due to contact with the airflow is reduced or substantially prevented. In addition, outgassing from the power source  64  is substantially prevented from entering into the cartomizer  25  via the sensor chamber  58 . Outgassing from the power source  64  will be via vent hole  65 . 
         [0037]      FIG. 3A  is a cross-section of a puff sensor holder, according to at least one example embodiment. In  FIG. 3A , the puff sensor holder  35  is a hollow cylinder having a first diameter section  35   a  and a second diameter section  35   b . The first diameter section  35   a  has a first inner diameter D 1  and defines a first cavity, and the second diameter section  35   b  has a second inner diameter D 2  and defines a second cavity. In example embodiments, D 1  is less than D 2  such that an inner annular flange  38  is formed in the puff sensor holder  35 . The space defined by the second inner diameter D 2  matches the shape of the puff sensor  40  such that the puff sensor  40  can be snuggly and substantially hermetically seated in the puff sensor holder  35 . 
         [0038]    In one embodiment, projections  31  are at an end of the second diameter section  35   b . It should be noted that, the puff sensor  40  is not limited to having, for example, a circular cross-section, and accordingly, the cross-section of the interior space of the second diameter section  35   b  is not limited to a circular cross-section. 
         [0039]    The first and second diameter sections  35   a  and  35   b  have the same outer diameter, which closely matches the inner diameter of the housing for the power source section  75  such that the puff sensor holder  35  is substantially hermetically seated in the power source section  75 . The combination of the puff sensor  40  and the puff sensor holder  35  forms a seal that substantially hermetically isolates the sensing portion  68  from the power source portion  70 . In one embodiment, the puff sensor holder  35  may include polydimethyisiloxane (PDMS) or silicone. 
         [0040]    In one embodiment, the projections  31  provide a physical separation between the puff sensor holder  35  and a battery  64  housed in the power source portion  70 . Accordingly, the projections  31  are configured to, for example, prevent the battery  64  from contacting the puff sensor holder  35 , preventing potential short of battery connection with control circuitry contacts, or to substantially prevent either or both of the puff sensor holder  35  and the battery  64  from moving. 
         [0041]      FIG. 3B  is an end view of the puff sensor holder  35  at the end of the first diameter section  35   a  in  FIG. 3A . In  FIG. 3B , the puff sensor holder  35  includes a circular opening  36  having diameter D 1 . It should be noted that the opening  36  may have a shape other than circular. For example, the opening  36  may have a square or a rectangular shape, among other shapes.  FIG. 3C  is an end view of the puff sensor holder  35  of the second diameter section  35   b  in  FIG. 3A .  FIG. 3C  illustrates annular flange  38  upon which the puff sensor  40  seats. 
         [0042]      FIG. 3D  is a longitudinal cross-section of a puff sensor  40 , according to at least one example embodiment. In one embodiment, the puff sensor  40  is coupled to the control circuitry  45 . The control circuitry  45  is configured to control the flow of power (e.g., current) from the battery  64 . In one embodiment, the control circuitry  45  includes electrodes  44  and a processor configured to control the application of power from the battery  64  when an air pressure drop in the chamber  58  (illustrated in  FIG. 2 ) is sensed by the puff sensor  40  due to the use of the e-vaping device by an adult vaper. Although the control circuitry  45  is illustrated as having a cylindrical shape concentric with the shape of the puff sensor  40 , the control circuitry  45  may have other shapes and may include one or more additional control components configured to control the application of power from the battery  64 . 
         [0043]      FIG. 3E  is a longitudinal cross-sectional view of a puff sensor being held in a puff sensor holder, according to at least one example embodiment. In  FIG. 3E , the puff sensor  40  is snuggly seated within the puff sensor holder  35 . In one embodiment, the puff sensor holder  35  is snuggly fit against an inside wall of the power source section  75 . For example, the cylindrical puff sensor holder  35  is substantially hermetically secured against the inside cylindrical walls of the power source section  75 . In one embodiment, the puff sensor  40  abutts against the flange  38  of the puff sensor holder  35 . The flange  38  may be configured to snuggly seat the puff sensor  40  within the puff sensor holder  35 . At an opposite end of the puff sensor  40  from the flange  38  in a longitudinal direction of the puff sensor  40 , the electrodes  44  are configured to ensure electrical and control coupling with the battery  64  housed in the power source portion  70 . Accordingly, in operation, when an adult vaper uses the e-vaping device, the control circuitry  45  is configured to supply power in response to the puff sensor  40  sensing that an adult vaper is drawing on the e-vaping device. In one embodiment, the projections  31 , located at an opposite side of the puff sensor holder  35  from the opening  36  in a longitudinal direction of the puff sensor holder  35 , are configured to substantially prevent the battery  64  from contacting the puff sensor holder  35  and/or to substantially prevent either or both of the puff sensor holder  35  and the battery  64  from moving. 
         [0044]    In view of the above description illustrated in  FIGS. 3A-3E , during use of the e-vaping device, air that penetrates through the vents  55  and that circulates at the puff sensor  40  is substantially prevented from entering the power source portion  70  by the puff sensor holder  35 . As a result, degradation of the battery  64  housed in the power source portion  70  can be substantially prevented or reduced. In addition, outgassing from the power source  64  is substantially prevented from entering into the cartomizer  25  via the sensor chamber  58 . Outgassing from the power source  64  will be via vent hole  65 . 
         [0045]      FIG. 4  is a cross-sectional view of cartomizer according to at least one example embodiment. In  FIG. 4 , the replaceable cartomizer  25  may include a liquid supply reservoir  22  including a liquid, a wick  28  configured to wick the liquid from the liquid supply reservoir  22 , and a heater element  14  configured to heat the liquid in the wick  28  to form a vapor. In an example embodiment, the heater  14  is contained in the cartomizer  25  downstream of, and in spaced apart relation to, the portion of central air passage  20  defined by a seal  15 . When an adult vaper uses the e-vaping device, the air flows from vents  55  and the suction post  30  of the power source section  75  into the bore of the central air passage  20  and into the outer air passage  9 . According to example embodiment, the heater  14  can be in the form of a wire coil, a planar body, a ceramic body, a single wire, a cage of resistive wire or any other suitable form. The wick  28  may be in communication with both the liquid material in the liquid supply reservoir  22  and with the heater  14 , such that the wick  28  provides a path for the liquid material to flow between the liquid supply reservoir  22  and the heater  14 . The wick  28  may be constructed of a fibrous and flexible material, and/or may include at least one filament having a capacity to draw a liquid. In one example embodiment, the power supply  64  included in the power source section  75  may be operably connected by the control circuitry  45  to the heater  14  to apply a voltage across the heater  14  in order to heat the liquid and generate a vapor. The cartomizer  25  and the power source section  75  are coupled together physically and electrically at threaded connections  50   a  and  50   b , where  50   a  is a male threaded connection on the power source section  75  (see  FIG. 2 ), and  50   b  is a female threaded connection on the cartomizer  25  (see  FIG. 4 ). 
         [0046]    In one example embodiment, a ground (negative) connection may be formed via an electrical connection between the threaded connections  50   a  and  50   b , and a (positive) voltage connection may be formed via the electrical connection between the post  30  of the power source section  75  and a post (not shown) of the cartomizer  25 . For example, lead wires may connect the post  30  of the power source section  75  and the threaded connector  50   a  to control circuitry (not shown) in the power source section  75 , and other lead wires may connect the threaded connector  50   b  and a post of the cartomizer  25  to the heater element  14 . Accordingly, in operation, when the cartomizer  25  and the power source section  75  are coupled, a circuit is formed. 
         [0047]    According to at least one example embodiment, the cartomizer  25  further includes a mouth-end insert  8  having at least one or two off-axis, diverging outlets  24 . The mouth-end insert  8  may be in fluid communication with the central air passage  20  via the interior of inner tube  62 , which extends through the stopper  10 . Moreover, the heater  14  extends in a direction transverse to the longitudinal direction and heats the liquid material to a temperature sufficient to vaporize the liquid material and form a vapor. In other example embodiments, other orientations of the heater  14  may be contemplated. For example, the heater  14  and the heated portion of the wick  28  may be arranged longitudinally within the inner tube  62 . The heater  14  may also be arranged centrally within the inner tube  62 . However, in other example embodiments, the heater  14  may be arranged adjacent an inner surface of the inner tube  62 . 
         [0048]    In at least one example embodiment, the wick  28 , liquid supply reservoir  22  and mouth-end insert  8  are contained in the cartomizer  25 , and the power supply  64  is contained in the power source section  75 . 
         [0049]    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.