Patent Publication Number: US-2016227837-A1

Title: Disposable electronic cigarette tank

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is related to and claims the benefit of U.S. Provisional Patent Application Ser. No. 62/112,759, filed Feb. 6, 2015, and entitled “Electronic Cigarette Device with Closed, Disposable Tank and Filtration,” which is hereby incorporated by reference for all purposes. 
    
    
     TECHNICAL FIELD 
     The disclosures herein generally relate to personal vaporizers used to simulate smoking. In particular, the disclosures relate to vaporizing consumables, and more particularly relate to a disposable, permanently-sealed consumable tank and apparatus for use therewith. 
     BACKGROUND 
     Vaporizing devices typically include a variety of structural elements defining, in, and around a consumable reservoir retaining the material to be vaporized. Such elements can include heating elements for generating vaporization heat, electrical elements for powering the heating element, inlets and outlets assisting with the movement of liquid, air, or vaporized materials, and others. Vaporizing devices typically require refilling, and in some instances require maintenance or replacement of more than the consumable (e.g., changing of heating elements). Refilling and maintenance can be inconvenient and lead to spilled consumables, consumable contamination outside the consumable tank, and lost or broken components. 
     SUMMARY 
     An embodiment of a system can include a tank having at least one outer side wall, a top wall, and a bottom wall. The tank can include a consumable fluid reservoir adapted to receive at least a consumable fluid, a heating element extending through at least a portion of the consumable fluid reservoir, and an air chamber extending through at least a portion of the consumable fluid reservoir. The system can also include a mouthpiece adapter extending away from the top wall of the tank. The mouthpiece adapter is in fluid communication with the air chamber and configured to couple with a mouthpiece for drawing fluid from the air chamber. The system can also include a power connection extending away from the bottom wall of the tank. The power connection is in electrical communication with at least the heating element and configured to couple with a battery. 
     In another embodiment, a method of making a disposable consumable container for a vaporizing device includes providing a tank having at least one outer side wall, and a bottom wall. The tank includes at least a consumable fluid reservoir adapted to receive at least a consumable fluid, and the bottom wall has an electrical interface. The method further includes installing at least a heating element and an air chamber through at least a portion of the consumable fluid reservoir. The heating element is in electrical communication with the electrical interface. The method also includes providing at least one consumable fluid in the consumable fluid reservoir and installing a top wall to permanently seal the tank, the top wall having a vapor interface for fluid communication with the air chamber. 
     These and other embodiments are described in greater detail elsewhere herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To better understand and appreciate the invention, refer to the following detailed description in connection with the accompanying drawings: 
         FIG. 1  shows example system using a tank configured to contain a vaporizing consumable; 
         FIG. 2  shows a cutaway view of example system using a tank configured to contain a vaporizing consumable; 
         FIG. 3  illustrates an example top section for use with a tank configured to contain a vaporizing consumable; 
         FIG. 4  illustrates a partial cutaway view of an example tank configured to contain a vaporizing consumable; 
         FIG. 5  illustrates an example bottom section for use with a tank containing a vaporizing consumable; 
         FIGS. 6A-E  illustrate assembly and disassembly of an example system using a tank configured to contain a vaporizing consumable; 
         FIG. 7  illustrates operation of an example system using a tank configured to contain a vaporizing consumable; 
         FIG. 8  illustrates an alternative embodiment of an example system using a tank configured to contain a vaporizing consumable; 
         FIG. 9  illustrates an example flow chart depicting a methodology for making a tank containing a vaporizable consumable; and 
         FIG. 10  illustrates an example flow chart depicting a methodology for using a tank containing a vaporizable consumable. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure may provide personal vaporizing system that can be used to simulate smoking, which may colloquially be referred to as an electronic cigarette, e-cigarette, e-cig mod-box, or other terms in common use. The disclosure includes a disposable tank that is at least partially filled with a liquid (or other material) to be vaporized. The disposable tank may be provided with filtration and liquid filling capabilities. In some embodiments, the electronic cigarette device may include a closed tank that is intended to be opened only by a manufacturer or designated refilling entity to avoid tampering with the contents of the tank and/or provide a simple-to-use, disposable product. The tank may be sealed to discourage a consumer from filling and/or opening the tank and to prevent inadvertent opening of the tank. 
     Embodiments of the present disclosure may provide a coil attached to the electronic cigarette device, wherein the coil may or may not be independent to the disposable tank. In some embodiments of the present disclosure, a disposable liquid filled tank may be attached to the atomizer coil to form a seal and allow flow to atomizer for vaporization process or the disposable tank may contain liquid, coil, air chamber and filter and attach to battery device for vaporization. 
     Embodiments of the present disclosure may provide a chamber that runs through a disposable liquid filled tank and to a mouthpiece to allow easy air flow for inhaling vapor. In embodiments of the present disclosure, prior to inhaling, vapor may pass through a filter that may contain carbon and or another filtration-type device to filter out chemical vapors or additives, including formaldehyde or other irritants. 
     As used herein, “permanently sealed” means irreversibly closed in lieu of at least partial destruction of the structure. Permanent sealing can be accomplished using various adhesives, welding, monolithic construction, et cetera. Where elements are “removably coupled,” in contrast, they are connected by attachment means which facilitating install or uninstall avoiding destruction or deformation of either component being attached. Similarly, an “interchangeable” element is one which can be easily exchanged for a similar (if not dimensionally, qualitatively, or aesthetically equivalent) element. “Operative coupling” or “communication” (e.g., fluid communication, electrical communication) refers to components working together, even if such components are not in physical contact (though they may be in physical contact). A “consumable fluid” can be any vaporizable fluid, such as the fluids used with electronic cigarettes or for “vaping.” Further, while consumable fluids are discussed herein, nothing precludes the use of consumable solids or other materials capable of being vaporized with systems set forth herein. Where components are described as “extending away from” (or in similar terms), such elements need not necessarily be disposed on one another or attached (e.g., a power connection may extend away from a bottom wall even though it is attached to an intervening bottom section structurally distinct from the bottom wall; or the power connection extending away from a bottom wall may reside on the bottom wall itself in an alternative embodiment). 
       FIGS. 1-7  illustrate an example system  100  disclosed herein used for vaporizing fluids such as water or mixtures of water and various flavors as used to simulate smoking or otherwise facilitate personal vaporizing activity. System  100  includes top section  110 , tank section  120 , bottom section  140 , and cover  150 . Tank section  120  may be permanently sealed, disposable, and/or other-wise constructed to limit the tank to a single use. 
     Tank section  120  can be a disposable, non-refillable tank containing a consumable fluid for use with system  100  in consumable fluid reservoir  121 . Tank section  120  comprises a tank  124  can be defined in terms of at least one outer side wall, a top wall disposed toward top section  110 , and a bottom wall disposed toward bottom section  140 . Tank  124  also includes a heating element  127  or “coil” extending through at least a portion of tank  124  and consumable fluid reservoir  121  which, when provided with electrical power, generates heat in or around the consumable fluid to cause its vaporization. Air chamber  123  also extends through at least a portion of tank  124  and consumable fluid reservoir  121 . Air chamber  123  can include a vapor interface  122  disposed toward or beyond the top wall of tank  124 . Air chamber  123  can also include consumable inlet  131  located toward heating element  127  and the bottom wall of tank  124  for receiving a consumable fluid from consumable fluid reservoir  121  or vapor produced therefrom. Tank  124  also includes electrical interface  126  disposed toward its bottom wall for providing electrical communication between heating element  127  and power connection  146  (described hereafter). Also disposed toward the bottom wall of tank  124  is air chamber inlet  128  which includes an opening proximate to the bottom of air chamber  123  through which outside air can at least be drawn. In embodiments, o-ring  125  can surround at least a portion of tank  124 . As suggested by the structure described above, tank section  120  can in part or in whole define an atomizer, cartomizer, or clearomizer. 
     Top section  110  operatively couples with tank section  120 , establishing fluid communication with air chamber  123 . Top section  110  includes mouthpiece adapter  112 , which couples with at least vapor interface  122 . In some embodiments, mouthpiece adapter  112  is configured to accept interchangeable filter  118 . Interchangeable filter  118  can be, but is not limited to, one or more filters that may be used to perform chemical, biological, or mechanical filtration of the fluid drawn through the filter; to restrict or prevent fluid flow; a flow resistance component to change the draw resistance during use; a flavoring component that imbues a flavor as fluid passes through it; a thermal insulating component to cool vapor before inhalation, or other flow control elements. Interchangeable filter  118  can be maintained in filter chamber  119  of mouthpiece adapter  112 . To remove or exchange interchangeable filter  118 , mouthpiece  111  can be removed and interchangeable filter  118  removed in a direction opposite tank section  120 . To ensure interchangeable filter  118  is not inadvertently misplaced within the system, filter chamber  119  is has a bore equal to or greater than the dimensions of interchangeable filter  118 , and adjacent portions of mouthpiece  111  and/or mouthpiece adapter  112  in fluid communication therewith (and with air chamber  123 ) can be bored to smaller dimensions impassable to interchangeable filter  118 . In embodiments, no interchangeable filter  118  is included, or an included interchangeable filter  118  can be removed, without impact to the function of system  100 . 
     Mouthpiece adapter  112  extends away from the top wall of tank  124  and couples with mouthpiece  111 . Mouthpiece  111  is placed in fluid communication with air chamber  123  through connection with mouthpiece adapter  112  and is configured for drawing fluid from the air chamber. 
     In embodiments, one or more of the top wall of tank  124 , either end of mouthpiece adapter  112 , and/or a bottom side of mouthpiece  111  can include a sealing element (e.g., coating, gasket, et cetera) to ensure the surfaces over which these components meet is airtight or substantially fluid impermeable to ensure vapor drawn does not escape and is not diluted by outside air. 
     Opposite top section  110 , disposed toward the bottom wall of tank  124 , is bottom section  140 . Bottom section  140  includes bottom section connector  141  which mechanically couples with at least bottom adapter  129  of tank  124  to a personal vaporizer housing, which may contain a system control, display, and power source. Power source may be any suitable power source to provide energy to vaporize the liquid. To facilitate portability, power source may include a rechargeable battery, such as a lithium ion battery or the like. To such ends, housing may also include a port for connecting batteries to a recharging source. For example, the port may include a USB port, mini-USB port or other adapter. 
     Electrical connection of heating element  127  to the power source may be a wired connection, plug connection or the connection may be created when mounting the tank  120  on the device housing, as shown. For example, bottom section  140  also includes a power connection  146  extending away from the bottom wall of tank  124 , such as a 510 pin connection or the like. Power connection  146  is configured to couple with a battery or other electrical power source, and can include one or more electrical contacts to such effect. As depicted in, e.g.,  FIGS. 1-7 , these and other connecting elements are threaded, but it will be appreciated that alternative coupling techniques can be provided without diverging from the scope or spirit of the innovation. 
     Bottom section  140  also includes bottom inlet  145 . Bottom inlet  145  provides fluid communication between air chamber inlet  128 , which extends into bottom section  140 , and an outside environment thereby permitting airflow through air chamber  123 . In embodiments, bottom inlet  145  is adjustable to increase or decrease the amount of the aperture of bottom inlet  145  is open for airflow, thereby providing a mechanism to increase or restrict resistance to airflow. Such embodiments can provide a sliding or rotating element to “open” or “close” bottom inlet  145 . In alternative or complementary embodiments, a portion of air chamber inlet  128  and/or bottom section  140  is movable to provide similar function. 
     System  100  can also include cover  150 . Cover  150  can be a decorative cover providing aesthetic elements over at least a portion of tank section  120 . Cover  150  can also serve as a structural reinforcement (e.g., to protect and prevent deformation of tank section  120  or other elements) or a thermal insulator (e.g., to prevent heat from heating element  127  from being transmitted to a holder of the device). Cover  150  can slide on or off tank section  120  from at least one direction. In embodiments, cover  150  can include cover coupler  151  which attaches to one or both of bottom section  140  and/or tank section  120 . In alternative or complementary embodiments, one or both of top portion and/or bottom portion can retain cover  150  in its position over tank section  120  by blocking its removal when coupled. 
       FIGS. 3 to 6E  show various portions of system  100  in isolation. Specifically,  FIG. 3  shows an example embodiment of top section  110  in greater detail, including mouthpiece  111  and mouthpiece adapter  112 . Mouthpiece adapter  112  generally includes a body to which the mouthpiece  111  is attached. It will be understood that it is possible to interchange or occasionally remove the mouthpiece  111  from mouthpiece adapter  112 . To that end, a mouthpiece coupler  114  may be used to selectively attach the mouthpiece  111  to the body. Mouthpiece coupler  114  may be any suitable connector including for example the snap ring shown in  FIG. 3 . Mouthpiece adapter  112  may further include a coupling ring  115  at one end, which can contact tank section  120  when coupled, and air conduit  116  in fluid communication with air chamber  123 . In the example shown, coupling ring  115  has a skirt-like form with a peripheral wall that extends downward from body and beyond the end of the mouthpiece to overly a portion of the tank section  120 . While aspects herein can be described as “rings” or in terms of circular geometry, it is understood that other shapes and cross-sections (e.g., rectangular shapes or others) can be employed without departing from the scope or spirit of the innovation. 
       FIG. 4  shows tank section  120  in closer detail. In embodiments, tank section  120  may include tank  124  which is transparent, allowing the user to view the fluid level therein with an outer protective shell that at least partially covers a transparent tank. In the example shown, tank  124  can be constructed of glass and the shell includes a metal cover that encloses a portion of the tank while leaving a portion of the glass exposed for viewing of the tank contents. 
       FIG. 5  shows bottom section  140  in greater detail including the female bottom section connector  141 , the male bottom outer connector  142 , bottom body  144 , bottom inlet  145 , and power connection  146 . In an embodiment similar to one discussed above, body  144  is rotatable and includes bottom inlet  145  (e.g., a slot, hole, aperture) that corresponds to an interior slot such that rotation of the outer ring selectively expands or contracts the opening of the inner slot to allow more air to be drawn into the system. The power connector  146  is shown in more detail in  FIG. 5 , may include a threaded connection and contact tip to engage a corresponding internally threaded receiver on the device housing to provide a secure electrical connection. 
       FIGS. 6A-6E  show details of a coupling system according to aspects of the innovation. In general, mouthpiece adaptor  112  may be selectively connected to tank section as discussed above. The coupling system may include any suitable connection including clips, snaps, threaded connections, bayonet connections, quick connections and the like. In an example, coupling system includes a detent assembly that includes a movable detent (see, e.g.,  FIG. 2 ) that selectively moves radially to engage a connector extending upward from tank section  120 . The connector extending upward from the tank section  120  can be a generally cylindrical protrusion that is sized to be received within the bore of mouthpiece adapter  112 . The protrusion includes an annular channel or other receiver that accepts the detent to connect the mouthpiece adaptor to the tank section  120 . In this example, detent can be a ball bearing mounted within the bore of mouthpiece adaptor  112 . The ball bearing is driven radially outward by the protrusion as it is inserted into the bore, and permitted to move radially inward when aligned with the annular recess. The bearing is biased inward and is received within the recess to connect mouthpiece adaptor  112  and tank section  120  (embodiments depicted in, e.g.,  FIGS. 2 and 6A ). An outer sleeve of mouthpiece adaptor  112  can be used to hold the ball bearing in the connected position by preventing radial outward movement thereof. 
     As shown in  FIG. 6B , selective release of the mouthpiece adaptor is accomplished by sliding the sleeve upward to remove the positive stop on the ball bearing and allow it to retract, e.g., move radially outward as tank section  120  is moved axially outward (down arrow) from mouthpiece adaptor  112 .  FIG. 6C  shows the mouthpiece adaptor and tank section  120  in a released condition.  FIGS. 6D and 6E  depict disassembly of tank section  120 . As shown, the tank  124  may be removed from an assembly that includes decorative cover  150  and bottom section  140 . It will be understood that this provides the user with the ability to interchange tanks while retaining a common decorative element, or change decorative elements as desired. The particular decorative outer cover shown is not limiting. 
       FIG. 7  provides a further view of an example system  100  in operation with optional battery section  190 . Battery section  190  couples with bottom section  140 . Battery section  190  can, but need not, include battery coupler  191 , which mates with power connection  146 , and battery  192  which contains cells for powering system  100 . 
       FIG. 8  depicts an alternative embodiment of a system  200  including a tank section  220  including a consumable fluid. System  200  includes top section  210  having mouthpiece adapter  212  and top section coupler  213 , and bottom section  240  having bottom section connector  241 , bottom outer connector  242 , and power connection  246 . Bottom section  240  also includes bottom inlet  245 . Tank section  220  can include vapor interface  222 , air chamber  223 , tank  224 ,  26 , and heating element  227 . 
     Additional elements can be included in various embodiments of systems disclosed herein. As shown in, e.g.,  FIG. 8 , system  200  can include wick  262 , which can be retained by wick cap  260 . Wick  262  can be in fluid communication with consumable fluid reservoir  221  and any fluid(s) therein. Wick  262  can also be in thermal communication with heating element  227 . 
       FIGS. 9 and 10  illustrate example methodologies for making and using systems and components such as those described. While particular orders and arrangements are show in the example flow charts provided, it will be appreciated that the order and arrangement may vary without departing from the scope or spirit of the innovation. 
       FIG. 9  particularly shows an example block diagram of a methodology  900  for making a tank containing a consumable for vaporization. Methodology  900  begins at  902  and proceeds to  904  where a tank is provided. The tank can have at least one outer side wall, and a bottom wall. The tank can include at least a consumable fluid reservoir adapted to receive at least a consumable fluid, and the bottom wall can include an electrical interface. At  906  methodology  900  includes installing at least a heating element and an air chamber through at least a portion of the consumable fluid reservoir. The heating element is in electrical communication with the electrical interface. At  908 , at least one consumable fluid is provided in the consumable fluid reservoir. Thereafter, at  910 , methodology  900  includes installing a top wall to permanently seal the tank, the top wall having a vapor interface for fluid communication with the air chamber. Once permanently sealed, methodology  900  proceeds to terminate at  912 . 
     Variants of methodology  900  can also include installing a mouthpiece adapter in fluid communication with the vapor interface. In embodiments, the tank of methodology  900  is configured to removably couple with a top tank ring in fluid communication with the vapor interface. In further such embodiments, the methodology can include installing an interchangeable filter between the vapor interface and the top tank ring. In alternative or complementary embodiments, the methodology includes installing a power connection in electrical communication with the electrical interface. In further such embodiments, the tank can be configured to removably couple with a bottom tank ring in electrical communication with the electrical interface. Further alternative or complementary embodiments can include installing a wick in fluid communication with the at least one consumable fluid and/or installing an interchangeable cover around the at least one outer side wall. 
       FIG. 10  illustrates an example block diagram of a methodology  1000  for using a tank containing a consumable for vaporization. Methodology  1000  begins at  1002  and proceeds to  1004  where a tank containing a consumable is provided. The tank can have at least one outer side wall, a bottom wall, and a top wall, and further include at least a consumable fluid reservoir containing a consumable fluid. The tank can also include an air chamber through at least a portion of the consumable fluid reservoir and in fluid communication with a vapor interface of the top wall. Also, the tank can include a heating element through at least a portion of the consumable fluid reservoir and in electrical communication with an electrical interface of the bottom wall. At  1006 , methodology  1000  can include attaching a mouthpiece in fluid communication with the vapor interface, and thereafter at  1008 , can include attaching a battery in electrical communication with the electrical interface. Optionally, methodology  1000  can further include providing power to the heating element from the battery. At  1012 , methodology  1000  terminates. 
     In further embodiments, methodology  1000  can also include attaching an interchangeable cover around at least a portion of the at least one outer side wall. In alternative or complementary embodiments, the methodology can include providing an interchangeable filter between the vapor interface and the mouthpiece. 
     In the specification and claims, reference is made to a number of terms described hereafter. The singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Approximating language, as used herein throughout the specification and claims, may be applied to modify a quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Moreover, unless specifically stated otherwise, a use of the terms “first,” “second,” etc., do not denote an order or importance, but rather the terms “first,” “second,” etc., are used to distinguish one element from another. 
     As used herein, the terms “may,” “may be,” “can,” and/or “can be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.” 
     As utilized herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form. 
     To the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. 
     Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.