Patent Publication Number: US-2023142022-A1

Title: Vaping systems and methods of manufacture

Description:
CLAIM FOR PRIORITY 
     CROSS REFERENCE TO RELATED APPLICATION 
     A claim for priority to the Nov. 6, 2021 filing date of U.S. Provisional Pat. Application No. 63/276,566, titled ELECTRONIC VAPING SYSTEM AND METHODS OF MANUFACTURE (“the ′566 Provisional Application”) is hereby made pursuant to 35 U.S.C. § 119(e). The disclosure of the ′566 Provisional Application is incorporated herein in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to devices using liquid inhalable precursors. More specifically, and without limitation, the present disclosure relates to devices for vaping and methods of manufacturing such devices. 
     RELATED ART 
     E-vaping devices, also referred to herein as vaping devices (EVDs), may be used for portable vaping. An e-vaping device may vaporize a pre-vapor formulation, such as an oil that may or may not contain one or more cannabinoids, to form a vapor. The e-vaping device may include a reservoir that holds a pre-vapor formulation and a heating element that vaporizes the pre-vapor formulation by applying heat to at least a portion of the pre-vapor formulation. E-vaping devices are often sold and shipped directly to local oil manufacturers, and then filled with a pre-vapor formulation, and capped by the local oil manufacturers. 
     One drawback EVDs is that they may be susceptible to breaking or cracking when they are filled with oil and capped. For this reason, they may be provided with external metal rings to support the tank or cartridge that acts as the reservoir for the pre-vapor formulation. 
     Another drawback of some vaping devices is the difficulty in achieving the right temperature for the heating element to create vapor. In some cases, the heating element may generate excess heat, which may result in an increased temperature in one or more portions of the cartridge. Excessive heat, internal temperatures, etc., may result in an overheat condition in the cartridge. Overheating of the cartridge may result in degradation of the oil within the cartridge, formation of one or more reaction products which may detract from the sensory experience when included in a vapor, etc. 
     There is a need for improved design of an EVD that has a tank with improved structural integrity that is less susceptible to breaking or cracking during filling, and improved vapor temperature control. 
     SUMMARY 
     According to one aspect, a vaping system may include: a tank with a reservoir for holding a liquid to be vaporized, the tank having a proximal end for connection to a mouthpiece and a distal end for connection to a cartridge base; an atomizer housing within the tank, the atomizer housing comprising a distal base portion for receiving the liquid to be vaporized, an atomizer for vaporizing the liquid, and a central lumen for a vapor to be drawn proximally, the central lumen in connection with the mouthpiece; the mouthpiece attachable to proximal portion of the tank and the central lumen of the atomizer housing; the cartridge base comprising an external wall extending upwardly and forming a slot in the cartridge base between the external wall and the internal wall, the slot for receiving at least a portion of the distal end of the tank. 
     According to another aspect, a vaping system may include: a tank with a reservoir for holding a liquid to be vaporized, the tank having a proximal end for connection to a mouthpiece and a distal end for connection to a cartridge base, the tank further comprising an external rib towards the proximal end of the tank and an internal flange towards the proximal end of the tank; an atomizer housing within the tank, the atomizer housing comprising a distal base portion for receiving the liquid to be vaporized, an atomizer for vaporizing the liquid, and a central lumen for a vapor to be drawn proximally, the central lumen in connection with the mouthpiece; and the mouthpiece attachable to proximal portion of the tank and the central lumen of the atomizer housing. 
     According to yet another aspect, a vaping system may include: a tank with a reservoir for holding a liquid to be vaporized, the tank having a proximal end for connection to a mouthpiece and a distal end for connection to a cartridge base; an atomizer housing within the tank, the atomizer housing comprising a distal base portion for receiving the liquid to be vaporized, an atomizer for vaporizing the liquid, and a central lumen for a vapor to be drawn proximally, the central lumen in connection with the mouthpiece, the central lumen having one or more ridges extending outwardly from the outer edge thereof to cool a vapor within the central lumen; and the mouthpiece attachable to proximal portion of the tank and the central lumen of the atomizer housing. 
     In some embodiments, a proximal end of the central lumen may include at least one projection for a one-way press-fit onto the mouthpiece. The system may include: a tank with a reservoir for holding a liquid to be vaporized, the tank having a proximal end for connection to a mouthpiece and a distal end for connection to a cartridge base, the proximal end of the tank comprising a stepped portion, the stepped portion having a smaller diameter than a diameter of the distal end; an atomizer housing within the tank, the atomizer housing comprising a distal base portion for receiving the liquid to be vaporized, an atomizer for vaporizing the liquid, and a central lumen for a vapor to be drawn proximally, the central lumen in connection with the mouthpiece; and the mouthpiece attachable to proximal portion of the tank and the central lumen of the atomizer housing. 
     Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The following drawings illustrate what are currently considered to be specific representative embodiments for carrying out the disclosed subject matter and are not limiting as to embodiments which may be made in accordance with this disclosure. The components in the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding parts throughout the several views. 
         FIG.  1    is a perspective, exploded view of an embodiment of a vaping system; 
         FIG.  2    is a perspective, cross-sectional view of the vaping system of claim  1  (the mouthpiece portion is not shown for clarity); 
         FIG.  3    is a perspective, partially exploded view of another embodiment of a vaping system; 
         FIG.  4    a perspective view of the vaping system of  FIG.  3   ; 
         FIG.  5    is a perspective view of another embodiment of a vaping system; 
         FIG.  6    is a cross-sectional view of  FIG.  3   ; 
         FIG.  7    is a cross-sectional view of  FIG.  4   ; 
         FIG.  8    is a cross-sectional view of  FIG.  5   ; 
         FIG.  8 A  is a perspective view of a proximal end of another embodiment of a vaping system having an internal support flange; 
         FIG.  9    is a partially exploded perspective view of another embodiment of a vaping system; 
         FIG.  10    is a perspective view of the vaping system of  FIG.  9   ; 
         FIG.  11 A  is a perspective view of the vaping system of claim  9 ; 
         FIG.  11 B  is a perspective, cross-sectional view of the tank portion of the vaping system of  FIGS.  9 - 10   ; 
         FIG.  12    is a cross-sectional view of portions of another embodiment of a vaping device and its associated mouthpiece; 
         FIG.  13    is a front, plan view of the vaping device of  FIG.  12    with the mouthpiece shown in a removed position; 
         FIGS.  14 - 16    are perspective views of various embodiments of atomizer housings having different external geometries on the central post; and 
         FIG.  17    is a perspective, partially exploded view of another embodiment of a vaping device. 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Advantages and features of the present disclosure and methods accomplishing them will become apparent from the following description of embodiments with reference to the accompanying drawings. Various aspects discussed in reference to one drawing may be present and/or used in conjunction with the embodiment shown in another drawing, and each element shown in multiple drawings may be discussed only once. 
     Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the embodiments of the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. In one embodiment, the terms “about” and “approximately” refer to numerical parameters within 10% of the indicated range. 
     Reference in the specification to “one embodiment,” “one embodiment,” “a embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment, but it is not a requirement that such feature, structure, or characteristic be present in any particular embodiment unless expressly set forth in the claims as being present. The appearances of the phrase “in one embodiment” in various places may not necessarily limit the inclusion of a particular element of the invention to a single embodiment, rather the element may be included in other or all embodiments discussed herein. 
     The terms “a,” “an,” “the,” and similar referents used in the context of describing the embodiments of the present disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Thus, for example, reference to “a hole for receiving pre-vapor fluid” may include one or more of such holes. Structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. 
     Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the embodiments of the present disclosure and does not pose a limitation on the scope of the present disclosure. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the embodiments of the present disclosure. 
     Groupings of alternative elements or embodiments disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims. 
     Certain components of the vaping system described herein will be described as being coupled or connected to one another and such connections and couplings may be achieved in any suitable manner. Additionally, such components may be integrated with one another or distributed in any suitable fashion. As used herein, the vaping system may be described as having parts or portions that are more proximal and parts or portions which are more distal. This is relative to the distance from a user’s mouth with the vaping system is in use. For example, the mouthpiece of the vaping system will be more proximal, or on a proximal end of the vaping system. In one embodiment, a portion or feature of the system which is towards the proximal end is closer to the proximal end than the distal end. Similarly, in an embodiment, a portion or feature of the system which is towards the distal end is closer to the distal end than the proximal end. 
     This disclosure generally relates to systems and methods for improved vaping systems. According to one aspect, a vaping system  10  ( FIGS.  1 - 2   ) may generally include: a cartridge tank  15  or body with an interior reservoir may be filled with oil for vaping; a cartridge base  19  for attachment to a distal end of the tank  15 , which may hold an atomizer housing  24  that includes an atomizer or heating element for heating oil to create vapor; and a mouthpiece  30  for attachment to a proximal end of the tank  15 . The base  19  may include a means for connection to a battery to provide power to the heating element (shown, by way of example, as threaded distal projection  33  in  FIG.  1   ). 
     Also shown in  FIG.  1    are the holes  37  in the atomizer housing  24  which allow oil from the reservoir of the tank  15  to enter the atomizer housing  24 , contact one or more heating elements, and be heated into vapor. As the oil is vaporized, it travels upward through the lumen of the central post  39  (as indicated by the arrow in  FIG.  2   ) of the atomizer housing  24  to the mouthpiece  30  to be inhaled by the user. The vaping system  10  may include one or more gaskets or seals  41  between the mouthpiece  30  and the tank  15  to ensure the oil or other pre-vapor formulation does not leak out the mouthpiece  30 . 
     The tank  15  may form a reservoir to hold oil to be vaped, as well as an atomizer to heat the oil to create vapor. Tanks  15  are typically formed of glass or plastics, but may be formed of any suitable material, such as ceramics, mixtures of glass and plastics, etc. The vaping system  10  is often shipped without oil directly to a local oil manufacturer. The oil manufacturer then fills the tanks  15  with the desired oil or other pre-vapor formulation and caps them with a mouthpiece  30 . The filling and capping process is typically done by automatic filling and capping machines, although it can also be done by hand or by any other suitable means. 
     Tanks  15  may be prone to cracking when the tank reservoir is automatically filled with oil and capped with a mouthpiece  30 . For this reason, tanks  15  are often provided with one or more external rings  45  to support the tank  15  and prevent and/or limit tank cracking during filling and capping. In some embodiments, an external ring may be placed towards the proximal end of the tank with a second external ring placed towards the distal end of the tank. To improve ease of manufacturing, it may be desirable to provide additional structural integrity to the tank  15  to eliminate the need for one or more of the external rings. 
     As mentioned above, the system  10  may also include a cartridge base  19  that holds an atomizer housing  24 . The tank  15  may attach to the cartridge base  19  through any suitable means. For example, supporting the tank  15  within the cartridge base  19  may prevent and/or limit tank cracking during filling and capping. In some embodiments, it may be desirable to eliminate an external support ring  45  provided at the base of the cartridge, while still providing support to the tank  15 . In other embodiments, the external support ring  45  may be used. In the embodiment shown in  FIGS.  1 - 2   , the cartridge base  19  may include an external wall  47  that extends upwardly, forming a slot  50  in the cartridge base  19  between the external wall  47  and an internal wall  52 . The slot  50  may be any suitable shape and size and in one embodiment, the slot  50  may be sized to receive at least a portion of the tank  15 . In some embodiments, the external wall  47  may extend up farther to create a larger or deeper slot, or be shorter to create a shallower slot as needed for tank structural support. 
     As the distal end  55  of the tank  15  is positioned within slot  50 , the cartridge base  19  is supported by the external wall  47 . Any outward pressure on the distal end  55  of the tank may be transferred to the external wall  47 . In this embodiment, an external support ring  45  may not be required. In other embodiments, an external support ring may be provided in addition to the slot  50  to support the distal end  55  of the tank  15 . In embodiments where the external support ring at the base of the tank is eliminated, it may simplify and reduce costs of manufacturing and assembly of the vaping system  10 . 
     According to another aspect, the exterior wall  53  of the tank  15  may be stepped  58  or otherwise change in diameter near the distal end  55  of the tank  15 . For example, the wall step down, or change from a first, larger thickness to a second, smaller thickness, near the distal end  55  of the tank  15 . The bottom face of this step-down may provide an interface for the top face of the external wall  47  of the cartridge base  19  to abut when the exterior wall  53  of the tank  15  is placed within the slot  50 . 
     Other embodiments of the vaping system  10  may also be used to eliminate one or more external support rings and/or provide further support to the tank  15  to reduce cracking during the filling and capping process. For example, as shown in  FIGS.  3  through  8   , a rib  60  may be provided towards the proximal end  65  of the tank  15 . The rib  60  may have any desired outward thickness and any desired height. For example,  FIGS.  3  and  4    have a thinner rib  60  compared to the rib  60  shown in  FIG.  5   . Depending on the intended use of the vaping system  10 , the rib  60  may be provided with a suitable thickness and height. 
     Thicker portions of the tank  15  not be desirable in some settings. For example, a tank  15  that has a portion that is thicker or exceeds the rest of the footprint of the tank  15  may not fit well or interface well with other parts of a vaping system, such as a battery, pen, filling machines, etc. However, providing a rib  60  that has a thickness that extends outwardly about 2 mm or less or about 1 mm or less may still allow for the vaping system to interface well with filling machines, batteries, etc. In some embodiments, the rib  60  may be faceted, or have any other suitable shape or size desired, both based on structural support and/or aesthetic appeal. 
     Also shown in  FIGS.  3 - 8    is an internal flange  67 . Similar to the external rib  60 , the flange  64  may serve to increase the stability of the tank  15  and reduce stretching and/or cracking of the tank  15  during the filling and capping process. The flange  64  may also have a suitable thickness, and in some embodiments, the thickness of the flange  64  may be optimized such that the capacity of the reservoir of the tank  15  is not substantially affected by the flange  64 . In some embodiments, an internal flange  64  may be used to support the proximal end  65 , and an external rib  60  may not be required. In other embodiments, the external rib  60  may be used and not the internal flange  64 . 
     The external rib  60  and/or the internal flange  64  may be positioned towards the proximal end of the tank  15 , or in other words, more closely to the proximal end of the tank that towards the distal end. In other embodiments, the external rib and/or the internal flange  64  may be positioned towards the distal end of the tank  15 .  FIG.  8 A  shows a perspective view looking into the tank  15  from the proximal end, with the internal flange  64  visible. The mouthpiece may interface directly or abut the internal flange  64 . 
     The embodiments shown in  FIGS.  3 - 8    may be used to eliminate an external support ring near the proximal end  65  of the tank, while the embodiments shown in  FIGS.  1 - 2    may be used to eliminate an external support ring near the distal end  55  of the tank  15 . It will be appreciated that these two embodiments and aspects of each may also be used in conjunction to eliminate an external support ring at both the proximal end  65  and/or the distal end  55 . 
     Turning now to  FIGS.  9 - 11   , another embodiment is shown which may provide structural support to tank  15 . In this embodiment, the proximal end  65  of the tank  15  may be provided with a stepped opening. The stepped opening may create a proximal portion or stepped portion  70  that has a smaller cross-section compared to the rest of the tank  15 . The stepped portion  70  may be created, for example, by reducing the thickness of the outer wall of the tank  15  near the proximal end  65  of the tank  15 . Alternatively, seen best in  FIGS.  11 A- 11 B , the outer wall and the inner wall may be stepped. 
     The structural support provided by the stepped opening may reduce or eliminate the need for an external support ring at the proximal end of the tank  15 . The shape of the proximal portion  70  may be circular, such that it may fit with a complementary circular mouthpiece  30  for capping in any direction. Alternatively, in some embodiments, the shape of the proximal portion  70  may be “keyed” such that the tank and cartridge base must be in alignment with a complementary mouthpiece in order to be fitted to the mouthpiece  30 . Depending on the desired usage for the vaping system  10 , it may or may not be desirable for the tank  15  to be keyed to the mouthpiece. 
     Additionally, the proximal portion  70  may be provided with one or more features to allow the mouthpiece  30  to snap-fit to the tank  15 . For example, a projection  74  may be provided on the stepped portion  70 , and the mouthpiece  30  may have a complementary notch  76  ( FIG.  11 A ) such that the mouthpiece  30  may be press-fit onto the stepped portion  70  of the proximal end of the tank  15 . 
     The stepped opening of the tank  15  may also allow the mouthpiece  30  to extend longer or farther down the tank  15  when the mouthpiece is in place on the tank. This makes the mouthpiece  30  longer visually, which may be aesthetically pleasing. Additionally, the mouthpiece  30  extending around the proximal end of the tank  15  ensures that as the mouthpiece  30  is capped over the tank  15 , the mouthpiece  30  itself limits any outward bending or cracking of the tank  15 . Any outward pressure on the proximal end of the tank  15  would press outwardly against the interior side of the mouthpiece  30 , and the mouthpiece  30  would structurally support the proximal end of the tank  15 . 
     Mouthpieces may be fit to the tank in any suitable manner. In some embodiments, it may be desirable to have the mouthpiece  30  non-removably attached to the tank  15 . This may ensure a one-way tamper resistant fit. According to one aspect illustrated in  FIGS.  12 - 13   , the mouthpiece  30  may be non-removably attached to the tank  15  by press fit against a bur center post  77  of the tank. In this type of embodiment, the central post  39  of the atomizer housing  24  may be provided with a burred proximal end  77 . This burred proximal end  77  may provide a 1-way connection to the mouthpiece  30 , such that when the mouthpiece  30  is pressed downward onto the burred proximal end  77 , it cannot be removed. This one-way press-fit design may be tamper-resistant. It will be appreciated that this burred proximal end  77  of the central post  39  may be used in conjunction with other designs as described herein. 
     According to another aspect of this disclosure, the exterior of the central post  39  of the atomizer housing may have a faceted or ribbed design ( FIGS.  14 - 16   ). Various geometries are possible, and in some embodiments, one or more ribs extending from the central post  39  may help cool the vapor as it rises from the atomizer proximally through the central lumen to the mouthpiece  30 . Typical geometries may include, for example, an octagon on the exterior of the central post  39   a  ( FIG.  14   ), a hexagon on the exterior of the central post  39   b  ( FIG.  15   ). etc. In other geometries, one or more ribs may extend outwardly from the central post  39   c  ( FIG.  16   ). The number of ribs and spacing may be optimized for temperature control as the ribs may act as heat sinks to cool the vapor as it travels upwardly through the lumen of the central post. 
     Turning now to  FIG.  17   , another method of connecting the mouthpiece  30  to the tank is shown. In this embodiment, a spring steel snap  81  may be provided. The spring steel snap may be press fit into the mouthpiece  30 , and have a central hole therethrough to receive the proximal end of the central post  39 . This may provide a one-way snap to connect the proximal end of the central post  39 —connected to the atomizer housing  24  and cartridge base  19 —to the mouthpiece  30 . The spring steel snap  81  may have a plurality of cut-aways  83  at a proximal edge thereof. The cut-aways  83  may allow the proximal edge a degree of flexibility to be press-fit into the mouthpiece  30 . In the specific embodiment shown in  FIG.  17   , three cut-aways are provided, spaced approximately evenly apart. In other embodiments, more or fewer cut-aways may be provided. The spring steel snap may be formed of stamped metal. Other types of caps may also be used in the mouthpiece to provide one-way, non-removable attachment of the mouthpiece  30  to the proximal end of the tank  15 . 
     While the present methods and devices have been specifically described with respect to use in vaping systems, it will be appreciated that other applications are possible and contemplated herein. The various aspects described above, including elements of the various embodiments described above, can be combined to provide further embodiments. Various portions and components of apparatus within the scope of this disclosure, including for example, structural components, can be formed by one or more various suitable manufacturing processes known to those in the art. Similarly, various portions and components of apparatuses within the scope of this disclosure can be made from suitable materials known to those in the art. 
     The above description has set out various features, functions, methods, and other aspects of the disclosure. Time and further development may change the manner in which the various aspects are implemented. The scope of protection defined by the claims is not intended to be limited to the specific sizes, shapes, features, or other aspects of the disclosed embodiments. The claimed inventions may be implemented or embodied in other forms while still being within the scopes of the concepts disclosed hereby. Also included are equivalents of the elements of the claims that can be made without departing from the scopes of concepts properly protected by the claims that follow.