Patent Publication Number: US-2016235125-A1

Title: Cartomizer E-Cigarette

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a Continuation of, and claims the benefit of, U.S. application Ser. No. 13/629,541, filed Sep. 27, 2012, by Robert Safari and titled “Cartomizer E-Cigarette”, which claims the benefit of U.S. Provisional Application No. 61/541,039 filed Sep. 29, 2011, by Robert Safari and titled “Cartomizer E-Cigarette”, both of which are included by reference herein and for which benefit of the priority date is hereby claimed. 
    
    
     FEDERALLY SPONSORED RESEARCH 
     Not applicable. 
     SEQUENCE LISTING OR PROGRAM 
     Not applicable. 
     FIELD OF INVENTION 
     The present invention relates to electronic cigarettes (e-cigarettes) and, in particular, to a cartomizer e-cigarette in which a battery unit is connected to a cartomizer unit which includes a liquid chamber, an atomization chamber and a guiding wick that provides liquid solution from the liquid chamber to the atomization chamber. 
     BACKGROUND OF THE INVENTION 
     An electronic cigarette, or e-cigarette, is an electronic device that simulates the act of tobacco smoking by producing an inhaled mist or aerosol bearing the physical sensation, appearance, and the flavor and nicotine of inhaled tobacco smoke, without the odor and health risks associated with tobacco cigarettes. An e-cigarette generally uses heat or ultrasonics to vaporize a propylene glycol- or glycerin-based liquid solution into an aerosol for inhalation. 
     E-cigarettes are portable, self-contained cylindrical devices the size of which depends upon battery capacity. E-cigarettes have been designed to resemble actual cigarettes, cigars or even pipes. Some e-cigarettes are reusable, with replaceable and refillable parts; others are disposable. 
     E-cigarettes share three essential components. A “cartridge” serves as a mouthpiece and usually doubles as a small reservoir that holds the liquid that is to be vaporized. An atomizer serves as the heating element responsible for vaporizing the liquid to provide the aerosol mist. A battery unit serves as a battery supply in portable e-cigarette models. Other electronic components necessary for e-cigarette operation are housed within the battery unit. 
     A “cartomizer” option is available for many e-cigarettes. The cartomizer replaces the separate cartridge and atomizer components with a single integrated component, hence the nomenclature “cartomizer.” The cartomizer is disposable, as opposed to stand-alone atomizers that are reusable and comparatively expensive. 
     The cartridge is a small, usually disposable plastic container, with openings on each end. One end is placed in the user&#39;s mouth; the other end attaches to the atomizer. The cartridge serves as both a liquid reservoir and mouthpiece, and as such, must allow the passage of liquid to the atomizer, as well as aerosol from the atomizer back to the user&#39;s mouth without allowing liquid into the mouth. This is usually accomplished using an absorbent sponge-like material placed in the cartridge to keep the liquid in place and which rests on a plastic barrier separating it from the mouthpiece opening. The mouthpiece casing is constructed with side channels that allow aerosol mist to pass from the atomizer, around the liquid reservoir, to the mouthpiece opening and, thus, into the user&#39;s mouth. When the liquid in the cartridge has been depleted, the user can usually chose between refilling it or replacing it with another pre-filled cartridge. 
     The atomizer is a heating element that is responsible for vaporizing the liquid solution. The atomizer typically includes a simple filament and metal mesh to draw the liquid solution in from the cartridge. The atomizer is positioned in the center of the three components. That is, the cartridge attaches to one end of the atomizer and the battery unit attaches to the other end of the atomizer. The atomizer&#39;s filament tends to lose efficiency over time due to a build-up of sediment, or burns out entirely, requiring replacement. 
     Most portable e-cigarette battery units contain a rechargeable lithium-ion battery. The housing for the battery and the electronic circuitry required for operation of the e-cigarette is usually the largest component of the e-cigarette. The battery unit typically contains an electronic airflow sensor so that activation of the e-cigarette is triggered by drawing breath through the device. A colored LED may also be included in the battery unit to announce activation of the e-cigarette. 
     The contents of the liquid solution used to produce aerosol mist in e-cigarettes vary widely, but their common aspects include water and flavorings (e.g., tobacco smoke) in a propylene glycol or glycerin base. Nicotine is also included in solutions intended to fulfill a nicotine replacement role, without the carcinogenic tar associated with tobacco smoke. 
     U.S. Pat. No. 7,832,410, which issued on Nov. 16, 2010, discloses an example of an electronic atomization cigarette. U.S. Pat. No. 7,832,410 is hereby incorporated by reference herein in its entirety to provide background information regarding the present invention. 
     SUMMARY OF THE INVENTION 
     An embodiment of the invention provides a cartomizer unit for use in an electronic cigarette. The cartomizer unit includes a liquid chamber for receiving a liquid solution, an atomization chamber disposed adjacent to the liquid chamber and separated therefrom by a dividing wall, the dividing wall having a dividing wall opening formed therein, and a guiding wick that extends through the dividing wall opening from the liquid chamber to the atomization chamber to supply liquid solution from the liquid chamber to the atomization chamber. 
     The features and advantages of the present invention will be more fully understood and appreciated upon consideration of the following detailed description and accompanying drawings, which set forth illustrative embodiments in which the concepts of the invention are utilized. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which: 
         FIG. 1  is a drawing illustrating an embodiment of a cartomizer e-cigarette in accordance with the concepts of the present invention comprising a battery unit connected to a cartomizer unit. 
         FIG. 2  is a drawing illustrating the battery unit shown in  FIG. 1   
         FIG. 3  is an enlarged drawing illustrating the cartomizer component which is part of the cartomizer unit shown in  FIG. 1 . 
         FIG. 4  is a drawing illustrating the cartomizer unit shown in  FIG. 1 . 
         FIG. 5  is a drawing illustrating the  FIG. 1  embodiment in more detail of a cartomizer e-cigarette wherein the cartomizer unit is connected to the battery unit to provide a unitary cartomizer e-cigarette device. 
     
    
    
     DETAILED DESCRIPTION 
     Before the invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. 
     Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed with the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention. 
     Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein. 
     It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. 
     All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, if dates of publication are provided, they may be different from the actual publication dates and may need to be confirmed independently. 
       FIG. 1  generally shows an embodiment of a cartomizer e-cigarette  100 . The cartomizer e-cigarette  100  includes a cartomizer unit  102  and a battery unit  104  that attaches to the cartomizer unit  102 , as described in greater detail below. 
     Turning now to  FIG. 2 , the battery unit  104  is shown in detail and separated from the cartomizer unit  102 . The battery unit  104  is disposed within a cylindrical battery unit tube  200  to provide a battery unit annular space  204  between an inside wall of the battery unit tube  200  and the battery  206 . In one embodiment, the cylindrical battery unit tube  200  is made from a metal to provide a durable product. In another embodiment, the cylindrical battery unit tube  200  is made from a plastic material to provide a more light weight product that more closely mimics the experience of a real cigarette. In the illustrated embodiment, the battery unit  104  has one or more battery unit air intake openings  202  formed near the “lighted” end of the e-cigarette  100 . The one or more battery unit air intake openings  202  are in air flow communication with the battery unit annular space  204 . The battery unit  104  includes a battery (e.g., a rechargeable lithium-ion battery)  206  that is electrically connected to switch controller circuitry  208 . Switch controller circuitry  208  provides an activation signal to the heating element in the cartomizer unit  104  as discussed hereunder. A pressure sensor  210  is connected to the switch controller circuitry  208  and is in air flow communication with the one or more battery unit air intake openings  202 . The pressure sensor  210  responds to an air pressure change stimulus by causing the switch controller circuitry  208  to provide the activation signal to the heating element in the cartomizer unit  104 . 
     In the illustrated embodiment, a light emitting diode (LED)  212  is communicatively connected to the switch controller circuitry  208 . A light cap  214  fits into an open end of the battery unit tube  200 . The light cap  214  may be translucent and tinted so that, when the LED  212  is illuminated in response to the activation signal received from the switch controller circuitry  208 , the light cap  214  simulates the burning end of a lit tobacco cigarette. Battery units of the type described above are commercially available from Desay Polypower Battery Co., Ltd. located in Guangdong, China. 
     In the illustrated embodiment, a second threaded male brass fitting  216  is disposed at a second end of the battery tube  200 . The second fitting  216  has an axial second air flow opening  218  formed therein. The second fitting  216  further includes one or more second fitting air intake openings  220  formed therein to provide air flow communication through the second fitting  216  to the battery unit annular space  204 . The second fitting  216  is adapted for sealing connection to the first fitting of the cartomizer unit  104  such that the axial second fitting air flow opening  218  aligns with the axial first fitting air flow opening of the cartomizer unit  104  to provide air flow communication between the battery unit annular space  204  and the cartomizer annular space in the cartomizer unit  104 , as more fully described below. 
     Turning now to  FIG. 3 , the cartomizer component  300  of the cartomizer unit  104  is shown in detail. In the illustrated embodiment, the cartomizer component  300  includes a liquid chamber  310  that contains a liquid solution. In some embodiments, the liquid chamber  310  is refillable by removing the liquid chamber end cap  315  and introducing new liquid solution to the liquid chamber  310 . In other embodiments, the liquid chamber end cap  315  may be configured with an air intake opening  370  covered with a semi-permeable membrane  375  allowing air into the liquid chamber while retaining the liquid solution within the liquid chamber. In other embodiments, the liquid chamber  310  may be sealed. In either case, the cartomizer component  300  may be removable and may be replaced with a new cartomizer component  300  that contains new liquid solution in the liquid chamber  310 . The liquid solution in the replacement cartomizer component  300  may be the same as or different than the liquid solution contained in the previous cartomizer component  300 . The liquid solution typically is a propylene glycol- or glycerin-based solution of the type well known to those skilled in the art. The liquid solution typically includes a flavoring, e.g., tobacco, and may also include nicotine, as is also well known to those skilled in the art. 
     In the illustrated embodiment, the cartomizer component  300  further includes an atomization chamber  320  disposed adjacent to the liquid chamber  310  and separated therefrom by a dividing wall  325  that has a dividing wall opening  330  formed therein. A guiding wick  335 , e.g., a cotton wick, extends through the dividing wall opening  330  from the liquid chamber  310  to the atomization chamber  320  to supply liquid solution from the liquid chamber  310  to the atomization chamber  320 . In the illustrated embodiment, an atomization chamber air intake opening  340  is formed in an end wall  345  of the atomization chamber  320 . In one embodiment of the invention, the atomization chamber air intake opening  340  is an oval shape and disposed diagonally in the end wall  345 . Those skilled in the art will appreciate that one or more air intake openings may be formed in the walls of the atomization chamber  320 . The atomization chamber  320  also has one or more vapor exit openings  365  formed therein to provide liquid solution aerosol mist communication between the atomization chamber  320  and the cartomizer unit annular space, as discussed in greater detail below. 
     A heating element  350  is disposed within the atomization chamber  320  in proximity to the guiding wick  335 . In the illustrated embodiment, the heating element  350  comprises a simple wire coil filament that is wrapped around a cylindrical insulating core. The heating element  350  responds to an activation signal by vaporizing the liquid solution supplied to the atomization chamber  320  to provide liquid solution aerosol mist. 
     Turning now to  FIG. 4 , the cartomizer component  300  is shown disposed in the cartomizer unit  102 . The generally cylindrical cartomizer component  300  is disposed within a cylindrical mouthpiece tube  400 . In one embodiment, the cylindrical mouthpiece tube  400  is made from a metal to provide a durable product. In another embodiment, the cylindrical mouthpiece tube  400  is made from a plastic material to provide a more light weight product that more closely mimics the experience of a real cigarette. The cartomizer component  300  is of lesser diameter than the mouthpiece tube  400  so as to provide a cartomizer unit annular space  405  between the inside wall of the mouthpiece tube  400  and the outside wall of the cartomizer unit  102 . In some embodiments, a plurality of spaced apart ribs  305  are formed on the outside wall of the cartomizer component  300  to provide stability to the cartomizer component  300  within the mouthpiece tube  400  while still permitting air flow in the cartomizer unit annular space  405 . The mouthpiece tube  400  has a draw opening  410  formed in it so that a user can apply the inhale portion of the user&#39;s breath to the cartomizer unit annular space  405 . In the illustrated embodiment, a draw end cap  415 , e.g., a plastic cap, covers the draw end of the cylindrical mouthpiece tube  400  except for the axially located draw opening  410  formed through the cap  415 . 
     The illustrated embodiment also includes a metal mesh pad  420  and a porous vinyl foam pad  425  disposed within the mouthpiece tube  400  between the liquid chamber  310  and the draw end of the mouthpiece tube  400 . Both the metal mesh pad  420  and the vinyl foam pad  425  are circular in shape and of approximately the same diameter as the inner wall of the mouthpiece tube  400 . The metal mesh pad  420  and the vinyl foam pad  425  remove liquid solution droplets that may exist within the aerosol mist passing from the cartomizer unit annular space  405  to the draw opening  410  to prevent the liquid solution droplets from reaching the user&#39;s mouth during a user inhale. 
     As discussed above, the illustrated cartomizer unit  102  is, in keeping with the cylindrical shape of the e-cigarette  100 , a generally cylindrical unitary structure that may be formed in a variety of physical formations and may be formed by any suitable technique well known to those skilled in the art, including encapsulation techniques. The cartomizer component  300  may be made of any suitable material well known to those skilled in the art, such as those used for drug delivery, liquid encapsulated capsules, or other encapsulation materials. Single wall or multi-wall structures may be used to tailor stability, strength and rupture resistance of the cartomizer component  300 . 
     In the illustrated embodiment, a first threaded female brass fitting  435  is disposed at a second end of the mouthpiece tube  400 . The first fitting  435  has an axial air flow opening  445  formed therein to enable air flow through the first fitting  435  to the cartomizer unit annular space  405 . The first fitting  435  also includes one or more first fitting air intake openings  440  formed at the end of the threaded portion of the first fitting  435 . 
       FIG. 5  shows the sealed connection of the cartomizer unit  102  and the battery unit  104  by the threaded engagement of the male fitting  216  of the battery unit  104  with the female fitting  435  of the cartomizer unit  102  to provide the unitary structure of the cartomizer e-cigarette  100 .  FIG. 5  further shows that, when the first and second fittings are connected, the one or more first fitting air intake openings  440  are in air flow communication with the one or more second fitting air intake openings  220  to provide air intake flow to the battery unit annular space  204 . 
     With reference to  FIG. 5 , when a user applies an inhale portion of the user&#39;s breath to the mouthpiece end of the cartomizer unit  102 , the pressure sensor  210  senses a pressure change in the interior of the e-cigarette  100  and causes the switch controller circuitry  208  to activate the heating element  350  by applying a current from the electronically connected battery  206 , thereby producing a liquid solution aerosol mist in the atomization chamber  320 . The user&#39;s inhale also causes air intake at the first fitting air intake openings  440 , which is passed through the second fitting air intake openings  220 , through the axial second air flow opening  218  and axial first air flow opening  445  in the second fitting  216  and first fitting  435 , respectively, to combine with the liquid solution aerosol mist formed in the atomization chamber  320  and pass through cartomizer unit annular space  405  and the draw end opening  410  into the user&#39;s mouth. At the same time, air flow passes through the battery unit air intake openings  202 , through the battery unit annular space  204  and the axial second air flow opening  218  and axial first air flow opening  445  in the second fitting  216  and first fitting  435 , respectively, to also combine with the liquid solution aerosol mist flowing to the user&#39;s mouth through the draw opening  410 . 
     It should be further understood that the examples and embodiments pertaining to the systems and methods disclosed herein are not meant to limit the possible implementations of the present technology. Further, although the subject matter has been described in a language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the Claims. 
     Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. 
     Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. 
     Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.