Patent Publication Number: US-2019174828-A1

Title: Heating element and heater assemblies, cartridges, and e-vapor devices including a heating element

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. application Ser. No. 15/135,930, filed Apr. 22, 2016, which claims priority to U.S. provisional application No. 62/151,809 filed on Apr. 23, 2015, the entire contents of each of which are hereby incorporated by reference. 
    
    
     BACKGROUND 
     Field 
     At least some example embodiments relate generally to an electronic vaping (e-vaping or e-vapor) device. 
     Related Art 
     Electronic vaping devices are used to vaporize a pre-vapor formulation into a vapor. These electronic vaping devices may be referred to as e-vaping devices. E-vaping devices include a heater, which vaporizes the pre-vapor formulation to produce the vapor. The e-vaping device may include several e-vaping elements including a power source, a cartridge or e-vaping tank including the heater and a reservoir capable of holding the pre-vapor formulation. 
     SUMMARY 
     At least one example embodiment relates to a heater assembly. 
     In at least one example embodiment, a heater assembly comprises a heating element including a planar portion including a filament, the filament defining an air channel through the planar portion, the filament arranged so as to form a plurality of curves, each of the curves having a closed end and an open end, and at least one of the curves having a tip thereon, a first lead portion, and a second lead portion. At least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion are generally coplanar with the planar portion of the heating element. The heater assembly also includes a support. The heating element is in contact with the support such that the tip of the at least one of the curves rests thereon. 
     In at least one example embodiment, at least one of the curves generally has a keyhole shape. In at least one example embodiment, at least one of the curves generally has an omega shape. In at least one example embodiment, at least one of the curves generally has a U-shape. In at least one example embodiment, the tip extends from the closed end of the at least one of the curves. In at least one example embodiment, the filament defines the air channel through a central area of the planar portion. In at least one example embodiment, the tip of the at least one of the curves extends away from the air channel, and the open end of each of the curves is adjacent the air channel. 
     In at least one example embodiment, the filament includes stainless steel. In at least one example embodiment, the filament follows a circuitous path. A width of the filament varies along the circuitous path. In at least one example embodiment, a width of the filament gradually increases in a direction away from the air channel. 
     In at least one example embodiment, the first lead portion extends into the air channel and the second lead portion extends away from the air channel. 
     In at least one example embodiment, the first lead portion and the second lead portion extend away from the air channel. The support includes a support ring. In at least one example embodiment, the support ring is formed of one or more materials including polyetheretherketone. In at least one example embodiment, the support ring includes at least one electrical contact molded within the support ring. In at least one example embodiment, the tip has a generally trapezoidal shape. In at least one example embodiment, the tip has a generally rectangular shape. In at least one example embodiment, the tip has a generally triangular shape. 
     In at least one example embodiment, at least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion having a generally spiral shape. 
     In at least one example embodiment, at least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion having a generally L-shape. 
     At least one example embodiment relates to a cartridge for an e-vapor device. 
     In at least one example embodiment, a cartridge for an e-vapor device, comprises a housing, a reservoir in the housing, a transfer material adjacent a portion of the reservoir, and a heater assembly. The heater assembly includes a heating element and a support. The heating element includes a planar portion including a filament, the filament defining an air channel through the planar portion, the filament arranged so as to form a plurality of curves, each of the curves having a closed end and an open end, and at least one of the curves having a tip thereon, a first lead portion, and a second lead portion. At least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion are generally coplanar with the planar portion of the heating element. The heating element is in contact with the support such that the tip of the at least one of the curves rests thereon. 
     In at least one example embodiment, the planar portion, the first lead portion, and the second lead portion are a unitary body. 
     In at least one example embodiment, the cartridge further comprise an inner tube within the housing. The inner tube defines an airway through the housing, and an outer surface of the inner tube and an inner surface of the housing at least partially define a portion of the reservoir. 
     In at least one example embodiment, the filament includes stainless steel. The filament follows a circuitous path. In at least one example embodiment, a width of the filament varies along the circuitous path. In at least one example embodiment, the width of the filament gradually increases in a direction away from the air channel. In at least one example embodiment, the first lead portion extends into the air channel and the second lead portion extends away from the air channel. In at least one example embodiment, the first lead portion and the second lead portion extend away from the air channel. 
     In at least one example embodiment, the support includes a support ring. The support ring is formed of one or more materials including polyetheretherketone. The support ring includes at least one electrical contact molded within the support ring. 
     In at least one example embodiment, the tip of the at least one of the curves has a generally trapezoidal shape. In at least one example embodiment, the tip of the at least one of the curves has a generally rectangular shape. In at least one example embodiment, the tip of the at least one of the curves has a generally triangular shape. 
     In at least one example embodiment, at least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion having a generally spiral shape. In at least one example embodiment, at least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion having a generally L-shape. 
     In at least one example embodiment, the support is a generally cylindrical wall having a top edge, and the tip of the at least one of the curves rests on the top edge of the generally cylindrical wall. In at least one example embodiment, at least one of the curves generally has a keyhole shape. In at least one example embodiment, at least one of the curves generally has an omega shape. In at least one example embodiment, at least one of the curves generally has a U-shape. In at least one example embodiment, the tip extends from the closed end of the at least one of the curves. In at least one example embodiment, the tip has a generally pointed shape. 
     In at least one example embodiment, the heating element is in contact with the transfer material. 
     In at least one example embodiment, the tip of the at least one of the curves has a generally pointed shape. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated. 
         FIGS. 1A-1C  are perspective views of a heating element and portions of the heating element according to at least one example embodiment. 
         FIGS. 2A and 2B  illustrate a heating element according to at least one example embodiment. 
         FIGS. 3A and 3B  are perspective views of heating elements according to at least one example embodiment. 
         FIGS. 4A and 4B  are cross-sectional views of an e-vapor device including a heating element according to an example embodiment. 
         FIGS. 5A-5H  illustrate elements of a cartridge of the e-vapor device in  FIG. 4 . 
         FIG. 6  is a three-dimensional rendering of the cartridge shown in  FIGS. 5A and 5B . 
         FIG. 7  is a perspective view of a heater assembly according to at least one example embodiment. 
         FIG. 8  is a partial cross-sectional view of a cartridge including the heater assembly of  FIG. 7  according to at least one example embodiment. 
         FIG. 9  is a perspective view of a heating element for use in the cartridge of  FIG. 8  according to at least one example embodiment. 
         FIG. 10  is a top view of a heater assembly including a heating element according to at least one example embodiment. 
         FIG. 11  is an exploded view of the heater assembly of  FIG. 10  according to at least one example embodiment. 
         FIG. 12  is an exploded view of a cartridge including the heating element of  FIG. 10  according to at least one example embodiment. 
         FIG. 13  is a perspective view of a heater assembly according to at least one example embodiment. 
         FIG. 14  is a perspective view of a heater assembly according to at least one example embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     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. 
     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. 
     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. 
     It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, regions, layers and/or sections, these elements, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments. 
     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. 
     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, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof. 
     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 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. 
     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. 
       FIGS. 1A-1C  are perspective views of a heating element and portions of the heating element according to at least one example embodiment. 
       FIG. 1A  illustrates a heating element  10  for an e-vapor device. The heating element  10  includes a planar portion  20  having at least one filament  50 . The filament  50  may define an air channel  60  through the planar portion  20 . For example, the filament  50  defines the air channel  60  through a central area of the planar portion  20  (e.g., such that air flowing through the central area is unobstructed). The air channel  60  may have a substantially circular shape. 
     The planar portion  20  (with the filament  50 ) may have a substantially flat or planar structure. Alternatively, a portion of the filament  50  may be punched in or punched out so as to change the flat structure into a three-dimensional structure. This may allow for the heating element  10  to heat additional surface area of a porous substrate of an e-vapor device. The structure of the filament  50  is described in further detail below with reference to  FIGS. 1B and 1C . 
     The heating element  10  may include stainless steel or alloy thereof. Stainless steel (e.g., stainless steel  304 ) has a relatively high temperature coefficient, which allows for accurate temperature control of the filament  50 . Alternatively, the heating element  10  may include Nichrome (e.g., 80% nickel, 20% chromium) or other materials. Examples of other suitable electrically resistive materials for the heating element  10  include titanium, zirconium, tantalum, and metals from the platinum group. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, and stainless steel. For instance, the heating element  10  may include nickel aluminides, a material with a layer of alumina on the surface, iron aluminides, and other composite materials. The electrically resistive material may optionally be embedded in, encapsulated, or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required. In a non-limiting example embodiment, the heating element  10  may comprise at least one material selected from the group consisting of stainless steel, copper, copper alloys, nickel-chromium alloys, superalloys, and combinations thereof. In another non-limiting example embodiment, the heating element  10  includes iron-chromium alloys. A higher resistivity for the heating element  10  lowers the current draw or load on the power supply or battery of an e-vapor device. 
     Still referring to  FIG. 1A , the heating element  10  may include a first lead portion  30  and a second lead portion  40  extending away from the planar portion  20 . For example, the first lead portion  30  and the second lead portion  40  extend away from the planar portion  20  in a direction that is substantially perpendicular to the planar portion  20 . As shown in  FIG. 1A , the planar portion  20 , the first lead portion  30 , and the second lead portion  40  are a unitary body, which allows for efficient manufacturing of the heating element  10 . For example, the heating element  10  may be initially formed as a substantially flat element before first and second lead portions  30  and  40  are bent as shown in  FIG. 1A . Accordingly, the heating element  10  may be referred to as a single piece heating element. A tip  31  of the first lead portion  30  and a tip  41  of the second lead portion  40  may be bent or bendable in a direction that is parallel to the planar portion  20  (this bending is explicitly shown in  FIGS. 2B and 5B , for example). 
     A height H 10  of the heating element  10  may be between 6.0 mm and 10 mm, for example, 8.5 mm. A width W 10  of the heating element  10  may be between 4.5 mm and 5 mm, for example, 4.72 mm. A width W 20  of the first lead portion  30  and the second lead portion  40  may be between 1.0 mm and 3.0 mm, for example, 1.9 mm. A length L 10  of the heating element  10  may be between 4.7 mm and 7.8 mm, for example, 7.4 mm. A thickness T 10  of the planar portion  20  may be between 0.05 mm and 0.30 mm, for example, 0.10 mm. The thickness T 10  may be uniform throughout the planar portion  20 , the first lead portion  30 , and the second lead portion  40 . However, example embodiments are not limited thereto. For example, the thickness of the planar portion  20  may be less than a thickness of the first lead portion  30  and the second lead portion  40 . 
     The first lead portion  30  and the second lead portion  40  may be substantially rectangular shaped and have step portions  33  and  35  at ends closest to the planar portion  20 . Step portions  35  may rest on a surface of a support for the heating element  10  while step portions  33  may provide a force that allows for the heating element  10  to be push fit into the support (see support  350  in  FIGS. 5A and 5B , for example). Although two step portions  33  and  35  are shown, the first and second lead portions  30  and  40  may have one step portion or additional step portions as desired. 
     As illustrated in further detail by  FIG. 1B , the filament  50  may follow a circuitous or sinuous path  51  to define the air channel  60 . For example, the filament  50  may follow the circuitous path  51  such that the air channel  60  is substantially circular and has a diameter d 10  between 1.2 mm and 2.0 mm, for example, 1.6 mm. The filament  50  may have a diameter d 20  between 3.0 mm and 7.0 mm, for example, 4.1 mm. The filament  50  may be spaced apart from other sections of the planar portion  20  except at connection points  25  and  26 . As a result, the electrical connection between the first lead portion  30  and the second lead portion  40  is through the filament  50  (i.e., during operation, current must travel between lead portions  30  and  40  through filament  50  and parts of the planar portion  20  connected to the connection points  25  and  26 ). 
     As illustrated in further detail by  FIG. 1C , the filament  50  includes a plurality of filament portions  70  that are substantially u-shaped. The plurality filament portions  70  change from one to the other at end sections  80  of each u-shape. As further illustrated by  FIG. 1C , a width of the filament  50  may vary along the circuitous path  51 . For example, as indicated by increasing widths W 30 , W 40 , and W 50 , the width of the filament  50  gradually increases in a direction away from the air channel  60 . A width W 30  may be between 0.05 mm and 0.30 mm, for example. A width W 40  may be between 0.05 mm and 1.0 mm, for example 0.16 mm. A width W 50  may be between 0.25 mm and 1.00 mm, for example, 0.65 mm. A length L 20  of each filament portion  70  may be between 0.5 mm and 3.5 mm, for example, 2.5 mm. It should be understood that a number of filament portions  70  may vary as desired. For example, the number of filament portions  70  may be between 3 and 25. 
     Spaces  110  between adjacent ones of the plurality of filament portions  70  may gradually increase in a direction away from the air channel  60 . For example, a width W 60  of the space  110  closest to the air channel  60  may less than a width W 70  of the space  110  furthest from the air channel  60 . In at least one example embodiment, a width W 60  and a width W 70  may be set so that a widest section of the spaces  110  at width W 70  occupies between 2° and 90°, for example, 8.3° of a 360° circle around the filament  50  (shown in  FIG. 1C  by angle θ). The same dimensions may be set for widths W 75  and W 80  of spaces  111  between u-shaped portions of each filament portion  70 . However, example embodiments are not limited thereto, and the spaces  110  and the spaces  111  may have different dimensions as desired. A length L 30  between an end of space  111  that is furthest from the air channel  60  and a part of the u-shaped portion furthest away from the air channel  60  may be between 0.1 mm and 0.7 mm, for example, 0.3 mm. 
     A thickness T 20  of the filament portions  70  may be between 0.05 mm and 0.30 mm, for example, 0.10 mm. 
     Due to the above described structure, the filament  50  may generate a gradient of heat that is most intense near the air channel  60  and gradually dissipates in a direction away from the air channel  60 . It should be understood that an electrochemical etching process may be used to manufacture heating element  10  with the above described dimensions. Alternatively, the heating element  10  may be formed using a stamping process. It should also be understood that some parts of or the entire heating element  10  may be scaled up or down (e.g., scaled up 2.5 times larger than described above) depending on the desired implementation an e-vapor device. 
       FIGS. 2A and 2B  illustrate a heating element according to at least one example embodiment. For example,  FIG. 2A  is a top-view of a heating element  10 ′ before bending and  FIG. 2B  is a perspective view of the heating element  10 ′ after bending. 
     As illustrated in  FIGS. 2A and 2B , heating element  10 ′ is similar to the heating element  10  in  FIGS. 1A-1C , and includes a planar portion  20 ′, a first lead portion  30 ′, a second lead portion  40 ′. However, heating element  10 ′ does not include an air channel  60  through the filament  50 ′. The transition from  FIG. 2A  to  FIG. 2B  shows how the heating element  10 ′ in  FIG. 2A  is bent along the dotted lines to form the heating element  10 ′ in  FIG. 2B  with bent first and second lead portions  30 ′ and  40 ′ and bent tips  31 ′ and  41 ′. It should be appreciated that tips  31  and  41  in  FIG. 1  may be bent in the same mariner as shown by tips  31 ′ and  41 ′ in  FIG. 2B . 
       FIGS. 3A and 3B  are perspective views of heating elements according to at least one example embodiment. 
       FIG. 3A  is a perspective view of a dual heating element according to at least one example embodiment. The dual heating element  10 ″ may include two or more heating elements (e.g., two heating elements  10  from  FIG. 1 ) stacked on top of one another. The heating elements  10  may be electrically connected to one another via welding, soldering, or a pressure-based connection. If a porous substrate in fluid communication with a pre-vapor formulation is placed between the two heating elements  10 , the dual heating element  10 ″ may uniformly heat both sides of the porous substrate to create a high efficiency vapor production. A pre-vapor formulation is a material or combination of materials that may be transformed into a vapor. For example, the pre-vapor formulation may be a liquid, solid, and/or gel formulation including, but not limited to, water, beads, solvents, active ingredients, ethanol, plant extracts, natural or artificial flavors, and/or vapor formers such as glycerine and propylene glycol. 
     Although  FIG. 3A  shows that the dual heating element  10 ″ may be formed from two heating or more elements  10 , it should be understood that the dual heating element  10 ″ may include two or more heating elements  10 ′ from  FIGS. 2A and 2B , or one or more heating elements  10  and one or more heating elements  10 ′ stacked in a desired configuration. 
       FIG. 3B  is a perspective view of a heating element according to at least one example embodiment.  FIG. 3B  illustrates a heating element  10 ′″ with a filament  50 ′″ that defines an opening  60 ′″. The heating element  10 ′″ may have substantially the same dimensions as the heating element  10  from  FIGS. 1A-1C  except that the filament  50 ′″ has filament portions  70 ′″ that have a substantially same width and substantially rounded ends throughout the circuitous or sinuous path. 
       FIGS. 4A and 4B  are cross-sectional views of an e-vapor device including a heating element according to an example embodiment. 
       FIGS. 4A and 4B  illustrate sections of an e-vapor device  200 . For example, the e-vapor device  200  may have a mouthpiece section  210 , a cartridge  220 , and a power supply section  230 . The mouthpiece section  210  may fit (e.g., pressure fit, or thread fit) onto the cartridge  220  in order to allow for an adult vaper to apply a negative pressure to the mouthpiece section  210  and draw vapor from e-vapor device. It should be understood that the mouthpiece  210  may be excluded from the configuration shown in  FIGS. 4A and 4B  or integrated with the cartridge  220  to reduce the number of parts. The cartridge  220  may include a heating element (e.g., one of the heating elements of  FIGS. 1A-3 ). The cartridge  220  may be replaceable. The cartridge  220  is described in more detail below with reference to  FIGS. 5A-5H, and 6 . The cartridge  220  and the power supply section  230  may be releasably connected (e.g., by a threading engagement). Alternatively, the cartridge  220  and the power supply section  230  may be in a unitary housing. 
     The power supply section  230  may be configured to selectively supply power to the heating element in the cartridge  220  via a battery  250 . The power supply section  230  may include an indicator  235 , control electronics  240 , battery  250 , air inlet  255 , conductive post  260 , and a connector  265 . The indicator  235  may be, for example, a light emitting diode (LED) located at one end of the power supply section  230 . The LED may flash different colors and/or different patterns to indicate different information about the e-vapor device  200 . For example, the LED may flash one color to indicate activation of the e-vapor device  200  and another color to indicate a battery level of the battery  250 . However, example embodiments are not limited thereto, and the LED may be used to indicate other information through various colors and patterns of flashes. 
     The battery  250  may selectively supply power to the indicator  235 , the control electronics  240 , and the heating element  10  (see  FIGS. 5A and 5B ). For example, the battery  250  may selectively supply power under a control of the control electronics  240 . The control electronics  240  may include control circuitry including a puff sensor for sensing a negative pressure applied by an adult vaper. The puff sensor is operable to sense an air pressure drop in the e-vapor device  200 , which causes the control electronics  240  to initiate the application of voltage from the battery  250  to the heating element  10 . For example, if the puff sensor indicates that an adult vaper is applying a negative pressure to the e-vapor device  200 , the control electronics  240  initiates a puff cycle by connecting the battery  250  to the heating element  10  to heat the heating element  10 , thereby vaporizing a pre-vapor formulation in a porous substrate in contact with the heating element  10 . Upon termination applying negative pressure by an adult vaper, the puff sensor ceases to sense the air pressure drop and the control electronics  240  disconnects the battery  250  from the heating element  10  to end the puff cycle. 
     The control electronics  240  may be between the indicator  235  and the battery  250  within the power supply section  230 . The connector  265  may facilitate a threaded connection to the cartridge  220 . For example, the threaded connection may be a combination of a conductive male threaded member on the connector  265  and a conductive or non-conductive female threaded receiver on the cartridge  220  (or vice versa). Alternatively, the threaded connection may be in a form of other suitable structures, such as a snug-fit, detent, clamp, and/or clasp arrangement. Although not explicitly shown, one terminal of the battery  250  is electrically connected to the conductive post  260  and the other terminal of the battery  250  is electrically connected to the connector  265  via the control electronics  240 . 
     The power supply section  230  may include an air inlet/outlet  255  at an end of the power supply section  230  nearest to the control electronics  240 . As shown by the arrows in in  FIG. 4B , when air is drawn through the mouthpiece  210 , air enters the tip of the e-vapor device  200  at air inlet/outlet  255 , travels past the control electronics  240  that includes the puff sensor through the spaces provided around the puff sensor (thereby detecting a negative pressure and activating the heating element  10 ), and continues past the battery  250 . The air then goes through an opening in the axis of a conductive post  260  of the battery&#39;s  250  male connector, and straight into a conductive rivet engaged with the female connector of the cartridge  220  (see element  360  in  FIGS. 5A and 5B ). The air is then inundated with particles of vapor (produced by the heating of a porous substrate containing a pre-vapor formulation as a result of the activated heating element  10 ) and exits through the mouthpiece section  210 . As shown by the return arrows in  FIG. 4B , excess vapor travels through the e-vapor device  200  and may be exhausted from the air inlet/outlet  255 . 
     Although  FIGS. 4A and 4B  shows one air inlet/outlet  255 , the e-vapor device  200  may include additional air inlets/outlets at other locations on the e-vapor device, for example, at or closer to a connection between the cartridge  220  and the power supply section  230 . This may allow for air intake at other locations of the e-vapor device  200 . 
     The battery  250  may be a Lithium-ion battery or one of its variants (e.g., a Lithium-ion polymer battery). The battery  250  may also be a Nickel-metal hydride battery, a Nickel cadmium battery, a Lithium-manganese battery, a Lithium-cobalt battery, or a fuel cell. 
       FIGS. 5A-5H  illustrate elements of a cartridge of the e-vapor device in  FIG. 4 . 
     For example,  FIG. 5A  is an exploded view of a cartridge of the e-vapor device shown in  FIG. 4 .  FIG. 5B  is a cross-sectional view of the cartridge in  FIG. 5A  taken along line VB-VB′.  FIGS. 5C-5H  illustrate the details of various parts of the cartridge shown in  FIGS. 5A and 5B . 
       FIGS. 5A and 5B  illustrate that the cartridge  220  includes a housing  300 . The housing  300  may include a reservoir portion  310  and a connector portion  320 . The connector portion  320  is configured to connect the cartridge  220  to a power supply section (e.g., the power supply section  230  in  FIG. 4 ). With reference to  FIGS. 5A, 5B, and 5C , the connector portion  320  may be substantially hollow and have a substantially cylindrical shape. The connector portion  320  may include a female thread  321  for releasably engaging with a male thread of the connector  265  of power supply section  230  in  FIG. 4 . The connector portion  320  may be made of, for example, a synthetic polymer or other material suitable for e-vapor devices such as solid plastic, and/or metal (e.g., stainless steel). An inner wall of the connector portion  320  may be conductive or non-conductive. The connector portion  320  may include substantially rectangular tabs (e.g., flexible tabs)  510  and  520  on opposing edges of the connector portion  320 . The tabs  510  and  520  provide a releasable snap fit connection to connection points  490  of the reservoir portion  310  (see  FIG. 6 ). A body  525  of the connector portion  320  may have a height H 20  of between 3.0 mm and 10.0 mm, for example, 4.70 mm. A diameter D 30  of the connector portion  320  may be between 8.5 mm and 9.5 mm, for example, 9.0 mm. The diameter D 30  may be larger or smaller depending on the application. For example, diameter D 30  may be the same as the diameter D 35  of the reservoir portion  310 . Alternatively, the connector portion  320  and the power supply section  230  may be fixed together (i.e., not releasable). 
     With reference to  FIGS. 5A, 5B, and 5D , the reservoir portion  310  is a storage portion configured to store a pre-vapor formulation in a cavity  311  of the reservoir portion  310 . Although not shown, the cavity  311  may include a pre-vapor formulation containing material (e.g., a material to draw the pre-vapor formulation via capillary action). The reservoir portion  310  may have a substantially cylindrical shape and be made of, for example, a synthetic polymer or other material suitable for e-vapor devices such as, glass, ceramic, and/or metal (e.g., stainless steel). The reservoir portion  310  may have a closed end, an open end, and a cylindrically shaped inner tube  315  may define an airway  600  that passes through a central area of the reservoir portion  310  from the closed end to the open end. The airway  600  may have a diameter of between 1.0 mm and 4.0 mm, for example, 1.60 mm. The reservoir portion  310  may have a height H 30  of between 15 mm and 60 mm, for example, 32.9 mm. The reservoir portion  310  may have a diameter D 35  of between 6.5 mm and 25 mm, for example, 9.0 mm. That is, the reservoir portion  310  and the connector portion  320  may have a same diameter. The reservoir portion  310  includes at least two connection points  490  (due to the symmetry of reservoir portion  310 , only one connection point  490  is shown in  FIGS. 5A and 5D ). Tabs  510  and  520  of the connector portion  320  may be releasably engaged with the at least two connection points  490  (see  FIG. 6 ). 
     With reference to  FIGS. 5A, 5B, and 5E , the reservoir portion  310  includes a porous substrate  400  in fluid communication with the cavity  311 . The porous substrate  400  may be substantially disc shaped and have a diameter of between 5.0 mm and 24 mm, for example, 8.0 mm. The porous substrate may have a thickness T 30  between 0.5 mm and 2.0 mm, for example, 1.0 mm. The porous substrate  400  may have a capacity to draw a pre-vapor formulation via capillary action as a result of the interstitial spacing between filaments of the porous substrate  400 . For example, the porous substrate  400  may be a ceramic material or other porous material capable of withstanding varying temperatures of the heating element  10  such as a ceramic, mineral fibrous material, metal (in a honeycomb or mesh structure), and glass fibers. A central area of the porous substrate  400  includes an opening  410  with a diameter D 40  between 1.0 mm and 4.0 mm, for example, 2.0 mm. The opening  410  may be aligned with the air channel  60  of the heating element  10  and with the airway  600  of the reservoir portion  310 . 
     With reference to  FIGS. 5A, 5B, and 5F , the reservoir portion  310  includes a gasket  420  configured to provide the fluid communication between the porous substrate  400  and the cavity  311 . The gasket  420  may include rubber or silicon, or some other material capable of preventing pre-vapor formulation in the cavity  311  from passing between the gasket  420  and walls of the reservoir portion  310  such as organic elastomers and/or inorganic elastomers. The gasket  420  may have a thickness T 40  between 1.0 mm and 3.0 mm, for example, 2.0 mm. The gasket  420  may have a diameter D 50  between 7.7 mm and 8.5 mm, for example, 8.1 mm. It should be understood that the diameter D 50  may vary from these values so long as the gasket  420  provides an effective seal in the reservoir  310 . A central area of the gasket  420  includes an opening  440  with a diameter D 53  between 2.6 mm and 2.8 mm, for example, 2.7 mm so that the gasket  420  fits around the airway  600 . The gasket  420  is configured to provide the fluid communication between the porous substrate  400  and the cavity  311  via at least one aperture  430  disposed adjacent to the opening  440 . According to at least one example embodiment, the gasket  420  includes two or more apertures  430  (e.g., four apertures) disposed in a diamond configuration on opposing sides of the opening  440 . The apertures  430  may be substantially circular in shape and have a diameter D 55  between 0.8 mm and 1.2 mm, for example, 1.0 mm. However, example embodiments are not limited to the shape and size of the apertures shown in  FIG. 5F  and it should be understood that the apertures  430  may be of various sizes and shapes so long as the porous substrate  400  does not become oversaturated with pre-vapor formulation and leak from the e-vapor device  200 . 
       FIGS. 5A and 5B  further illustrate that the cartridge  220  includes a heater assembly  330 . The heater assembly  330  includes a heating element  10 , a support  350 , and a conductive rivet  360 . The conductive rivet  360  may be optional. The heating element  10  may be, for example, one of the heating elements shown in  FIGS. 1A-3 . 
     With reference to  FIGS. 5A, 5B, and 5G , the support  350  may support the heating element  10  and be disposed in the housing  300 . The support  350  may include silicon or some other material capable of withstanding varying temperatures of the heating element  10  such as organic elastomers and/or inorganic elastomers. The support  350  may have a substantially cylindrical shape and a diameter D 60  between 7.7 mm and 8.5 mm, for example, 8.1 mm. It should be understood that the diameter D 60  may vary from these values so long as the support  350  provides an effective seal in the reservoir  310 . A central area of an end surface of the support  350  includes a through hole  450  with a diameter D 65  between 1.7 mm and 2.1 mm, for example, 1.93 mm. It should be understood that the diameter D 65  may vary from these values so long as the support  35  provides an effective seal between an outer wall of the inner tube  315  and the gasket  420 . The support  350  may have a height H 40  between 3.0 mm and 8.0 mm, for example, 5.1 mm. The through hole  450  may be aligned with the air channel  60 , opening  410 , and airway  600 . If the conductive rivet  360  is not used, then the support  350  may include grooves along a lateral surface of the support  350  instead of the through hole  450 . Here, the grooves allow for the airflow formerly provided by the through hole  450  and electrical connection to the powers supply  250  is provided via direct connection with the tip  41 . 
     A first slot  460  and a second slot  470  may be on the end surface of the support  35  and disposed at opposing sides of the through hole  450 . The first slot  460  and the second slot  470  may have a shape and size that accommodates the first lead portion  30  and the second lead portion  40  of the heating element  10 . For example, as shown in  FIG. 5B , the slots  460  and  470  have substantially rectangular shapes so that the first lead portion  30  extends through first slot  460 , and the second lead portion  40  extends through the second slot  470 . As also shown in  FIG. 5B , the first lead portion  30  and the second lead portion  40  are bent in a direction that is substantially parallel to the planar portion  20  at tips  31  and  41 . Although tip  31  is shown in  FIG. 5B  as not contacting a wall of the connector portion  320 , the tip  31  may extend to contact the wall of the connector portion  320  if desired. For example, if the inner wall of connector portion  320  is electrically conductive, the tip  31  may be extended to electrically connect to the inner wall of the connector portion  320  so that the first lead portion  30  is electrically connected to the connector portion  320 . As shown in  FIG. 5B , the support  350  may include a thin membrane  351  in the first and second slots  460  and  470 . The membrane  351  may be penetrated by the first and second lead portions  30  and  40  upon assembly and provide a seal at the penetration point. A thickness of the membrane  351  may be between 0.1 mm and 1.0 mm, for example, 0.3 mm. 
     Still referring to  FIGS. 5A, 5B, and 5G , the lateral surface of the support  350  may have a male thread engagement portion  530  for thread engagement with a female thread engagement of the reservoir portion  310 . Alternatively, the support  350  may push fit into the reservoir portion  310 . As another alternative, the support  350  may affixed to the reservoir portion  310  with ultrasonic welding. In yet another alternative, the support  350  and the reservoir portion  310  may have a bayonet connection. It should be appreciated that other connections between the support  350  and the reservoir portion  310  are within the scope of example embodiments. The support  350  may include at least two recesses  480  on opposing sides of the lateral surface of the support  350 . The recesses  480  may have a size, shape, and location that accommodate the tabs  510  and  520  of the connector portion  320 . As shown in  FIG. 5G , the recesses  480  have a substantially rectangular shape and extend from one end of the support  350  to a stop surface  485  to provide a tight fit with the tabs  510  and  520  (see  FIG. 6  for connection between connector portion  320  and reservoir portion  310 ). 
     With reference to  FIGS. 5A, 5B, and 5H , the support  350  includes a conductive rivet  360  extending through the through hole  450 . The conductive rivet  360  may include metal or some other conductive material such as a brass coat with a nickel base and sliver plating. The conductive rivet  360  may include a substantially cylindrical body portion  361  and a substantially circular head portion  363  at one end of the body portion  363 . The body portion  361  may have a diameter D 70  between 1.77 mm and 2.17 mm, for example, 2.0 mm such that the conductive rivet  360  may push fit into the through hole  450  of the support  350 . Alternatively, the conductive rivet  360  may be welded or soldered to a tip  41  of the second lead portion  40 . The head portion  363  may have a diameter D 75  larger than diameter D 70 . Diameter D 75  may be between 2.5 mm and 4.5 mm, for example, 4.0 mm. The conductive rivet  360  may be substantially hollow. For example, an airway  365  may pass through a central area of conductive rivet  360 . The airway  365  may have a diameter D 77  between 1.2 mm and 1.7 mm, for example, 1.6 mm. A height H 50  from a top surface of the head portion  363  to an opposing end of the conductive rivet  360  may be between 4.0 mm and 7.1 mm, for example, 6.5 mm. A height H 55  from an end of the conductive rivet  360  to a bottom surface of the head portion  363  may be between 3.6 mm and 6.7 mm, for example, 6.1 mm. 
     An electrical connection of the heating element  10  to the battery  250  is described below with reference to  FIGS. 4A, 4B, 5A, 5B, and 5H . As shown in  FIG. 5B , the bottom surface of the head portion  363  is in electrical contact with a tip  41  of the second lead portion  40  while the top surface of the head portion  363  is in electrical contact with the conductive post  260  of the power supply section  230 . However, the head portion  363  is spaced apart from a tip  31  of the first lead portion  30  so as to be electrically isolated from the tip  31 . The tip  31  of the first lead portion  30  is electrically connected to connector  265  of the power supply section  230  upon engagement of the cartridge  220  and power supply section  230 . For example, the connector  265  may be a conductive male thread of the power supply section  230  that makes electrical contact with the tip  31  upon engagement with a female thread of the connector portion  320 . Alternatively, if an inner wall of connector portion  320  (e.g., the female thread) is electrically conductive, the tip  31  may be extended to electrically connect to the inner wall of the connector portion  320  so that the first lead portion  30  is electrically connected to the connector portion  320 . In this case, the conductive male thread of the connector  265  may be in electrical contact with tip  31  through the inner wall of the connector portion  320 . 
     As explained with reference to  FIGS. 4A and 4B , when an adult vaper draws air through the mouthpiece  210 , the puff sensor in control electronics  240  is operable to sense an air pressure drop in the e-vapor device  200  to cause the control electronics  240  to initiate the application of voltage from the battery  250  to the heating element  10  via the above described electrical contacts between the conductive post  260 , the conductive rivet  360 , and the tip  41  and between the tip  31  and the connector  265 . It should be understood that the puff sensor acts as a switch that completes a closed loop circuit through the heating element  10  upon sensing the air pressure drop. The heating element  10  heats vapor drawn into the filament  50  from the porous substrate  400  to form vapor, which enters the adult vaper&#39;s mouth via air channel  60 , opening  410  and airway  600 . 
     Although not explicitly shown in  FIGS. 5A-5H , it should be understood that the support  350  may have alternative structures that allow air to pass through. For example, in addition to or an alternative to the location of the airway  365 , there may be other airways at the outer edge of the support  350  so that air is able to pass between the reservoir portion  310  and the support  350 . It should be further understood that the conductive rivet  360  may be eliminated. In this case, the connector  265  may be in electrical contact with the tip  41  without the conductive rivet  360  in between. 
       FIG. 6  is a three-dimensional rendering of the cartridge shown in  FIGS. 5A-5H . 
       FIG. 6  shows a completed cartridge  220  that is ready for connection to the mouthpiece  210  and/or connection to power supply section  230  in  FIG. 4  via the female thread  321 . As illustrated in  FIG. 6 , the heating element  10  may be spaced apart from the end surface of the support  350  with the aid of step portions  33  and/or  35  to provide efficient heat transfer to the porous substrate  400 . 
       FIG. 7  is a perspective view of a heater assembly according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 7 , the heating element  710  may generally include one or more features of the heating element of  FIG. 1A , and the first lead  730  and the second lead  740  are adjacent to one another, the filament  750  may include tip portions  700  that rest on a support  760 , and the support  760  includes a support ring. Further, the heater  710  may be formed of a thicker metal material, such as a stainless steel foil, instead of including the leads  730 ,  740  that extend away from the planar portion  720  of the heating element  710 , which provide support to the heating element  710  (some example embodiments may include both a thicker metal material as well as leads  730 ,  740  that extend away from the planar portion  720  of the heating element  710 ). In at least one example embodiment, the support  760  may be formed of a substantially heat-resistant material, such as polyetheretherketone (PEEK), ceramic, and/or a ceramic-coated metal. 
     In at least one example embodiment, the filament  750  is arranged such that a plurality of curves are formed. Each of the at least one curves generally has a keyhole shape, an omega shape, a U-shape, or any combination of these. In other example embodiments, the at least one curve has a rectangular, square, and/or polygonal shape. In at least one example embodiment, the filament  750  defines an air channel  60  through a central area of the planar portion  720  of the heating element  710 . The tip portions  700  extend away from the air channel  60 , and the open end of each of the curves is adjacent the air channel  60 . 
       FIG. 8  is a partial cross-sectional view of a cartridge including the heater assembly of  FIG. 7  according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 8 , a first contact  770  and a second contact  780  are overmolded in the support  760 , such that the first contact  770  is electrically isolated from the second contact  780 . The leads  730 ,  740  of the heating element  710  may each be spot-welded or otherwise placed into contact with a respective one of the first contact  770  and the second contact  780 . 
     In at least one example embodiment, as shown in  FIG. 8 , the heating element  710  may contact at least one transfer material  725 , such as the transfer material disclosed in application Ser. No. 15/729,895 filed Oct. 11, 2017, the entire content of which is incorporated herein by reference, and/or any other suitable transfer material. In some example embodiments, the heating element  710  may be spaced apart from the transfer material  725 , and a wick (not shown) may be placed between the transfer material  725  and the heating element  710 . 
       FIG. 9  is a perspective view of a heating element for use in the cartridge of  FIG. 8  according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 9 , the heating element  910  is generally the same as in  FIGS. 7-8 , except that one or more of the tip portions  900  that extend from the filament  950  are generally trapezoidal or rectangular in shape. The first lead  930  and the second lead  940  are generally L-shaped. 
       FIG. 10  is a top view of a heater assembly including a heating element according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 10 , one or more features of the heating element  1010  are generally the same as in  FIGS. 7-8 , and the first lead  1030  extends into the air channel  1060  and the second lead  1040  extends outwardly. 
       FIG. 11  is an exploded view of the heater assembly of  FIG. 10  according to at least one example embodiment. 
     In at least one example embodiment, a support  1105  is a ring  1100  that may be formed of one or more of PEEK, ceramic, and/or a ceramic coated metal. The ring  1100  is sized and configured to mate with a base portion  1110  that is formed of an electrically conductive material. The base portion  1110  is generally cylindrical and includes at least one air channel  1115  defined in an outer surface  1120  of the base portion  1110 . The base portion  1110  also defines a passage  1130  extending through the base portion  1110  from a first end to a second end thereof. The base portion  1110  also includes a protrusion  1125  extending longitudinally from a top surface  1135  of the base portion  1110 . The second lead  1040  of the heating element  1010  contacts the protrusion  1125  to form a first electrical contact. An electrically insulating shell  1150  in the form of a ring is positioned at a second end  1155  of the base portion  1110 . The electrically insulating shell  1150  defines a hole  1160  therethrough. A post  1170  formed of an electrically conductive material extends through the hole  1160  and the passage  1130 . The post  1170  contacts the first lead  1030  to form a second electrical contact. 
       FIG. 12  is an exploded view of a cartridge including the heating element of  FIG. 10  according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 12 , instead of the first lead  1030  and the second lead  1040  contacting the post  1170  and protrusion  1125 , the cartridge may include a support  1260  and two side-by-side electrically conductive posts  1220 ,  1230 . The posts  1220 ,  1230  are electrically insulated from each other, and may be molded into the support  1260  in some example embodiments. Moreover, the heating element  1010  may abut transfer material  725 , which may abut a gasket  1200  having weep holes  1210  therein. The gasket  1200  defines a portion of the reservoir, and pre-vapor formulation from the reservoir may flow through the weep holes  1210  in at least one example embodiment. 
       FIG. 13  is a perspective view of a heater assembly according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 13 , one or more features of the heating element  1310  are generally the same as in  FIG. 11  and the first lead  1330  extends inwardly from the heating element  1310  and is not planar with the heating element  1310 , the second lead  1340  has a generally L-shape, the post  1170  is shorter than the post of  FIG. 11 , and air channels  1300  are defined in sides of the support  1350 , such that air may flow between the support  1350  and an inner surface of a housing  300  of a cartridge  220 . In addition, a second electrical contact (not shown) may be overmolded in the support  1350 , such that the second lead  1340  contacts the second electrical contact when the heating element  1310  is placed on the support  1350 . 
       FIG. 14  is a perspective view of a heater assembly according to at least one example embodiment. 
     In at least one example embodiment, as shown in  FIG. 13 , one or more features of the heating element  1410  are generally the same as in  FIG. 11 , and the first contact  1430  has a generally spiral shape and the second lead  1430  has a generally L-shape. The tip portions  1450  of the heating element  1410  rest on a top surface of the support  1350 . 
     In other example embodiments, not shown, the heating element  10  may be reduced in size, such that tips of the heating element  10  are not supported by a support. 
     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 such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.