Patent Description:
Vaporizer devices, which can also be referred to as vaporizers, electronic vaporizer devices, or e-vaporizer devices, can be used for delivery of an aerosol (for example, a vapor-phase and/or condensed-phase material suspended in a stationary or moving mass of air or some other gas carrier) containing one or more active ingredients by inhalation of the aerosol by a user of the vaporizing device. For example, electronic nicotine delivery systems (ENDS) include a class of vaporizer devices that are battery powered and that can be used to simulate the experience of smoking. Vaporizers are gaining increasing popularity both for prescriptive medical use, in delivering medicaments, and for consumption of tobacco, nicotine, and other plant-based materials. Vaporizer devices can be portable, self-contained, and/or convenient for use.

In use of a vaporizer device, the user inhales an aerosol, colloquially referred to as "vapor," which can be generated by a heating element that vaporizes a vaporizable material, for example, by causing the vaporizable material to transition at least partially to a gas phase. The vaporizable material may be a liquid, a solution, a solid, a paste, a wax, and/or any other form compatible for use with a specific vaporizer device. Moreover, the vaporizable material used with a vaporizer can be provided within a vaporizer cartridge, which may be a separable part of the vaporizer device that contains the vaporizable material and having an outlet (e.g., a mouthpiece) for delivering the aerosol generated by the vaporization of the vaporizable material to a user.

To receive the inhalable aerosol generated by a vaporizer device, a user may, in certain examples, activate the vaporizer device by taking a puff, by pressing a button, and/or by some other approach. A puff as used herein can refer to inhalation by the user in a manner that causes a volume of air to be drawn into the vaporizer device such that the inhalable aerosol is generated when the vaporized vaporizable material is combined with the volume of air.

An approach by which a vaporizer device generates an inhalable aerosol from a vaporizable material involves heating the vaporizable material in a vaporization chamber (e.g., a heater chamber) to cause the vaporizable material to be converted to the gas (or vapor) phase. A vaporization chamber can refer to an area or volume in the vaporizer device within which a heat source (for example, a conductive, convective, and/or radiative heat source) causes heating of a vaporizable material to produce a mixture of air and vaporized material to form a vapor for inhalation of the vaporizable material by a user of the vaporization device.

In some embodiments, vaporizer cartridges configured to heat solid vaporizable material (e.g. plant material such as tobacco leaves and/or parts of tobacco leaves) can require higher temperatures for inner tobacco regions to reach a minimum required temperature for vaporization. As a result, burning the solid vaporizable material at these high peak temperatures can produce toxic byproducts (e.g., chemical elements or chemical compounds).

Vaporizer devices can be categorized into two classes, those that heat through conduction and those that heat through convection. For example, conduction-based vaporizer devices may be configured to vaporize liquid vaporizable material using a heating element contacting the liquid vaporizable material. As such, the liquid vaporizable material may contaminate the heating element, which can compromise performance of the vaporizer device. Some vaporizers may incorporate the heating element into the disposable part of the vaporizer device (e.g., the cartridge), such that the heating element may be replaced with each new cartridge and thereby limit, but not eliminate, heating element contamination. However, this can increase manufacturing labor and costs associated with the disposable. Furthermore, uniform heating of the vaporizable material in current conduction-based vaporizers may be difficult to achieve due to the low thermal conductivity of certain vaporizable materials (e.g., plant materials, such as tobacco).

Convection-based vaporizers may also present a challenge in uniformly heating the vaporizable material, particularly solid vaporizable material. For example, as hot air flows through the reservoir, a temperature gradient may develop along the vaporizable material. In conventional convection-based systems, upstream portions of the vaporizable material (e.g., portions located closer to the heater) may be heated to a higher temperature than portions of the vaporizable material that are located further downstream (e.g., closer to the user/air outlet). If the upstream portions of the vaporizable material become too hot, then the vaporizable material may char and/or burn, resulting in an unpleasant taste and/or release of undesirable byproducts. If, on the other hand, the vaporizer temperature is kept low enough to ensure that the vaporizable material does not char or burn, then portions of the vaporizable material that are downstream may not be fully vaporized, which may result in a waste of materials and/or decreased vapor production. Additionally, because the vaporizable material may change shape while drying, the path along which hot air flows through the material may be altered, causing uneven and/or unpredictable heating and further exacerbating the issues noted above.

In regard to the prior art, reference is made to the documents <CIT>, <CIT>, and <CIT>.

In certain aspects of the current subject matter, challenges associated with efficiently and effectively forming an inhalable aerosol from vaporizable material can be addressed by inclusion of one or more of the features described herein or comparable/equivalent approaches as would be understood by one of ordinary skill in the art. Aspects of the current subject matter relate to methods and system associated with a vaporizable material insert for inserting in a vaporizer device to form an inhalable aerosol.

In one aspect, a vaporizable material insert is described for use with a vaporizer device to form an inhalable aerosol. The vaporizable material insert can include a housing including an inlet and an outlet. The vaporizable material insert can include an airflow control feature comprising a vaporizable material, and the airflow control feature can extend between the inlet and the outlet of the housing. The vaporizable material insert can further include an airflow pathway extending between the inlet and the outlet of the housing and at least partly formed by the airflow control feature. The airflow pathway can allow a heated airflow to travel therealong and include an upstream section and a downstream section. The upstream section can include a first airflow pathway characteristic that controls a first airflow characteristic of the heated airflow for achieving a first amount of heat transfer between the heated airflow at a first temperature and the vaporizable material along the upstream section. The downstream section can include a second airflow pathway characteristic that controls a second airflow characteristic of the heated airflow for achieving a second amount of heat transfer between the heated airflow at a second temperature and the vaporizable material along the downstream section. The first temperature can be higher than the second temperature, and the first amount of heat transfer can be approximately the same as the second amount of heat transfer.

In some variations one or more of the following features can optionally be included in any feasible combination. For example, the first airflow pathway characteristic and the second airflow pathway characteristic can each include a diameter, a cross-section area, a shape, or a length of the upstream section and the downstream section, respectively. The first airflow pathway characteristic can be different than the second airflow pathway characteristic. The first airflow characteristic and the second airflow characteristic can each comprise an airflow rate, an airflow resistance, an airflow pressure, or an airflow travel length. The first airflow characteristic can be different than the second airflow characteristic.

In some embodiments, the upstream section can include a single airflow pathway and the downstream section can include a plurality of secondary pathways. The single airflow pathway can be in fluid communication with each secondary pathway included in the plurality of secondary pathways. In some embodiments, the plurality of secondary pathways can extend in a helical shape along the airflow control feature. The airflow pathway can include a diameter that decreases along the airflow pathway between the inlet and the outlet of the housing.

In some embodiments, the upstream section of the airflow pathway can be formed by a first part of the airflow control feature and the downstream section of the airflow pathway can be formed by a second part of the airflow control feature. The first part can have a different shape than the second part. For example, the first part can form a ring shape and the second part can form a cross shape.

In some embodiments, the vaporizable material includes a solid vaporizable material. The airflow control feature can include a porous substrate containing liquid vaporizable material. In some embodiments, the vaporizable material insert further includes a cooling filter positioned adjacent the outlet of the housing for reducing a temperature of the inhalable aerosol prior to inhalation by a user.

In another aspect, a system for generating an inhalable aerosol is described. The system can include a vaporizable material insert that includes a housing including an inlet and an outlet. The vaporizable material insert can include an airflow control feature comprising a vaporizable material, and the airflow control feature can extend between the inlet and the outlet of the housing. The vaporizable material insert can further include an airflow pathway extending between the inlet and the outlet of the housing and at least partly formed by the airflow control feature. The airflow pathway can allow a heated airflow to travel therealong and include an upstream section and a downstream section. The upstream section can include a first airflow pathway characteristic that controls a first airflow characteristic of the heated airflow for achieving a first amount of heat transfer between the heated airflow at a first temperature and the vaporizable material along the upstream section. The downstream section can include a second airflow pathway characteristic that controls a second airflow characteristic of the heated airflow for achieving a second amount of heat transfer between the heated airflow at a second temperature and the vaporizable material along the downstream section. The first temperature can be higher than the second temperature, and the first amount of heat transfer can be approximately the same as the second amount of heat transfer. The system can further include a vaporizer device including a vaporizable material insert receptacle configured to receive the vaporizable material insert. The vaporizer device of the system can further include a heating element configured to heat airflow upstream from the vaporizable material insert for allowing heated airflow to travel along the airflow pathway of the vaporizable material insert and generate the inhalable aerosol.

In some variations one or more of the following features can optionally be included in any feasible combination of the system. For example, the first airflow pathway characteristic and the second airflow pathway characteristic can each include a diameter, a cross-section area, a shape, or a length of the upstream section and the downstream section, respectively. The first airflow pathway characteristic can be different than the second airflow pathway characteristic. The first airflow characteristic and the second airflow characteristic can each include an airflow rate, an airflow resistance, an airflow pressure, or an airflow travel length. The first airflow characteristic can be different than the second airflow characteristic.

In another interrelated aspect of the current subject matter, a method for generating an inhalable aerosol for inhalation by a user includes receiving a vaporizable material insert into a compartment of a vaporizer device. The vaporizable material insert can include a housing including an inlet and an outlet. The vaporizable material insert can include an airflow control feature comprising a vaporizable material, and the airflow control feature can extend between the inlet and the outlet of the housing. The vaporizable material insert can further include an airflow pathway extending between the inlet and the outlet of the housing and at least partly formed by the airflow control feature. The airflow pathway can allow a heated airflow to travel therealong and include an upstream section and a downstream section. The upstream section can include a first airflow pathway characteristic that controls a first airflow characteristic of the heated airflow for achieving a first amount of heat transfer between the heated airflow at a first temperature and the vaporizable material along the upstream section. The downstream section can include a second airflow pathway characteristic that controls a second airflow characteristic of the heated airflow for achieving a second amount of heat transfer between the heated airflow at a second temperature and the vaporizable material along the downstream section. The first temperature can be higher than the second temperature, and the first amount of heat transfer can be approximately the same as the second amount of heat transfer. The method can further include activating a heating element configured to heat airflow upstream from the vaporizable material insert and forming, as a result of the heated airflow traveling along the airflow pathway of the vaporizable material insert, the inhalable aerosol.

The claims that follow this disclosure are intended to define the scope of the protected subject matter.

Implementations of the current subject matter include devices and methods relating to vaporizing of one or more materials for inhalation by a user. For example, various embodiments of a vaporizer cartridge or vaporizable material insert for use with a vaporizer device are described herein. The term "vaporizer device" as used in the following description and claims refers to any of a self-contained apparatus, an apparatus that includes two or more separable parts (for example, a vaporizer body that includes a battery and other hardware, and a cartridge or insert that includes a vaporizable material), and/or the like. A "vaporizer system," as used herein, can include one or more components, such as a vaporizer device. Examples of vaporizer devices consistent with implementations of the current subject matter include electronic vaporizers, electronic nicotine delivery systems (ENDS), and/or the like. In general, such vaporizer devices are hand-held devices that heat (such as by convection, conduction, radiation, and/or some combination thereof) a vaporizable material to provide an inhalable dose of the material.

The vaporizable material used with a vaporizer may optionally be provided within a vaporizable material insert or cartridge (e.g., a part of the vaporizer that contains the vaporizable material) which can be refillable when empty, or disposable such that a new cartridge containing additional vaporizable material of a same or different type can be used. A vaporizer device can be a cartridge-using vaporizer device, a cartridge-less vaporizer device, or a multi-use vaporizer device capable of use with or without a cartridge. Some cartridge embodiments can include a vaporizable material insert. For example, embodiments of vaporizable material inserts can be at least partly made of a non-liquid vaporizable material. As such, some embodiments of the vaporizer device can be configured to receive a vaporizable material insert that is at least partly made of one or more vaporizable materials for heating and forming an inhalable aerosol, as will be described in greater detail below. In some embodiments, a vaporizer device can include a heating chamber or compartment (e.g., a vaporizable material insert receptacle) configured to receive a vaporizable material insert directly therein and heat the vaporizable material insert for forming an inhalable aerosol.

In some implementations, a vaporizer device can be configured for use with a liquid vaporizable material (for example, a carrier solution in which an active and/or inactive ingredient(s) are suspended or held in solution, or a liquid form of the vaporizable material itself) and/or a non-liquid vaporizable material (e.g., a paste, a wax, a gel, a solid, a plant material, and/or the like). A non-liquid vaporizable material can include a plant material that emits some part of the plant material as the vaporizable material (for example, some part of the plant material remains as waste after the material is vaporized for inhalation by a user) or optionally can be a solid form of the vaporizable material itself, such that all of the solid material can eventually be vaporized for inhalation. A liquid vaporizable material can likewise be capable of being completely vaporized, or can include some portion of the liquid material that remains after all of the material suitable for inhalation has been vaporized.

<FIG> depicts a block diagram illustrating an example of a vaporizer device <NUM> consistent with implementations of the current subject matter. Referring to <FIG>, the vaporizer device <NUM> can include a power source <NUM> (for example, a battery, which can be a rechargeable battery), and a controller <NUM> (for example, a processor, circuitry, etc. capable of executing logic) for controlling delivery of heat from a heating element <NUM> to cause a vaporizable material <NUM> of a vaporizable material insert <NUM> to be converted from a condensed form (such as a solid, a liquid, a solution, a suspension, a part of an at least partially unprocessed plant material, etc.) to the gas phase. The controller <NUM> can be part of one or more printed circuit boards (PCBs) consistent with certain implementations of the current subject matter.

After conversion of the vaporizable material <NUM> to the gas phase, at least some of the vaporizable material <NUM> in the gas phase can condense to form particulate matter in at least a partial local equilibrium with the gas phase as part of an aerosol, which can form some or all of an inhalable dose provided by the vaporizer device <NUM> during a user's puff or draw on the vaporizer device <NUM>. It should be appreciated that the interplay between gas and condensed phases in an aerosol generated by a vaporizer device <NUM> can be complex and dynamic, due to factors such as ambient temperature, relative humidity, chemistry, flow conditions in airflow paths (both inside the vaporizer and in the airways of a human or other animal), and/or mixing of the vaporizable material <NUM> in the gas phase or in the aerosol phase with other air streams, which can affect one or more physical parameters of an aerosol. In some vaporizer devices, and particularly for vaporizer devices configured for delivery of volatile vaporizable materials, the inhalable dose can exist predominantly in the gas phase (for example, formation of condensed phase particles can be very limited).

The heating element <NUM> can include one or more of a conductive heater, a radiative heater, and/or a convective heater. One type of heating element is a resistive heating element, which can include a material (such as a metal or alloy, for example a nickel-chromium alloy, or a non-metallic resistor) configured to dissipate electrical power in the form of heat when electrical current is passed through one or more resistive segments of the heating element. In some implementations of the current subject matter, the heating element <NUM> (e.g., a resistive heating element and/or the like) is configured to generate heat for vaporizing the vaporizable material <NUM> to generate an inhalable dose of the vaporizable material <NUM>. As noted, the vaporizable material <NUM> may be a liquid or non-liquid (or combination of both liquid and non-liquid). For example, the heating element <NUM> may be wrapped around, positioned within, integrated into a bulk shape of, pressed into thermal contact with, or otherwise arranged to deliver heat to the vaporizable material <NUM> to be vaporized for subsequent inhalation by a user in a gas and/or a condensed (for example, aerosol particles or droplets) phase.

In some embodiments, the vaporizable material <NUM> may be a non-liquid vaporizable material including, for example, a solid-phase material (such as a gel, a wax, or the like) or plant material (e.g., tobacco leaves and/or parts of tobacco leaves). Where the vaporizable material <NUM> is a non-liquid vaporizable material, the heating element <NUM> can be part of, or otherwise incorporated into or in thermal contact with, the walls of a heating chamber or compartment (e.g., vaporizable material insert receptacle <NUM>) into which the vaporizable material insert <NUM> is placed. Alternatively, the heating element <NUM> can be used to heat air passing through or past the vaporizable material insert <NUM>, to cause convective heating of the vaporizable material <NUM> of the vaporizable material insert <NUM>. In still other examples, the heating element <NUM> can be disposed in intimate contact with the vaporizable material <NUM> such that direct conductive heating of the vaporizable material <NUM> of the vaporizable material insert <NUM> occurs from within a mass of the vaporizable material <NUM>, as opposed to only by conduction inward from walls of the heating chamber (e.g., an oven and/or the like). In some embodiments, the heating element <NUM> can be a part of the vaporizer body <NUM> (e.g., part of the durable or reusable part of the vaporizer <NUM>), as shown in <FIG>.

The heating element <NUM> can be activated in association with a user puffing (e.g., drawing, inhaling, etc.) on an end and/or mouthpiece of the vaporizer device <NUM> to cause air to flow from an air inlet, along an airflow path for assisting with forming an inhalable aerosol that can be delivered out through an air outlet in the mouthpiece. Incoming air moving along the airflow path moves over or through the heating element <NUM> and/or vaporizable material <NUM> where vaporizable material <NUM> in the gas phase is entrained into the air. The heating element <NUM> can be activated via the controller <NUM>, which can optionally be a part of the vaporizer body <NUM> as discussed herein, causing current to pass from the power source <NUM> through a circuit including the heating element <NUM>, which can be part of the vaporizer body <NUM>. As noted herein, the entrained vaporizable material <NUM> in the gas phase can condense as it passes through the remainder of the airflow path such that an inhalable dose of the vaporizable material <NUM> in an aerosol form can be delivered from the air outlet (for example, the mouthpiece) for inhalation by a user.

Activation of the heating element <NUM> can be caused by automatic detection of a puff based on one or more signals generated by one or more sensor(s) <NUM>. The sensor <NUM> and the signals generated by the sensor <NUM> can include one or more of: a pressure sensor or sensors disposed to detect pressure along the airflow path relative to ambient pressure (or optionally to measure changes in absolute pressure), a motion sensor or sensors (for example, an accelerometer) of the vaporizer device <NUM>, a flow sensor or sensors of the vaporizer device <NUM>, a capacitive lip sensor of the vaporizer device <NUM>, detection of interaction of a user with the vaporizer device <NUM> via one or more input devices <NUM> (for example, buttons or other tactile control devices of the vaporizer device <NUM>), receipt of signals from a computing device in communication with the vaporizer device <NUM>, and/or via other approaches for determining that a puff is occurring or imminent.

As discussed herein, the vaporizer device <NUM> consistent with implementations of the current subject matter can be configured to connect (such as, for example, wirelessly or via a wired connection) to a computing device (or optionally two or more devices) in communication with the vaporizer device <NUM>. To this end, the controller <NUM> can include communication hardware <NUM>. The controller <NUM> can also include a memory <NUM>. The communication hardware <NUM> can include firmware and/or can be controlled by software for executing one or more cryptographic protocols for the communication.

A computing device can be a component of a vaporizer system that also includes the vaporizer device <NUM>, and can include its own hardware for communication, which can establish a wireless communication channel with the communication hardware <NUM> of the vaporizer device <NUM>. For example, a computing device used as part of a vaporizer system can include a general-purpose computing device (such as a smartphone, a tablet, a personal computer, some other portable device such as a smartwatch, or the like) that executes software to produce a user interface for enabling a user to interact with the vaporizer device <NUM>. In other implementations of the current subject matter, such a device used as part of a vaporizer system can be a dedicated piece of hardware such as a remote control or other wireless or wired device having one or more physical or soft (e.g., configurable on a screen or other display device and selectable via user interaction with a touch-sensitive screen or some other input device like a mouse, pointer, trackball, cursor buttons, or the like) interface controls. The vaporizer device <NUM> can also include one or more outputs <NUM> or devices for providing information to the user. For example, the outputs <NUM> can include one or more light emitting diodes (LEDs) configured to provide feedback to a user based on a status and/or mode of operation of the vaporizer device <NUM>.

In the example in which a computing device provides signals related to activation of the heating element, or in other examples of coupling of a computing device with the vaporizer device <NUM> for implementation of various control or other functions, the computing device executes one or more computer instruction sets to provide a user interface and underlying data handling. In one example, detection by the computing device of user interaction with one or more user interface elements can cause the computing device to signal the vaporizer device <NUM> to activate the heating element to reach an operating temperature for creation of an inhalable dose of vapor/aerosol. Other functions of the vaporizer device <NUM> can be controlled by interaction of a user with a user interface on a computing device in communication with the vaporizer device <NUM>.

The temperature of the heating element <NUM> of the vaporizer device <NUM> can depend on a number of factors, including an amount of electrical power delivered to the heating element <NUM> and/or a duty cycle at which the electrical power is delivered, conductive heat transfer to other parts of the vaporizer device <NUM> and/or to the environment, latent heat losses due to vaporization of the vaporizable material <NUM>, and convective heat losses due to airflow (e.g., air moving across the heating element <NUM> when a user inhales on the vaporizer device <NUM>). As noted herein, to reliably activate the heating element <NUM> or heat the heating element <NUM> to a desired temperature, the vaporizer device <NUM> may, in some implementations of the current subject matter, make use of signals from the sensor <NUM> (for example, a pressure sensor) to determine when a user is inhaling. The sensor <NUM> can be positioned in the airflow path and/or can be connected (for example, by a passageway or other path) to an airflow path containing an inlet for air to enter the vaporizer device <NUM> and an outlet via which the user inhales the resulting vapor and/or aerosol such that the sensor <NUM> experiences changes (for example, pressure changes) concurrently with air passing through the vaporizer device <NUM> from the air inlet to the air outlet. In some implementations of the current subject matter, the heating element <NUM> can be activated in association with a user's puff, for example by automatic detection of the puff, or by the sensor <NUM> detecting a change (such as a pressure change) in the airflow path.

The sensor <NUM> can be positioned on or coupled to (e.g., electrically or electronically connected, either physically or via a wireless connection) the controller <NUM> (for example, a printed circuit board assembly or other type of circuit board). To take measurements accurately and maintain durability of the vaporizer device <NUM>, it can be beneficial to provide a seal resilient enough to separate an airflow path from other parts of the vaporizer device <NUM>. The seal, which can be a gasket, can be configured to at least partially surround the sensor <NUM> such that connections of the sensor <NUM> to the internal circuitry of the vaporizer device <NUM> are separated from a part of the sensor <NUM> exposed to the airflow path. Such arrangements of the seal in the vaporizer device <NUM> can be helpful in mitigating against potentially disruptive impacts on vaporizer components resulting from interactions with environmental factors such as water in the vapor or liquid phases and/or to reduce the escape of air from the designated airflow path in the vaporizer device <NUM>. Unwanted air, liquid or other fluid passing and/or contacting circuitry of the vaporizer device <NUM> can cause various unwanted effects, such as altered pressure readings, and/or can result in the buildup of unwanted material, such as moisture, errant portions of the vaporizable material <NUM>, etc., in parts of the vaporizer device <NUM> where they can result in poor pressure signal, degradation of the sensor <NUM> or other components, and/or a shorter life of the vaporizer device <NUM>. Leaks in the seal can also result in a user inhaling air that has passed over parts of the vaporizer device <NUM> containing, or constructed of, materials that may not be desirable to be inhaled.

In some implementations, the vaporizable material insert <NUM> can be configured for insertion in the vaporizable material insert receptacle <NUM>, can have a non-circular cross section transverse to the axis along which the vaporizable material insert <NUM> is inserted into the vaporizable material insert receptacle <NUM>. For example, the non-circular cross section can be approximately rectangular, approximately elliptical (e.g., have an approximately oval shape), non-rectangular but with two sets of parallel or approximately parallel opposing sides (e.g., having a parallelogram-like shape), or other shapes having rotational symmetry of at least order two. In this context, approximate shape indicates that a basic likeness to the described shape is apparent, but that sides of the shape in question need not be completely linear and vertices need not be completely sharp. Rounding of both or either of the edges or the vertices of the cross-sectional shape is contemplated in the description of any non-circular cross section referred to herein.

When a user puffs on the vaporizer <NUM>, air may pass between an outer surface of the vaporizable material insert <NUM> and an inner surface of a vaporizable material insert receptacle <NUM> of the vaporizer body <NUM>. Air can then be drawn into and through at least a part of the vaporizer material insert <NUM> and out through an outlet of the vaporizable material insert <NUM> and/or vaporizer body <NUM> (e.g., a mouthpiece) for delivery of the inhalable aerosol to a user.

In some embodiments, the vaporizer device <NUM> can be configured to heat a non-liquid vaporizable material including, for example, a plant material (e.g., tobacco leaves), a plant material based product (e.g., reconstituted tobacco) and/or the like. For example, some embodiments of the vaporizer body <NUM> of the vaporizer device <NUM> can be configured to receive a vaporizable material insert <NUM> that is at least partly made out the non-liquid vaporizable material. For example, some embodiments of the vaporizable material insert <NUM> can include a housing (e.g., made out of a biodegradable material) that defines an inner chamber configured to contain vaporizable material (e.g., non-liquid vaporizable material). As such, some embodiments of the vaporizable material insert receptacle <NUM> can be configured to receive and heat the vaporizable material insert <NUM>, such as for forming an inhalable aerosol. For example, an embodiment of the vaporizable material insert receptacle <NUM> can include a compartment that is configured for receiving and heating a variety of vaporizable material insert <NUM>, as will be described below.

In some embodiments, the vaporizable material insert receptacle <NUM> can include all or part of the heating element <NUM> (e.g., a heating coil, etc.) that is configured to heat the vaporizable material insert <NUM> received in the vaporizable material insert receptacle <NUM>, such as for forming the inhalable aerosol. Various vaporizable material insert embodiments are described herein for use with a variety of vaporizer bodies <NUM> for forming inhalable aerosol.

For example, some embodiments of the vaporizable material insert <NUM> can include a housing that forms a vaporization chamber configured to contain a vaporizable material and an airflow pathway. The airflow pathway can extend at least partly between an inlet and an outlet of the housing and allow a heated airflow to travel therealong. Various embodiments of the vaporizable material insert <NUM> are described herein that include one or more airflow pathway characteristics that change along the airflow pathway to allow a similar (e.g., the same or approximately the same) amount of heat transfer to be achieved between the heated airflow and the vaporizable material along the length of the airflow pathway. For example, the airflow pathway characteristics may enable a similar amount of heat to be transferred (e.g., per unit area of vaporizable material or per unit volume of vaporizable material) such that the vaporizable material is heated to the same or a similar temperature near the inlet and the outlet of the housing, despite heated air at the inlet having a higher temperature than heated air at the outlet.

For example, at least one airflow pathway characteristic (e.g., diameter, cross-section area, shape, length, etc.) can change along the airflow pathway to achieve a similar amount of heat transfer along the length of the airflow pathway. For example, by changing at least one airflow pathway characteristic, at least one airflow characteristic of the heated airflow can be changed, such as one or more of an airflow rate, an airflow resistance/pressure, and an airflow travel length. For example, an upstream portion of the airflow pathway (e.g., adjacent the inlet of the housing) can be sized and shaped to allow the heated airflow at higher temperatures to flow at a faster airflow rate and along a shorter length of the airflow pathway compared to the heated airflow at lower temperatures along a downstream portion of the airflow pathway (e.g., adjacent the outlet of the housing). Such differences in airflow temperatures and airflow characteristics can achieve a similar amount of heat transfer along the upstream and downstream portions of the airflow pathway. Such similar amounts of heat transfer along the length of the airflow pathway can more evenly distribute heat through the vaporizable material of the vaporizable material insert <NUM>, which can result in improved inhalable aerosol formation and efficient and effective consumption of the vaporizable material of the vaporizable material insert <NUM>. Additionally, the vaporizable material insert <NUM> embodiments described herein can reduce or prevent overheating of the vaporizable material <NUM>, as well as reduce or prevent waste of the vaporizable material <NUM>.

In some embodiments, the vaporizable material insert <NUM> can include one or more airflow control features configured to control the variable airflow characteristics along the airflow pathway. For example, the airflow control feature can include a first part configured to cause a first airflow rate along the upstream section of the airflow pathway and a second part configured to cause a second airflow rate along the downstream portion to be greater. Additionally, the upstream section of the airflow pathway can have a shorter length compared to the downstream section of the airflow pathway. As discussed above, airflow characteristics and airflow temperatures (e.g., which effect a temperature gradient between the heated airflow and vaporizable material) can affect the amount of heat transferred between the heated airflow and the vaporizable material, such as to achieve similar amounts of heat transfer between the heated airflow and the vaporizable material along the length of the airflow pathway.

In some embodiments, the airflow control feature can include one or more vaporizable materials. For example, the vaporizable material of the airflow control feature can be contained in a substrate that is, at most, minimally air permeable. Additionally, in some embodiments, the airflow control feature can include the vaporizable material formed in a shape or configuration that assists with controlling the airflow along the airflow pathway. For example, the formed vaporizable material of the airflow control feature can define at least a part of the airflow pathway, which can include more than one pathway collectively forming the airflow pathway. The airflow pathway can include one or more of a variety of airflow pathway characteristics that assist with controlling one or more airflow characteristics of the heated airflow traveling therealong.

<FIG> and <FIG> illustrate a first embodiment of the vaporizable material insert <NUM> that can be inserted in a receptacle (e.g., vaporizable material insert receptacle <NUM> of <FIG>) of a vaporizer body <NUM> for heating and forming an inhalable aerosol. As shown in <FIG> and <FIG>, the vaporizable material insert <NUM> can include an airflow control feature <NUM> at least partly contained in a housing <NUM>. As shown in <FIG>, the housing <NUM> can be cylindrical, however, other housing shapes are within the scope of this disclosure. The housing <NUM> can form an inner chamber that extends between and inlet <NUM> and an outlet <NUM> of the housing <NUM>. The airflow control feature <NUM> can be positioned within the inner chamber and extend at least partly between the inlet <NUM> and the outlet <NUM> of the housing <NUM>. The housing <NUM> can be made out of a variety of materials, including one or more of a thermally conductive material, an insulative material, a biodegradable material, a vaporizable material, and a non-vaporizable material.

The airflow control feature <NUM> can be formed at least partly out of a non-liquid vaporizable material <NUM>. The airflow control feature <NUM> can be shaped such that at least a part of an airflow pathway <NUM> extends through and/or along one or more sides of the airflow control feature <NUM>. As such, at least part of the airflow pathway <NUM> can be formed by the airflow control feature <NUM>, as shown in <FIG> and <FIG>. For example, the airflow pathway <NUM> can extend between an inlet <NUM> and an outlet <NUM> of the housing <NUM>, as well as extend along and/or through the airflow control feature <NUM>. As will be described in greater detail below, heated airflow can travel along the airflow pathway <NUM> and heat the vaporizable material <NUM> comprising at least a part of the airflow control feature <NUM> for forming (e.g., via convection) an inhalable aerosol.

One or more airflow pathway characteristics of the airflow pathway <NUM> can change along the airflow pathway <NUM> thereby causing at least one airflow characteristic of the heated airflow to change while traveling along the airflow pathway <NUM>. As discussed above, such change in airflow characteristics can affect the amounts of heat transfer between the heated airflow passing along the airflow pathway <NUM> and the vaporizable material <NUM> of the airflow control feature <NUM>.

For example, a first part of the airflow control feature can define an upstream section of the airflow pathway <NUM> including a first diameter or cross-section area that results in a first amount of heat transfer between the heated airflow and the vaporizable material <NUM> along the first part of the airflow control feature <NUM>. Furthermore, a second part of the airflow control feature can define a downstream section of the airflow pathway <NUM> including a second diameter or cross-section area that results in a second amount of heat transfer between the heated airflow and the vaporizable material <NUM> along the second part of the airflow control feature <NUM>. In some embodiments, the first diameter or cross-section area of the first part can be greater than the second diameter or cross-section area of the second part and the airflow temperature traveling along the first part can be greater than the airflow temperature traveling along the second part. As such, the first amount of heat transfer along the first part can be similar (e.g., the same as or approximately equal) to the second amount of heat transferred (e.g., per unit of vaporizable material) along the second part. Additionally, in some embodiments, the first part and/or upstream section can include a shorter length compared to a length of the second part and/or downstream section, however, such lengths can be the same without departing from the scope of this disclosure. The airflow control feature <NUM> can include more than one parts that each include different airflow pathway characteristics (e.g., size, shape, diameter, cross-section area, length, etc.) for causing varying airflow characteristics (e.g., airflow rate, airflow resistance/pressure, airflow travel length) to achieve a similar amount of heat transfer between the heated airflow and vaporizable material along each part of the airflow control feature, as will be described in greater detail below.

As shown in <FIG>, the airflow control feature <NUM> can include a first part <NUM> that includes a ring shape extending along a first length of the housing <NUM>. The ring shape of the first part <NUM> can include an inner-wall or diameter defining a cylindrical upstream section <NUM> of the airflow pathway <NUM>. For example, the upstream section <NUM> can include a single airflow pathway that can have a same or similar inner-wall or diameter along the length of the upstream section <NUM>. The outer diameter or outer-wall of the ring-shaped first portion <NUM> can mate with the housing <NUM>, as shown in <FIG>.

As shown in <FIG>, the airflow control feature <NUM> can include a second part <NUM> that includes a cross shape extending along a second length of the housing <NUM>. The cross-shape of the second part <NUM> of the airflow control feature <NUM> can form a downstream section <NUM> of the airflow pathway <NUM> including more than one secondary airflow pathways <NUM>, such as four secondary airflow pathways <NUM>, as shown in <FIG>. For example, each of the secondary airflow pathways <NUM> can be defined by an inner wall of the housing <NUM> and one or more sides or outer surfaces of the second part <NUM> of the airflow control feature <NUM>.

The first part <NUM> and second part <NUM> of the airflow control feature <NUM> can each include one or more of a variety of shapes and sizes, including forming a variety of airflow pathways having a variety of airflow pathway characteristics. As such, various shaped airflow control features and airflow pathways having a variety of airflow pathway characteristics are within the scope of this disclosure for achieving the variable and desirable airflow characteristics along the airflow pathway, as discussed herein.

For example, the upstream section <NUM> of the airflow pathway <NUM> can include a diameter and a cross-sectional area that is greater than a diameter and cross-sectional area, respectively, associated with each secondary airflow pathway <NUM> of the downstream section <NUM>. In some embodiments, the cross-sectional area of the upstream section <NUM> of the airflow pathway <NUM> is greater than the combined or total cross-sectional area of the secondary airflow pathways <NUM>. Additionally, the upstream section <NUM> can include a shorter length compared to the downstream section <NUM>. As such, one or more airflow characteristics (e.g., airflow rate and airflow travel length, etc.) along the upstream section <NUM> of the airflow pathway <NUM> can be different from one or more airflow characteristics along the secondary pathways <NUM>. Such differences in airflow pathway characteristics, and thus airflow characteristics, can achieve a similar amount of heat transferred along the upstream section <NUM> and the downstream section <NUM>.

The vaporizable material insert <NUM>, when positioned in the vaporizable material insert receptacle <NUM>, can be positioned and oriented such that the upstream section <NUM> of the airflow pathway <NUM> is positioned to first receive airflow heated by the heating element <NUM>. As such, the first part <NUM> of the airflow control feature <NUM> can be positioned closer downstream from the heating element <NUM> compared to the second part <NUM> of the airflow control feature <NUM>. As such, airflow having the highest temperatures can be introduced into and travel along the upstream section <NUM> of the airflow pathway <NUM> compared to the temperatures of the airflow that is introduced and travels along the downstream section <NUM> (e.g., due to heat loss along the upstream section <NUM>). As such, the airflow control feature <NUM> can be configured to cause the heated airflow having a temperature within a higher temperature range to have a shorter amount of time to heat the vaporizable material along the upstream section <NUM>, such as compared to the downstream section <NUM> where the heated airflow temperature is within a lower temperature range and can be allowed a longer amount of time to heat the vaporizable material along the downstream section <NUM>. For example, the shorter amount of time can be a result of one or more of a faster airflow rate, a shorter airflow pathway length, and less airflow resistance/pressure along the upstream section <NUM>. Additionally, the longer amount of time can be a result of one or more of a slower airflow rate, a longer airflow pathway length, and more airflow resistance/pressure along the downstream section <NUM>.

The first part <NUM> and the second part <NUM> of the airflow control feature <NUM> can each include one or more of a variety of shapes and sizes, including forming a variety of airflow pathways each having a variety of airflow pathway characteristics. As such, airflow control features having a variety of shapes and sizes and airflow pathways having a variety of airflow pathway characteristics are within the scope of this disclosure for achieving similar heat transfer rates along the airflow pathway <NUM>, as discussed herein. Additionally, the airflow control feature <NUM> can include two or more parts, such as two or more parts that each form or assist with forming airflow pathways having different airflow pathway characteristics. The airflow pathway <NUM> can also include more than two sections, such as two or more sections that each include different airflow pathway characteristics for achieving different airflow characteristics and similar amounts of heat transfer between the heated airflow (e.g., within different temperature ranges) and the vaporizable material along each section.

<FIG> illustrates a second embodiment of the vaporizable material insert <NUM> including an airflow control feature <NUM> at least partly contained in a housing <NUM>. As shown in <FIG>, a first part <NUM> of the airflow control feature <NUM> can extend along a length of the housing <NUM> and include a vaporizable material <NUM> that can be formed in a ring shape. The ring-shaped first part <NUM> can include an inner diameter defining an upstream section <NUM> of the airflow pathway <NUM>. The upstream section <NUM> can include a same or similar diameter across the length of the first part <NUM> of the airflow control feature <NUM>.

As shown in <FIG>, the airflow control feature <NUM> can include a second part <NUM> extending along another length of the housing <NUM>. For example, the first part <NUM> can be shorter in length than the second part <NUM>, as shown in <FIG>. The second part <NUM> can also include vaporizable material <NUM> and can be formed in a twisted or helical shape defining a downstream section <NUM> of the airflow pathway <NUM>. As shown in <FIG>, the second part <NUM> can define or include one or more secondary airflow pathways <NUM> extending helically along the second part <NUM> (e.g., along a longitudinal axis of the second part <NUM>). The airflow pathway <NUM> can include at least one airflow pathway characteristic that changes along the airflow pathway <NUM> such that a second airflow pathway characteristic along the downstream section <NUM> is different than a first airflow pathway characteristic along the upstream section <NUM>. For example, the downstream section <NUM> can include a total cross-section area that is less than the cross-section area of the upstream section <NUM>. Alternatively or in addition, each of the secondary airflow pathways <NUM> of the downstream section <NUM> can include a diameter that is smaller than the diameter of the upstream section <NUM> of the airflow pathway <NUM>. As such, one or more airflow characteristics (e.g., airflow rate, airflow resistance/pressure, airflow travel length) along the helical secondary airflow pathways <NUM> can be different from one or more airflow characteristics of the airflow along the upstream section <NUM> of the airflow pathway <NUM>.

Furthermore, the airflow characteristics of the heated airflow traveling along the helical secondary airflow pathways <NUM> can result in an amount of heat transfer between the heated airflow and the vaporizable material along the second part <NUM> of the airflow control feature that is similar to an amount of heat transfer achieved along the first part <NUM> of the airflow control feature <NUM>. The upstream section <NUM> can be positioned adjacent or closest to the heating element <NUM> thereby encountering airflow having the highest temperatures. As such, the airflow control feature <NUM> can be configured to achieve a similar amount of heat transfer between the heated airflow and the vaporizable material along the length of the airflow pathway (e.g., extending between the inlet and outlet of the housing).

<FIG> illustrates a third embodiment of the vaporizable material insert <NUM> including an airflow control feature <NUM> at least partly contained in a housing <NUM>. As shown in <FIG>, the airflow control feature <NUM> can include a vaporizable material <NUM> and form an airflow pathway <NUM> extending along a longitudinal axis of the airflow control feature <NUM>. The airflow pathway <NUM> formed by the airflow control feature <NUM> can have a cylindrical or conical shape with an inner diameter that decreases (e.g., linearly, logarithmically) along the length of the airflow control feature <NUM>. As shown in <FIG>, the airflow pathway <NUM> can decrease in diameter or cross-sectional area along the length of the airflow pathway <NUM> in the direction of airflow along the airflow pathway <NUM>. Such decreasing diameter along the airflow pathway <NUM> can cause one or more airflow characteristics of the heated airflow traveling along the airflow pathway <NUM> to vary therealong. The temperature of the heated airflow can also decrease as the heated airflow travels along the airflow pathway. As such, one or more of the airflow characteristics can change to accommodate a lower temperature of the heated airflow to achieve a similar amount of heat transfer between the heated airflow and the vaporizable material along the length of the airflow pathway <NUM>.

For example, the amount of heat transfer between the heated airflow and the vaporizable material <NUM> of the airflow control feature <NUM> at an inlet end <NUM> (e.g., where a diameter of the airflow pathway <NUM> is largest) compared to an outlet end <NUM> (e.g., where a diameter of the airflow pathway <NUM> is smallest) can be similar. Furthermore, a rate of change of at least one airflow characteristic can change in relation/proportionate to a rate in change of at least one airflow characteristic, thereby achieving a similar amount of heat transfer between the heated airflow and the vaporizable material <NUM> along the airflow pathway <NUM>. Such changes in airflow pathway characteristics, and thus changes in airflow characteristics, can achieve a similar amount of heat transfer between the heated airflow and vaporizable material along the airflow pathway <NUM> and/or airflow control feature <NUM>. Other configurations for achieving uniform heat transfer along an airflow pathway are within the scope of this disclosure.

In some embodiments, the vaporizable material insert (e.g., any of the vaporizable material inserts <NUM>, <NUM>, <NUM>, <NUM> described herein) may include a cooling filter <NUM> positioned adjacent the outlet of the housing (as shown, for example, in <FIG>). The cooling filter <NUM> can cause airflow exiting the housing and airflow pathway to decrease in temperature prior to inhalation. For example, the cooling filter <NUM> may be formed of a porous substrate containing liquid vaporizable material and may be disposed adjacent the mouthpiece.

In some embodiments, the airflow control feature (e.g., any of the airflow control features <NUM>, <NUM>, <NUM> described herein) may include a substrate, such as a porous substrate (e.g., wick), saturated with liquid vaporizable material. In some embodiments, the airflow control feature may include a solid vaporizable material formed into a porous, moldable media, which can be saturated with a liquid vaporizable material, and/or a combination of both.

Terminology used herein is for the purpose of describing particular embodiments and implementations only and is not intended to be limiting.

Spatially relative terms, such as "forward", "rearward", "under", "below", "lower", "over", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.

Although various illustrative embodiments are described above, any of a number of changes may be made to various embodiments without departing from the teachings herein. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments, one or more method steps may be skipped altogether. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the claims.

Claim 1:
A vaporizable material insert (<NUM>, <NUM>, <NUM>) for use with a vaporizer device (<NUM>) to form an inhalable aerosol, the vaporizable material insert (<NUM>, <NUM>, <NUM>) comprising:
a housing (<NUM>, <NUM>, <NUM>) including an inlet and an outlet;
an airflow control feature (<NUM>, <NUM>, <NUM>) comprising a vaporizable material, the airflow control feature (<NUM>, <NUM>, <NUM>) extending between the inlet and the outlet of the housing (<NUM>, <NUM>, <NUM>); and
an airflow pathway (<NUM>, <NUM>, <NUM>) extending between the inlet and the outlet of the housing (<NUM>, <NUM>, <NUM>) and at least partly formed by the airflow control feature (<NUM>, <NUM>, <NUM>), the airflow pathway (<NUM>, <NUM>, <NUM>) allowing a heated airflow to travel therealong and including an upstream section (<NUM>, <NUM>, <NUM>) and a downstream section (<NUM>, <NUM>, <NUM>), the upstream section (<NUM>, <NUM>, <NUM>) including a first airflow pathway (<NUM>, <NUM>, <NUM>) characteristic that controls a first airflow characteristic of the heated airflow for achieving a first amount of heat transfer between the heated airflow at a first temperature and the vaporizable material along the upstream section (<NUM>, <NUM>, <NUM>), the downstream section (<NUM>, <NUM>, <NUM>) including a second airflow pathway (<NUM>, <NUM>, <NUM>) characteristic that controls a second airflow characteristic of the heated airflow for achieving a second amount of heat transfer between the heated airflow at a second temperature and the vaporizable material along the downstream section (<NUM>, <NUM>, <NUM>), the first temperature being higher than the second temperature, and the first amount of heat transfer being approximately the same as the second amount of heat transfer.