Patent Description:
A non-nicotine electronic vaping or e-vaping device includes a heating element that vaporizes a non-nicotine pre-vapor formulation to produce a non-nicotine vapor.

A non-nicotine e-vaping device includes a power supply, such as a rechargeable battery, arranged in the device. The power supply is electrically connected to the heater. The power supply provides power to the heater such that the heater heats to a temperature sufficient to convert the non-nicotine pre-vapor formulation to a non-nicotine vapor. The non-nicotine vapor exits the non-nicotine e-vaping device through a mouthpiece including at least one outlet.

<CIT> discloses a cartridge for an aerosol delivery device such as a smoking article. The cartridge may include a base, a reservoir substrate, and an atomizer. The reservoir substrate may define a cavity therethrough. The atomizer may comprise a liquid transport element and a heating element extending at least partially about the liquid transport element. The atomizer may extend through the cavity through the reservoir substrate such that the heating element is positioned proximate an end of the reservoir substrate. Ends of the liquid transport element may extend to an opposing end of the reservoir substrate. A related method for assembling a cartridge for a smoking article is also provided.

The present invention provides an apparatus as defined in the present claim <NUM> and a method as defined in the present claim <NUM>.

The present invention, as further defined in claim <NUM>, provides an apparatus for assembling a heater assembly for a non-nicotine pod assembly and includes a base, a wick feed, a slide, and a holder. The wick feed extends toward the base and defines a channel configured to receive a wick structured to draw a non-nicotine pre-vapor formulation via capillary action. The slide is configured to move along a plane on a top face of the base. The holder is disposed on the top face of the base.

The apparatus may include a wick retainer extending parallel and adjacent to the wick feed for retaining the wick in the channel.

The apparatus may include a cutter having a blade configured to slide along a top surface of the slide to cut the wick.

The wick feed in the apparatus may be configured to rotate relative to the base.

The apparatus may include a block fixed to the base. The wick feed may be rotatably attached to and supported by the block.

The holder of the apparatus may be configured to receive a support of the heater assembly therein, the holder being configured to fix the support relative to the base for inserting the wick.

The channel in the wick feed of the apparatus may be configured to guide the wick into alignment with a heater on the support.

The wick feed of the apparatus may extend orthogonally to the base.

The holder of the apparatus may include a locking finger configured to engage a support of the heater assembly and retain the support within the holder.

The holder of the apparatus according to the invention, as defined in claim <NUM>, is configured to secure a support of the heater assembly. The slide includes a front face that is orthogonal to the top face of the base. The slide is configured to contact a finger of a heater on the support to move the finger to a vertical position so as to compress the wick.

The wick feed of the apparatus may include a plate and a retainer. The plate may be disposed orthogonal to the base and may define the channel. The retainer may be disposed orthogonal to the base and adjacent to the plate. The retainer and the plate may define a slot for guiding the wick.

The apparatus may include a block fixed to the base. The plate may be rotatably attached to and supported by the block.

The retainer of the apparatus may be fixed to the plate such that the retainer and the plate are configured to rotate relative to the base and the block.

The holder of the apparatus may be configured to secure a support of the heater assembly and to lock a position of the support relative to the base.

The holder of the apparatus may include a locking finger configured to engage the support and retain the support within the holder.

The apparatus may include a blade configured to slide along a top surface of the slide.

According to the present invention, as further defined in claim <NUM>, there is provided a method of assembling a heater assembly for a non-nicotine pod assembly and includes securing, with a holder, a support of the heater assembly relative to a base; aligning, with a guide plate mounted to the base, a wick strip in a heater of the support, the wick strip structured to draw a non-nicotine pre-vapor formulation via capillary action; cutting, with a blade configured to slide relative to the base, a portion of the wick strip; clamping, with a slide configured to slide relative to the base, a portion of the heater around the portion of the wick strip; and releasing, with the holder, the support from the base.

The securing the support relative to the base of the example method includes locking the support in the holder.

The aligning the wick strip in the heater of the support of the example method includes inserting the wick strip into a channel in the guide plate, the channel extending towards the base.

The aligning the wick strip in the heater of the support may include inserting the wick strip into a gap defined by a channel in the guide plate and a retainer plate fixed to the guide plate.

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 example embodiments set forth herein.

Accordingly, while example embodiments are capable of various modifications and alternative forms, example 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.

A non-nicotine electronic vaping device, or non-nicotine e-vaping device, includes a heating element that vaporizes a non-nicotine pre-vapor formulation to produce a non-nicotine vapor. The non-nicotine pre-vapor formulation may be enclosed in a housing or non-nicotine pod assembly. The non-nicotine electronic vaping device includes a power supply, such as a rechargeable battery, arranged in the device. The power supply is electrically connected to a heater assembly for the non-nicotine pod assembly. The power supply provides power to the heater assembly such that the heater assembly heats to a temperature sufficient to convert the non-nicotine pre-vapor formulation in the non-nicotine pod assembly to a non-nicotine vapor. The non-nicotine vapor exits the non-nicotine electronic vaping device through a mouthpiece including at least one outlet.

The non-nicotine pre-vapor formulation is a material or combination of materials that is devoid of nicotine and that may be transformed into a non-nicotine vapor. For example, the non-nicotine pre-vapor formulation may include a liquid, solid, and/or gel formulation. These may include, for example and without limitation, solutions and suspensions (e.g., emulsions) containing water, oil, beads, solvents, active ingredients, ethanol, plant extracts, non-nicotine compounds, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, and/or any other ingredients that may be suitable for vaping. During vaping, the non-nicotine e-vaping device is configured to heat the non-nicotine pre-vapor formulation to generate a non-nicotine vapor. Non-nicotine vapor, non-nicotine aerosol, and non-nicotine dispersion are used interchangeably and refer to the matter generated or outputted by the devices disclosed, claimed, and/or equivalents thereof, wherein such matter is devoid of nicotine.

In an example embodiment, the non-nicotine pre-vapor formulation neither includes tobacco nor is derived from tobacco. A non-nicotine compound of the non-nicotine pre-vapor formulation may be part of, or included in a liquid or a partial-liquid that includes an extract, an oil, an alcohol, a tincture, a suspension, a dispersion, a colloid, a general non-neutral (slightly acidic or slightly basic) solution, or combinations thereof. During the preparation of the non-nicotine pre-vapor formulation, the non-nicotine compound may be infused into, comingled, or otherwise combined with the other ingredients of the non-nicotine pre-vapor formulation.

In an example embodiment, the non-nicotine compound undergoes a slow, natural decarboxylation process over an extended duration of time at relatively low temperatures, including at or below room temperature (e.g., <NUM> °F). In addition, the non-nicotine compound may undergo a significantly elevated decarboxylation process (e.g., <NUM>% decarboxylation or greater) if exposed to elevated temperatures, especially in the range of about <NUM> °F or greater over a period of time (minutes or hours) at a relatively low pressure such as <NUM> atmosphere. Higher temperatures of about <NUM> °F or greater can cause a rapid or instantaneous decarboxylation to occur at a relatively high decarboxylation rate, although further elevated temperatures can cause a degradation of some or all of the chemical properties of the non-nicotine compound(s).

In an example embodiment, the non-nicotine compound may be from a medicinal plant (e.g., a naturally-occurring constituent of a plant that provides a medically-accepted therapeutic effect). The medicinal plant may be a cannabis plant, and the constituent may be at least one cannabis-derived constituent. Cannabinoids (e.g., phytocannabinoids) and terpenes are examples of cannabis-derived constituents. Cannabinoids interact with receptors in the body to produce a wide range of effects. As a result, cannabinoids have been used for a variety of medicinal purposes. Cannabis-derived materials may include the leaf and/or flower material from one or more species of cannabis plants, or extracts from the one or more species of cannabis plants. For instance, the one or more species of cannabis plants may include Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some example embodiments, the non-nicotine pre-vapor formulation includes a mixture of cannabis and/or cannabis-derived constituents that are, or are derived from, <NUM>-<NUM>% (e.g., <NUM>%) Cannabis sativa and <NUM>-<NUM>% (e.g., <NUM>%) Cannabis indica.

Non-limiting examples of cannabis-derived cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), while cannabidiolic acid (CBDA) is precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an example embodiment, heat from the heater may cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) in the non-nicotine pre-vapor formulation to tetrahydrocannabinol (THC), and/or to convert cannabidiolic acid (CBDA) in the non-nicotine pre-vapor formulation to cannabidiol (CBD).

In instances where both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in the non-nicotine pre-vapor formulation, the decarboxylation and resulting conversion will cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least <NUM>% (e.g., at least <NUM>%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC), via the decarboxylation process, during the heating of the non-nicotine pre-vapor formulation for purposes of vaporization. Similarly, in instances where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in the non-nicotine pre-vapor formulation, the decarboxylation and resulting conversion will cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least <NUM>% (e.g., at least <NUM>%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD), via the decarboxylation process, during the heating of the non-nicotine pre-vapor formulation for purposes of vaporization.

The non-nicotine pre-vapor formulation may contain the non-nicotine compound that provides the medically-accepted therapeutic effect (e.g., treatment of pain, nausea, epilepsy, psychiatric disorders). Details on methods of treatment may be found in <CIT>, titled "VAPORIZING DEVICES AND METHODS FOR DELIVERING A COMPOUND USING THE SAME.

In an example embodiment, at least one flavorant is present in an amount ranging from about <NUM>% to about <NUM>% by weight (e.g., about <NUM>% to <NUM>%, about <NUM>% to <NUM>%, or about <NUM>% to <NUM>%) based on a total weight of the non-nicotine pre-vapor formulation. The at least one flavorant may be at least one of a natural flavorant, an artificial flavorant, or a combination of a natural flavorant and an artificial flavorant. The at least one flavorant may include volatile cannabis flavor compounds (flavonoids) or other flavor compounds instead of, or in addition to, the cannabis flavor compounds. For instance, the at least one flavorant may include menthol, wintergreen, peppermint, cinnamon, clove, combinations thereof, and/or extracts thereof. In addition, flavorants may be included to provide other herb flavors, fruit flavors, nut flavors, liquor flavors, roasted flavors, minty flavors, savory flavors, combinations thereof, and any other desired flavors.

<FIG> and <FIG> are front and rear perspective views of an apparatus or fixture for assembling a heater assembly for a non-nicotine pod assembly according to at least one example embodiment. The apparatus may be used in conjunction with the cutter illustrated in <FIG>, in at least one example embodiment, and the slicing guide and blade illustrated in <FIG>, in at least one example embodiment, to prepare and assemble a heater assembly for a non-nicotine pod assembly as described herein.

Referring to <FIG> and <FIG>, in at least one example embodiment, the apparatus, or fixture, <NUM> includes a base <NUM>, a guide <NUM>, a slide <NUM>, a wick guide <NUM> (or non-nicotine wick guide), a holder <NUM>, and a block <NUM>.

In at least one example embodiment, a detailed illustration of the base <NUM> is shown in <FIG>. The base <NUM> may include a longitudinal channel <NUM> with sidewalls <NUM>, <NUM>. Each sidewall includes a step <NUM>, <NUM> that increases a width of the longitudinal channel <NUM>. The longitudinal channel <NUM> may have a first width W1 at a base or bottom <NUM> of the longitudinal channel <NUM> and may have a second width W2 at a top <NUM> of the longitudinal channel <NUM> above the steps <NUM>, <NUM>, with the second width W2 being greater than the first width W1.

In the example embodiment shown in <FIG>, <FIG>, and <FIG>, for example, the base <NUM> may include a lateral channel <NUM> with sidewalls <NUM>, <NUM> defining the lateral channel <NUM>. The lateral channel <NUM> may extend orthogonal to and intersect the longitudinal channel <NUM>. One of the sidewalls <NUM> of the lateral channel <NUM> may include a step <NUM>, while the other of the sidewalls <NUM> is flat. The step <NUM> may increase a width of the lateral channel <NUM>. The lateral channel <NUM> may have a first width LW1 at a bottom or base <NUM> of the lateral channel <NUM> and may have a second width LW2 at a top <NUM> of the lateral channel <NUM> above the step <NUM>, with the second width LW2 being greater than the first width LW1.

The sidewall <NUM> may include a notch <NUM> at a position of the holder <NUM>. Thus, the notch <NUM> may separate the sidewall <NUM> into two parts <NUM>(a) and <NUM>(b).

In the example embodiment shown in <FIG>, <FIG>, and <FIG>, for example, the base <NUM> may include a plurality of apertures <NUM>, <NUM>, <NUM> extending orthogonally through the base <NUM>. Apertures <NUM> may receive a fastener (for example, a bolt, screw, or other fastener) for fixing the guide <NUM> on a top surface <NUM> the base <NUM>. Apertures <NUM> may receive a fastener (for example, a bolt, screw, or other fastener) for fixing the holder <NUM> to the base <NUM>. Apertures <NUM> may receive a fastener (for example, a bolt, screw, or other fastener) for fixing the block <NUM> to the base <NUM>. A slot <NUM> may also be defined by the base <NUM> between the apertures <NUM>. The slot <NUM> may receive a portion of the block <NUM>.

The base <NUM> may additionally include a holder cutout <NUM> aligned with the longitudinal channel <NUM> and the apertures <NUM> for receiving the holder <NUM>. The holder cutout <NUM> may correspond in width to a width of the holder <NUM>, thus simplifying the assembly of the holder <NUM> on the base <NUM>.

At an intersection between the longitudinal channel <NUM> and the lateral channel <NUM>, a support cutout <NUM> may be defined by the base <NUM>. The support cutout <NUM> may provide a track or guide for inserting a component of a heater assembly for a non-nicotine pod assembly into the holder <NUM>. A width of the support cutout SW may be less than the width W1 of the longitudinal channel <NUM> and a width HCW of the holder cutout <NUM>. The support cutout <NUM> may extend from the intersection between the longitudinal channel <NUM> and the lateral channel <NUM>, beyond a plane of the sidewall <NUM>, into notch <NUM>, and to a section of the base <NUM> having the holder cutout <NUM>.

<FIG> and <FIG> are perspective views of an example embodiment of an assembled base <NUM> and guide <NUM> of the apparatus, or fixture, <NUM> shown in <FIG>. As previously mentioned, the guide <NUM> may be fixed to the base <NUM> at apertures <NUM> on the base <NUM>. The guide <NUM> may include corresponding first apertures <NUM> that align with the apertures <NUM> in the base <NUM> and receive a fastener to fix the guide <NUM> to the base <NUM>.

The guide <NUM> may include second apertures <NUM>, a third aperture <NUM>, and a slot <NUM>. The slot <NUM> may be positioned longitudinally along a center of the guide <NUM> above the channel <NUM> in the base <NUM>. The second apertures <NUM> may be positioned along each side <NUM>, <NUM> and at a front end <NUM> of the slot <NUM>. The second apertures <NUM> may receive pins, rods, or screws that extend through the second apertures <NUM> to apply light pressure on the slide <NUM> to ensure the motion of the slide <NUM> is controlled by the actuation of the pin <NUM>. The third aperture <NUM> receive a pin, rod, or screw to set the functional travel distance of the slide <NUM> and may be positioned in a lateral center of a front face <NUM> of the guide <NUM> and extend through to the front end <NUM> of the slot <NUM>.

<FIG> and <FIG> are perspective views of an example embodiment of an assembled base <NUM> and slide <NUM> of the apparatus, or fixture, <NUM> shown in <FIG>. The slide <NUM> is slideable within the longitudinal channel <NUM>. The slide <NUM> may include a plate <NUM> and a pin <NUM> extending from a top surface <NUM> thereof. The plate <NUM> may rest and be slideable on a top surface <NUM>, <NUM> of each step <NUM>, <NUM>. A front end <NUM> of the plate <NUM> may include a tab or projection <NUM> having a front face <NUM> that is slideable within the notch <NUM> in the base <NUM>.

The pin <NUM> may extend orthogonally to the plate <NUM> and may be received within the slot <NUM> in the guide <NUM>, as illustrated, for example, in <FIG> and <FIG>. The slot <NUM> may serve as a guide track and stop for the pin <NUM>. In a fully-forward position, the pin <NUM> is adjacent to (e.g., contacts) the front end <NUM> of the slot <NUM> and a plane along the front face <NUM> of the tab <NUM> on the slide <NUM> aligns with a plane along the sidewall <NUM> of the lateral channel <NUM>. In a fully-rearward position, the pin <NUM> is adjacent to (e.g., contacts) a rear end <NUM> of the slot <NUM> and a plane along a rear face <NUM> of the plate <NUM> of the slide <NUM> aligns with a plane along a rear face <NUM> of the base <NUM>.

Referring to <FIG>, a perspective view of an example embodiment of the apparatus, or fixture, <NUM> shown in <FIG> with the guide removed is illustrated. As shown in <FIG>, <FIG>, and <FIG>, for example, the wick guide <NUM> may be fixed on the base <NUM> by block <NUM>. As previously stated, block <NUM> may be secured to the base <NUM> at apertures <NUM> by fasteners and at slot <NUM>. Additionally, a retract spring <NUM> may be fixed to an outer, forward face <NUM> of block <NUM> and a forward face <NUM> of base <NUM>, causing a plane along forward face <NUM> to align with a plane along forward face <NUM> and restrict movement of the forward face <NUM> of block <NUM> from protruding beyond the forward face <NUM> of base <NUM>.

The wick guide <NUM> may be fixed to the block <NUM> by a fastener, such as a shoulder screw, <NUM>, as illustrated in <FIG> and <FIG>, for example. In some example embodiments, the fastener <NUM> (<FIG>) may include a top <NUM> and a body <NUM> having a smooth portion <NUM> and a threaded portion <NUM>. The threaded portion <NUM> may engage with threads in an aperture <NUM> in block <NUM> (<FIG>). The aperture <NUM> may be a counter-sunk aperture having a large-diameter portion <NUM> that mates with part of the smooth portion <NUM> of the fastener <NUM> and a small-diameter portion <NUM> that is threaded and mates with the threaded portion <NUM> of the fastener <NUM>. The top <NUM> of the fastener <NUM> may be knurled, slotted, or knurled and slotted for easy insertion and removal from the aperture <NUM>.

The wick guide <NUM>, as illustrated in example embodiments of <FIG>, may include a wick feed <NUM> (or non-nicotine wick feed) and a wick retainer <NUM> (or non-nicotine wick retainer). The wick feed <NUM> may be a plate, or channeled plate, having a channel or slot <NUM> formed therein. The channel <NUM> may extend across a width of the wick feed <NUM> and may be a width sufficient to accommodate a wick configured to draw a non-nicotine pre-vapor formulation via capillary action (discussed in further detail below). For example, the channel <NUM> may have a width within a range of <NUM> inches to <NUM> inch, and more specifically within a range of <NUM> inches and <NUM> inches. Although an example width is provided, it is understood that the width of the channel <NUM> may be sized differently to fit various sized wicks configured to draw a non-nicotine pre-vapor formulation via capillary action.

The wick retainer <NUM> may be a flat plate that aligns with (and is fixed to) the wick feed <NUM> to define a guide or track <NUM> with the channel <NUM> in the wick feed <NUM> in which the wick for non-nicotine wicking is inserted during assembly (discussed in further detail below). The wick retainer <NUM> may include apertures <NUM> that align with apertures <NUM> (<FIG>) in the wick feed <NUM> which receive fasteners therein to fix the wick retainer <NUM> to the wick feed <NUM>. A fastener or pin extending through one of the apertures <NUM> may extend beyond the wick feed <NUM> and fit within a track <NUM> in block <NUM>, thereby allowing the wick feed <NUM> to pivot relative to the block <NUM>. Additionally, the smooth portion <NUM> of the fastener <NUM> is received within an aperture in the wick guide <NUM>, providing a pivot point around which the wick guide <NUM> may rotate.

<FIG> illustrate detailed views of an example embodiment of the holder of the apparatus, or fixture, <NUM> shown in <FIG>. The holder <NUM> may include a base <NUM>, a lock <NUM>, and a resilient member <NUM> (e.g., spring). The base <NUM> may further include slots <NUM> for receiving one or more fingers of a heater assembly for a non-nicotine pod assembly (further described below) and/or portions of the lock <NUM>. The base <NUM> may also include apertures <NUM> configured to align with apertures <NUM> in the base <NUM> and receive fasteners to fix the holder <NUM> to the base <NUM>.

In some example embodiments, the lock <NUM> may further include a toggle <NUM> and at least one locking finger <NUM>. The lock <NUM> may be rotatably fixed to the base <NUM> at apertures <NUM> in the toggle <NUM>. Apertures <NUM> in the toggle <NUM> may align with apertures <NUM> in the base <NUM> to receive a rod or pin therein. The rod or pin may provide a pivot point about which the toggle <NUM> may rotate. The toggle <NUM> may include a projection or lever <NUM> configured to be manipulated by an assembly technician to move the toggle <NUM> between a first, forward position and a second, rearward position. In the first position, the locking fingers <NUM> may be in an open, or unlocked, position (further described below), and in the second position, the locking fingers <NUM> may be in a closed, or locked, position (further described below).

The locking fingers <NUM> may be fixed to a front face <NUM> of the toggle <NUM> and may rotate with the rotation of the toggle <NUM>. In some example embodiments, three locking fingers <NUM> may be fixed to the toggle <NUM>. However, it is understood that any number of locking fingers <NUM> may be included. In some example embodiments, each of the locking fingers <NUM> may be a plate including a rectangular body <NUM> and a hook <NUM> (<FIG>). The hook <NUM> may be defined by a dip <NUM> and a point <NUM>.

A tab <NUM> on an opposite side of the toggle <NUM> from the front face <NUM> contacts the resilient member <NUM>. The resilient member <NUM> is a flat, plate-like spring having a body <NUM> and a tab or projection <NUM> extending from the body <NUM>. The body <NUM> of the resilient member <NUM> is fixed to the base <NUM> at apertures <NUM> by fasteners (for example only, screws or bolts). Apertures <NUM> align with apertures <NUM> in the base <NUM> and are configured to receive the fasteners. The tab <NUM> extends similar to a cantilever beam and overlays the tab <NUM> of the toggle <NUM>. The tab <NUM> of the resilient member <NUM> provides a counter force on the toggle <NUM> to bias the toggle <NUM> in the second, rearward, position such that the locking fingers <NUM> are biased in the locked, closed, position.

<FIG> is a perspective view of an example embodiment of a cutter <NUM> that may be used with the apparatus, or fixture, <NUM> shown in <FIG>. The cutter <NUM> includes a block <NUM> and a blade <NUM>. The blade <NUM> may be positioned on a front face <NUM> of the block <NUM>. In some embodiments, the blade <NUM> may be fixed to the block <NUM> by one or more fasteners.

The cutter <NUM> may be slideable along the top surface <NUM> of the slide <NUM> from a first position to a second position. In the first position, the cutter <NUM> may be disposed on the top surface <NUM> of the slide <NUM> between the wick guide <NUM> and the guide <NUM>. In the second position, the cutter <NUM> may be disposed on the top surface <NUM> of the slide <NUM> with the blade <NUM> disposed adjacent the holder <NUM> and under the wick guide <NUM>.

Still referring to the example embodiment shown in <FIG>, the apparatus, or fixture, <NUM> and cutter <NUM> may be used in a method <NUM> of preparing and assembling a heater assembly for a non-nicotine pod assembly. Method <NUM> may start at <NUM>. At step <NUM>, a wick pad <NUM> (<FIG>) is covered by a slicing guide <NUM> (<FIG>). For example, the slicing guide <NUM> may be set on the wick pad <NUM>.

In at least one example embodiment, the wick pad <NUM> (or non-nicotine wick pad) may include filaments (or threads) having a capacity to draw the non-nicotine pre-vapor formulation via capillary action. For example, the wick pad <NUM> may be a sheet of glass (or ceramic) fibers or filaments woven together. In at least one example embodiment, the wick pad <NUM> may include any suitable material or combination of materials. Examples of suitable materials may be, but not limited to, glass, ceramic-based, or graphite-based materials.

The wick pad <NUM> may have any suitable capillary drawing action to accommodate non-nicotine pre-vapor formulations having different physical properties such as density, viscosity, surface tension and vapor pressure. The capillary drawing action is the movement of the non-nicotine pre-vapor formulation (e.g., liquid with non-nicotine substances dissolved therein) within the spaces of the porous wick pad <NUM> material due to the forces of adhesion, cohesion, and surface tension. Capillary action occurs when molecules of a liquid stay close together (cohesion) while being attracted to and adhering to internal surfaces of a porous structure (adhesion). Notably, capillary action occurs when the adhesion of the molecules of the liquid to the wall of the structure is stronger than the cohesive forces between the molecules. Because the non-nicotine pre-vapor formulation may include various substances (such as, without limitation, water, oil, emulsions, beads, solvents, active ingredients, ethanol, plant or other extracts, non-nicotine compounds, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, an alcohol, a tincture, a suspension, a dispersion, a colloid, a general non-neutral slightly acidic or slightly basic solution, cannabis-derived constituents, and/or any other ingredients that may be suitable for vaping, as previously mentioned), a wicking material structured to draw the non-nicotine pre-vapor formulation may be designed for the specific formulation. Therefore, the material of the wick pad <NUM> may have a different structure and/or compound to promote capillary action for a specific non-nicotine pre-vapor formulation. For example, the diameter of the pores and/or dimension of the interstitial spaces in the wick pad <NUM> material may be sized appropriately to facilitate the drawing of the non-nicotine pre-vapor formation via capillary action based on the physical properties of the formulation (e.g., surface tension) and the material (e.g., hydrophilicity). For example, a size of the capillary space may need to increase as a density of the liquid increases. Additionally, in an example embodiment, the wick pad <NUM> may be non-conductive.

Although the example wick pad <NUM> is illustrated as a circular sheet in <FIG>, it is understood that the wick pad <NUM> may take any shape, to include a rectangular sheet, a square sheet, or any other-shaped sheet.

As illustrated in <FIG>, the example slicing guide <NUM> may include one or more slots or channels <NUM> penetrating a thickness thereof. Each of the channels <NUM> may extend in a length direction of the slicing guide <NUM> and may be aligned in a width direction of the slicing guide <NUM>. The channels <NUM> may be evenly spread in the width direction, so that when the wick pad <NUM> is cut or divided, equal width strips are created.

An aperture <NUM> may be on one end of each channel <NUM>. In some embodiments, the aperture <NUM> may be on alternating ends of the channels <NUM>. The aperture <NUM> on the end of the channel <NUM> may facilitate insertion of a blade <NUM> (further described below). With the aperture <NUM> on alternating ends of the channels <NUM>, the blade <NUM> may be inserted and sliced through each channel in a more efficient manner.

At step <NUM>, the blade <NUM>, or razor, is sliced through each channel <NUM> in the slicing guide <NUM> to cut or divide the wick pad <NUM> into wick strips <NUM> (<FIG>). In an example embodiment illustrated in <FIG>, the blade <NUM> may include a cutting edge <NUM> and a grip <NUM>. The cutting edge <NUM> may be a sharp edge used to cut or divide the wick pad <NUM> into wick strips <NUM> (or non-nicotine wick strips). The grip <NUM> may be for example, a dulled edge of the blade <NUM> or an overlay on an edge of the blade <NUM> opposite the cutting edge <NUM> to provide a portion of the blade <NUM> for an assembly technician to grasp.

As illustrated in <FIG>, the cutting edge <NUM> of the blade <NUM> is inserted into the aperture <NUM> of each channel <NUM> of the slicing guide <NUM> and passed, or sliced, through the length of the channel <NUM>. This movement of the blade <NUM> cuts or separates the wick pad <NUM> positioned beneath the slicing guide <NUM>. The blade <NUM> is then moved to the next channel <NUM> until a slice has been made in each channel <NUM> of the slicing guide <NUM>.

At step <NUM>, the slicing guide <NUM> is removed and the wick strips <NUM> are separated from the wick pad <NUM>. As illustrated in <FIG>, when the slicing guide <NUM> is removed from the wick pad <NUM>, the wick pad <NUM> is divided into a plurality of wick strips <NUM> corresponding to the position of the channels <NUM>. Each wick strip <NUM> may be separated from the adjacent strips <NUM>.

At step <NUM>, the wick strip <NUM> is inserted in the guide or track <NUM> of the wick guide <NUM>. As illustrated in <FIG>, the width of the channel <NUM> defining the guide or track <NUM> is slightly larger than the width of the wick strip <NUM> to accommodate and guide the wick strip <NUM>.

At step <NUM>, the end of the wick strip <NUM> is removed using the cutter <NUM>. As illustrated in <FIG> and <FIG>, the slide <NUM> of the apparatus, or fixture, <NUM> is moved to a position clamping the wick strip <NUM> against the holder <NUM> to restrain movement of the wick strip <NUM> during cutting. The cutter <NUM> is moved from a position not contacting the wick strip <NUM> to a position contacting the wick strip <NUM>. Specifically, the blade <NUM> of the cutter <NUM> is moved to a position slicing the wick strip <NUM>, creating an edge that extends parallel to a plane on the top surface <NUM> of the slide <NUM>.

At step <NUM>, the wick guide <NUM> is rotated about the fastener <NUM>. In at least one example embodiment, the wick guide <NUM> is rotatably fixed to the block <NUM> by a fastener <NUM>. The body <NUM> of the fastener <NUM> extends through the wick retainer <NUM>, the wick plate <NUM>, and the aperture <NUM> in the block <NUM>. A projection or other portion extending from a back side of the wick plate <NUM> may slide within the track <NUM> in the block <NUM> as the wick guide <NUM> rotates relative to the block <NUM>. As illustrated in <FIG>, the wick guide <NUM> may be rotated from a position where a longitudinal axis A of the wick guide <NUM> is parallel to a plane on the top surface <NUM> of the base <NUM> to a position where the longitudinal axis A of the wick guide <NUM> intersects the plane on the top surface <NUM> of the base <NUM>. In some embodiments, the wick guide <NUM> may be rotated clockwise such that the longitudinal axis A forms an angle with the plane on the top surface <NUM> of the base <NUM> that is within a range of <NUM>°-<NUM>°, and more specifically within a range of <NUM>°-<NUM>°.

At step <NUM>, the lever <NUM> on the toggle <NUM> of the lock <NUM> is engaged to move the locking fingers <NUM> to the first position such that the fingers are unlocked and in an open position. In some embodiments, the lock <NUM> may be rotatably fixed to the base <NUM> to rotate about a rod or pin within apertures <NUM> in the toggle <NUM>. The locking fingers <NUM> may rotate with the rotation of the toggle <NUM>. In one embodiment, as illustrated in <FIG>, lever <NUM> on the toggle <NUM> is pressed forward to move the locking fingers <NUM> to the first position.

The tab <NUM> on the opposite side of the toggle <NUM> from the front face <NUM> contacts the resilient member <NUM>. The resilient member <NUM> is a flat, plate-like, spring having a body <NUM> and a tab or projection <NUM> extending from the body <NUM>. The body <NUM> of the resilient member <NUM> is fixed to the base <NUM>. The tab <NUM> extends similar to a cantilever beam and overlays the tab <NUM> of the toggle <NUM>. The tab <NUM> of the resilient member <NUM> provides a counter force on the toggle <NUM> to bias the toggle <NUM> in the second, rearward, position such that the locking fingers <NUM> are biased in the locked, closed, position.

Thus, when the lever <NUM> on the toggle <NUM> of the lock <NUM> is engaged to move the locking fingers <NUM> to the first position, a force is exerted on the resilient member <NUM> by the tab <NUM>.

At step <NUM>, a preliminary heater arrangement <NUM> (or preliminary non-nicotine heater arrangement) for a non-nicotine pod assembly is inserted into the holder <NUM>. As illustrated in <FIG> and <FIG>, in at least one example embodiment, the preliminary heater arrangement <NUM> for the non-nicotine pod assembly may include a base <NUM> and a heating element <NUM> having wire loops or a wire extending in a serpentine shape forming a coil <NUM>. The wire used to form the coil may be metal. A first set of wire loops 536a may extend perpendicular to a top surface <NUM> of the base <NUM>. A second set of wire loops 536b may extend at an angle to the first set of wire loops 536a and the top surface <NUM>. For example only, the second set of wire loops 536b may extend at an angle within a range of <NUM>°-<NUM>° relative to the top surface <NUM>, and more particularly, may extend at an angle of <NUM>° relative to the top surface <NUM>.

The heating element <NUM> may extend fully or partially across a width of the base <NUM>. In some example embodiments, the heating element <NUM> may be in contact (for example, direct contact) with an assembled wick (further described below).

The holder <NUM> is disposed in the holder cutout <NUM> of the base <NUM> such that the notch <NUM> exists between the holder <NUM> and the base <NUM> at a location above the support cutout <NUM>. Thus, as the preliminary heater arrangement <NUM> for the non-nicotine pod assembly is inserted into the holder <NUM>, the base <NUM> is inserted into the support cutout <NUM> and notch <NUM>, in a position at least partially under the holder <NUM>.

The preliminary heater arrangement <NUM> for the non-nicotine pod assembly is inserted into the holder <NUM> until the first set of wire loops 536a contact the holder <NUM> at a location near the slots <NUM> on the holder <NUM>.

At step <NUM>, the lever <NUM> of the toggle <NUM> is released such that the toggle <NUM> returns to the second position. As previously stated, the tab <NUM> of the resilient member <NUM> provides a counter force on the toggle <NUM> to bias the toggle <NUM> in the second, rearward, position such that the locking fingers <NUM> are biased in the locked, closed, position. As shown in <FIG>, as the toggle <NUM> moves to the second position, the locking fingers <NUM> engage with the first set of wire loops 536a to retain the preliminary heater arrangement <NUM> against the holder <NUM>.

At step <NUM> the wick guide <NUM> is rotated counterclockwise to a position where the longitudinal axis A of the wick guide <NUM> is parallel to a plane on the top surface <NUM> of the base <NUM>. As previously stated, the wick guide <NUM> is rotatably fixed to the block <NUM> by a fastener <NUM>. The body <NUM> of the fastener <NUM> extends through the wick retainer <NUM>, the wick plate <NUM>, and the aperture <NUM> in the block <NUM>. The projection or other portion extending from the back side of the wick plate <NUM> may slide within the track <NUM> in the block <NUM> as the wick guide <NUM> rotates relative to the block <NUM>. The wick guide <NUM> may be rotated from the position where the longitudinal axis A of the wick guide <NUM> intersects the plane on the top surface <NUM> of the base <NUM> to the position where the longitudinal axis A of the wick guide <NUM> is parallel to the plane on the top surface <NUM> of the base <NUM>.

At step <NUM>, the wick strip <NUM> is slid into the channel <NUM> in the wick guide <NUM> to a position contacting the top surface <NUM> of the base <NUM> of the preliminary heater arrangement <NUM> for the non-nicotine pod assembly. As illustrated in <FIG> and <FIG>, the wick strip <NUM> includes an edge <NUM> that extends parallel to a plane on the top surface <NUM> of the slide <NUM>. The edge <NUM> is moved into a position contacting the top surface <NUM> of the base <NUM> of the preliminary heater arrangement <NUM>. The wick strip <NUM> additionally contacts the first set of wire loops 536a.

At step <NUM>, the pin <NUM> of the slide <NUM> is moved to the fully-forward position, where the pin <NUM> contacts the front end <NUM> of the slot <NUM> and the plane along the front face <NUM> of the tab <NUM> on the slide <NUM> aligns with the plane along the sidewall <NUM> of the lateral channel <NUM>.

As illustrated in <FIG> and <FIG>, during movement of the slide <NUM> to the fully-forward position, the front face <NUM> of the tab <NUM> on the slide <NUM> contacts the second set of wire loops 536b and bends the second set of wire loops 536b from the position angled to the first set of wire loops 536a and the top surface <NUM> to a position substantially parallel to the first set of wire loops 536a and contacting the wick strip <NUM>. In the fully-forward position, the front face <NUM> of the tab <NUM> on the slide <NUM> clamps the first set of wire loops 536a and the second set of wire loops 536b together to compress the wick strip <NUM> and fix the wick strip <NUM> in relation to the preliminary heater arrangement <NUM>, forming a heater assembly, or heater-wick assembly, <NUM>'.

At step <NUM>, the wick strip <NUM> is cut to create a wick <NUM> (or non-nicotine wick). In some embodiments, the end of the wick strip <NUM> is removed using the cutter <NUM>. As illustrated in <FIG> 1D, the cutter <NUM> is moved from a position not contacting the wick strip <NUM> to a position contacting the wick strip <NUM>. Specifically, the blade <NUM> of the cutter <NUM> is moved to a position slicing the wick strip <NUM>, creating an edge that extends parallel to a plane on the top surface <NUM> of the slide <NUM>. The resulting cut piece is the wick <NUM>.

At step <NUM>, the wick guide <NUM> is rotated clockwise. As illustrated in <FIG>, the wick guide <NUM> is rotated about the fastener <NUM>. The wick guide <NUM> may be rotated from a position where the longitudinal axis A of the wick guide <NUM> is parallel to the plane on the top surface <NUM> of the base <NUM> to a position where the longitudinal axis A of the wick guide <NUM> intersects the plane on the top surface <NUM> of the base <NUM>. In some embodiments, the wick guide <NUM> may be rotated clockwise such that the longitudinal axis A forms an angle with the plane on the top surface <NUM> of the base <NUM> that is within a range of <NUM>°-<NUM>°, and more specifically within a range of <NUM>°-<NUM>°.

At step <NUM>, the pin <NUM> of the slide <NUM> is moved to release the heater assembly <NUM>' (or non-nicotine heater assembly) for the non-nicotine pod assembly. In some embodiments, the pin <NUM> moves to the fully-rearward position as shown in <FIG>. In the fully-rearward position, the pin <NUM> may contact a rear end <NUM> of the slot <NUM> and a plane along a rear face <NUM> of the plate <NUM> of the slide <NUM> may align with a plane along a rear face <NUM> of the base <NUM>.

At step <NUM>, the lever <NUM> of the toggle <NUM> is engaged to release the lock <NUM>. Engagement of the lever <NUM> may move the locking fingers <NUM> to the first position such that the fingers are unlocked and in the open position. In some embodiments, the lock <NUM> may be rotatably fixed to the base <NUM> to rotate about a rod or pin within apertures <NUM> in the toggle <NUM>. The locking fingers <NUM> may rotate with the rotation of the toggle <NUM>. In one embodiment, as illustrated in <FIG>, lever <NUM> on the toggle <NUM> is pressed forward to move the locking fingers <NUM> to the first position.

The tab <NUM> on the opposite side of the toggle <NUM> from the front face <NUM> contacts the resilient member <NUM>. The resilient member <NUM> extends similar to a cantilever beam and overlays the tab <NUM> of the toggle <NUM>. The resilient member <NUM> provides a counter force on the toggle <NUM> to bias the toggle <NUM> in the second, rearward, position such that the locking fingers <NUM> are biased in the locked, closed, position. Thus, when the lever <NUM> on the toggle <NUM> of the lock <NUM> is engaged to move the locking fingers <NUM> to the first position, a force is exerted on the resilient member <NUM> by the tab <NUM>.

At step <NUM>, the heater assembly <NUM> for the non-nicotine pod assembly is removed from the holder <NUM>. As illustrated in <FIG> and <FIG>, the heater assembly <NUM>' is removed from the holder <NUM> by sliding the heater assembly <NUM>' in the notch <NUM> and support cutout <NUM> away from the holder <NUM> until the heater assembly <NUM>' clears an edge of the holder <NUM>. The heater assembly <NUM>' for the non-nicotine pod assembly is then removed from the support cutout <NUM>.

At step <NUM>, the lever <NUM> of the toggle <NUM> is released such that the toggle <NUM> returns to the second position. As previously stated, the tab <NUM> of the resilient member <NUM> provides a counter force on the toggle <NUM> to bias the toggle <NUM> in the second, rearward, position such that the locking fingers <NUM> are biased in the locked, closed, position.

Now referring to <FIG>, an embodiment of an assembled heater assembly <NUM>' for a non-nicotine pod assembly is illustrated. The wick <NUM> is clamped between the first set of wire loops 536a and the second set of wire loops 536b such that the wick <NUM> is fixed relative to the heater assembly <NUM>'. An example heater assembly is disclosed in <CIT>, titled "NON-NICOTINE POD ASSEMBLIES AND NON-NICOTINE E-VAPING DEVICES.

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.

It should be understood that, although the terms first, second, third, or the like, may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, 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'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. Thus, the term "below" may encompass both an orientation of above and below.

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. 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, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, 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. 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.

Claim 1:
An apparatus (<NUM>) for assembling a heater assembly (<NUM>') for a non-nicotine pod assembly, the apparatus comprising:
a base (<NUM>);
a wick guide (<NUM>) extending toward the base and defining a channel (<NUM>) configured to receive a wick (<NUM>) structured to draw a non-nicotine pre-vapor formulation via capillary action;
a slide (<NUM>) configured to move along a plane on a top face of the base; and
a holder (<NUM>) disposed on the top face of the base, wherein
the holder is configured to secure a support of the heater assembly, the slide includes a front face (<NUM>) that is orthogonal to the top face of the base, and the slide is configured to contact a finger of a heater (<NUM>) on the support to move the finger to a vertical position so as to compress the wick.