Patent ID: 12232224

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the 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.

It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, 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. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, 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. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

FIG.1is a side view of an e-vaping device according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.1, an electronic vaping device (e-vaping device)10may include a replaceable cartridge (or first section)15and a reusable battery section (or second section)20, which may be coupled together at a threaded connector25. It should be appreciated that the connector25may be any type of connector, such as a snug-fit, detent, clamp, bayonet, and/or clasp. An air inlet55extends through a portion of the connector25.

In at least one example embodiment, the connector25may be the connector described in U.S. patent application Ser. No. 15/154,439, filed May 13, 2016, the entire contents of which is incorporated herein by reference thereto. As described in U.S. patent application Ser. No. 15/154,439, filed May 13, 2016, the entire content of which is incorporated herein by reference thereto, the connector25may be formed by a deep drawn process. As described in U.S. patent application Ser. No. 15/349,377, filed Nov. 11, 2016, the entire content of which is incorporated herein by reference thereto, the connector25may be formed by an in molding process.

In at least one example embodiment, the first section15may include a first housing30and the second section20may include a second housing30′. The e-vaping device10includes a mouth-end insert35at a first end45.

In at least one example embodiment, the first housing30and the second housing30′ may have a generally cylindrical cross-section. In other example embodiments, the housings30and30′ may have a generally triangular cross-section along one or more of the first section15and the second section20. Furthermore, the housings30and30′ may have the same or different cross-section shape, or the same or different size. As discussed herein, the housings30,30′ may also be referred to as outer or main housings.

In at least one example embodiment, the e-vaping device10may include an end cap40at a second end50of the e-vaping device10. The e-vaping device10also includes a light60between the end cap40and the first end45of the e-vaping device10.

FIG.2is a cross-sectional view along line II-II of the e-vaping device ofFIG.1.

In at least one example embodiment, as shown inFIG.2, the first section15may include a reservoir95configured to store a pre-vapor formulation and a vaporizer80that may vaporize the pre-vapor formulation. The vaporizer80includes a heating element85and a wick90. The wick90may draw the pre-vapor formulation from the reservoir95. The e-vaping device10may include the features set forth in U.S. Patent Application Publication No. 2013/0192623 to Tucker et al. filed Jan. 31, 2013 and/or features set forth in U.S. patent application Ser. No. 15/135,930 to Holtz et al, filed Apr. 22, 2016, the entire contents of each of which are incorporated herein by reference thereto. In other example embodiments, the e-vaping device may include the features set forth in U.S. patent application Ser. No. 15/135,923 filed Apr. 22, 2016, and/or U.S. Pat. No. 9,289,014 issued Mar. 22, 2016, the entire contents of each of which is incorporated herein by this reference thereto.

In at least one example embodiment, the pre-vapor formulation is a material or combination of materials that may be transformed into a vapor. For example, the pre-vapor formulation may be a liquid, solid and/or gel formulation including, but not limited to, water, beads, solvents, active ingredients, ethanol, plant extracts, natural or artificial flavors, and/or vapor formers such as glycerin and propylene glycol. The pre-vapor formulation may further include plant material, such as tobacco material or non-tobacco material.

In at least one example embodiment, the first section15may include the housing30extending in a longitudinal direction and an inner tube (or chimney)70coaxially positioned within the housing30.

In at least one example embodiment, a first connector piece155may include a male threaded section for affecting the connection between the first section15and the second section20.

At an upstream end portion of the inner tube70, a nose portion245of a gasket (or seal)240may be fitted into the inner tube70; and an outer perimeter of the gasket240may provide a seal with an interior surface of the housing30. The gasket240may also include a central, longitudinal air passage235in fluid communication with the inner tube70to define an inner passage (also referred to as a central channel or central inner passage)120. A transverse channel230at a backside portion of the gasket240may intersect and communicate with the air passage235of the gasket240. This transverse channel230assures communication between the air passage235and a space250defined between the gasket240and the first connector piece155.

In at least one example embodiment, the first connector piece155may include a male threaded section for effecting the connection between the first section15and the second section20.

In at least one example embodiment, at least two air inlets55may be included in the housing30. Alternatively, a single air inlet55may be included in the housing30. Such arrangement allows for placement of the air inlet55close to the connector25without occlusion by the presence of the first connector piece155. This arrangement may also reinforce the area of air inlets55to facilitate precise drilling of the air inlets55.

In at least one example embodiment, the air inlets55may be provided in the connector25instead of in the housing30. In other example embodiments, the connector25may not include threaded portions.

In at least one example embodiment, the at least one air inlet55may be formed in the housing30, adjacent the connector25to minimize the chance of an adult vaper's fingers occluding one of the ports and to control the resistance-to-draw (RTD) during vaping. In at least one example embodiment, the air inlet55may be machined into the housing30with precision tooling such that their diameters are closely controlled and replicated from one e-vaping device10to the next during manufacture.

In at least one example embodiment, the air inlets55may be sized and configured such that the e-vaping device10has a resistance-to-draw (RTD) in the range of from about 60 mm H2O to about 150 mm H2O (e.g. about 70 mm H2O to about 140 mm H2O, about 80 mm H2O to about 130 mm H2O, or about 90 mm H2O to about 120 mm H2O). The size and number of air inlets55may be adjusted to adjust the RTD.

In at least one example embodiment, a nose portion110of a gasket65may be fitted into a first end portion105of the inner tube70. An outer perimeter of the gasket65may provide a substantially tight seal with an interior surface125of the housing30. The gasket65may include a central channel115disposed between the inner passage120of the inner tube70and the interior of the mouth-end insert35, which may transport the vapor from the inner passage120to the mouth-end insert35. The mouth-end insert35includes at least two outlets100, which may be located off-axis from the longitudinal axis of the e-vaping device10. The outlets100may be angled outwardly in relation to the longitudinal axis of the e-vaping device10. The outlets100may be substantially uniformly distributed about the perimeter of the mouth-end insert35so as to substantially uniformly distribute vapor.

In at least one example embodiment, the space defined between the gasket65, the gasket240, the housing30, and the inner tube70may establish the confines of the reservoir95. The reservoir95may contain a pre-vapor formulation, and optionally a storage medium (not shown) configured to store the pre-vapor formulation therein. The storage medium may include a winding of cotton gauze or other fibrous material about the inner tube70.

The inner tube70may have an outer diameter ranging from about 2.0 mm to about 3.5 mm. The outer diameter may be chosen to maximize a size of the reservoir95.

In at least one example embodiment, the reservoir95may at least partially surround the inner passage120. Thus, the reservoir95may at least partially surround the inner passage120. The heating element85may extend transversely across the inner passage120between opposing portions of the reservoir95. In some example embodiments, the heater85may extend parallel to a longitudinal axis of the inner passage120. In other example embodiments, the heating element85may not be in the inner passage120of the inner tube70.

In at least one example embodiment, the reservoir95may be sized and configured to hold enough pre-vapor formulation such that the e-vaping device10may be configured for vaping for at least about 200 seconds. Moreover, the e-vaping device10may be configured to allow each puff to last a maximum of about 5 seconds.

In at least one example embodiment, the storage medium may be a fibrous material including at least one of cotton, polyethylene, polyester, rayon and combinations thereof. The fibers may have a diameter ranging in size from about 6 microns to about 15 microns (e.g., about 8 microns to about 12 microns or about 9 microns to about 11 microns). The storage medium may be a sintered, porous or foamed material. Also, the fibers may be sized to be irrespirable and may have a cross-section which has a Y-shape, cross shape, clover shape or any other suitable shape. In at least one example embodiment, the reservoir95may include a filled tank lacking any storage medium and containing only pre-vapor formulation.

During vaping, pre-vapor formulation may be transferred from the reservoir95and/or storage medium to the proximity of the heating element85via capillary action of the wick90. The wick90may include at least a first end portion and a second end portion, which may extend into opposite sides of the reservoir95. The heating element85may at least partially surround a central portion of the wick90such that when the heating element85is activated, the pre-vapor formulation in the central portion of the wick90may be vaporized by the heating element85to form a vapor.

In at least one example embodiment, the wick90may include a sheet of wicking material having a capacity to draw the pre-vapor formulation. In at least one example embodiment, the wick90may include one or more sheets of material, such as a sheet formed of borosilicate fibers. The sheet of material may be folded, braided, twisted, adhered together, etc. to form the wick90. The sheet of material may include one or more layers of material. The sheet of material may be folded and/or twisted. If multiple layers of material are included, each layer may have a same density or a different density than other layers. The layers may have a same thickness or a different thickness. The wick90may have a thickness ranging from about 0.2 mm to about 2.0 mm (e.g., about 0.5 mm to about 1.5 mm or about 0.75 mm to about 1.25 mm). In at least one example embodiment, the wick90includes braided amorphous silica fibers.

A thicker wick90may deliver a larger quantity of pre-vapor formulation to the heating element85so as to produce a larger amount of vapor, while a thinner wick90may deliver a smaller quantity of pre-vapor formulation to the heating element85so as to produce a smaller amount of vapor.

In at least one example embodiment, the wick90may include a stiff, structural layer and at least one additional less rigid layer. The addition of a stiff, structural layer may aid in automated manufacture of the cartridge. The stiff, structural layer could be formed of a ceramic or other substantially heat resistant material.

In other example embodiments, the wick90may be a bundle of glass (or ceramic) filaments, a bundle including a group of windings of glass filaments, etc., all of which arrangements may be capable of drawing pre-vapor formulation via capillary action by interstitial spacings between the filaments. The filaments may be generally aligned in a direction perpendicular (transverse) to the longitudinal direction of the e-vaping device10. In at least one example embodiment, the wick90may include one to eight filament strands, each strand comprising a plurality of glass filaments twisted together. The end portions of the wick90may be flexible and foldable into the confines of the reservoir95. The filaments may have a cross-section that is generally cross-shaped, clover-shaped, Y-shaped, or in any other suitable shape.

In at least one example embodiment, the wick90may include any suitable material or combination of materials. Examples of suitable materials may be, but not limited to, glass, ceramic- or graphite-based materials. The wick90may have any suitable capillarity drawing action to accommodate pre-vapor formulations having different physical properties such as density, viscosity, surface tension and vapor pressure. The wick90may be non-conductive.

In at least one example embodiment, the heating element85may include a folded metal sheet (discussed below with respect toFIGS.3A,3B, and4), which at least partially surrounds the wick90. The heating element85may extend fully or partially along a length of the wick90. The heating element85may further extend fully or partially around the circumference of the wick90. In some example embodiments, the heating element85may or may not be in contact with the wick90.

In at least one example embodiment, the heating element85may be formed of any suitable electrically resistive materials. Examples of suitable electrically resistive materials may include, but not limited to, copper, titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include, but not limited to, stainless steel, nickel, cobalt, chromium, aluminum-titanium-zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel. For example, the heating element85may be formed of nickel aluminide, a material with a layer of alumina on the surface, iron aluminide and other composite materials, the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required. The heating element85may include at least one material selected from the group consisting of stainless steel, copper, copper alloys, nickel-chromium alloys, super alloys and combinations thereof. In an example embodiment, the heating element85may be formed of nickel-chromium alloys or iron-chromium alloys. In another example embodiment, the heating element85may be a ceramic heater having an electrically resistive layer on an outside surface thereof.

The inner tube70may include a pair of opposing slots, such that the wick90and the first and second electrical leads225,225′ or ends260,260′ of the heating element85may extend out from the respective opposing slots. The provision of the opposing slots in the inner tube70may facilitate placement of the heating element85and wick90into position within the inner tube70without impacting edges of the slots and the folded section of the heating element85. In at least one example embodiment, the inner tube70may have a diameter of about 4 mm and each of the opposing slots may have major and minor dimensions of about 2 mm by about 4 mm.

In at least one example embodiment, the first lead225is physically and electrically connected to the male threaded connector piece155. As shown, the male threaded first connector piece155is a hollow cylinder with male threads on a portion of the outer lateral surface. The connector piece is conductive, and may be formed or coated with a conductive material. The second lead225′ is physically and electrically connected to a first conductive post130. The first conductive post130may be formed of a conductive material (e.g., stainless steel, copper, etc.), and may have a T-shaped cross-section as shown inFIG.2. The first conductive post130nests within the hollow portion of the first connector piece155, and is electrically insulated from the first connector piece155by an insulating shell135. The first conductive post130may be hollow as shown, and the hollow portion may be in fluid communication with the air passage120. Accordingly, the first connector piece155and the first conductive post130form respective external electrical connection to the heating element85.

In at least one example embodiment, the heating element85may heat pre-vapor formulation in the wick90by thermal conduction. Alternatively, heat from the heating element85may be conducted to the pre-vapor formulation by means of a heat conductive element or the heating element85may transfer heat to the incoming ambient air that is drawn through the e-vaping device10during vaping, which in turn heats the pre-vapor formulation by convection.

As shown inFIG.2, the second section20includes a power supply145, a control circuit185, and a sensor190. As shown, the control circuit185and the sensor190are disposed in the housing30′. The control circuit185may include a printed circuit board200. A female threaded second connector piece160forms a second end. As shown, the second connector piece160has a hollow cylinder shape with threading on an inner lateral surface. The inner diameter of the second connector piece160matches that of the outer diameter of the first connector piece155such that the two connector pieces155,160may be threaded together to form the connection25. Furthermore, the second connector piece160, or at least the other lateral surface is conductive, for example, formed of or including a conductive material. As such, an electrical and physical connection occurs between the first and second connector pieces155,160when connected.

As shown, a first lead165electrically connects the second connector piece160to the control circuit185. A second lead170electrically connects the control circuit185to a first terminal180of the power supply145. A third lead175electrically connects a second terminal140of the power supply145to the power terminal of the control circuit185to provide power to the control circuit185. The second terminal140of the power supply145is also physically and electrically connected to a second conductive post150. The second conductive post150may be formed of a conductive material (e.g., stainless steel, copper, etc.), and may have a T-shaped cross-section as showFIG.2. The second conductive post150nests within the hollow portion of the second connector piece160, and is electrically insulated from the second connector piece160by a second insulating shell215. The second conductive post150may also be hollow as shown. When the first and second connector pieces155,160are mated, the second conductive post150physically and electrically connects to the first conductive post130. Also, the hollow portion of the second conductive post150may be in fluid communication with the hollow portion of the first conductive post130.

While the first section15has been shown and described as having the male connector piece and the second section20has been shown and described as having the female connector piece, an alternative embodiment includes the opposite where the first section15has the female connector piece and the second section20has the male connector piece.

In at least one example embodiment, the power supply145includes a battery arranged in the e-vaping device10. The power supply145may be a Lithium-ion battery or one of its variants, for example a Lithium-ion polymer battery. Alternatively, the power supply145may be a nickel-metal hydride battery, a nickel cadmium battery, a lithium-manganese battery, a lithium-cobalt battery or a fuel cell. The e-vaping device10may be vapable by an adult vapor until the energy in the power supply145is depleted or in the case of lithium polymer battery, a minimum voltage cut-off level is achieved.

In at least one example embodiment, the power supply145is rechargeable. The second section20may include circuitry configured to allow the battery to be chargeable by an external charging device. To recharge the e-vaping device10, an USB charger or other suitable charger assembly may be used as described below.

In at least one example embodiment, the sensor190is configured to generate an output indicative of a magnitude and direction of airflow in the e-vaping device10. The control circuit185receives the output of the sensor190, and determines if (1) the direction of the airflow indicates a draw on the mouth-end insert8(versus blowing) and (2) the magnitude of the draw exceeds a threshold level. If these vaping conditions are met, the control circuit185electrically connects the power supply145to the heating element85; thus, activating the heating element85. Namely, the control circuit185electrically connects the first and second leads165,170(e.g., by activating a heater power control transistor forming part of the control circuit185) such that the heating element85becomes electrically connected to the power supply145. In an alternative embodiment, the sensor190may indicate a pressure drop, and the control circuit185activates the heating element85in response thereto.

In at least one example embodiment, the control circuit185may also include a light60, which the control circuit185activates to glow when the heating element85is activated and/or the battery145is recharged. The light60may include one or more light-emitting diodes (LEDs). The LEDs may include one or more colors (e.g., white, yellow, red, green, blue, etc.). Moreover, the light60may be arranged to be visible to an adult vaper during vaping, and may be positioned between the first end45and the second end50of the e-vaping device10. In addition, the light60may be utilized for e-vaping system diagnostics or to indicate that recharging is in progress. The light60may also be configured such that the adult vaper may activate and/or deactivate the heater activation light60for privacy.

In at least one example embodiment, the control circuit185may include a time-period limiter. In another example embodiment, the control circuit185may include a manually operable switch for an adult vesper to initiate heating. The time-period of the electric current supply to the heating element85may be set or pre-set depending on the amount of pre-vapor formulation desired to be vaporized.

Next, operation of the e-vaping device to create a vapor will be described. For example, air is drawn primarily into the first section15through the at least one air inlet55in response to a draw on the mouth-end insert35. The air passes through the air inlet55, into the space250, through the transverse channel230into the air passage235, into the inner passage120, and through the outlet100of the mouth-end insert35. If the control circuit185detects the vaping conditions discussed above, the control circuit185initiates power supply to the heating element85, such that the heating element85heats pre-vapor formulation in the wick90. The vapor and air flowing through the inner passage120combine and exit the e-vaping device10via the outlet100of the mouth-end insert35.

When activated, the heating element85may heat a portion of the wick90for less than about 10 seconds or less than about 1 second.

In at least one example embodiment, the first section15may be replaceable. In other words, once the pre-vapor formulation of the cartridge is depleted, only the first section15may be replaced. An alternate arrangement may include an example embodiment where the entire e-vaping device10may be disposed once the reservoir95is depleted. In at least one example embodiment, the e-vaping device10may be a one-piece e-vaping device.

In at least one example embodiment, the e-vaping device10may be about 80 mm to about 110 mm long and about 7 mm to about 8 mm in diameter. For example, in one example embodiment, the e-vaping device10may be about 84 mm long and may have a diameter of about 7.8 mm.

FIG.3Ais a front view of a vaporizer including a folded heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.3A, a folded heating element85is a single integral member that is cut and/or laser etched from a sheet of metal, which is folded about at least a portion of a wick90. The folded heating element85contacts the wick90on three sides.

In at least one example embodiment, the folded heating element85includes a first plurality of U-shaped segments270arranged in a first direction and defining a first side275of the heating element85. The folded heating element also includes a second plurality of U-shaped segments280arranged in the first direction and defining a second side285of the heating element85(shown inFIGS.3B and4and discussed in detail below). The second side285is substantially parallel to the first side275.

In at least one example embodiment, the folded heating element85also includes ends, which form a first lead portion260and a second lead portion260′. As shown inFIG.3A, both ends260,260′ may be on the second side285of the folded heating element85.

In at least one example embodiment, the first plurality of U-shaped segments270, the second plurality of U-shaped segments280, the first lead portion260, and the second lead portion260′ are a single integral member.

In at least one example embodiment, each of the first plurality of U-shaped segments270is connected to at least one of the second plurality of U-shaped segments280by one of a third plurality of U-shaped segments290.

In at least one example embodiment, each of the third plurality of U-shaped segments290includes a folded portion295. The third plurality of U-shaped shaped segments290extend in a second direction. The second direction is substantially perpendicular to the first direction. Thus, the third plurality of U-shaped segments290extends substantially perpendicular to the first plurality of U-shaped segments270and the second plurality of U-shaped segments280.

In at least one example embodiment, each of the first plurality of U-shaped segments270is in a first plane, and each of the second plurality of U-shaped segments280is in a second plane, which is different from the first plane. The first plane is substantially parallel to the second plane. In other example embodiments, the first plane may not be parallel to the second plane.

In at least one example embodiment, each of the third plurality of U-shaped segments290is in a different plane from other ones of the third plurality of U-shaped segments290. Each of the third plurality of U-shaped segments290is in a different plane from the first plurality of U-shaped segments270and in a different plane from the second plurality of U-shaped segments280. For example, the third plurality of U-shaped segments290extends perpendicular to the first plurality of U-shaped segments270and in a different plane from the second plurality of U-shaped segments280.

In at least one example embodiment, the first plurality of U-shaped segments270, the second plurality of U-shaped segments280, and the third plurality of U-shaped segments290may each include one to twenty U-shaped segments (e.g., two to eighteen U-shaped segments, three to fifteen U-shaped segments, four to twelve U-shaped segments, or five to ten U-shaped segments). The number of U-shaped segments in each of the first plurality of U-shaped segments270, the second plurality of U-shaped segments280, and the third plurality of U-shaped segments290may be chosen depending on the desired resistance and/or the desired size of the heating element85.

In at least one example embodiment, each one of the first plurality of U-shaped segments270is offset from ones of the second plurality of U-shaped segments280. The first plurality of U-shaped segments270may include a same number or a different number of U-shaped segments than the second plurality of U-shaped segments280. In at least one example embodiment, the first plurality of U-shaped segments270has more or less U-shaped segments than the second plurality of U-shaped segments280.

Each of the first plurality of U-shaped segments270and each of the second plurality of U-shaped segments280include at least one side (or leg)300and a tip310. The tips310have at least one of a rounded shape, a rectangular shape, an oval, a square shape, and a triangular shape.

In at least one example embodiment, the heating element85has a resistance ranging from about 0.5 ohm to about 5.0 ohms (e.g., about 1.0 ohm to about 4.5 ohms, about 2.0 ohms to about 4.0 ohms, or about 2.5 ohms to about 3.5 ohms). The resistance may be chosen based on desired vapor output and/or battery life.

FIG.3Bis a side view of the heating element ofFIG.3Aaccording to at least one example embodiment.

In at least one example embodiment, as shown inFIG.3B, the heating element85is the same as inFIG.3A, but is shown from a side. As shown, the folded portion295has an inner width W1ranging from about 0.05 mm to about 2.0 mm (e.g., about 0.5 mm to about 1.75 mm or about 0.75 mm to about 1.5 mm). The inner width W1may vary depending upon the resistance of the heating element85. Heating elements85having a lower resistance have a wider inner width W1than heating elements85having a higher resistance. For example, if the heating element85has a resistance of about 2.9 ohms, the inner width W1of the folded portion295may be about 0.25 mm to about 0.50 mm, while a heating element285having a resistance of about 3.5 ohms may have an inner width W1of the folded portion295of about 0.5 mm to about 1.5 mm.

In at least one example embodiment, the folded portion295does not include sharp corners (e.g., has rounded edges and/or corners). In other example embodiments, the folded portion295includes sharp corners. The folded portion295may be substantially perpendicular to the sides300of the first plurality of U-shaped portions270and the second plurality of U-shaped portions280.

In at least one example embodiment, the folded portion295is formed such that three sides of the heating element85contact the wick90so as to increase the surface area contact between the wick90and the heating element85. Moreover, the inner width W1is chosen so as to snugly hold the wick90between the first plurality of U-shaped portions270and the second plurality of U-shaped portions280, such that only a defined amount of pre-vapor formulation reaches the heating element85between activations of the heating element85.

In at least one example embodiment, the width W1is narrow enough so that only a set amount of pre-vapor formulation can flow into the wick90thereby preventing too much pre-vapor formulation from reaching the heating element85at a given time. The narrow width W1may also substantially prevent and/or reduce cooling of the heating element85by the pre-vapor formulation since only a set amount of pre-vapor formulation is able to wick to the heating element85at a time.

In at least one example embodiment, as shown inFIG.3B, each of the third plurality of U-shaped segments290include at least one side (or leg)300and a tip310. The tips310have at least one of a rounded shape, a rectangular shape, an oval, a square shape, and a triangular shape. The tips310may have an inner corner radius of about 0.10 mm to about 0.20 mm and an outer corner radius of about 0.25 mm to about 0.30 mm. The tips310of the third plurality of U-shaped segments290may have a same or different shape than the tips310of the first plurality of U-shaped segments270and the second plurality of U-shaped segments280.

In at least one example embodiment, the heating element85may have a thickness T1(shown inFIG.3B) ranging from about 0.001 mm to about 0.20 mm (e.g., about 0.01 mm to about 0.15 mm or about 0.05 mm to about 0.10 mm).

FIG.3Cis a perspective view of the heating element ofFIGS.3A and3Baccording to at least one example embodiment.

In at least one example embodiment, as shown inFIG.3C, the heating element85is the same as inFIGS.3A and3B, but is shown in a perspective view. As shown, the tips310of the first plurality of U-shaped segments270are offset from the tips310of the second plurality of U-shaped segments280.

In at least one example embodiment, the leads260,260′ may be wider and/or thicker than other portions of the heating element85to provide rigidity, stability, resistance, and ease of spot welding.

FIG.4is a top view of the heating element ofFIG.3Ain an unfolded condition according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.4, the heating element85is in a flat, planar form before being folded about the wick90. As discussed above, the heating element85may be cut (e.g., laser cut), stamped, and/or etched (e.g., photochemical etched) from a sheet of metal. The metal may include any suitable material including Nichrome 80, Nichrome 60, stainless steel 304, stainless steel 316, and Nicrothal 30.

In at least one example embodiment, as shown, the heating element85, when in the unfolded condition, has a length L1of about 4.0 mm to about 15.0 mm (e.g., about 4.5 mm to about 6.5 mm or about 5.0 mm to about 6.0 mm). The lead portions260,260′ extend beyond the second plurality of U-shaped segments280.

In at least one example embodiment, the lead portions260,260′ have a width W3ranging from about 1.0 mm to about 3.0 mm (e.g., about 1.25 mm to about 2.75 mm or about 1.75 mm to about 2.25 mm), and a length L2ranging from about 1.0 mm to about 2.5 mm (e.g., about 1.25 mm to about 2.25 mm or about 1.75 mm to about 2.0 mm).

In at least one example embodiment, a length L3is a length of the heating element85from an outer surface320of the tips310of the first plurality of U-shaped segments270to the outer surface320of the tips310of the second plurality of U-shaped segments280. The length L3ranges from about 4.5 mm to about 6.0 mm (e.g., about 4.75 mm to about 5.75 mm or about 5.0 mm to about 5.25 mm).

In at least one example embodiment, a length L4is the length between an inner surface330of the tips310of the first plurality of U-shaped segments270to the inner surface330of the tips310of the second plurality of U-shaped segments280. The length L4ranges from about 3.25 mm to about 7.0 mm (e.g., about 4.0 mm to about 6.0 mm or about 4.5 mm to about 5.5 mm).

In at least one example embodiment, a width W4of each of the tips310ranges from about 0.25 mm to about 0.50 mm.

In at least one example embodiment, a width W5of each side300of the first plurality of U-shaped segments270and the second plurality of U-shaped segments280ranges from about 0.05 mm to about 0.20 mm (e.g., about 0.10 mm to about 0.15 mm).

In at least one example embodiment, the width W4of each of the tips310of the first plurality of U-shaped segments270and the second plurality of U-shaped segments280is greater than the width W5of each of the sides300of the first plurality of U-shaped segments270and the second plurality of U-shaped segments280.

In at least one example embodiment, the first lead portion260and the second lead portion260′ each have a width W3greater than the width W5of the side300. The width W4of the tip300of each of the first plurality of U-shaped segments270is substantially the same as the width W4of the tip300of each of the second plurality of U-shaped segments280. The tip300of each of the first plurality of U-shaped segments270is offset from the tip300of each of the second plurality of U-shaped segments280when the heating element85is in the folded condition.

In at least one example embodiment, the dimensions of the heating element85may be adjusted to adjust the resistance of the heating element85. The dimensions of the heating element85may also be adjusted to form larger or smaller heaters for use in other vaping device including the devices set forth in U.S. patent application Ser. No. 15/135,930 to Holtz et al., filed Apr. 22, 2016, U.S. patent application Ser. No. 15/135,923 to Holtz, filed Apr. 22, 2016, U.S. patent application Ser. No. 15/224,866 to Gavrielov et al., filed Aug. 1, 2016, U.S. patent application Ser. No. 14/998,020 to Hawes et al., filed Apr. 22, 2015, U.S. patent application Ser. No. 15/147,454 to Li et al., filed May 5, 2016, and U.S. patent application Ser. No. 15/135,932 to Hawes et al., filed Apr. 22, 2016, the entire contents of each of which are incorporated herein by reference thereto.

In at least one example embodiment, the heating element85may extend substantially perpendicular to a longitudinal axis of the electronic vaping device. In other example embodiments, the heating element85may be substantially parallel to the longitudinal axis of the electronic vaping device.

FIG.5is a cross-sectional view of a cartridge of an electronic vaping device including a vaporizer according to at least one example embodiment.

In at least one example embodiment, the first section15including the heating element85is the same as inFIG.2, but the inner tube70excludes opposing slots and the heating element85and wick90are not within the inner tube70as discussed in detail below.

In at least one example embodiment, as shown inFIG.5, instead of a second gasket or seal at a second end of the reservoir95, a disk340is arranged between the inner tube70and the housing30. Thus, the reservoir95is defined by the seal65, the inner tube70, the housing30, and the disk340. The disk340may be formed of a polymer or metal that is substantially non-porous. Weep holes360may be formed in the disk340so as to allow pre-vapor formulation from the reservoir95to exit the reservoir95. The size and/or number of weep holes260defined in the disk340may be chosen based on desired pre-vapor formulation delivery amounts and/or timing. The disk240defines a central channel362in fluid communication with the inner passage120of the inner tube70. The central channel362has about a same diameter as an inner diameter of the inner passage120

In at least one example embodiment, a transfer material tube350abuts the disk340, such that any pre-vapor formulation exiting the reservoir95via the weep holes360is transferred to the transfer material tube350. The material used to form the transfer material tube350may depend on the material used to form the wick and the viscosity, density, etc. of the pre-vapor formulation. The transfer material tube350may have a density ranging from about 0.08 g/cc to about 0.3 g/cc.

The transfer material tube350defines a channel370that is in fluid communication with the inner passage120of the inner tube70.

In at least one example embodiment, the heating element85is arranged between the first connector155and the transfer material tube350. As vapor is formed, the vapor passes through the channel370and travels into the central channel362, and into the inner passage120.

FIG.6is an enlarged, perspective view of the first connector of the cartridge ofFIG.5according to at least one example embodiment.

In at least on example embodiment, as shown inFIG.6, the first connector155may include an inner post430. Both the connector155and the inner post430are formed of plastic. Thus, the electrical connection to the heater is made via a first connector ring385and a second connector ring395. The first connector ring385includes a first tab380that extends substantially perpendicular to the first connector ring385. The second connector ring395includes a second tab390that extends substantially perpendicular to the second connector ring395. Each of the first tab380and the second tab390defines a slot therein, which is sized and configured to receive one of the tabs260,260′.

In at least one example embodiment, the first connector ring385and the second connector ring395are electrically separated from each other by a separation disk500.FIG.6shows only a portion of the separation disk500to show the first connector ring385and the second connector ring395. The separation disk500defines two slots510,510′ therein. The first tab and the second tab380,390each extend through or of the two slots510,510′ in the separation disk500. Moreover, the first connector ring385and the second connector ring395have different inner and/or outer diameters to that one is smaller than the other and does not contact the other even when nested together.

In at least one example embodiment, the first and second connector rings385,395allow for the formation of the electrical connection with the heating element85without the need for crimping and/or soldering. In other example embodiments, the ends260,260′ may be held in the slots700,700′ defined by the first and second connecting tabs380,390, while also being crimped and/or soldered for added strength. The tabs380,390may have a guiding surface that converges (e.g., are dovetailed) to the slots700,700′ for ease of placement of the heating element tabs260,260′ therein. Thus, the slots700,700′ further facilitate automated manufacture of the electronic vaping device.

FIG.7is a graph illustrating aerosol output and battery exhaustion of an electronic vaping device including a vaporizer including a folded heating element according to at least one example embodiment.

A MarkTen XL electronic vaping device was compared to (1) a first vaping device including the battery section of the MarkTen XL, a cartridge as set forth inFIGS.5and6, and the heating element ofFIGS.3A,3B, and4having a resistance of about 3.0 ohms, (2) a second vaping device including the battery section of the MarkTen XL, a cartridge as set forth inFIGS.5and6, and the heating element ofFIGS.3A,3B, and4having a resistance of about 3.5 ohms, and (3) a third vaping device including the battery section of the MarkTen XL, a cartridge as set forth inFIGS.5and6, and the heating element ofFIGS.3A,3B, and4having a resistance of about 3.5 ohms. The first, second, and third vaping devices included 3.0 mm internal diameter inner tubes and the transfer material was formed of an Essentra pad having a density of about 0.115 g/cc. The wick of the first vaping device was formed from an Ahlstrom Grade 181 wick material. The wick of the second and third vaping devices was formed of Sterlitech 934-AH wick material. Each of the four tested cartridges was filled with. MarkTen XL classic formulation.

Each vaping device was test using a Mettler AE240 Balance (used to weight pads to determine amount of aerosol collected), Serial number GS9700, PM03715, a Fluke 287 RMS Multimeter, a Borgwaldt PV 10 RTD Machine, and a Borgwaldt Single Port Smoking Machine. The Single Port Smoking Machine was set to a four second duration, a 55 cc puff volume with a 26 second delay between puffs. 10 puffs were taken per measurement, and the cartridges were oriented to ensure that the wicks were fully saturated. The batteries of each device were fully charged prior to testing.

As shown inFIG.7, the MarkTen XL provides substantially consistent aerosol mass over initial puffs and a battery life that lasts for at least about 150 puffs. In comparison, the vaping device including the heating element having a resistance of 3.0 ohms provided a higher aerosol mass over the initial puffs, but a shorter battery life than the MarkTen XL. The vaping devices including the heating element having a resistance of about 3.5 ohms provided higher aerosol mass than the MarkTen XL, while still providing a battery life that exceeded 150 puffs.

FIG.8is an illustration of a heating element etched into a sheet of material according to at least one example embodiment.

In at least one example embodiment, the heating element may be etched using a photochemical etching and cleaning process. The photochemical etching process may be accomplished in an electrolytic bath containing a mixture of diluted inorganic acids.

In at least one example embodiment, the photochemical etching and cleaning process may include cleaning surfaces of the material using alcohol. A photo resistant dray film may be applied to surfaces of the material by lamination at a temperature of about 80° C. The raw material coated with Dray Film may be exposed through the plate with vacuum contact using UV light. The plate may be developed with a solvent solution in a development machine. The plate is then cleaned of remnants and residual solvent solution. The raw material plate may then be etched in an etching machine using an acidic solvent including ferric chloride with other additives. The photo resistance material is removed using a basic solvent, such as sodium carbonate, and the plate is rinsed with water, dried, and inspected for quality.

In at least one example embodiment, as shown inFIG.8, the heating element85is the same as inFIGS.3A,3B, and4, but the ends260,260′ are generally square in shape and extend, such that when the heating element85is folded, the ends260,260′ are along the folded portion295.

FIG.9is an illustration of a heating element in an unfolded condition according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.9, the heating element85is the same as inFIGS.3A,3B, and4, but the heating element includes the ends260,260′ and additional ends262,262′. The addition of the ends262,262′ allows for a more secure electrical connection with the heating element85.

A cartridge may include additional electrical leads and/or slots (shown inFIG.6to receive the additional ends262,262′.

FIG.10is an illustration of a heating element in an unfolded condition according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.10, the heating element85is the same as inFIGS.3A,3B, and4, but the ends260,260′ extend from opposite sides of the folded portion295.

The cartridge may be adapted to receive ends260,260′ that are in different planes.

FIG.11is a side view of a heating element according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.11, the heating element85is the same as inFIGS.3A,3B, and4, but the first side275is at an angle to the second side285, and the folded portion295includes a single fold, such that the folded heating element85is substantially V-shaped when viewed from a side. The first side275may be at an angle of about to about 90° to the second side285(e.g., about 10° to about 80°, about 20° to about 70°, about 30° to about 60°, or about 40° to about 50°).

FIG.12is a perspective view of a heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.12, the heating element85is the same as inFIGS.3A,3B, and4, but the ends260,260′ extend from the first side275and are bent such that the ends260,260′ are substantially perpendicular to the first side275. In addition, the wick90may include one or more twisted portions, which extend beyond edges of the heating element85.

FIG.13is a side view of a heating element according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.13, the heating element85is the same as inFIGS.3A,3B, and4, but the first side275and the second side285may be bowed and/or bent, such that the first side275is not parallel to the second side285. The bowed and/or bent shape of the first side275and the second side285may accommodate a thicker wick90.

FIG.14is a front view of a heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.14, the heating element85is the same as inFIGS.3A,3B, and4, except that the wick90does not extend beyond edges of the heating element85.

FIG.15is a perspective view of a heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.15, the heating element85is the same as inFIGS.3A,3B, and4, except that the wick90extends beyond edges of the heating element85.

FIG.16is a perspective view of a heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shownFIG.16, the heating element and wick may be the same as inFIGS.3A and5, except that the wick has a top portion1600having an end surface1610that is about a same size and shape as the transfer material350, such that the wick90may extends at least partially along an end surface of the transfer material350.

FIG.17is a side view of a heating element according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.17, the heating element85is the same as inFIGS.3A,3B, and4, except that the second side285of the heating element85is longer than the first side275of the heating element85. In other example embodiments, not shown, the first side275and/or the second side285may be concave and/or convex.

FIG.18is a perspective view of a heating element and a wick according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.18, the heating element85is substantially the same as inFIG.6, except that the tabs260,260′ are adjacent the folded portion295, the first plurality of U-shaped segments270and the second plurality of U-shaped segments280extend towards the reservoir (not shown), and the tabs260,260′ are bent, such that the tabs260,260′ are substantially parallel to the folded portion295. Moreover, each of the tabs260,260′ includes a hole1800therethrough. During manufacture, the tabs260,260′ may be spot welded to pins1820,1820′. The holes1800provide a line of sight for ease of spot welding during manufacture. The pin1820is electrically insulated from the pin1820′ as shown and described with respect toFIG.19.

Because the greatest amount of heat may be generated at the folded portion295, placing the folded portion295closest to location air enters allows for efficient movement of airflow and heat.

FIG.19is an exploded view of a cartridge according to at least one example embodiment.

In at least one example embodiment, as shown inFIG.19, the cartridge is the same as the cartridge ofFIGS.5and6, except that the tabs260,260′ contact pins1820,1820′ instead of first and second connecting brackets380,390. As shown, the connector piece1900houses a disk of insulating material1910, which defines an air channel1920therethrough. The air channel1920is in fluid communication with the channel370in the transfer material350. Two arcuately shaped bars1840,1840′ fit against the disk of insulating material1920. Each bar1840,1840′ includes one of the pins1820,1820′ extending from a top surface of each of the bars1840,1840′. The pins1820,1820′ extend through respective ones of pin-holes1930,1930′ defined in the disk of insulating material1920.

In addition, the housing30may be integrally formed with the inner tube70, such that the gasket is not needed. The housing30and the inner tube70may connect at a transverse, end wall defining an outlet therein. The mouth-end insert35may be fitted around an end portion of the housing30, such that the outlet in the end wall is in fluid communication with outlets in the mouth-end insert35.

Example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.