US20200221785A1 - Vaping device with insert - Google Patents

Abstract

A vaping device may include a pre-vapor formulation housing, a heating element, and an insert. The pre-vapor formulation housing may be configured to house a pre-vapor formulation and may define a channel there through. The heating element may be configured to heat at least a portion of the pre-vapor formulation into a vapor and provide the vapor to a first portion of the channel. The insert may be disposed at a second portion of the channel and positioned to receive the vapor. The insert may be subdivided into a first section and a second section. The first section may contain a first material that releases at a first temperature, and the second section may contain a second material that releases at a second temperature. The second temperature may be less than the first temperature.

Description

BACKGROUNDField
• Example embodiments relate to electronic vaping devices.
Description of Related Art
• E-vaping devices, also referred to herein as electronic vaping devices (EVDs) may be used by adult vapers for portable vaping.
• E-vaping devices include a heater which vaporizes pre-vapor formulation to produce a vapor. An e-vaping device may include several e-vaping elements including a power source, a cartridge or e-vaping tank including the heater and along with a reservoir capable of holding the pre-vapor formulation.
SUMMARY
• This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
• According to some example embodiments, vaping device may include a pre-vapor formulation housing, a heating element, and an insert. The pre-vapor formulation housing may be configured to house a pre-vapor formulation and may define a channel there through. The heating element may be configured to heat at least a portion of the pre-vapor formulation into a vapor and provide the vapor to a first portion of the channel. The insert may be disposed at a second portion of the channel and positioned to receive the vapor. The insert may be subdivided into at least a first section and a second section. The first section may contain a first material that releases at a first temperature, and the second section may contain a second material that releases at a second temperature. The second temperature may be less than the first temperature.
• In some example embodiments, the insert and the heating element may be at opposing ends of the channel.
• In some example embodiments, the insert may be a removable insert.
• In some example embodiments, the insert may include a perforated aluminum foil tube encasing the first section, the second section, or both the first section and the second section.
• In some example embodiments, the insert may include a porous paper tube containing a flavorant, an aromatic source, or both a flavorant and an aromatic source.
• In some example embodiments, the first material, the second material, or both the first and the second material may be included in the aromatic source.
• In some example embodiments, the first material, the second material, or both the first and the second material may be included in the flavorant.
• In some example embodiments, the insert may include an absorbing material.
• In some example embodiments, the absorbing material may be soaked with a flavor.
• In some example embodiments, the first material, the second material, or both the first material and the second material may be included in the absorbing material.
• In some example embodiments, the first section and the second section may be separated by porous dividers.
• In some example embodiments, the insert may include lemon tea granules, and the first material, second material, or both the first and second material may be included in the lemon tea granules.
• In some example embodiments, the insert may include tobacco or tobacco-derived material.
• In some example embodiments, the insert may be a removable insert configured to release a flavorant, an aroma, or a flavorant and an aroma into the received vapor.
• In some example embodiments, the removable insert may include a perforated aluminum foil tube encasing the first section and the second section.
• In some example embodiments, the first material may include the flavorant.
• In some example embodiments, the first material may include the aroma.
• In some example embodiments, the second material may include the flavorant.
• In some example embodiments, the second material may include the aroma.
• In some example embodiments, the second section may be arranged in the insert farther from the heating element than the first section.
• In some example embodiments, the insert may receive the vapor via the first section.
• In some example embodiments, the first material, the second material, or both the first material and the second material may be included in a flavorant.
• In some example embodiments, the first material, the second material, or both the first material and the second material may be included in an aromatic source.
• In some example embodiments, the insert may include a hollow acetate tube that contains the first material, the second material, or both the first material and the second material.
• According to some example embodiments, a vaping device may include a power supply section and a vaping element. The power supply section may be configured to supply power. The vaping element may be configured to receive the supplied power and may include a pre-vapor formulation housing, a heating element, and an insert. The pre-vapor formulation housing may be configured to house a pre-vapor formulation and may define a channel there through. The heating element may be configured to heat at least a portion of the pre-vapor formulation into a vapor using the supplied power and provide the vapor to a first portion of the channel. The insert may be disposed at a second portion of the channel and positioned to receive the vapor. The insert may be subdivided into at least a first section and a second section. The first section may contain a first material that releases at a first temperature, and the second section may contain a second material that releases at a second temperature. The second temperature may be less than the first temperature.
• In some example embodiments, the insert and the heating element may be at opposing ends of the channel.
• In some example embodiments, the insert may be a removable insert configured to be inserted into the channel.
• In some example embodiments, the insert may be a perforated aluminum foil tube encasing the first section and the second section.
• In some example embodiments, the insert may include a porous paper tube containing a flavorant, an aromatic source, or both a flavorant and an aromatic source.
• In some example embodiments, the insert may include an absorbing material.
• In some example embodiments, the first section and the second section may be separated by porous dividers.
• In some example embodiments, the insert may include lemon tea granules.
• In some example embodiments, the insert may include tobacco or tobacco-derived material.
• In some example embodiments, the second section may be arranged in the insert farther from the heating element than the first section.
• Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
• The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated.
• FIG. 1A is a side view of an e-vaping device according to some example embodiments.
• FIG. 1B is a cross-sectional view along line IB-IB′ of the e-vaping device ofFIG. 1A.
• FIG. 1C is an exploded view of an e-vaping device according to some example embodiments.
• FIG. 2A is a cross-sectional view of a pre-vapor formulation tank section according to some example embodiments.
• FIG. 2B is a cross-sectional view of a pre-vapor formulation tank section according to some example embodiments.
• FIG. 3A,FIG. 3B,FIG. 3C,FIG. 3D,FIG. 3E,FIG. 3F, andFIG. 3G are cross sectional views of flavor inserts according to some example embodiments.
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 thereof. 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,” “attached to,” “adjacent to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, attached to, adjacent 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 or sub-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, region, layer, or section from another element, 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.
• When the words “about” and “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value include a tolerance of ±10% around the stated numerical value, unless otherwise explicitly defined.
• 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.
• Hardware may be implemented using processing or control circuitry such as, but not limited to, one or more processors, one or more Central Processing Units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more System-on-Chips (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more Application Specific Integrated Circuits (ASICs), or any other device or devices capable of responding to and executing instructions in a defined manner.
• FIG. 1A is a side view of ane-vaping device60 according to some example embodiments.FIG. 1B is a cross-sectional view along line IB-IB′ of the e-vaping device ofFIG. 1A.FIG. 1C is an exploded view of an e-vaping device according to some example embodiments. Thee-vaping device60 may include one or more of the features set forth in U.S. Patent Application Publication No. 2013/0192623 to Tucker et al. filed Jan. 31, 2013 and U.S. Patent Application Publication No. 2013/0192619 to Tucker et al. filed Jan. 14, 2013, the entire contents of each of which are incorporated herein by reference thereto. As used herein, the term “e-vaping device” (or “electronic vaping device”) is inclusive of all types of electronic vaping devices, regardless of form, size, shape or configuration.
• Referring toFIGS. 1A-C, thee-vaping device60 includes a replaceable pre-vapor formulation tank section (or first section)70, sometimes referred to herein as an “e-vaping tank,” a reusable power supply section (or second section)72, and aflavor insert80. Thesections70,72 may be coupled together atcomplimentary interfaces74,84 of therespective sections70,72. Theflavor insert80 may be coupled to the pre-vaporformulation tank section70 via being inserted into anoutlet opening50bof thechannel28 in the pre-vaporformulation tank section70. Theflavor insert80 may be positioned at an outlet portion of thechannel28 based on being inserted into the outlet opening50b. Theflavor insert80 may be positioned to receive a vapor formed by the pre-vaporformulation tank section70, based on being positioned at the outlet portion ofchannel28.
• In some example embodiments, theinterfaces74,84 are threaded connectors. It should be appreciated that aninterface74,84 may be any type of connector, including, without limitation, a snug-fit, detent, clamp, bayonet, sliding fit, sleeve fit, alignment fit, threaded connector, magnetic, clasp, or any other type of connection, and/or combinations thereof. In some embodiments,70 and72 may be part of the same piece without the need forinterfaces74,84.
• Pre-vaporformulation tank section70 may include apre-vapor formulation tank22 and anadaptor90. Thepre-vapor formulation tank22 andadaptor90 may be connected viaconnector elements29,12a(e.g., respective male and female threaded connectors and/or any other type of connector), respectively.Connector elements29,12amay be complimentary connectors. Theadaptor90 includesinterface74 and couplespre-vapor formulation tank22 to thepower supply section72 through the coupling ofinterfaces74,84 and29,12a.
• Still referring toFIGS. 1A-C,pre-vapor formulation tank22 includes anouter housing24 extending in a longitudinal direction, aninner tube25 extending in the longitudinal direction, and agasket assembly51 defining an outlet end of thepre-vapor formulation tank22. An opposite end (tip end) of thepre-vapor formulation tank22 includes tip ends of theouter housing24 andinner tube25, respectively.
• In some example embodiments, theouter housing24 may be a single tube housing both the pre-vaporformulation tank section70 and thepower supply section72 and the entiree-vaping device60 may be disposable. In example embodiments, theouter housing24 may have a generally cylindrical cross-section. In some example embodiments, theouter housing24 may have a generally polygonal cross-section (e.g., triangular, rectangular, etc.), curved, or any other shapes that may be desired, along the pre-vaporformulation tank section70 and/or thepower supply section72. In some example embodiments, theouter housing24 may have greater or smaller dimensions at a tip end than at an outlet end of thee-vaping device60.
• Theinner tube25 may define at least a portion of achannel28 through thepre-vapor formulation tank22. The tip end of theinner tube25 may define opening50aat a tip portion (or “first portion”) ofchannel28. As shown inFIG. 1B, the outlet end of theinner tube25 is coupled with thegasket assembly51 to define anoutlet opening50bat an outlet portion (or “second portion”) of thechannel28. In some example embodiments, theinner tube25 extends through thegasket assembly51 to define the outlet portion of thechannel28. Thegasket assembly51 defines achannel51cthat extends through the center of the gasket. In the example embodiments illustrated inFIG. 1B, the outlet end of theinner tube25 extends through thegasket assembly channel51cto define the outlet portion ofchannel28 and outlet opening50bofchannel28.
• In some example embodiments, thegasket assembly51 may couple with theinner tube25 such that thegasket assembly channel51chas a same or smaller cross-section thaninner tube25, such thatinner tube25 does not extend through the gasket, or only partially extends through the gasket, andchannel51cdefines part of channel28 (i.e.,channel51cand theinner tube25 define separate portions of the channel28) and thegasket assembly channel51cdefines both the outlet opening50band the outlet portion of the channel28 (an example is shown inFIG. 2A).
• In some example embodiments, thepre-vapor formulation tank22 includes a pre-vapor formulation reservoir in the form of areservoir23. In some example embodiments, including the example embodiments illustrated inFIGS. 1A-C,pre-vapor formulation tank22 includes anannular reservoir23. Thereservoir23 is defined by the inner surface of theouter housing24, the outer surface of theinner tube25, thegasket assembly51 at the outlet end of thepre-vapor formulation tank22, and agasket assembly8 included in theadaptor90 coupled to theouter housing24 andinner tube25 viaconnector elements12aand15, respectively.
• Gasket assembly51 is coupled to outlet ends of theouter housing24 and theinner tube25, respectively, to define an outlet end of thereservoir23.
• In the example embodiments shown inFIGS. 1A-C, thereservoir23 is an annulus positioned around thechannel28, with thechannel28 being a central air channel. Thechannel28 is at least partially defined by the inner surface of theinner tube25. Thepre-vapor formulation tank22 may be refillable via a reservoir opening using any commercially-available pre-vapor formulation in order to continually reusepre-vapor formulation tank22. In some example embodiments, the reservoir opening is included in thegasket assembly51 and enables access to thereservoir23 from an exterior of thepre-vapor formulation tank22 through thegasket assembly51.
• At least a portion ofpre-vapor formulation tank22 may have a transparent wall to enable visual observation and monitoring of an amount of pre-vapor formulation in thereservoir23. For example, at least a portion of theouter housing24 may be a transparent material, translucent material, some combination thereof, or the like. At least a portion of theinner tube25 may be a transparent material, translucent material, some combination thereof, or the like. As shown inFIGS. 1A-C, theouter housing24 may include a set of graduation marks71 that may provide a visually-observable indication of an amount of pre-vapor formulation held within thereservoir23.
• As shown inFIG. 1C, thepre-vapor formulation tank22 may include areservoir opening50dthat is defined between the tip ends of theouter housing24 and theinner tube25, respectively. As shown inFIG. 1C, thereservoir opening50dmay be an annulus opening extending aroundchannel28 defined by theinner tube25. Thereservoir opening50dmay provide an opening for an adult vaper to access an interior ofpre-vapor formulation tank22 and add one or more pre-vapor formulations into thereservoir23. Such adding may include decoupling thepre-vapor formulation tank22 andadaptor90, adding pre-vapor formulation to thereservoir23 throughopening50d, and re-coupling thepre-vapor formulation tank22 andadaptor90 together.
• Thegasket assembly51 and/orinner tube25 includes one ormore connector elements52 configured to couple aflavor insert80 to thee-vaping device60 if and/or when theflavor insert80 is inserted through the passage of thegasket assembly51 to position theflavor insert80 at an outlet end of thechannel28. In some example embodiments, aconnector element52 extends around an inner surface of thechannel28.
• Thepre-vapor formulation tank22 may include aconnector element29 at the tip end ofouter housing24.Connector element29 is configured to couple withconnector element12aofadaptor90. The tip end of theinner tube25 may be configured to couple with aconnector element15 ofadaptor90. Theouter housing24, theinner tube25, or each may include a separately formed, self-supporting (discrete) hollow body constructed of a heat-resistant plastic or woven fiberglass.
• Still referring toFIGS. 1A-C,adapter90 includes agasket assembly8, dispensinginterface32,heating element34, andinterface74. As shown, theadaptor90 further includes aconnector element91 and electrical leads36-1 and36-2. The electrical leads36-1 and36-2 couple theheating element34. The electrical leads36-1 and36-2 also couple to interface74 andconnector element91, respectively.
• Theconnector element91 may include an insulatingmaterial91aand aconductive material91b. Theconductive material91bmay electrically couple lead36-2 topower supply12, and the insulatingmaterial91amay insulate theconductive material91bfrom theinterface74, such that a probability of an electrical short between the lead36-2 and theinterface74 is reduced and/or prevented. For example, the insulatingmaterial91amay be in an outer portion of theconnector element91 and theconductive material91bmay be in an inner portion of theconnector element91, such that the insulatingmaterial91asurrounds theconductive material91band reduces and/or prevents a probability of an electrical connection between theconductive material91band theinterface74.
• Thegasket assembly8 includes anose portion30 that is configured to couple with a tip end ofinner tube25. Thegasket assembly8 includes achannel14 that extends through thenose portion30 and opens into an interior of theinner tube25 that defines a tip portion ofchannel28.
• Adaptor90 includes an interior space10 at a backside portion of thegasket assembly8. The space10 is defined by anouter housing38 of theadaptor90,interface74,gasket assembly8, and theconnector element91. The space10 assures communication between thechannel14 and one or moreair inlet ports44 located between thegasket assembly8 and aconnector element91. Theconnector element91 may be included in theinterface74.
• In some example embodiments, at least oneair inlet port44 may be formed in theouter housing38, adjacent to theinterface74 to minimize the probability of an adult vaper's fingers occluding one of theair inlet ports44 and to control the resistance-to-draw (RTD) during vaping. In some example embodiments, theair inlet ports44 may be machined into theouter housing38 with precision tooling such that their diameters are closely controlled and replicated from onee-vaping device60 to the next during manufacture.
• In some example embodiments, theair inlet ports44 may be drilled with carbide drill bits or other high-precision tools and/or techniques. In some example embodiments, theouter housing38 may be formed of metal or metal alloys such that the size and shape of theair inlet ports44 stay relatively consistent during manufacturing operations, packaging, and vaping. Thus, theair inlet ports44 may provide consistent RTD. In some example embodiments, theair inlet ports44 may be sized and configured such that thee-vaping device60 has a RTD in the range of from about 60 mm H₂O to about 150 mm H₂O. Other sizes and configurations may be used. For example, in some example embodiments, theair inlet ports44 may be sized and configured such that thee-vaping device60 has a RTD smaller than 60 mm H₂O or greater than 150 mm H₂O.
• As shown inFIG. 1B, thegasket assembly8 is configured to define a tip end of thereservoir23 if and/or when theadaptor90 is coupled to thepre-vapor formulation tank22 throughconnector elements12aand15.Gasket assembly8 includes aconnector element15 coupled to an inner surface of thechannel14. Theconnector element15 may couple the tip end of theinner tube25 to thegasket assembly8 to seal or substantially seal thereservoir23 from the space10 andchannels14,28.
• Thegasket assembly8 includes a dispensinginterface32 configured to draw pre-vapor formulation from thereservoir23, and aheating element34 configured to vaporize the drawn pre-vapor formulation to form avapor95. The dispensinginterface32 and theheating element34 may be collectively referred to as a vaporizer assembly.
• The dispensinginterface32 is coupled to thegasket assembly8, such that the dispensinginterface32 may extend transversely across thechannel14. In the example embodiments illustrated inFIG. 1B, the dispensinginterface32 is coupled to thenose portion30 and extends through thechannel14 in thenose portion30.
• The dispensinginterface32 may include one or more ends that protrude through one or more side portions of thegasket assembly8, such that the one or more ends of the dispensinginterface32 may be exposed to an interior of thereservoir23 if and/or when theadaptor90 is coupled to thepre-vapor formulation tank22. The one or more ends of the dispensinginterface32 may be submerged in a pre-vapor formulation held within thereservoir23. In the example embodiments illustrated inFIG. 1B, for example, theadaptor90 includes a dispensinginterface32 that is coupled to thenose portion30 of thegasket assembly8 such that a central portion (“trunk”) of the dispensinginterface32 extends through thechannel14 and end portions (“roots”) of the dispensinginterface32 extend from separate exterior surfaces of thenose portion30. As shown inFIG. 1B, the end portions of the dispensinginterface32 are positioned within thereservoir23 if and/or when theadaptor90 andpre-vapor formulation tank22 are coupled together, such that the dispensinginterface32 is configured to draw pre-vapor formulation from thereservoir23.
• Theheating element34 is coupled to the dispensinginterface32 and is configured to generate heat. As shown in the example embodiment illustrated inFIG. 1B, theheating element34 may extend transversely across thechannel14 between opposing portions of thegasket assembly8. In some example embodiments, theheating element34 may extend parallel to a longitudinal axis of thechannel14, or in other directions.
• The dispensinginterface32 is configured to draw pre-vapor formulation from thereservoir23, such that the pre-vapor formulation may be vaporized from the dispensinginterface32 based on heating of the dispensinginterface32 by theheating element34.
• During vaping, pre-vapor formulation may be transferred from thereservoir23 and/or storage medium in the proximity of theheating element34 via capillary action of a dispensinginterface32. Theheating element34 may at least partially surround a portion of the dispensinginterface32 such that when theheating element34 is activated to generate heat, the pre-vapor formulation in the surrounded portion of the dispensinginterface32 may be vaporized by theheating element34 to form avapor95.
• Still referring toFIGS. 1A-C, theadaptor90 includes aconnector element91.Connector element91 may include a cathode connector element, an anode connector element, or both. In the example embodiment illustrated inFIG. 1B, for example, electrical lead36-2 is coupled to theconnector element91. As further shown inFIG. 1B, theconnector element91 is configured to couple with apower supply12 included in thepower supply section72. If and/or wheninterfaces74,84 are coupled together, theconnector element91 andpower supply12 may be coupled together.Coupling connector element91 andpower supply12 together may electrically couple electrical lead36-2 andpower supply12 together.
• In some example embodiments, one or more of theinterfaces74,84 include a cathode connector element, an anode connector element, or both. In the example embodiment illustrated inFIG. 1B, for example, electrical lead36-1 is coupled to theinterface74. As further shown inFIG. 1B, thepower supply section72 includes a lead92 that couples the control circuitry11 to theinterface84. If and/or wheninterfaces74,84 are coupled together, the coupled interfaces74,84 may electrically couple electrical leads36-1 and92 together.
• If and/or wheninterfaces74,84 are coupled together, one or more electrical circuits through the pre-vaporformulation tank section70 andpower supply section72 may be established. The established electrical circuits may include at least theheating element34, the control circuitry11, and thepower supply12. The electrical circuit may include electrical leads36-1 and36-2, lead92, and interfaces74,84.
• Still referring toFIGS. 1A-C, thereservoir23 may include a pre-vapor formulation that is free of flavorants, such that when theheating element34 vaporizes pre-vapor formulation in the dispensinginterface32 to form avapor95, thevapor95, also referred to herein as a “generated vapor,” may be substantially absent of flavor. In other embodiments, thereservoir23 may include a pre-vapor formulation that includes one or more flavorants, such that when theheating element34 vaporizes pre-vapor formulation in the dispensinginterface32 to form avapor95, the generated vapor is a flavored vapor that includes one or more flavors.
• E-vaping device60 includes aflavor insert80 that is configured to be coupled to the pre-vaporformulation tank section70 such that theflavor insert80 is positioned at the outlet portion of thechannel28 and is configured to receive thevapor95 passing through thechannel28. In an example embodiment, the pre-vaporformulation tank section70 is configured to position theflavor insert80 and the vaporizer assembly (comprising the dispensinginterface32 and heating element34) at opposite ends of thechannel28. As shown inFIG. 1B, for example, the dispensinginterface32 andheating element34 are proximate to theopening50aat the tip portion ofchannel28. In addition, theflavor insert80 is proximate to the outlet opening50bat the outlet portion of thechannel28.
• As shown inFIG. 1B, theflavor insert80 may include ahousing82 enclosing an interior of theflavor insert80. Theflavor insert80 may include aflavor material85. Theflavor material85 may include one or more flavorants. Theflavor insert80 may include one ormore filter elements86 configured to filter one or more types of particulate matter from a vapor passing through the interior of theflavor insert80.
• A flavorant can include a compound or combination of compounds that may provide flavor and/or aroma to an adult vaper. In some example embodiments, a flavorant is configured to interact with at least one adult vaper sensory receptor. For example, a flavorant may be configured to interact with the sensory receptor via taste stimulation, orthonasal stimulation, retronasal stimulation, etc., or combinations thereof. A flavorant may include one or more volatile flavor substances.
• A flavorant may include a natural flavorant and/or an artificial (“synthetic”) flavorant. A flavorant may include one or more plant extract materials. In some example embodiments, the at least one flavorant is one or more of tobacco flavor, menthol, wintergreen, peppermint, herb flavors, fruit flavors, nut flavors, liquor flavors, teas, and combinations thereof. In some example embodiments, the flavorant is included in a botanical material. A botanical material may include material of one or more plants. A botanical material may include one or more herbs, spices, fruits, roots, leaves, grasses, tea leaves, or the like. For example, a botanical material may include orange rind material, sweetgrass material, and/or lemon tea granules. In another example, a botanical material may include tobacco material. In some example embodiments, a flavorant includes at least one of a synthetic material, a plant extract material or both a synthetic material and a plant material. A plant extract material included in a tobacco flavorant may be an extract from one or more tobacco materials.
• In some example embodiments, a tobacco material may include material from any member of the genusNicotiana. In some example embodiments, the tobacco material includes a blend of two or more different tobacco varieties. Examples of suitable types of tobacco materials that may be used include, but are not limited to, flue-cured tobacco, Burley tobacco, Dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, blends thereof and the like. The tobacco material may be provided in any suitable form, including, but not limited to, tobacco lamina, processed tobacco materials, such as volume expanded or puffed tobacco, processed tobacco stems, such as cut-rolled or cut-puffed stems, reconstituted tobacco materials, blends thereof, and the like. In some example embodiments, the tobacco material is in the form of a substantially dry tobacco mass.
• In some example embodiments, theflavor insert80 includes a tobacco rod that holds aflavor material85 that is one or more types of tobacco. In some example embodiments, theflavor insert80 may be configured to be at least partially combusted such that at least a portion of the flavor material85 (e.g., a tobacco flavor material) is combusted and directed out of an end of theflavor insert80. In other example embodiments, theflavor insert80 may not be combusted. In other example embodiments, theflavor insert80 may be heated. The tobacco rod may include afilter element86 that is configured to filter one or more instances of particular matter.
• In some example embodiments, the pre-vaporformulation tank section70 may direct the generatedvapor95 through thechannel28 and through the flavor insert positioned at the outlet portion ofchannel28 such that one or more flavorants are eluted fromflavor material85 into the generatedvapor95 to form a flavoredvapor97.
• In some example embodiments, the generatedvapor95 may be at an elevated temperature, relative to a temperature of theflavor material85. If and/or when the generatedvapor95 passes through theflavor insert80, the generatedvapor95 may transfer heat to theflavor material85. In some example embodiments, flavorant elution from theflavor material85 to the generatedvapor95 may be improved based on the heating of theflavor material85 by the generatedvapor95. Based on an improved elution of flavorant into the generatedvapor95, a flavoredvapor97 may include an increased amount of eluted flavorant, relative to example embodiments where theflavor material85 is unheated.
• As shown in the illustrated embodiments ofFIGS. 1A-C, theflavor insert80 may be inserted through outlet opening50binto thechannel28 such that theflavor insert80 is coupled with the one ormore connector elements52 therein. Theconnector elements52 may form an airtight or substantially airtight seal between ahousing82 of theflavor insert80 and an inner surface of thechannel28, such thatvapor95 passing through thechannel28 is directed to exit thee-vaping device60 through an interior of theflavor insert80. Some example embodiments may not include one ormore connector elements52, and theflavor insert80 may be coupled directly with an inner surface ofinner tube25. Some example embodiments may not include one ormore connector elements52, and theflavor insert80 may be coupled directly with an inner surface ofchannel51cofgasket51, if for example, the cross section ofchannel51cis smaller than that ofinner tube25 andgasket51 defines outlet opening50b.
• In some example embodiments, one ormore connector elements52 are absent, and theflavor insert80housing82 forms an airtight or substantially airtight seal with an inner surface of thechannel28 if and/or when theflavor insert80 is inserted into thechannel28. The inner surface of thechannel28 may be configured to form a friction fit with thehousing82 of theflavor insert80 to couple theflavor insert80 with the pre-vaporformulation tank section70 and to hold theflavor insert80 in place at the outlet portion of thechannel28.
• In some example embodiments, theflavor insert80 may be removably coupled with thechannel28, such that one or more flavor inserts80 may be swapped from thee-vaping device60. In some example embodiments, theflavor insert80 may be referred to as a detachable insert.
• As shown inFIG. 1B, theflavor insert80 that is positioned at the outlet end of thechannel28 through outlet opening50bis positioned in flow communication with thechannel14 in which a portion of the dispensinginterface32 and theheating element34 coupled thereto are located. Thechannel28 may be configured to direct generatedvapors95 formed in thechannel14 to exit the pre-vaporformulation tank section70 via an interior of theflavor insert80 at the outlet end of thechannel28.
• Theflavor material85 of certain example embodiments may be a porous structure that includes one or more instances offlavor material85. The porous structure may hold a flavorant in flow communication with thechannel28 so that generatedvapors95 formed in the pre-vaporformulation tank section70, received at theflavor insert80 via thechannel28, and passing through theflavor insert80 may pass at least partially through the porous structure and in flow communication with the flavorants held by the porous structure. The generatedvapor95 may act as an eluent, eluting the flavorant from theflavor insert80 and into the generatedvapor95 to form an eluate. The eluate may include the generatedvapor95 and the flavorant.
• In some example embodiments, the flavorants eluted into the generatedvapor95 are in a particulate phase. A particulate phase may include a liquid phase, solid phase, or the like. In some example embodiments, the flavorants eluted into the generatedvapor95 are in a vapor phase, gas phase, etc. A flavorant may include a volatile flavor substance, and the volatile flavor substance may be eluted into the generatedvapor95. In some example embodiments, a flavorant eluted into the generatedvapor95 includes a nonvolatile flavor substance.
• In some example embodiments, the pre-vaporformulation tank section70 is configured to direct generatedvapors95 through theflavor insert80 subsequent to formation of the generatedvapor95 and the generatedvapor95 may be cooled from an initial temperature atchannel14. Where the generatedvapor95 passing through theflavor insert80 is cooled from the initial temperature, chemical reactions between the flavorants eluted into the generatedvapor95 and the elements of the generatedvapor95 may be at least partially mitigated.
• In some example embodiments, aflavor insert80 is configured to cool a generatedvapor95 passing through theflavor insert80. Theflavor insert80 may cool the generatedvapor95 based on heat transfer from the generatedvapor95 to at least one of the flavorant eluted into the generatedvapor95, a material included in theflavor insert80 or both the flavorant eluted into the generatedvapor95 and the material included in theflavor insert80. In some example embodiments, the transfer of heat from a generatedvapor95 into at least one of the flavorant, a material included in theflavor insert80 or both the flavorant and the material included in theflavor insert80 may increase the amount of flavorant eluted into the generatedvapor95. In some example embodiments, a flavoredvapor97 exiting theflavor insert80 may be cooler than a generatedvapor95 entering theflavor insert80.
• In some example embodiments, the flavorants included in aflavor insert80 may be replaceable independently of the pre-vapor formulation in the pre-vapor formulation tank section70 (which may also include flavorants or which may not include flavorants), as theflavor insert80 is separate from the pre-vaporformulation tank section70 in which the pre-vapor formulation is included. Theflavor insert80 may be replaced with anotherflavor insert80. Theflavor insert80 may be replaced with anotherflavor insert80 without replacing pre-vaporformulation tank section70 and/or pre-vapor formulation held therein, where thereservoir23 may include sufficient pre-vapor formulation to support additional vaping. Similarly, the pre-vaporformulation tank section70 and/or pre-vapor formulation tank20 may be replaced independently of other parts of thee-vaping device60, for example, once the pre-vapor formulation is depleted or if another pre-vapor formulation is desired.
• Still referring toFIG. 1A andFIG. 1B, thepower supply section72 includes anouter housing17 extending in a longitudinal direction, asensor13 responsive to air drawn into thepower supply section72 via anair inlet port44a(which may be adjacent to a free end or tip end of thee-vaping device60 or in other locations of the e-vaping device60), at least onepower supply12, and control circuitry11. Thepower supply12 may include a rechargeable battery. Thesensor13 may be one or more of a pressure sensor, a microelectromechanical system (MEMS) sensor, etc.
• In some example embodiments, thepower supply12 includes a battery arranged in thee-vaping device60 such that the anode is downstream of the cathode, or the cathode is downstream of the anode. Aconnector element91 contacts the downstream end of the battery. Theheating element34 may be coupled to thepower supply12 by at least the two electrical leads36-1 and36-2, theinterfaces74,84, theconnector element91,electrical lead92, and control circuitry11.
• Thepower supply12 may be a Lithium-ion battery or one of its variants, for example a Lithium-ion polymer battery. Alternatively, thepower supply12 may be a nickel-metal hydride battery, a nickel cadmium battery, a lithium-manganese battery, a lithium-cobalt battery or a fuel cell. Other types of battery or power supplies may also be used. Thee-vaping device60 may be usable by an adult vaper until the energy in thepower supply12 is depleted or a minimum voltage cut-off level is achieved.
• Further, thepower supply12 may be rechargeable and may include circuitry configured to allow the battery to be chargeable by an external charging device. To recharge thee-vaping device60, a Universal Serial Bus (USB) charger or other suitable charger assembly may be used. In some embodiments, thepower supply12 may include a solar powered power supply.
• Upon completing the connection between the pre-vaporformulation tank section70 and thepower supply section72, the at least onepower supply12 may be electrically connected with theheating element34 of the pre-vaporformulation tank section70 upon actuation of thesensor13. Air is drawn primarily into the pre-vaporformulation tank section70 through one or moreair inlet ports44. The one or moreair inlet ports44 may be located along theouter housing24,38,17 of the first andsecond sections70,72 and/or at one or more of the coupled interfaces74,84 and/or at one or more of theconnector elements12a,29, etc.
• Thesensor13 may be configured to sense an air pressure drop and initiate application of voltage from thepower supply12 to theheating element34. As shown in the example embodiment illustrated inFIG. 1B, some example embodiments of thepower supply section72 include aheater activation light48 configured to glow when theheating element34 is activated. Theheater activation light48 may include a light emitting diode (LED). Moreover, theheater activation light48 may be arranged to be visible to an adult vaper during vaping. In addition, theheater activation light48 may be utilized for e-vaping system diagnostics or to indicate that recharging is in progress. Theheater activation light48 may also be configured such that the adult vaper may activate and/or deactivate theheater activation light48 for privacy. As shown inFIGS. 1A-C, theheater activation light48 may be located on the tip end of thee-vaping device60. In some example embodiments, theheater activation light48 may be located on a side portion of the outer housing of thee-vaping device60. Some embodiments may not include aheater activation light48.
• In addition, anair inlet port44amay be located adjacent to thesensor13. Thesensor13 may activate thepower supply12 and theheater activation light48 to indicate that theheating element34 is activated.
• In some example embodiments, the control circuitry11 may control the supply of electrical power to theheating element34 responsive to thesensor13. In some example embodiments, the control circuitry11 may include a maximum, time-period limiter. In some example embodiments, the control circuitry11 may include a manually operable switch for an adult vaper to manually initiate vaping. The time-period of the electric current supply to theheating element34 may be pre-set depending on the amount of pre-vapor formulation desired to be vaporized. In some example embodiments, the control circuitry11 may control the supply of electrical power to theheating element34 as long as thesensor13 detects a pressure drop. In some example embodiments, the control circuitry11 may control the supply of electrical power to theheating element34 as long as thesensor13 detects a pressure drop, up to a maximum, time-period limiter. Other control configurations may be used.
• To control the supply of electrical power to aheating element34, the control circuitry11 may execute one or more instances of computer-executable program code. The control circuitry11 may include a circuit customized for a particular use, a processor and/or a memory. The memory may be a computer-readable storage medium storing computer-executable code.
• The control circuitry11 may include processing circuitry including, but not limited to, a processor, Central Processing Unit (CPU), a controller, an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, or any other device capable of responding to and executing instructions and/or an algorithm in a defined manner. In some example embodiments, the control circuitry11 may be an application-specific integrated circuit (ASIC).
• The control circuitry11 may be configured as a special purpose machine by executing computer-readable program code stored on a storage device. The program code may include program or computer-readable instructions, software elements, software modules, data files, data structures, and/or the like, capable of being implemented by one or more hardware devices, such as one or more instances of the control circuitry11 mentioned above. Examples of program code include both machine code produced by a compiler and higher level program code that is executed using an interpreter.
• The control circuitry11 may include one or more storage devices. The one or more storage devices may be tangible or non-transitory computer-readable storage media, such as random access memory (RAM), read only memory (ROM), a permanent mass storage device (such as a disk drive), solid state (e.g., NAND flash) device, and/or any other like data storage mechanism capable of storing and recording data. The one or more storage devices may be configured to store computer programs, program code, instructions, or some combination thereof, for one or more operating systems and/or for implementing the example embodiments described herein. The computer programs, program code, instructions, or some combination thereof, may also be loaded from a separate computer readable storage medium into the one or more storage devices and/or one or more computer processing devices using a drive mechanism. Such separate computer readable storage medium may include a USB flash drive, a memory stick, a Blu-ray/DVD/CD-ROM drive, a memory card, and/or other like computer readable storage media. The computer programs, program code, instructions, or some combination thereof, may be loaded into the one or more storage devices and/or the one or more computer processing devices from a remote data storage device via a network interface, rather than via a local computer readable storage medium. Additionally, the computer programs, program code, instructions, or some combination thereof, may be loaded into the one or more storage devices and/or the one or more processors from a remote computing system that is configured to transfer and/or distribute the computer programs, program code, instructions, or some combination thereof, over a network. The remote computing system may transfer and/or distribute the computer programs, program code, instructions, or some combination thereof, via a wired interface, an air interface, and/or any other like medium.
• The control circuitry11 may be a special purpose machine configured to execute the computer-executable code to control the supply of electrical power to theheating element34. In some embodiments, controlling the supply of electrical power to theheating element34 includes activating theheating element34.
• 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. Additional examples of pre-vapor formulation may include those described in U.S. Patent Application Publication No. 2015/0020823 to Lipowicz et al. filed Jul. 16, 2014 and U.S. Patent Application Publication No. 2015/0313275 to Anderson et al. filed Jan. 21, 2015, the entire contents of each of which is incorporated herein by reference thereto. Any other pre-vapor formulations may be used.
• In some example embodiments, the pre-vapor formulation includes one or more of propylene glycol, glycerin and combinations thereof.
• The pre-vapor formulation may include nicotine or may exclude nicotine. The pre-vapor formulation may include one or more flavors.
• In some example embodiments, a pre-vapor formulation that includes nicotine may also include one or more acids. The one or more acids may be one or more of pyruvic acid, formic acid, oxalic acid, glycolic acid, acetic acid, isovaleric acid, valeric acid, propionic acid, octanoic acid, lactic acid, levulinic acid, sorbic acid, malic acid, tartaric acid, succinic acid, citric acid, benzoic acid, oleic acid, aconitic acid, butyric acid, cinnamic acid, decanoic acid, 3,7-dimethyl-6-octenoic acid, 1-glutamic acid, heptanoic acid, hexanoic acid, 3-hexenoic acid, trans-2-hexenoic acid, isobutyric acid, lauric acid, 2-methylbutyric acid, 2-methylvaleric acid, myristic acid, nonanoic acid, palmitic acid, 4-penenoic acid, phenylacetic acid, 3-phenylpropionic acid, hydrochloric acid, phosphoric acid, sulfuric acid and combinations thereof.
• Thereservoir23, in some example embodiments, may include a storage medium that may hold or partially hold the pre-vapor formulation. The storage medium may be a fibrous material including, for example, cotton, polyethylene, polyester, rayon, etc., a sub-combination thereof or a combination 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), but any other suitable sizes may be used. 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 that has a Y-shape, cross shape, clover shape or any other suitable shape. In some example embodiments, thereservoir23 may include a filled tank lacking any storage medium and containing only pre-vapor formulation.
• Thereservoir23 may be sized and configured to hold enough pre-vapor formulation such that thee-vaping device60 may be configured for vaping for at least a particular amount of time (e.g., about 200 seconds, 150 seconds, 220 seconds, etc.).
• The dispensinginterface32 may include a wick. The dispensinginterface32 may include filaments (or threads) having a capacity to draw the pre-vapor formulation. For example, a dispensinginterface32 may be a wick that is 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 thee-vaping device60. In some example embodiments, the dispensinginterface32 may include one to eight filament strands, each strand comprising a plurality of glass filaments twisted together. The end portions of the dispensinginterface32 may be flexible and foldable into the confines of thereservoir23. The filaments may have a cross-section that is generally cross-shaped, clover-shaped, Y-shaped, or in any other suitable shape.
• The dispensinginterface32 may include any suitable material or combination of materials, also referred to herein as wicking materials. Examples include, but are not limited to, glass, ceramic- or graphite-based materials. The dispensinginterface32 may have any suitable capillary drawing action to accommodate pre-vapor formulations having different physical properties such as density, viscosity, surface tension, vapor pressure, etc.
• In some example embodiments, theheating element34 may include a wire coil. The wire coil may at least partially surround the dispensinginterface32 in thechannel14. The wire may be a metal wire and/or the wire coil may extend fully or partially along the length of the dispensinginterface32. The wire coil may further extend fully or partially around the circumference of the dispensinginterface32. In some example embodiments, the wire coil may be isolated from direct contact with the dispensinginterface32. Any other suitable type of heaters may be used.
• Theheating element34 may be formed of any suitable electrically resistive materials. Examples of suitable electrically resistive materials may include, but not limited to, 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, theheating element34 may 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. Theheating element34 may include stainless steel, copper, copper alloys, nickel-chromium alloys, super alloys or combinations thereof. In some example embodiments, theheating element34 may be formed of nickel-chromium alloys or iron-chromium alloys. In some example embodiments, theheating element34 may be a ceramic heater having an electrically resistive layer on an outside surface thereof. Any other types ofheating elements34 suitable to heat a pre-vapor formulation may be used.
• It should be appreciated that, instead of using a dispensinginterface32, the pre-vaporformulation tank section70 may include aheating element34 that is a porous material which incorporates a resistance heater formed of a material having an electrical resistance capable of generating heat.
• In some example embodiments, one or more portions of the pre-vaporformulation tank section70 may be replaceable. Such one or more portions may include one or more of thepre-vapor formulation tank22, theadaptor90, and/or theflavor insert80. In other words, once flavorant of theflavor insert80 or of the pre-vapor formulation (if it includes a flavorant) of thepre-vapor formulation tank22 is depleted, theflavor insert80, or thepre-vapor formulation tank22 may be replaced, respectively (the entire pre-vaporformulation tank section70 may also be replaced, as well as the adaptor90). In some example embodiments, the entiree-vaping device60 may be disposed once one of thereservoir23 or theflavor insert80 is depleted.
• In some example embodiments, if and/or when thee-vaping device60 includes aflavor insert80 that holds a flavorant separate from thepre-vapor formulation tank22, thee-vaping device60 may be configured to mitigate a probability of chemical reactions between the flavorant and one or more elements of thepre-vapor formulation tank22. Such chemical reactions may include chemical reactions between one or more portions of the flavorant. An absence of such chemical reactions may result in an absence of reaction products in the flavoredvapor97. Such reaction products may detract from a sensory experience provided by the flavoredvapor97. As a result, ane-vaping device60 that is configured to mitigate the probability of such chemical reactions may provide a more consistent and improved sensory experience through the flavoredvapor97.
• FIG. 2A is a cross-sectional view of a pre-vaporformulation tank section70 according to some example embodiments.FIG. 2B is a cross-sectional view of a pre-vaporformulation tank section70 according to some example embodiments. The example embodiments of pre-vaporformulation tank sections70 shown inFIG. 2A andFIG. 2B may be included in any of the example embodiments included herein, including the pre-vaporformulation tank section70 shown inFIGS. 1A-C. Other forms, sizes, shapes or configurations may also be used.
• Referring toFIG. 2A, in some example embodiments, a pre-vaporformulation tank section70 includes apre-vapor formulation tank22 that includes anouter housing24, aninner tube25, and agasket assembly51 that at least partially define areservoir23 that may hold pre-vapor formulation. Theinner tube25 at least partially defines thechannel28 through the interior of thepre-vapor formulation tank22.
• Gasket assembly51 may includeconnector elements51aand51bthat couple with theouter housing24 and theinner tube25, respectively, to define an outlet end. In the example embodiments illustrated inFIG. 2A, thegasket assembly51 includes achannel51cextending through an inner portion of the gasket. Theconnector element51adefines at least a portion of the outer boundary of thegasket assembly51, such that theconnector element51ais configured to coupleouter housing24 to the outer boundary of thegasket assembly51. Thus, the gasket assembly may cooperate with theinner tube25 and theouter housing24 to define an end of thereservoir23.
• In the example embodiments illustrated inFIG. 2A, thechannel51cdoes not extend through an interior space of thegasket assembly51 defined by theconnector elements51bbut instead extends to an end of the space defined by theconnector elements51b, such that aninner tube25 may be received into the space defined by theconnector elements51band may further be restricted from being received intochannel51c. In some example embodiments, including the example embodiments illustrated inFIGS. 1A-C, thechannel51cextends through the interior space ofgasket assembly51 that is defined by theconnector elements51b. As shown inFIG. 1B, in some example embodiments thechannel51cis configured to receive theinner tube25 through at least a portion of thechannel51c.
• As shown inFIG. 2A, thegasket assembly51 includes achannel51cthat defines an outlet portion of thechannel28. Thechannel51cdefines an outlet portion of thechannel28 that extends beyond theinner tube25 and through thegasket assembly51 to outlet opening50b.
• In the example embodiments illustrated inFIG. 2A, thegasket assembly51 includes one ormore connector elements52 configured to couple theflavor insert80 to the pre-vaporformulation tank section70 if and/or when theflavor insert80 is inserted through the outlet opening50bto position theflavor insert80 at an outlet portion (second portion) of thechannel28. In some example embodiments, the one ormore connector elements52 include an individual connector element that extends around an inner surface of thechannel28. In some example embodiments, including the example embodiments illustrated inFIG. 2A, the one ormore connector elements52 are coupled to an inner surface of thechannel51cof thegasket assembly51. In the example embodiments illustrated inFIG. 2A, one ormore connector elements52 extend through a portion ofchannel51c, such that a gap is present between theconnector elements52 and an end of thechannel51cthat is proximate toconnector elements51b. It will be understood that, in some example embodiments, one ormore connector elements52 may extend through an entirety of the length of thechannel51c. In some example embodiments, one ormore connector elements52 are coupled to the inner surface of theinner tube25.
• The one ormore connector elements52 may include one or more types of connectors. In some example embodiments, one ormore connector elements52 are friction fit connectors that are configured to couple theflavor insert80 to thepre-vapor formulation tank22 through a friction fit between an outer surface of theflavor insert80 and the one ormore connector elements52. In some example embodiments, one ormore connector elements52 are coupling devices configured to mechanically couple with one or more connector elements included in theflavor insert80. For example, one ormore connector elements52 may be a threaded connector, a bayonet connector, etc. configured to couple with a complementary connector included in theflavor insert80 if and/or when theflavor insert80 is inserted into the pre-vaporformulation tank section70 through outlet opening50b.
• In some example embodiments, one or more of theconnector elements52 is configured to establish an airtight or substantially airtight seal between theflavor insert80 and a surface of thechannel28 if and/or when theflavor insert80 is inserted through the outlet opening50band into thechannel28. The one ormore connector elements52 may configure the pre-vaporformulation tank section70 to direct a generatedvapor95 passing through thechannel28 to pass through theflavor insert80 to exit the pre-vaporformulation tank section70. Some example embodiments may not include one ormore connector elements52, and theflavor insert80 may be coupled directly with an inner surface ofinner tube25, and an airtight or substantially airtight seal may be established between theflavor insert80 and the inner surface ofinner tube25. Some example embodiments may not include one ormore connector elements52, and theflavor insert80 may be coupled directly with an inner surface ofchannel51cofgasket51 and an airtight or substantially airtight seal may be established between theflavor insert80 and theinner surface channel51c, if for example, the cross section ofchannel51cis smaller than that ofinner tube25.
• Referring toFIG. 2B, in some example embodiments, a pre-vaporformulation tank section70 includes apre-vapor formulation tank22 that excludes agasket assembly51 at an outlet end, such that thepre-vapor formulation tank22 includes anouter housing24 and aninner tube25 that at least partially define areservoir23 that may hold pre-vapor formulation. As shown inFIG. 2B, theouter housing24 andinner tube25 collectively define an outlet end of thereservoir23. The example embodiments illustrated inFIG. 2B show theouter housing24 being curved towards theinner tube25. However, it will be understood that other configurations of theouter housing24 and theinner tube25 are encompassed by the example embodiments.
• In the example embodiments illustrated inFIG. 2B, theouter housing24 andinner tube25 are coupled together at an outlet end of thepre-vapor formulation tank22 to define an outlet end enclosure of thereservoir23. Theouter housing24 andinner tube25 may be coupled together via one or more of an adhesive, a coupling device, a weld, a sealing element, some combination thereof, or the like.
• In some example embodiments, theouter housing24 and theinner tube25 comprise an individual element that defines both thereservoir23 and thechannel28. For example, thepre-vapor formulation tank22 may include a single piece of material that is shaped approximately annularly, such that the piece of material defines thereservoir23 and thechannel28 as separate spaces that are separated by one or more portions of the piece of material. The piece of material may be a translucent and/or transparent piece of material.
• In the example embodiments illustrated inFIG. 2B, thepre-vapor formulation tank22 includes one ormore connector elements52 configured to couple theflavor insert80 to the pre-vaporformulation tank section70 if and/or when theflavor insert80 is inserted through the outlet opening50bto position theflavor insert80 at an outlet portion of thechannel28. In some example embodiments, the one ormore connector elements52 are an individual connector element that extends around an inner surface of theinner tube25.
• Referring toFIGS. 2A-B, in some example embodiments, the one ormore connector elements52 may be absent from thepre-vapor formulation tank22, and thegasket assembly channel51c, the outlet end of theinner tube25, or both, are configured to establish a friction fit connection with an outer surface of theflavor insert80 if and/or when theflavor insert80 is inserted through the outlet opening50b. Such a friction fit connection may seal or substantially seal the interface between the outer surface of theflavor insert80 and thechannel28. As a result, a generatedvapor95 passing through thechannel28 towards outlet opening50bmay be directed to pass through theflavor insert80 to form a flavoredvapor97. In embodiments where generatedvapor95 is a flavored vapor, passing throughflavor insert80 may alter the flavor of the vapor, other properties of the vapor, and/or components of the vapor, resulting invapor97.
• FIG. 3A-3G are cross sectional views of flavor inserts80A-80G according to some example embodiments.
• Referring toFIGS. 3A-G, the flavor inserts80A-80G include an inlet end opening80aand an outlet end opening80b. The flavor inserts80A-80G are configured to receive a vapor, including a generatedvapor95, through the inlet end opening80aand into an interior of theflavor insert80. The flavor inserts80A-80G are further configured to direct a vapor, including a flavoredvapor97 formed through flavorant elution into the generatedvapor95, out of theflavor insert80 via the outlet end opening80b.
• Referring toFIG. 3A, in some example embodiments, theflavor insert80A includes aflavor material85 holding one or more flavorants and ahousing82 at least partially enclosing theflavor material85 within the interior of theflavor insert80A. Thehousing82 may enclose side portions of the flavor insert80A to defineopenings80a,80bat opposite ends of theflavor insert80A. Thehousing material82 is also referred to herein as an outer housing of theflavor insert80A.
• Theflavor material85 may be a porous structure in which one or more flavorants are included. In some example embodiments, theflavor material85 is a collection of flavor materials. In some example embodiments, theflavor material85 includes one or more botanical materials. In some example embodiments, theflavor material85 includes one or more types of tobacco. In some example embodiments, theflavor material85 includes one or more types of plant material.
• Referring toFIG. 3B, theflavor insert80B may include afilter element86 and ahousing material88 that encloses thefilter element86 and thehousing82 enclosing theflavor material85. Thefilter element86 may be configured to filter particulate matter from a vapor passing through theflavor insert80B. Thefilter element86 may, in some example embodiments, include a hollow acetate tube (HAT), or any other types of filters.
• Thehousing material88 may enclose side portions of thefilter element86 to direct vapor exiting theflavor material85 to pass through the filter element to the outlet end opening80b. In some example embodiments, thehousing material88 is a tipping paper, rolling paper, or other type of suitable paper material. In some example embodiments,housing material82 may be omitted, andhousing material88 encloses thefilter element86 and theflavor material85 without the need for ahousing82, as shown for example inFIG. 3G.
• Referring toFIG. 3C, thehousing material88 of flavor insert80C may enclose a limited portion of thefilter element86 and/orhousing82. As shown inFIG. 3C, thehousing material88 may overlap the outer surface area of thefilter element86 and a limited portion of the outer surface area of thehousing82.
• Referring toFIGS. 3D-3F, the flavor inserts80D,80E, and80F may include multipleseparate flavor materials85,89, etc. that each hold a different flavorant. For example, in some example embodiments theflavor material85 may be a first type of tobacco and theflavor material89 may be a second type of tobacco. In another example, theflavor material85 may be tobacco and theflavor material89 may be a non-tobacco material. In another example, theflavor material85 may be tobacco a non-tobacco material and theflavor material89 may also be a non-tobacco material. As shown inFIG. 3D, thehousing material88 may overlap a limited portion of an outer surface of theflavor material89. In some example embodiments, thehousing material88 may overlap at least a portion of the outer surface of theflavor material89 and at least a portion of the outer surface of theflavor material85. Other example flavor inserts80 may include one or more flavor material sections without afilter element86. Other example flavor inserts80 may include one or more flavor material sections and more than one filter element, each filter element having the same or different configuration as other of the filter elements.
• In some example embodiments, any of the flavor inserts may be a cigarette (or cigarette-like insert), cigar, cigarillo, etc. that includes a flavor material that includes one or more types of tobacco, plant material, reconstituted tobacco material, etc. In some example embodiments that include afilter element86, thefilter element86 may be a filter such as those used in cigarettes.
• In some example embodiments, at least the pre-vaporformulation tank section70 is configured to provide a flavoredvapor97 based on directing the generatedvapor95 through a flavoredinsert80 that includes a tobacco rod such that the generatedvapor95 elutes flavorant from the tobacco included in the tobacco rod to form the flavoredvapor97 independently of and/or without any combustion of the tobacco rod. The pre-vaporformulation tank section70 may thus be configured to form a flavoredvapor97 based on flavorant elution from tobacco included in the flavoredinsert80 without combustion of the tobacco rod.
• Referring toFIGS. 3E and 3F, in some example embodiments, each of the flavor inserts80E and80F may include multipleseparate flavor materials85,89,93,96 disposed within a housing (for example, such as a porous paper tube, a perforated aluminum foil tube, a hollow acetate tube (HAT), etc.)98. Thehousing98 may be placed into the channel28 (or within a close tank, a cartridge, or an open tank) through the mount end such that each of the inserts80E and80F are exposed to a combination of thermal energy from theheating element34 and/or to the generated vapor. In some examples, thehousing98 may have an inner diameter within a range of 2-10 millimeters (mm) and a length within a range of 5-50 mm. Dimensions greater than or smaller than the ranges provided may also be used in other example embodiments. Each of the flavor inserts80E and80F may be attached to theconnector element52 and used as a mouthpiece.
• The multipleseparate flavor materials85,89,93,96 may be discretely sectioned or layered within thehousing98. The multipleseparate flavor materials85,89,93,96 may or may not have separators, such as porous dividers,100 sectioning and separating each of the materials. In some example embodiments, the multiple separate flavor materials may be plant material flavorants or non-plant material flavorants. In some example embodiments, the multiple separate flavor materials may be tobacco or non-tobacco flavorants. In some example embodiments, one or more of the flavor materials may be individually wrapped by an additional housing material within thehousing material98 that encloses all the pieces together. In some example embodiments, there are no individual housings, or all the flavor materials are wrapped only by a housing material98 (e.g., as shown inFIGS. 3E-F). In some example embodiments, subsets of the flavor materials (e.g., two or more flavor materials) may be wrapped by an additional housing material within thehousing material98.
• In lieu of the multipleseparate flavor materials85,89,93,96 being layered within ahousing98, multipleseparate flavor materials85,89,93,96 (or at least one or more of them) may be individual absorbing material inserts soaked in differing flavor materials and inserted within thehousing98.
• In some example embodiments, multipleseparate flavor materials85,89,93,96 may fill the space within thehousing98 from the inlet end opening80ato the outlet end opening80b, as shown inFIG. 3E. In other example embodiments, the multipleseparate flavor materials85,89,93,96 may be separated from the inlet end opening80aand the outlet end opening80bbyspaces102, as shown inFIG. 3F. Thespaces102 may be void of material or one or both of thespaces102 may include thefilter element86. While a particular number of flavor materials are shown as examples in the figures, more or less number of flavor material sections may be used in example embodiments (e.g., one, two, three, four, etc.)
• Referring toFIGS. 3D-3F, the multipleseparate flavor materials85,89,93,96 may be arranged such that, as the temperature gradient changes, desired aromatic or other sensory components will be physically located to release at a desired temperature.
• As shown inFIGS. 3E and 3F, the temperature gradient experienced by each of the flavor inserts80E and80F may be, for example, 300-50° C. (or 250-100° C., etc.). The multipleseparate flavor materials85,89,93,96 may be arranged such that a first material85 (for example, nicotine salts, such as nicotine bitartrate) releasing at a first temperature (for example, approximately 300-220° C.) is positioned at the inlet end opening80a, a second material89 (for example, nicotine free base or menthol crystals) releasing at a second temperature, less than the first temperature, (for example, approximately 220-135° C.) is positioned adjacent thefirst material85, a third material93 (for example, flavor materials such as citrus or lemon oil or pyrazines, etc.) releasing at a third temperature, less than the second temperature, (for example, approximately 135-60° C.) is positioned adjacent thesecond material89, and a fourth material96 (for example, a more volatile compound, such as acetic acid) releasing at a fourth temperature, less than the third temperature, (for example, less than approximately 60° C.) is positioned adjacent thethird material93 and at the outlet end opening80b. Note that these temperatures and temperature ranges are examples only and may differ between different flavor inserts. As previously stated, the multipleseparate flavor materials85,89,93,96 may include separators, such as porous dividers,100 sectioning and separating each of thematerials85,89,93,96, or may be adjacent to each other withoutseparators100.
• While a number of example embodiments have been disclosed herein, it should be understood that other variations are 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.

Claims (34)

We claim:

1. A vaping device comprising:

a pre-vapor formulation housing configured to house a pre-vapor formulation, the pre-vapor formulation housing defining a channel there through;

a heating element configured to heat at least a portion of the pre-vapor formulation into a vapor and provide the vapor to a first portion of the channel; and

an insert at a second portion of the channel and positioned to receive the vapor, the insert being subdivided into at least a first section and a second section, the first section containing a first material that releases at a first temperature, the second section containing a second material that releases at a second temperature, the second temperature being less than the first temperature.

2. The vaping device ofclaim 1, wherein the insert and the heating element are at opposing ends of the channel.

3. The vaping device ofclaim 1, wherein the insert is a removable insert.

4. The vaping device ofclaim 1, wherein the insert includes a perforated aluminum foil tube encasing the first section, the second section, or both the first section and the second section.

5. The vaping device ofclaim 1, wherein the insert includes a porous paper tube containing a flavorant, an aromatic source or both a flavorant and an aromatic source.

6. The vaping device ofclaim 5, wherein the first material, the second material, or both the first and the second material are included in the aromatic source.

7. The vaping device ofclaim 5, wherein the first material, the second material, or both the first and the second material are included in the flavorant.

8. The vaping device ofclaim 1, wherein the insert includes an absorbing material.

9. The vaping device ofclaim 8, wherein the absorbing material is soaked with a flavor.

10. The vaping device ofclaim 8, wherein the first material, the second material, or both the first material and the second material are included in the absorbing material.

11. The vaping device ofclaim 1, wherein the first section and the second section are separated by porous dividers.

12. The vaping device ofclaim 1, wherein the insert includes lemon tea granules, and the first material, second material, or both the first and second material are included in the lemon tea granules.

13. The vaping device ofclaim 1, wherein the insert includes tobacco or tobacco-derived material.

14. The vaping device ofclaim 1, wherein the insert is a removable insert configured to release a flavorant, an aroma, or a flavorant and an aroma into the received vapor.

15. The vaping device ofclaim 14, wherein the removable insert includes a perforated aluminum foil tube encasing the first section and the second section.

16. The vaping device ofclaim 14, wherein the first material includes the flavorant.

17. The vaping device ofclaim 14, wherein the first material includes the aroma.

18. The vaping device ofclaim 14, wherein the second material includes the flavorant.

19. The vaping device ofclaim 14, wherein the second material includes the aroma.

20. The vaping device ofclaim 1, wherein the second section is arranged in the insert farther from the heating element than the first section.

21. The vaping device ofclaim 1, wherein the insert receives the vapor via the first section.

22. The vaping device ofclaim 1, wherein the first material, the second material, or both the first material and the second material are included in a flavorant.

23. The vaping device ofclaim 1, wherein the first material, the second material, or both the first material and the second material are included in an aromatic source.

24. The vaping device ofclaim 1, wherein the insert includes a hollow acetate tube that contains the first material, the second material, or both the first material and the second material.

25. A vaping device comprising:

a power supply section configured to supply power; and

a vaping element configured to receive the supplied power, the vaping element including,

a pre-vapor formulation housing configured to house a pre-vapor formulation, the pre-vapor formulation housing defining a channel there through,

a heating element configured to heat at least a portion of the pre-vapor formulation into a vapor using the supplied power, the heating element configured to provide the vapor to a first portion of the channel, and

an insert at a second portion of the channel and positioned to receive the vapor, the insert being subdivided into at least a first section and a second section, the first section containing a first material that releases at a first temperature, the second section containing a second material that releases at a second temperature, the second temperature being less than the first temperature.

26. The vaping device ofclaim 25, wherein the insert and the heating element are at opposing ends of the channel.

27. The vaping device ofclaim 25, wherein the insert is a removable insert configured to be inserted into the channel.

28. The vaping device ofclaim 25, wherein the insert is a perforated aluminum foil tube encasing the first section and the second section.

29. The vaping device ofclaim 25, wherein the insert includes a porous paper tube containing a flavorant, an aromatic source, or both a flavorant and an aromatic source.

30. The vaping device ofclaim 25, wherein the insert includes an absorbing material.

31. The vaping device ofclaim 25, wherein the first section and the second section are separated by porous dividers.

32. The vaping device ofclaim 25, wherein the insert includes lemon tea granules.

33. The vaping device ofclaim 25, wherein the insert includes tobacco or tobacco-derived material.

34. The vaping device ofclaim 25, wherein the second section is arranged in the insert farther from the heating element than the first section.

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