U.S. patent application number 16/077731 was filed with the patent office on 2019-04-11 for vaporizer devices with blow discrimination.
The applicant listed for this patent is JUUL Labs, Inc.. Invention is credited to Steven Christensen, Nicholas Jay Hatton.
Application Number | 20190104767 16/077731 |
Document ID | / |
Family ID | 59563575 |
Filed Date | 2019-04-11 |
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United States Patent
Application |
20190104767 |
Kind Code |
A1 |
Hatton; Nicholas Jay ; et
al. |
April 11, 2019 |
VAPORIZER DEVICES WITH BLOW DISCRIMINATION
Abstract
Methods and apparatuses for discriminating between user blowing
and drawing (sucking) in an electronic vaporization device.
Described herein are electronic aerosol devices and methods of
controlling or operating them which can accurately differentiate
between blowing and drawing (sucking) through the mouthpiece and
adjust the control of the vaporizer accordingly.
Inventors: |
Hatton; Nicholas Jay; (San
Francisco, CA) ; Christensen; Steven; (San Francisco,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JUUL Labs, Inc. |
|
|
|
|
|
Family ID: |
59563575 |
Appl. No.: |
16/077731 |
Filed: |
February 10, 2017 |
PCT Filed: |
February 10, 2017 |
PCT NO: |
PCT/US17/17496 |
371 Date: |
August 13, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62294271 |
Feb 11, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 47/008 20130101;
A24D 1/14 20130101; G01L 9/0072 20130101; A24F 40/51 20200101 |
International
Class: |
A24F 47/00 20060101
A24F047/00 |
Claims
1. A vaporizer device comprising: a reservoir configured to hold a
vaporizable material; a heater configured to heat the vaporizable
material; a mouthpiece in communication with the reservoir; a
pressure sensor configured to output instantaneous sensor readings;
and a microcontroller, wherein the microcontroller is configured
to: determine a baseline based on filtering the instantaneous
sensor readings; hold the baseline at a prior value of the baseline
while the instantaneous sensor readings are above the baseline by a
first offset value or below the baseline by a second offset value;
compare the instantaneous sensor readings to the baseline and
activate the heater to generate vapor from the vaporizable material
when the instantaneous sensor readings are offset from the baseline
by more than a third offset value indicating suction is being
applied to the mouthpiece.
2. A vaporizer device comprising: a reservoir configured to hold a
vaporizable material; a heater configured to heat the vaporizable
material; a mouthpiece in communication with the reservoir; a
pressure sensor configured to output instantaneous sensor readings;
and a microcontroller, wherein the microcontroller is configured
to: determine a baseline based on filtering the instantaneous
sensor readings; hold the baseline at a prior value of the baseline
while the instantaneous sensor readings are above the baseline by a
first offset value or below the baseline by a second offset value;
compare the instantaneous sensor readings to the baseline and
activate the heater to generate vapor from the vaporizable material
when the instantaneous sensor readings are below the baseline by
more than a third offset value indicating suction is being applied
to the mouthpiece.
3. A vaporizer device comprising: a reservoir configured to hold a
vaporizable material; a heater configured to heat the vaporizable
material; a mouthpiece in communication with the reservoir; a
pressure sensor comprising configured to output instantaneous
sensor readings; and a microcontroller, wherein the microcontroller
is configured to: determine a baseline based on filtering the
instantaneous sensor readings; hold the baseline at a prior value
of the baseline while the instantaneous sensor readings are above
the baseline by a first offset value or below the baseline by a
second offset value; compare the instantaneous sensor readings to
the baseline and activate the heater to generate vapor from the
vaporizable material when the instantaneous sensor readings are
above the baseline by more than a third offset value indicating
suction is being applied to the mouthpiece.
4. The device of claim 1, 2 or 3, wherein a first side of the
pressure sensor is exposed to a first air path through the
mouthpiece and a second side of the pressure sensor is exposed to a
second air path open to ambient pressure, and wherein the second
air path is sealed from the first air path by a gasket around the
pressure sensor.
5. The device of claim 1, 2 or 3, wherein the third offset value is
the same as the second offset value.
6. The device of claim 1, 2 or 3, wherein the third offset value is
the same as the first offset value.
7. The device of claim 1, 2 or 3, wherein the first offset value is
zero.
8. The device of claim 1, 2 or 3, wherein the second offset value
is zero.
9. The device of claim 1, 2 or 3, wherein the pressure sensor
comprise a capacitive membrane.
10. The devices of claim 1, 2, or 3, wherein the pressure sensor
comprises a MEMS pressure sensor.
11. The device of claims 1, 2 or 3, wherein the instantaneous
pressure sensor output is a capacitance.
12. The device of claim 1, 2 or 3, wherein the instantaneous
pressure sensor output is a pressure.
13. The device of claim 1, 2 or 3, wherein the microcontroller is
configured to determine the baseline based on filtering the
instantaneous sensor output by low pass filtering the instantaneous
sensor output.
14. The device of claim 1, 2 or 3, wherein the microcontroller is
configured to determine the baseline based on filtering the
instantaneous sensor output by taking a running average of the
instantaneous sensor output.
15. The device of claim 1, 2 or 3, wherein the microcontroller is
further configured to stop activating the heater to generate vapor
when the instantaneous sensor output is offset from the baseline by
less than the third offset value.
16. A method of controlling a vaporizer device to prevent heating
after blowing on a mouthpiece of the vaporizer device, the method
comprising: taking instantaneous sensor readings from a pressure
sensor in the vaporizer device, wherein the pressure sensor
comprises a differential pressure sensor; determining a baseline by
filtering the instantaneous sensor readings; holding the baseline
at a prior value of the baseline while the instantaneous sensor
readings are above the baseline by a first offset value; holding
the baseline at a prior value of the baseline while the
instantaneous sensor readings are below the baseline by a second
offset value; comparing the instantaneous sensor readings to the
baseline and activating a heater in the vaporizer to generate vapor
from a vaporizable material when the instantaneous sensor output is
offset from the baseline by more than a third offset value,
indicating that suction is being applied to the mouthpiece.
17. The method of claim 16, wherein the third offset value is the
same as the second offset value.
18. The method of claim 16, wherein the third offset value is the
same as the first offset value.
19. The method of claim 16, wherein the first offset value is
zero.
20. The method of claim 16, wherein the second offset value is
zero.
21. The method of claim 16, wherein the instantaneous pressure
sensor reading is a capacitance.
22. The method of claim 16, wherein the instantaneous pressure
sensor reading is a pressure.
23. The method of claim 16, wherein determining comprising
determining the baseline based on filtering the instantaneous
sensor readings by low pass filtering the instantaneous sensor
readings.
24. The method of claim 16, wherein determining comprising
determining the baseline based on filtering the instantaneous
sensor readings by taking a running average of the instantaneous
sensor readings.
25. The method of claim 16, further comprising stopping activating
the heater to generate vapor when the instantaneous sensor readings
are offset from the baseline by less than the third offset
value.
26. A method of controlling a vaporizer device to prevent heating
after blowing on a mouthpiece of the vaporizer device, the method
comprising: taking instantaneous sensor readings from a pressure
sensor in the vaporizer device; determining a baseline by filtering
the instantaneous sensor readings; holding the baseline at a prior
value of the baseline while the instantaneous sensor readings are
above the baseline; holding the baseline at a prior value of the
baseline while the instantaneous sensor readings are below the
baseline by an offset value; comparing the instantaneous sensor
readings to the baseline and activating a heater in the vaporizer
to generate vapor from a vaporizable material when the
instantaneous sensor output is below the baseline by more than the
offset value indicating that suction is being applied to the
mouthpiece.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to U.S. provisional
patent application No. 62/294,271, titled "VAPORIZER DEVICES WITH
BLOW DISCRIMINATION," filed on Feb. 11, 2016.
[0002] This patent application may be related to U.S. patent
application Ser. No. 14/581,666, filed on Dec. 23, 2014, and titled
"VAPORIZATION DEVICE SYSTEMS AND METHODS", which claimed priority
to U.S. Provisional Patent Application No. 61/920,225, filed Dec.
23, 2013, U.S. Provisional Patent Application No. 61/936,593, filed
Feb. 6, 2014, and U.S. Provisional Patent Application No.
61/937,755, filed Feb. 10, 2014.
[0003] This application may also be related to or may be used with
the inventions in one or more of the following patent applications:
U.S. patent application Ser. No. 14/578,193, filed on Dec. 19,
2014, and titled "METHOD AND SYSTEM FOR VAPORIZATION OF A
SUBSTANCE"; U.S. patent application Ser. No. 14/625,042, filed on
Feb. 18, 2015, and titled "AEROSOL DEVICES AND METHODS FOR INHALING
A SUBSTANCE AND USES THEREOF"; U.S. patent application Ser. No.
13/837,438, filed on Mar. 15, 2013, and titled "LOW TEMPERATURE
ELECTRONIC VAPORIZATION DEVICE AND METHODS"; U.S. patent
application Ser. No. 14/271,071, filed on May 6, 2014, and titled
"NICOTINE SALT FORMULATIONS FOR AEROSOL DEVICES AND METHODS
THEREOF"; U.S. patent application Ser. No. 14/304,847, filed on
Jun. 13, 2014, and titled "MULTIPLE HEATING ELEMENTS WITH SEPARATE
VAPORIZABLE MATERIALS IN AN ELECTRIC VAPORIZATION DEVICE"; U.S.
patent application Ser. No. 14/461,284, filed on Aug. 15, 2014, and
titled "METHODS AND DEVICES FOR DELIVERING AND MONITORING OF
TOBACCO, NICOTINE, OR OTHER SUBSTANCES"; PCT Patent Application No.
PCT/US2015/031152, filed on May 15, 2015, and titled "SYSTEMS AND
METHODS FOR AEROSOLIZING A SMOKEABLE MATERIAL"; PCT Patent
Application No. PCT/US2014/064690, filed on Nov. 7, 2014, and
titled "NICOTINE LIQUID FORMULATIONS FOR AEROSOL DEVICES AND
METHODS THEREOF"; U.S. patent application Ser. No. 14/960,259,
filed on Dec. 4, 2015, and titled "CALIBRATED DOSE CONTROL"; U.S.
patent application Ser. No. 15/257,748, titled "CARTRIDGE FOR USE
WITH A VAPORIZER DEVICE," filed on Sep. 6, 2016; U.S. patent
application Ser. No. 15/257,760, titled "VAPORIZER APPARATUS,"
filed on Sep. 6, 2016; U.S. patent application Ser. No. 15/257,768,
titled "VAPORIZER APPARATUS," filed on Sep. 6, 2016; U.S. patent
application Ser. No. 15/379,898, titled "VAPORIZATION DEVICE
SYSTEMS AND METHODS," filed on Dec. 15, 2016; U.S. patent
application Ser. No. 15/309,554, titled "SYSTEMS AND METHODS FOR
AEROSOLIZING A SMOKEABLE MATERIAL," filed on Nov. 8, 2016; U.S.
patent application Ser. No. 15/101,303, titled "NICOTINE LIQUID
FORMULATIONS FOR AEROSOL DEVICES AND METHODS THEREOF," filed on
Jun. 2, 2016; U.S. patent application Ser. No. 14/960,259, titled
"CALIBRATED DOSE CONTROL," filed on Dec. 4, 2015; U.S. patent
application Ser. No. 15/396,584, titled "LEAK-RESISTANT VAPORIZER
CARTRIDGES FOR USE WITH CANNABINOIDS," filed on Dec. 31, 2016. Each
of these applications is herein incorporated by reference in their
entirety.
INCORPORATION BY REFERENCE
[0004] All publications and patent applications mentioned in this
specification are herein incorporated by reference in their
entirety to the same extent as if each individual publication or
patent application was specifically and individually indicated to
be incorporated by reference.
FIELD
[0005] Described herein are electronic inhalable aerosol devices,
or electronic vaping devices, and particularly electronic aerosol
devices which can accurately differentiate between blowing and
drawing (sucking) through the mouthpiece and adjust the control of
the vaporizer accordingly.
BACKGROUND
[0006] Electronic cigarettes are typically battery-powered
vaporizers that simulate the feeling of smoking, but without
tobacco. Instead of cigarette smoke, the user inhales an aerosol,
commonly called vapor, typically released by a heating element that
atomizes a liquid solution (vaporizable material or solution).
Typically, the user activates the e-cigarette by taking a puff or
pressing a button. Some vaporizers look like traditional
cigarettes, but they come in many variations.
[0007] Many electronic cigarettes use a pressure sensor to
determine when the device should be heating or not. This may allow
for an intuitive user interface where the user simply draws from
(sucks on) the device to power it. It is advantageous over powering
the device with a button in that the device's heating element is
only powered when there is airflow over it assuming the device's
pressure sensor and microcontroller can accurately detect the start
and end of a draw.
[0008] Unfortunately, the vast majority of electronic cigarettes
described and currently in use have an unexpected failure mode
which may reduce the life of the battery and the overall device.
Specifically, such devices may inadvertently (and transiently)
detect a draw or inhalation following blowing or exhalation through
the device. A recent test of numerous pressure sensor-based
electronic cigarettes currently on the market found that these
devices can easily be turned on and apply power to the heating
element by blowing rather than inhaling into the mouthpiece of the
device as if the user had drawn from the device. Specifically, such
devices falsely indicate a draw (inhalation) and activate the
heater at the end of a blow into the device because they detect a
pressure drop at the end of the blow, and falsely interpret this is
the start of a draw. Depending on the controller for the vaporizer,
this pressure drop at the end of a blow may power the heater for
some amount of time, and potentially until a timeout for max draw
time. This failure mode may result in the device heating without
the user drawing on it, which pay provide a non-ideal user
experience, may waste of battery life and vaporizable material, and
in devices without temp control may overheat the vaporizable
material, which can produce e-juice degradants that taste bad and
are potentially more harmful when vaporized that the original
contents of the e-juice formulation.
[0009] Many commercially available electronic cigarettes use
pressure sensors that are mechanically similar to electret
microphones, but packaged with an ASIC (application specific
integrated circuit) instead of a standard electret microphone
circuit. An electret microphone is an electrostatic capacitor-based
microphone that does not require a polarizing power supply.
Pressure sensors of this type typically accept two power signals
and have one output signal to indicate whether or not a pressure
drop was recently detected. For the pressure sensor's ASIC to
accommodate changes in environment conditions (humidity and
temperature), slight differences in mechanical assembly from sensor
to sensor, and potential shifting of parts in the mechanical
assembly from vibration or drop, the ASIC's output usually depends
on changes in capacitance between the sensor's conductive diaphragm
(which deflects with a pressure differential across it) and a
conductive static plate in the sensor instead of depending on
absolute measured capacitance crossing some threshold. Given that
not all measured pressure drops indicate that the user is drawing
from the device, this approach is not ideal.
[0010] In all electronic cigarettes tested (some of which may not
use the standard modified electret microphone with ASIC), the
device can be made to start heating at the end of a blow into the
device's air/vapor outlet. In devices in which direct capacitance
measurements may be made by the microcontroller, the same behavior
can be produced, meaning there is no software actively handling
blows into the device correctly.
[0011] This failure mode may be largely unnoticed, but it is
relevant based on many user practices. For example, some electronic
cigarette users hold devices in their mouths, resulting in blowing
into the device. Devices that don't adequately distinguish between
drawing and the end of a blowing into the mouthpiece may start
heating after a user has exhaled onto the device.
[0012] Described herein are apparatuses (systems and devices) and
methods that may address the problem identified above.
SUMMARY OF THE DISCLOSURE
[0013] The present invention relates generally to apparatuses,
including systems and devices, for vaporizing material to form an
inhalable aerosol. Specifically, these apparatuses may include
vaporizers.
[0014] In particular, described herein are apparatuses including
vaporizers that are adapted to prevent one or more failure modes
that may result from blowing into the mouthpiece, which may be
referred to herein as blow rejection or blow discrimination. In
general, such vaporizers and methods of operating a vaporizer may
include a pressure sensor that regulates the baseline pressure
readings (which may be actual pressure readings or may be
unconverted sensor readings, such as capacitance measurements)
during a blow and/or a draw through the mouthpiece to prevent
instability that may otherwise result from blowing into the
mouthpiece.
[0015] For example, described herein are vaporizer devices
comprising: a reservoir configured to hold a vaporizable material;
a heater configured to heat the vaporizable material; a mouthpiece
in communication with the reservoir; a pressure sensor comprising a
differential pressure sensor (e.g., MEMS, capacitive membrane,
etc.) configured to output instantaneous sensor readings; and a
microcontroller, wherein the microcontroller is configured to:
determine a baseline based on filtering the instantaneous sensor
readings; hold the baseline at a prior value of the baseline while
the instantaneous sensor readings are above the baseline by a first
offset value or below the baseline by a second offset value;
compare the instantaneous sensor readings to the baseline and
activate the heater to generate vapor from the vaporizable material
when the instantaneous sensor readings are offset from the baseline
by more than a third offset value indicating suction is being
applied to the mouthpiece.
[0016] A vaporizer device may include a reservoir configured to
hold a vaporizable material; a heater configured to heat the
vaporizable material; a mouthpiece in communication with the
reservoir; a pressure sensor configured to output instantaneous
sensor readings; and a microcontroller, wherein the microcontroller
is configured to: determine a baseline based on filtering the
instantaneous sensor readings; hold the baseline at a prior value
of the baseline while the instantaneous sensor readings are above
the baseline by a first offset value or below the baseline by a
second offset value; compare the instantaneous sensor readings to
the baseline and activate the heater to generate vapor from the
vaporizable material when the instantaneous sensor readings are
below the baseline by more than a third offset value indicating
suction is being applied to the mouthpiece.
[0017] A vaporizer device may include: a reservoir configured to
hold a vaporizable material; a heater configured to heat the
vaporizable material; a mouthpiece in communication with the
reservoir; a pressure sensor configured to output instantaneous
sensor readings; and a microcontroller, wherein the microcontroller
is configured to: determine a baseline based on filtering the
instantaneous sensor readings; hold the baseline at a prior value
of the baseline while the instantaneous sensor readings are above
the baseline by a first offset value or below the baseline by a
second offset value; compare the instantaneous sensor readings to
the baseline and activate the heater to generate vapor from the
vaporizable material when the instantaneous sensor readings are
above the baseline by more than a third offset value indicating
suction is being applied to the mouthpiece.
[0018] The first side of the pressure sensor may be exposed to a
first air path through the mouthpiece and a second side of the
pressure sensor is exposed to a second air path open to ambient
pressure, and wherein the second air path is sealed from the first
air path by a gasket around the pressure sensor. The third offset
value may be the same as the second offset value or the third
offset value may be the same as the first offset value. The first
offset value may be zero, or the second offset value is zero.
[0019] The instantaneous pressure sensor output may be capacitance
or pressure.
[0020] In general, the pressure sensors described herein may be any
differential pressure sensor, such as MEMS, capacitive pressures
sensors (e.g., including a capacitive membrane), or any force
collector type pressure sensors that use a transducer to measure
pressure or pressure differences (e.g., diaphragm, piston, etc.),
piezorestrictive, electromagnetic, piezoelectric, optical,
potentiometric, resonant (including MEMS), etc. Differential
pressure sensors may measure the distance between two pressures,
one connected on different sides of the sensor. This includes
pressure sensors in which one side is open/connected to ambient
atmosphere (pressure).
[0021] The microcontroller may be configured to determine the
baseline based on filtering the instantaneous sensor output by low
pass filtering the instantaneous sensor output.
[0022] The microcontroller may be configured to determine the
baseline based on filtering the instantaneous sensor output by
taking a running average of the instantaneous sensor output.
[0023] The microcontroller may further be configured to stop
activating the heater to generate vapor when the instantaneous
sensor output is offset from the baseline by less than the third
offset value.
[0024] Also described herein are methods of controlling a vaporizer
device to prevent heating after blowing on a mouthpiece of the
vaporizer device that include: taking instantaneous sensor readings
from a pressure sensor in the vaporizer device, wherein the
pressure sensor comprises a capacitive membrane; determining a
baseline by filtering the instantaneous sensor readings; holding
the baseline at a prior value of the baseline while the
instantaneous sensor readings are above the baseline by a first
offset value; holding the baseline at a prior value of the baseline
while the instantaneous sensor readings are below the baseline by a
second offset value; comparing the instantaneous sensor readings to
the baseline and activating a heater in the vaporizer to generate
vapor from a vaporizable material when the instantaneous sensor
output is offset from the baseline by more than a third offset
value, indicating that suction is being applied to the
mouthpiece.
[0025] A method of controlling a vaporizer device to prevent
heating after blowing on a mouthpiece of the vaporizer device may
include: taking instantaneous sensor readings from a pressure
sensor in the vaporizer device, wherein the pressure sensor
comprises a capacitive membrane; determining a baseline by
filtering the instantaneous sensor readings; holding the baseline
at a prior value of the baseline while the instantaneous sensor
readings are above the baseline; holding the baseline at a prior
value of the baseline while the instantaneous sensor readings are
below the baseline by an offset value; comparing the instantaneous
sensor readings to the baseline and activating a heater in the
vaporizer to generate vapor from a vaporizable material when the
instantaneous sensor output is below the baseline by more than the
offset value indicating that suction is being applied to the
mouthpiece.
[0026] In some variations, the apparatuses described herein may
include an inhalable aerosol comprising: an oven comprising an oven
chamber and a heater for heating a vapor forming medium in the oven
chamber to generate a vapor; a condenser comprising a condensation
chamber in which at least a fraction of the vapor condenses to form
the inhalable aerosol; an air inlet that originates a first airflow
path that includes the oven chamber; and an aeration vent that
originates a second airflow path that allows air from the aeration
vent to join the first airflow path prior to or within the
condensation chamber and downstream from the oven chamber thereby
forming a joined path, wherein the joined path is configured to
deliver the inhalable aerosol formed in the condensation chamber to
a user.
[0027] The oven may be within a body of the device. The device may
further comprise a mouthpiece, wherein the mouthpiece comprises at
least one of the air inlet, the aeration vent, and the condenser.
The mouthpiece may be separable from the oven. The mouthpiece may
be integral to a body of the device, wherein the body comprises the
oven. The device may further comprise a body that comprises the
oven, the condenser, the air inlet, and the aeration vent. The
mouthpiece may be separable from the body.
[0028] In some variations, the oven chamber may comprise an oven
chamber inlet and an oven chamber outlet, and the oven further
comprises a first valve at the oven chamber inlet, and a second
valve at the oven chamber outlet. The aeration vent may comprise a
third valve. The first valve, or said second valve may be chosen
from the group of a check valve, a clack valve, a non-return valve,
and a one-way valve. The third valve may be chosen from the group
of a check valve, a clack valve, a non-return valve, and a one-way
valve. The first or second valve may be mechanically actuated. The
first or second valve may be electronically actuated. The first
valve or second valve may be manually actuated. The third valve may
be mechanically actuated. The third valve may be mechanically
actuated. The third valve may be electronically actuated. The third
valve may be manually actuated.
[0029] In some variations, the device may further comprise a body
that comprises at least one of: a power source, a printed circuit
hoard, a switch, and a temperature regulator. The device may
further comprise a temperature regulator in communication with a
temperature sensor. The temperature sensor may be the heater. The
power source may be rechargeable. The power source may be
removable. The oven may further comprise an access lid. The vapor
forming medium may comprise tobacco. The vapor forming medium may
comprise a botanical. The vapor forming medium may be heated in the
oven chamber wherein the vapor forming medium may comprise a
humectant to produce the vapor, wherein the vapor comprises a gas
phase humectant. The vapor may be mixed in the condensation chamber
with air from the aeration vent to produce the inhalable aerosol
comprising particle diameters of average size of about 1 micron.
The vapor forming medium may be heated in the oven chamber, wherein
the vapor is mixed in the condensation chamber with air from the
aeration vent to produce the inhalable aerosol comprising particle
diameters of average size of less than or equal to 0.9 micron. The
vapor forming medium may be heated in the oven chamber, wherein the
vapor is mixed in the condensation chamber with air from the
aeration vent to produce the inhalable aerosol comprising particle
diameters of average size of less than or equal to 0.8 micron. The
vapor forming medium may be heated in the oven chamber, wherein the
vapor is mixed in the condensation chamber with air from the
aeration vent to produce the inhalable aerosol comprising particle
diameters of average size of less than or equal to 0.7 micron. The
vapor forming medium may be heated in the oven chamber, wherein the
vapor is mixed in the condensation chamber with air from the
aeration vent to produce the inhalable aerosol comprising particle
diameters of average size of less than or equal to 0.6 micron. The
vapor forming medium may be heated in the oven chamber, wherein the
vapor is mixed in the condensation chamber with air from the
aeration vent to produce the inhalable aerosol comprising particle
diameters of average size of less than or equal to 0.5 micron.
[0030] In some variations, the humectant may comprise glycerol as a
vapor-forming medium. The humectant may comprise vegetable
glycerol. The humectant may comprise propylene glycol. The
humectant may comprise a ratio of vegetable glycerol to propylene
glycol. The ratio may be about 100:0 vegetable glycerol to
propylene glycol. The ratio may be about 90:10 vegetable glycerol
to propylene glycol. The ratio may be about 80:20 vegetable
glycerol to propylene glycol. The ratio may be about 70:30
vegetable glycerol to propylene glycol. The ratio may be about
60:40 vegetable glycerol to propylene glycol. The ratio may be
about 50:50 vegetable glycerol to propylene glycol. The humectant
may comprise a flavorant. The vapor forming medium may be heated to
its pyrolytic temperature. The vapor forming medium may heated to
200.degree. C. at most. The vapor forming medium may be heated to
160.degree. C. at most. The inhalable aerosol may be cooled to a
temperature of about 50.degree.-70.degree. C. at most, before
exiting the aerosol outlet of the mouthpiece.
[0031] Also described herein are methods for generating an
inhalable aerosol. Such a method may comprise: providing an
inhalable aerosol generating device wherein the device comprises:
an oven comprising an oven chamber and a heater for heating a vapor
forming medium in the oven chamber and for forming a vapor therein;
a condenser comprising a condensation chamber in which the vapor
forms the inhalable aerosol; an air inlet that originates a first
airflow path that includes the oven chamber; and an aeration vent
that originates a second airflow path that allows air from the
aeration vent to join the first airflow path prior to or within the
condensation chamber and downstream from the oven chamber thereby
forming a joined path, wherein the joined path is configured to
deliver the inhalable aerosol formed in the condensation chamber to
a user.
[0032] The oven may be within a body of the device. The device may
further comprise a mouthpiece, wherein the mouthpiece comprises at
least one of the air inlet, the aeration vent, and the condenser.
The mouthpiece may be separable from the oven. The mouthpiece may
be integral to a body of the device, wherein the body comprises the
oven. The method may further comprise a body that comprises the
oven, the condenser, the air inlet, and the aeration vent. The
mouthpiece may be separable from the body.
[0033] The oven chamber may comprise an oven chamber inlet and an
oven chamber outlet, and the oven further comprises a first valve
at the oven chamber inlet, and a second valve at the oven chamber
outlet.
[0034] The vapor forming medium may comprise tobacco. The vapor
forming medium may comprise a botanical. The vapor forming medium
may he heated in the oven chamber wherein the vapor forming medium
may comprise a humectant to produce the vapor, wherein the vapor
comprises a gas phase humectant. The vapor may comprise particle
diameters of average mass of about 1 micron. The vapor may comprise
particle diameters of average mass of about 0.9 micron. The vapor
may comprise particle diameters of average mass of about 0.8
micron. The vapor may comprise particle diameters of average mass
of about 0.7 micron. The vapor may comprise particle diameters of
average mass of about 0.6 micron. The vapor may comprise particle
diameters of average mass of about 0.5 micron.
[0035] In some variations, the humectant may comprise glycerol as a
vapor-forming medium. The humectant may comprise vegetable
glycerol. The humectant may comprise propylene glycol. The
humectant may comprise a ratio of vegetable glycerol to propylene
glycol. The ratio may be about 100:0 vegetable glycerol to
propylene glycol. The ratio may be about 90:10 vegetable glycerol
to propylene glycol. The ratio may be about 80:20 vegetable
glycerol to propylene glycol. The ratio may be about 70:30
vegetable glycerol to propylene glycol. The ratio may be about
60:40 vegetable glycerol to propylene glycol. The ratio may be
about 50:50 vegetable glycerol to propylene glycol. The humectant
may comprise a flavorant. The vapor forming medium may be heated to
its pyrolytic temperature. The vapor forming medium may heated to
200.degree. C. at most. The vapor forming medium may be heated to
160.degree. C. at most. The inhalable aerosol may be cooled to a
temperature of about 50.degree.-70.degree. C. at most, before
exiting the aerosol outlet of the mouthpiece.
[0036] The device may be user serviceable. The device may not be
user serviceable.
[0037] A method for generating an inhalable aerosol may include:
providing a vaporization device, wherein said device produces a
vapor comprising particle diameters of average mass of about 1
micron or less, wherein said vapor is formed by heating a vapor
forming medium in an oven chamber to a first temperature below the
pyrolytic temperature of said vapor forming medium, and cooling
said vapor in a condensation chamber to a second temperature below
the first temperature, before exiting an aerosol outlet of said
device.
[0038] A method of manufacturing a device for generating an
inhalable aerosol may include: providing said device comprising a
mouthpiece comprising an aerosol outlet at a first end of the
device; an oven comprising an oven chamber and a heater for heating
a vapor forming medium in the oven chamber and for forming a vapor
therein, a condenser comprising a condensation chamber in which the
vapor forms the inhalable aerosol, an air inlet that originates a
first airflow path that includes the oven chamber and then the
condensation chamber, an aeration vent that originates a second
airflow path that joins the first airflow path prior to or within
the condensation chamber after the vapor is formed in the oven
chamber, wherein the joined first airflow path and second airflow
path are configured to deliver the inhalable aerosol formed in the
condensation chamber through the aerosol outlet of the mouthpiece
to a user.
[0039] The method may further comprise providing the device
comprising a power source or battery, a printed circuit board, a
temperature regulator or operational switches.
[0040] A device for generating an inhalable aerosol may comprise a
mouthpiece comprising an aerosol outlet at a first end of the
device and an air inlet that originates a first airflow path; an
oven comprising an oven chamber that is in the first airflow path
and includes the oven chamber and a heater for heating a vapor
forming medium in the oven chamber and for forming a vapor therein;
a condenser comprising a condensation chamber in which the vapor
forms the inhalable aerosol; and an aeration vent that originates a
second airflow path that allows air from the aeration vent to join
the first airflow path prior to or within the condensation chamber
and downstream from the oven chamber thereby forming a joined path,
wherein the joined path is configured to deliver the inhalable
aerosol formed in the condensation chamber through the aerosol
outlet of the mouthpiece to a user.
[0041] A device for generating an inhalable aerosol may comprise: a
mouthpiece comprising an aerosol outlet at a first end of the
device, an air inlet that originates a first airflow path, and an
aeration vent that originates a second airflow path that allows air
from the aeration vent to join the first airflow path; an oven
comprising an oven chamber that is in the first airflow path and
includes the oven chamber and a heater for heating a vapor forming
medium in the oven chamber and for forming a vapor therein; and a
condenser comprising a condensation chamber in which the vapor
forms the inhalable aerosol and wherein air from the aeration vent
joins the first airflow path prior to or within the condensation
chamber and downstream from the oven chamber thereby forming a
joined path, wherein the joined path is configured to deliver the
inhalable aerosol through the aerosol outlet of the mouthpiece to a
user.
[0042] A device for generating an inhalable aerosol may comprise: a
device body comprising a cartridge receptacle; a cartridge
comprising: a fluid storage compartment, and a channel integral to
an exterior surface of the cartridge, and an air inlet passage
formed by the channel and an internal surface of the cartridge
receptacle when the cartridge is inserted into the cartridge
receptacle; wherein the channel forms a first side of the air inlet
passage, and an internal surface of the cartridge receptacle forms
a second side of the air inlet passage.
[0043] A device for generating an inhalable aerosol may comprise: a
device body comprising a cartridge receptacle; a cartridge
comprising: a fluid storage compartment, and a channel integral to
an exterior surface of the cartridge, and an air inlet passage
formed by the channel and an internal surface of the cartridge
receptacle when the cartridge is inserted into the cartridge
receptacle; wherein the channel forms a first side of the air inlet
passage, and an internal surface of the cartridge receptacle forms
a second side of the air inlet passage.
[0044] The channel may comprise at least one of a groove, a trough,
a depression, a dent, a furrow, a trench, a crease, and a gutter.
The integral channel may comprise walls that are either recessed
into the surface or protrude from the surface where it is formed.
The internal side walls of the channel may form additional sides of
the air inlet passage. The cartridge may further comprise a second
air passage in fluid communication with the air inlet passage to
the fluid storage compartment, wherein the second air passage is
formed through the material of the cartridge. The cartridge may
further comprise a heater. The heater may be attached to a first
end of the cartridge.
[0045] The heater may comprise a heater chamber, a first pair of
heater contacts, a fluid wick, and a resistive heating element in
contact with the wick, wherein the first pair of heater contacts
comprise thin plates affixed about the sides of the heater chamber,
and wherein the fluid wick and resistive heating element are
suspended there between. The first pair of heater contacts may
further comprise a formed shape that comprises a tab having a
flexible spring value that extends out of the heater to couple to
complete a circuit with the device body. The first pair of heater
contacts may be a heat sink that absorbs and dissipates excessive
heat produced by the resistive heating element. The first pair of
heater contacts may contact a heat shield that protects the heater
chamber from excessive heat produced by the resistive heating
element. The first pair of heater contacts may be press-fit to an
attachment feature on the exterior wall of the first end of the
cartridge. The heater may enclose a first end of the cartridge and
a first end of the fluid storage compartment. The heater may
comprise a first condensation chamber. The heater may comprise more
than one first condensation chamber. The first condensation chamber
may be formed along an exterior wall of the cartridge. The
cartridge may further comprise a mouthpiece. The mouthpiece may be
attached to a second end of the cartridge. The mouthpiece may
comprise a second condensation chamber. The mouthpiece may comprise
more than one second condensation chamber. The second condensation
chamber may be formed along an exterior wall of the cartridge.
[0046] The cartridge may comprise a first condensation chamber and
a second condensation chamber. The first condensation chamber and
the second condensation chamber may be in fluid communication. The
mouthpiece may comprise an aerosol outlet in fluid communication
with the second condensation chamber. The mouthpiece may comprise
more than one aerosol outlet in fluid communication with more than
one the second condensation chamber. The mouthpiece may enclose a
second end of the cartridge and a second end of the fluid storage
compartment.
[0047] The device may comprise an airflow path comprising an air
inlet passage, a second air passage, a heater chamber, a first
condensation chamber, a second condensation chamber, and an aerosol
outlet. The airflow path may comprise more than one air inlet
passage, a heater chamber, more than one first condensation
chamber, more than one second condensation chamber, more than one
second condensation chamber, and more than one aerosol outlet. The
heater may be in fluid communication with the fluid storage
compartment. The fluid storage compartment may be capable of
retaining condensed aerosol fluid. The condensed aerosol fluid may
comprise a nicotine formulation. The condensed aerosol fluid may
comprise a humectant. The humectant may comprise propylene glycol.
The humectant may comprise vegetable glycerin.
[0048] The cartridge may be detachable. The cartridge may be
receptacle and the detachable cartridge forms a separable coupling.
The separable coupling may comprise a friction assembly, a snap-fit
assembly or a magnetic assembly. The cartridge may comprise a fluid
storage compartment, a heater affixed to a first end with a
snap-fit coupling, and a mouthpiece affixed to a second end with a
snap-fit coupling.
[0049] A device for generating an inhalable aerosol may comprise: a
device body comprising a cartridge receptacle for receiving a
cartridge; wherein an interior surface of the cartridge receptacle
forms a first side of an air inlet passage when a cartridge
comprising a channel integral to an exterior surface is inserted
into the cartridge receptacle, and wherein the channel forms a
second side of the air inlet passage.
[0050] A device for generating an inhalable aerosol may comprise: a
device body comprising a cartridge receptacle for receiving a
cartridge; wherein the cartridge receptacle comprises a channel
integral to an interior surface and forms a first side of an air
inlet passage when a cartridge is inserted into the cartridge
receptacle, and wherein an exterior surface of the cartridge forms
a second side of the air inlet passage.
[0051] A cartridge for a device for generating an inhalable aerosol
may include: a fluid storage compartment; a channel integral to an
exterior surface, wherein the channel forms a first side of an air
inlet passage; and wherein an internal surface of a cartridge
receptacle in the device forms a second side of the air inlet
passage when the cartridge is inserted into the cartridge
receptacle.
[0052] A cartridge for a device for generating an inhalable aerosol
may comprise: a fluid storage compartment, wherein an exterior
surface of the cartridge forms a first side of an air inlet channel
when inserted into a device body comprising a cartridge receptacle,
and wherein the cartridge receptacle further comprises a channel
integral to an interior surface, and wherein the channel forms a
second side of the air inlet passage.
[0053] The cartridge may further comprise a second air passage in
fluid communication with the channel, wherein the second air
passage is formed through the material of the cartridge from an
exterior surface of the cartridge to the fluid storage
compartment.
[0054] The cartridge may comprise at least one of: a groove, a
trough, a depression, a dent, a furrow, a trench, a crease, and a
gutter. The integral channel may comprise walls that are either
recessed into the surface or protrude from the surface where it is
formed. The internal side walls of the channel may form additional
sides of the air inlet passage.
[0055] A device for generating an inhalable aerosol may comprise: a
cartridge comprising; a fluid storage compartment; a heater affixed
to a first end comprising; a first heater contact, a resistive
heating element affixed to the first heater contact; a device body
comprising; a cartridge receptacle for receiving the cartridge; a
second heater contact adapted to receive the first heater contact
and to complete a circuit; a power source connected to the second
heater contact; a printed circuit board (PCB) connected to the
power source and the second heater contact; wherein the PCB is
configured to detect the absence of fluid based on the measured
resistance of the resistive heating element, and turn off the
device.
[0056] The printed circuit board (PCB) may comprise a
microcontroller; switches; circuitry comprising a reference
resister; and an algorithm comprising logic for control parameters;
wherein the microcontroller cycles the switches at fixed intervals
to measure the resistance of the resistive heating element relative
to the reference resistor, and applies the algorithm control
parameters to control the temperature of the resistive heating
element.
[0057] The micro-controller may instruct the device to turn itself
off when the resistance exceeds the control parameter threshold
indicating that the resistive heating element is dry.
[0058] A cartridge for a device for generating an inhalable aerosol
may comprise: a fluid storage compartment; a heater affixed to a
first end comprising: a heater chamber, a first pair of heater
contacts, a fluid wick, and a resistive heating element in contact
with the wick; wherein the first pair of heater contacts comprise
thin plates affixed about the sides of the heater chamber, and
wherein the fluid wick and resistive heating element are suspended
there between.
[0059] The first pair of heater contacts may further comprise: a
formed shape that comprises a tab having a flexible spring value
that extends out of the heater to complete a circuit with the
device body. The heater contacts may be configured to mate with a
second pair of heater contacts in a cartridge receptacle of the
device body to complete a circuit. The first pair of heater
contacts may also be a heat sink that absorbs and dissipates
excessive heat produced by the resistive heating element. The first
pair of heater contacts may be a heat shield that protect the
heater chamber from excessive heat produced by the resistive
heating element.
[0060] A cartridge for a device for generating an inhalable aerosol
may comprise: a heater comprising; a heater chamber, a pair of thin
plate heater contacts therein, a fluid wick positioned between the
heater contacts, and a resistive heating element in contact with
the wick; wherein the heater contacts each comprise a fixation site
wherein the resistive heating element is tensioned
therebetween.
[0061] A cartridge for a device for generating an inhalable aerosol
may comprise a heater, wherein the heater is attached to a first
end of the cartridge.
[0062] The heater may enclose a first end of the cartridge and a
first end of the fluid storage compartment. The heater may comprise
more than one first condensation chamber. The heater may comprise a
first condensation chamber. The condensation chamber may be formed
along an exterior wall of the cartridge.
[0063] A cartridge for a device for generating an inhalable aerosol
may comprise a fluid storage compartment; and a mouthpiece, wherein
the mouthpiece is attached to a second end of the cartridge.
[0064] The mouthpiece may enclose a second end of the cartridge and
a second end of the fluid storage compartment. The mouthpiece may
comprise a second condensation chamber. The mouthpiece may comprise
more than one second condensation chamber. The second condensation
chamber may be formed along an exterior wall of the cartridge.
[0065] A cartridge for a device for generating an inhalable aerosol
may comprise: a fluid storage compartment; a heater affixed to a
first end; and a mouthpiece affixed to a second end; wherein the
heater comprises a first condensation chamber and the mouthpiece
comprises a second condensation chamber.
[0066] The heater may comprise more than one first condensation
chamber and the mouthpiece comprises more than one second
condensation chamber. The first condensation chamber and the second
condensation chamber may be in fluid communication. The mouthpiece
may comprise an aerosol outlet in fluid communication with the
second condensation chamber. The mouthpiece may comprise two to
more aerosol outlets. The cartridge may meet ISO recycling
standards. The cartridge may meet ISO recycling standards for
plastic waste.
[0067] A device for generating an inhalable aerosol may comprise: a
device body comprising a cartridge receptacle; and a detachable
cartridge; wherein the cartridge receptacle and the detachable
cartridge form a separable coupling, wherein the separable coupling
comprises a friction assembly, a snap-fit assembly or a magnetic
assembly.
[0068] A method of fabricating a device for generating an inhalable
aerosol may comprise: providing a device body comprising a
cartridge receptacle; and providing a detachable cartridge; wherein
the cartridge receptacle and the detachable cartridge form a
separable coupling comprising a friction assembly, a snap-fit
assembly or a magnetic assembly.
[0069] A method of fabricating a cartridge for a device for
generating an inhalable aerosol may comprise: providing a fluid
storage compartment; affixing a heater to a first end with a
snap-fit coupling; and affixing a mouthpiece to a second end with a
snap-fit coupling.
[0070] A cartridge for a device for generating an inhalable aerosol
with an airflow path may include: a channel comprising a portion of
an air inlet passage; a second air passage in fluid communication
with the channel; a heater chamber in fluid communication with the
second air passage; a first condensation chamber in fluid
communication with the heater chamber; a second condensation
chamber in fluid communication with the first condensation chamber;
and an aerosol outlet in fluid communication with second
condensation chamber.
[0071] A cartridge for a device for generating an inhalable aerosol
may comprise: a fluid storage compartment; a heater affixed to a
first end; and a mouthpiece affixed to a second end; wherein said
mouthpiece comprises two or more aerosol outlets.
[0072] A system for providing power to an electronic device for
generating an inhalable vapor may comprise; a rechargeable power
storage device housed within the electronic device for generating
an inhalable vapor; two or more pins that are accessible from an
exterior surface of the electronic device for generating an
inhalable vapor, wherein the charging pins are in electrical
communication with the rechargeable power storage device; a
charging cradle comprising two or more charging contacts configured
to provided power to the rechargeable storage device, wherein the
device charging pins are reversible such that the device is charged
in the charging cradle for charging with a first charging pin on
the device in contact a first charging contact on the charging
cradle and a second charging pin on the device in contact with
second charging contact on the charging cradle and with the first
charging pin on the device in contact with second charging contact
on the charging cradle and the second charging pin on the device in
contact with the first charging contact on the charging cradle.
[0073] The charging pins may be visible on an exterior housing of
the device. The user may permanently disable the device by opening
the housing. The user may permanently destroy the device by opening
the housing.
[0074] Additional aspects and advantages of the present disclosure
will become readily apparent to those skilled in this art from the
following detailed description, wherein only illustrative
embodiments of the present disclosure are shown and described. As
will be realized, the present disclosure is capable of other and
different embodiments, and its several details are capable of
modifications in various obvious respects, all without departing
from the disclosure. Accordingly, the drawings and description are
to be regarded as illustrative in nature, and not as
restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] FIG. 1 is an illustrative cross-sectional view of an
exemplary vaporization device.
[0076] FIG. 2 is an illustrative cross-sectional view of an
exemplary vaporization device with various electronic features and
valves.
[0077] FIG. 3 is an illustrative sectional view of another
exemplary vaporization device comprising a condensation chamber,
air inlet and aeration vent in the mouthpiece.
[0078] FIGS. 4A-4C is an illustrative example of an oven section of
another exemplary vaporization device configuration with an access
lid, comprising an oven having an air inlet, air outlet, and an
additional aeration vent in the airflow pathway, after the
oven.
[0079] FIG. 5 is an illustrative isometric view of an assembled
inhalable aerosol device.
[0080] FIGS. 6A-6D are illustrative arrangements and section views
of the device body and sub-components.
[0081] FIG. 7A is an illustrative isometric view of an assembled
cartridge.
[0082] FIG. 7B is an illustrative exploded isometric view of a
cartridge assembly
[0083] FIG. 7C is a side section view of FIG. 3A illustrating the
inlet channel, inlet hole and relative placement of the wick,
resistive heating element, and heater contacts, and the heater
chamber inside of the heater.
[0084] FIG. 8A is an illustrative end section view of an exemplary
cartridge inside the heater.
[0085] FIG. 8B is an illustrative side view of the cartridge with
the cap removed and heater shown in shadow/outline.
[0086] FIG. 9 is an illustrative sequence of the assembly method
for the cartridge.
[0087] FIGS. 10A-10C are illustrative sequences showing the
airflow/vapor path for the cartridge.
[0088] FIGS. 11-13 represent an illustrative assembly sequence for
assembling the main components of the device.
[0089] FIG. 14 illustrates front, side and section views of the
assembled inhalable aerosol device.
[0090] FIG. 15 is an illustrative view of an activated, assembled
inhalable aerosol device.
[0091] FIGS. 16A-16C are representative illustrations of a charging
device for the aerosol device and the application of the charger
with the device.
[0092] FIGS. 17A and 17B are representative illustrations of a
proportional-integral-derivative controller (PID) block diagram and
circuit diagram representing the essential components in a device
to control coil temperature.
[0093] FIG. 18 is a device with charging contacts visible from an
exterior housing of the device.
[0094] FIG. 19 is an exploded view of a charging assembly of a
device.
[0095] FIG. 20 is a detailed view of a charging assembly of a
device.
[0096] FIG. 21 is a detailed view of charging pins in a charging
assembly of a device.
[0097] FIG. 22 is a device in a charging cradle.
[0098] FIG. 23 is a circuit provided on a PCB configured to permit
a device to comprise reversible charging contacts.
[0099] FIGS. 24A-24D illustrate schematics for one variation of a
pressure sensor that may be used with any of the apparatuses
described herein. FIGS. 24A-24C show dimensional drawings of the
bottom, side and top, respectively, while FIG. 24D shows a section
through the structure. In some variations pins may replace the
solder pads labeled "gate" and "ground" in FIG. 24C.
[0100] FIG. 25 is a sectional view of a schematic illustration
through one variation of a vaporizer device as described herein,
showing an air path through the device.
[0101] FIG. 26 is a graph illustrating draw detection using an
apparatus as described herein, illustrating tracking of multiple
draws.
[0102] FIG. 27 is a graph illustrating blow detection (and
rejection) and draw detection using an apparatus as described
herein.
DETAILED DESCRIPTION
[0103] Provided herein are systems and methods for generating a
vapor from a material. The vapor may be delivered for inhalation by
a user. The material may be a solid, liquid, powder, solution,
paste, gel, or any a material with any other physical consistency.
The vapor may be delivered to the user for inhalation by a
vaporization device. The vaporization device may be a handheld
vaporization device. The vaporization device may be held in one
hand by the user.
[0104] The vaporization device may comprise one or more heating
elements the heating element may be a resistive heating element.
The heating element may heat the material such that the temperature
of the material increases. Vapor may be generated as a result of
heating the material. Energy may be required to operate the heating
element, the energy may be derived from a battery in electrical
communication with the heating element. Alternatively a chemical
reaction (e.g., combustion or other exothermic reaction) may
provide energy to the heating element.
[0105] One or more aspects of the vaporization device may be
designed and/or controlled in order to deliver a vapor with one or
more specified properties to the user. For example, aspects of the
vaporization device that may be designed and/or controlled to
deliver the vapor with specified properties may comprise the
heating temperature, heating mechanism, device air inlets, internal
volume of the device, and/or composition of the material.
[0106] In some cases, a vaporization device may have an "atomizer"
or "cartomizer" configured to heat an aerosol forming solution
(e.g., vaporizable material). The aerosol forming solution may
comprise glycerin and/or propylene glycol. The vaporizable material
may be heated to a sufficient temperature such that it may
vaporize.
[0107] An atomizer may be a device or system configured to generate
an aerosol. The atomizer may comprise a small heating element
configured to heat and/or vaporize at least a portion of the
vaporizable material and a wicking material that may draw a liquid
vaporizable material in to the atomizer. The wicking material may
comprise silica fibers, cotton, ceramic, hemp, stainless steel
mesh, and/or rope cables. The wicking material may be configured to
draw the liquid vaporizable material in to the atomizer without a
pump or other mechanical moving part. A resistance wire may be
wrapped around the wicking material and then connected to a
positive and negative pole of a current source (e.g., energy
source). The resistance wire may be a coil. When the resistance
wire is activated the resistance wire (or coil) may have a
temperature increase as a result of the current flowing through the
resistive wire to generate heat. The heat may be transferred to at
least a portion of the vaporizable material through conductive,
convective, and/or radiative heat transfer such that at least a
portion of the vaporizable material vaporizes.
[0108] Alternatively or in addition to the atomizer, the
vaporization device may comprise a "cartomizer" to generate an
aerosol from the vaporizable material for inhalation by the user.
The cartomizer may comprise a cartridge and an atomizer. The
cartomizer may comprise a heating element surrounded by a
liquid-soaked poly-foam that acts as holder for the vaporiable
material (e.g., the liquid). The cartomizer may be reusable,
rebuildable, refillable, and/or disposable. The cartomizer may be
used with a tank for extra storage of a vaporizable material.
[0109] Air may be drawn into the vaporization device to carry the
vaporized aerosol away from the heating element, where it then
cools and condenses to form liquid particles suspended in air,
which may then be drawn out of the mouthpiece by the user.
[0110] The vaporization of at least a portion of the vaporizable
material may occur at lower temperatures in the vaporization device
compared to temperatures required to generate an inhalable vapor in
a cigarette. A cigarette may be a device in which a smokable
material is burned to generate an inhalable vapor. The lower
temperature of the vaporization device may result in less
decomposition and/or reaction of the vaporized material, and
therefore produce an aerosol with many fewer chemical components
compared to a cigarette. In some cases, the vaporization device may
generate an aerosol with fewer chemical components that may be
harmful to human health compared to a cigarette. Additionally, the
vaporization device aerosol particles may undergo nearly complete
evaporation in the heating process, the nearly complete evaporation
may yield an average particle size (e.g., diameter) value that may
be smaller than the average particle size in tobacco or botanical
based effluent.
[0111] A vaporization device may be a device configured to extract
for inhalation one or more active ingredients of plant material,
tobacco, and/or a botanical, or other herbs or blends. A
vaporization device may be used with pure chemicals and/or
humectants that may or may not be mixed with plant material.
Vaporization may be alternative to burning (smoking) that may avoid
the inhalation of many irritating and/or toxic carcinogenic
by-products which may result from the pyrolytic process of burning
tobacco or botanical products above 300.degree. C. The vaporization
device may operate at a temperature at or below 300.degree. C.
[0112] A vaporizer (e.g., vaporization device) may not have an
atomizer or cartomizer. Instead the device may comprise an oven.
The oven may be at least partially closed. The oven may have a
closable opening. The oven may be wrapped with a heating element,
alternatively the heating element may be in thermal communication
with the oven through another mechanism. A vaporizable material may
be placed directly in the oven or in a cartridge fitted in the
oven. The heating element in thermal communication with the oven
may heat a vaporizable material mass in order to create a gas phase
vapor. The heating element may heat the vaporizable material
through conductive, convective, and/or radiative heat transfer. The
vapor may be released to a vaporization chamber where the gas phase
vapor may condense, forming an aerosol cloud having typical liquid
vapor particles with particles having a diameter of average mass of
approximately 1 micron or greater. In some cases the diameter of
average mass may be approximately 0.1-1 micron.
[0113] A used herein, the term "vapor" may generally refer to a
substance in the gas phase at a temperature lower than its critical
point. The vapor may be condensed to a liquid or to a solid by
increasing its pressure without reducing the temperature.
[0114] As used herein, the term "aerosol" may generally refer to a
colloid of fine solid particles or liquid droplets in air or
another gas. Examples of aerosols may include clouds, haze, and
smoke, including the smoke from tobacco or botanical products. The
liquid or solid particles in an aerosol may have varying diameters
of average mass that may range from monodisperse aerosols,
producible in the laboratory, and containing particles of uniform
size; to polydisperse colloidal systems, exhibiting a range of
particle sizes. As the sizes of these particles become larger, they
have a greater settling speed which causes them to settle out of
the aerosol faster, making the appearance of the aerosol less dense
and to shorten the time in which the aerosol will linger in air.
Interestingly, an aerosol with smaller particles will appear
thicker or denser because it has more particles. Particle number
has a much bigger impact on light scattering than particle size (at
least for the considered ranges of particle size), thus allowing
for a vapor cloud with many more smaller particles to appear denser
than a cloud having fewer, but larger particle sizes.
[0115] As used herein the term "humectant" may generally refer to
as a substance that is used to keep things moist. A humectant may
attract and retain moisture in the air by absorption, allowing the
water to be used by other substances. Humectants are also commonly
used in many tobaccos or botanicals and electronic vaporization
products to keep products moist and as vapor-forming medium.
Examples include propylene glycol, sugar polyols such as glycerol,
glycerin, and honey.
[0116] Rapid Aeration
[0117] In some cases, the vaporization device may be configured to
deliver an aerosol with a high particle density. The particle
density of the aerosol may refer to the number of the aerosol
droplets relative to the volume of air (or other dry gas) between
the aerosol droplets. A dense aerosol may easily be visible to a
user. In some cases the user may inhale the aerosol and at least a
fraction of the aerosol particles may impinge on the lungs and/or
mouth of the user. The user may exhale residual aerosol after
inhaling the aerosol. When the aerosol is dense the residual
aerosol may have sufficient particle density such that the exhaled
aerosol is visible to the user. In some cases, a user may prefer
the visual effect and/or mouth feel of a dense aerosol.
[0118] A vaporization device may comprise a vaporizable material.
The vaporizable material may be contained in a cartridge or the
vaporizable material may be loosely placed in one or more cavities
the vaporization device. A heating element may be provided in the
device to elevate the temperature of the vaporizable material such
that at least a portion of the vaporizable material forms a vapor.
The heating element may heat the vaporizable material by convective
heat transfer, conductive heat transfer, and/or radiative heat
transfer. The heating element may heat the cartridge and/or the
cavity in which the vaporizable material is stored.
[0119] Vapor formed upon heating the vaporizable material may be
delivered to the user. The vapor may be transported through the
device from a first position in the device to a second position in
the device. In some cases, the first position may be a location
where at least a portion of the vapor was generated, for example,
the cartridge or cavity or an area adjacent to the cartridge or
cavity. The second position may be a mouthpiece. The user may suck
on the mouthpiece to inhale the vapor.
[0120] At least a fraction of the vapor may condense after the
vapor is generated and before the vapor is inhaled by the user. The
vapor may condense in a condensation chamber. The condensation
chamber may be a portion of the device that the vapor passes
through before delivery to the user. In some cases, the device may
include at least one aeration vent, placed in the condensation
chamber of the vaporization device. The aeration vent may be
configured to introduce ambient air (or other gas) into the
vaporization chamber. The air introduced into the vaporization
chamber may have a temperature lower than the temperature of a gas
and/or gas/vapor mixture in the condensation chamber. Introduction
of the relatively lower temperature gas into the vaporization
chamber may provide rapid cooling of the heated gas vapor mixture
that was generated by heating the vaporizable material. Rapid
cooling of the gas vapor mixture may generate a dense aerosol
comprising a high concentration of liquid droplets having a smaller
diameter and/or smaller average mass compared to an aerosol that is
not rapidly cooled prior to inhalation by the user.
[0121] An aerosol with a high concentration of liquid droplets
having a smaller diameter and/or smaller average mass compared to
an aerosol that is not rapidly cooled prior to inhalation by the
user may be formed in a two-step process. The first step may occur
in the oven chamber where the vaporizable material (e.g., tobacco
and/or botanical and humectant blend) may be heated to an elevated
temperature. At the elevated temperature, evaporation may happen
faster than at room temperature and the oven chamber may fill with
the vapor phase of the humectants. The humectant may continue to
evaporate until the partial pressure of the humectant is equal to
the saturation pressure. At this point, the gas is said to have a
saturation ratio of 1 (S=Ppartial/Psat).
[0122] In the second step, the gas (e.g., vapor and air) may exit
the oven and enter a condenser or condensation chamber and begin to
cool. As the gas phase vapor cools, the saturation pressure may
decrease. As the saturation pressure decreases, the saturation
ratio may increase and the vapor may begin to condense, forming
droplets. In some devices, with the absence of added cooling
aeration, the cooling may be relatively slower such that high
saturation pressures may not be reached, and the droplets that form
in the devices without added cooling aeration may be relatively
larger and fewer in numbers. When cooler air is introduced, a
temperature gradient may be formed between the cooler air and the
relatively warmer gas in the device. Mixing between the cooler air
and the relatively warmer gas in a confined space inside of the
vaporization device may lead to rapid cooling. The rapid cooling
may generate high saturation ratios, small particles, and high
concentrations of smaller particles, forming a thicker, denser
vapor cloud compared to particles generated in a device without the
aeration vents.
[0123] For the purpose of this disclosure, when referring to ratios
of humectants such as vegetable glycerol or propylene glycol,
"about" means a variation of 5%, 10%, 20% or 25% depending on the
embodiment.
[0124] For the purpose of this disclosure, when referring to a
diameter of average mass in particle sizes, "about" means a
variation of 5%, 10%, 20% or 25% depending on the embodiment.
[0125] A vaporization device configured to rapidly cool a vapor may
comprise: a mouthpiece comprising an aerosol outlet at a first end
of the device; an oven comprising an oven chamber and a heater for
heating a vapor forming medium in the oven chamber and for forming
a vapor therein; a condenser comprising a condensation chamber in
which the vapor forms the inhalable aerosol; an air inlet that
originates a first airflow path that includes the oven chamber and
then the condensation chamber, an aeration vent that originates a
second airflow path that joins the first airflow path prior to or
within the condensation chamber after the vapor is formed in the
oven chamber, wherein the joined first airflow path and second
airflow path are configured to deliver the inhalable aerosol formed
in the condensation chamber through the aerosol outlet of the
mouthpiece to a user.
[0126] In some embodiments, the oven is within a body of the
device. The oven chamber may comprise an oven chamber inlet and an
oven chamber outlet. The oven may further comprise a first valve at
the oven chamber inlet, and a second valve at the oven chamber
outlet.
[0127] The oven may be contained within a device housing. In some
cases the body of the device may comprise the aeration vent and/or
the condenser. The body of the device may comprise one or more air
inlets. The body of the device may comprise a housing that holds
and/or at least partially contains one or more elements of the
device.
[0128] The mouthpiece may be connected to the body. The mouthpiece
may be connected to the oven. The mouthpiece may be connected to a
housing that at least partially encloses the oven. In some cases,
the mouthpiece may be separable from the oven, the body, and/or the
housing that at least partially encloses the oven. The mouthpiece
may comprise at least one of the air inlet, the aeration vent, and
the condenser. The mouthpiece may be integral to the body of the
device. The body of the device may comprise the oven.
[0129] In some cases, the one or more aeration vents may comprise a
valve. The valve may regulate a flow rate of air entering the
device through the aeration vent. The valve may be controlled
through a mechanical and/or electrical control system.
[0130] A vaporization device configured to rapidly cool a vapor may
comprise: a body, a mouthpiece, an aerosol outlet, a condenser with
a condensation chamber, a heater, an oven with an oven chamber, a
primary airflow inlet, and at least one aeration vent provided in
the body, downstream of the oven, and upstream of the
mouthpiece.
[0131] FIG. 1 shows an example of a vaporization device configured
to rapidly cool a vapor. The device 100, may comprise a body 101.
The body may house and/or integrate with one or more components of
the device. The body may house and/or integrate with a mouthpiece
102. The mouthpiece 102 may have an aerosol outlet 122. A user may
inhale the generated aerosol through the aerosol outlet 122 on the
mouthpiece 102. The body may house and/or integrate with an oven
region 104. The oven region 104 may comprise an oven chamber where
vapor forming medium 106 may be placed. The vapor forming medium
may include tobacco and/or botanicals, with or without a secondary
humectant. In some cases the vapor forming medium may be contained
in a removable and/or refillable cartridge.
[0132] Air may be drawn into the device through a primary air inlet
121. The primary air inlet 121 may be on an end of the device 100
opposite the mouthpiece 102. Alternatively, the primary air inlet
121 may be adjacent to the mouthpiece 102. In some cases, a
pressure drop sufficient to pull air into the device through the
primary air inlet 121 may be due to a user puffing on the
mouthpiece 102.
[0133] The vapor forming medium (e.g., vaporizable material) may be
heated in the oven chamber by a heater 105, to generate elevated
temperature gas phases (vapor) of the tobacco or botanical and
humectant/vapor forming components. The heater 105 may transfer
heat to the vapor forming medium through conductive, convective,
and/or radiative heat transfer. The generated vapor may be drawn
out of the oven region and into the condensation chamber 103a, of
the condenser 103 where the vapors may begin to cool and condense
into micro-particles or droplets suspended in air, thus creating
the initial formation of an aerosol, before being drawn out of the
mouthpiece through the aerosol outlet 122.
[0134] In some cases, relatively cooler air may be introduced into
the condensation chamber 103a, through an aeration vent 107 such
that the vapor condenses more rapidly compared to a vapor in a
device without the aeration vent 107. Rapidly cooling the vapor may
create a denser aerosol cloud having particles with a diameter of
average mass of less than or equal to about 1 micron, and depending
on the mixture ratio of the vapor-forming humectant, particles with
a diameter of average mass of less than or equal to about 0.5
micron
[0135] Also described herein are devices for generating an
inhalable aerosol said device comprising a body with a mouthpiece
at one end, an attached body at the other end comprising a
condensation chamber, a heater, an oven, wherein the oven comprises
a first valve in the airflow path at the primary airflow inlet of
the oven chamber, and a second valve at the outlet end of the oven
chamber, and at least one aeration vent provided in the body,
downstream of the oven, and upstream of the mouthpiece.
[0136] FIG. 2 shows a diagram of an alternative embodiment of the
vaporization device 200. The vaporization device may have a body
201. The body 201 may integrate with and/or contain one or more
components of the device. The body may integrate with or be
connected to a mouthpiece 202
[0137] The body may comprise an oven region 204, with an oven
chamber 204a having a first constricting valve 208 in the primary
air inlet of the oven chamber and a second constricting valve 209
at the oven chamber outlet. The oven chamber 204a may be sealed
with a tobacco or botanical and/or humectant/vapor forming medium
206 therein. The seal may be an air tight and/or liquid tight seal.
The heater may be provided to the oven chamber with a heater 205.
The heater 205 may be in thermal communication with the oven, for
example the heater may be surrounding the oven chamber during the
vaporization process. Heater may contact the oven. The heater may
be wrapped around the oven. Before inhalation and before air is
drawn in through a primary air inlet 221, pressure may build in the
sealed oven chamber as heat is continually added. The pressure may
build due to a phase change of the vaporizable material. Elevated
temperature gas phases (vapor) of the tobacco or botanical and
humectant/vapor forming components may be achieved by continually
adding heat to the oven. This heated pressurization process may
generate even higher saturation ratios when the valves 208, 209 are
opened during inhalation. The higher saturation ratios may cause
relatively higher particle concentrations of gas phase humectant in
the resultant aerosol. When the vapor is drawn out of the oven
region and into the condensation chamber 203a of the condenser 203,
for example by inhalation by the user, the gas phase humectant
vapors may be exposed to additional air through an aeration vent
207, and the vapors may begin to cool and condense into droplets
suspended in air. As described previously the aerosol may be drawn
through the mouthpiece 222 by the user. This condensation process
may be further refined by adding an additional valve 210, to the
aeration vent 207 to further control the air-vapor mixture
process.
[0138] FIG. 2 also illustrates an exemplary embodiment of the
additional components which would be found in a vaporizing device,
including a power source or battery 211, a printed circuit board
212, a temperature regulator 213, and operational switches (not
shown), housed within an internal electronics housing 214, to
isolate them from the damaging effects of the moisture in the vapor
and/or aerosol. The additional components may be found in a
vaporizing device that may or may not comprise an aeration vent as
described above.
[0139] In some embodiments of the vaporization device, components
of the device are user serviceable, such as the power source or
battery. These components may be replaceable or rechargeable.
[0140] Also described herein are devices for generating an
inhalable aerosol said device comprising a first body, a mouthpiece
having an aerosol outlet, a condensation chamber within a condenser
and an airflow inlet and channel, an attached second body,
comprising a heater and oven with an oven chamber, wherein said
airflow channel is upstream of the oven and the mouthpiece outlet
to provide airflow through the device, across the oven, and into
the condensation chamber where an auxiliary aeration vent is
provided.
[0141] FIG. 3 shows a section view of a vaporization device 300.
The device 300 may comprise a body 301. The body may be connected
to or integral with a mouthpiece 302 at one end. The mouthpiece may
comprise a condensation chamber 303a within a condenser section 303
and an airflow inlet 321 and air channel 323. The device body may
comprise a proximally located oven 304 comprising an oven chamber
304a. The oven chamber may be in the body of the device. A vapor
forming medium 306 (e.g., vaporizable material) comprising tobacco
or botanical and humectant vapor forming medium may be placed in
the oven. The vapor forming medium may be in direct contact with an
air channel 323 from the mouthpiece. The tobacco or botanical may
be heated by heater 305 surrounding the oven chamber, to generate
elevated temperature gas phases (vapor) of the tobacco or botanical
and humectant/vapor forming components and air drawn in through a
primary air inlet 321, across the oven, and into the condensation
chamber 303a of the condenser region 303 due to a user puffing on
the mouthpiece. Once in the condensation chamber where the gas
phase humectant vapors begin to cool and condense into droplets
suspended in air, additional air is allowed to enter through
aeration vent 307, thus, once again creating a denser aerosol cloud
having particles with a diameter of average mass of less than a
typical vaporization device without an added aeration vent, before
being drawn out of the mouthpiece through the aerosol outlet
322.
[0142] The device may comprises a mouthpiece comprising an aerosol
outlet at a first end of the device and an air inlet that
originates a first airflow path; an oven comprising an oven chamber
that is in the first airflow path and includes the oven chamber and
a heater for heating a vapor forming medium in the oven chamber and
for forming a vapor therein, a condenser comprising a condensation
chamber in which the vapor forms the inhalable aerosol, an aeration
vent that originates a second airflow path that allows air from the
aeration vent to join the first airflow path prior to or within the
condensation chamber and downstream from the oven chamber thereby
forming a joined path, wherein the joined path is configured to
deliver the inhalable aerosol formed in the condensation chamber
through the aerosol outlet of the mouthpiece to a user.
[0143] The device may comprise a mouthpiece comprising an aerosol
outlet at a first end of the device, an air inlet that originates a
first airflow path, and an aeration vent that originates a second
airflow path that allows air from the aeration vent to join the
first airflow path; an oven comprising an oven chamber that is in
the first airflow path and includes the oven chamber and a heater
for heating a vapor forming medium in the oven chamber and for
forming a vapor therein, a condenser comprising a condensation
chamber in which the vapor forms the inhalable aerosol and wherein
air from the aeration vent joins the first airflow path prior to or
within the condensation chamber and downstream from the oven
chamber thereby forming a joined path, wherein the joined path is
configured to deliver the inhalable aerosol through the aerosol
outlet of the mouthpiece to a user, as illustrated in exemplary
FIG. 3.
[0144] The device may comprise a body with one or more separable
components. For example, the mouthpiece may be separably attached
to the body comprising the condensation chamber, a heater, and an
oven, as illustrated in exemplary FIG. 1 or 2.
[0145] The device may comprise a body with one or more separable
components. For example, the mouthpiece may be separably attached
to the body. The mouthpiece may comprise the condensation chamber,
and may be attached to or immediately adjacent to the oven and
which is separable from the body comprising a heater, and the oven,
as illustrated in exemplary FIG. 3.
[0146] The at least one aeration vent may be located in the
condensation chamber of the condenser, as illustrated in exemplary
FIG. 1, 2, or 3. The at least one aeration vent may comprise a
third valve in the airflow path of the at least one aeration vent,
as illustrated in exemplary FIG. 2. The first, second and third
valve is a check valve, a clack valve, a non-return valve, or a
one-way valve. In any of the preceding variations, the first,
second or third valve may be mechanically actuated, electronically
actuated or manually actuated. One skilled in the art will
recognize after reading this disclosure that this device may be
modified in a way such that any one, or each of these openings or
vents could be configured to have a different combination or
variation of mechanisms as described to control airflow, pressure
and temperature of the vapor created and aerosol being generated by
these device configurations, including a manually operated opening
or vent with or without a valve.
[0147] The device may further comprise at least one of: a power
source, a printed circuit board, a switch, and a temperature
regulator. Alternately, one skilled in the art would recognize that
each configuration previously described will also accommodate said
power source (battery), switch, printed circuit board, or
temperature regulator as appropriate, in the body.
[0148] The device may be disposable when the supply of pre-packaged
aerosol-forming media is exhausted. Alternatively, the device may
be rechargeable such that the battery may be rechargeable or
replaceable, and /or the aerosol-forming media may be refilled, by
the user/operator of the device. Still further, the device may be
rechargeable such that the battery may be rechargeable or
replaceable, and/or the operator may also add or refill a tobacco
or botanical component, in addition to a refillable or replaceable
aerosol-forming media to the device.
[0149] As illustrated in FIG. 1, 2 or 3, the vaporization device
may comprise tobacco or a botanical heated in said oven chamber,
wherein said tobacco or botanical further comprises humectants to
produce an aerosol comprising gas phase components of the humectant
and tobacco or botanical. The gas phase humectant and tobacco or
botanical vapor produced by said heated aerosol forming media 106,
206, 306 may further be mixed with air from a special aeration vent
107, 207, 307 after exiting the oven area 104, 204, 304 and
entering a condensation chamber 103a, 203a, 303a to cool and
condense said gas phase vapors to produce a far denser, thicker
aerosol comprising more particles than would have otherwise been
produced without the extra cooling air, with a diameter of average
mass of less than or equal to about 1 micron.
[0150] Each aerosol configuration produced by mixing the gas phase
vapors with the cool air may comprise a different range of
particles, for example; with a diameter of average mass of less
than or equal to about 0.9 micron; less than or equal to about 0.8
micron; less than or equal to about 0.7 micron; less than or equal
to about 0.6 micron; and even an aerosol comprising particle
diameters of average mass of less than or equal to about 0.5
micron.
[0151] The possible variations and ranges of aerosol density are
great in that the possible number of combinations of temperature,
pressure, tobacco or botanical choices and humectant selections are
numerous. However, by excluding the tobacco or botanical choices
and limiting the temperatures ranges and the humectant ratios to
those described herein, the inventor has demonstrated that this
device will produce a far denser, thicker aerosol comprising more
particles than would have otherwise been produced without the extra
cooling air, with a diameter of average mass of less than or equal
to about 1 micron.
[0152] The humectant may comprise glycerol or vegetable glycerol as
a vapor-forming medium.
[0153] The humectant may comprise propylene glycol as a
vapor-forming medium.
[0154] In preferred embodiments, the humectant may comprise a ratio
of vegetable glycerol to propylene glycol as a vapor-forming
medium. The ranges of said ratio may vary between a ratio of about
100:0 vegetable glycerol to propylene glycol and a ratio of about
50:50 vegetable glycerol to propylene glycol. The difference in
preferred ratios within the above stated range may vary by as
little as 1, for example, said ratio may be about 99:1 vegetable
glycerol to propylene glycol. However, more commonly said ratios
would vary in increments of about 5, for example, about 95:5
vegetable glycerol to propylene glycol; or about 85:15 vegetable
glycerol to propylene glycol; or about 55:45 vegetable glycerol to
propylene glycol.
[0155] In a preferred embodiment the ratio for the vapor forming
medium will be between the ratios of about 80:20 vegetable glycerol
to propylene glycol, and about 60:40 vegetable glycerol to
propylene glycol.
[0156] In a most preferred embodiment, the ratio for the vapor
forming medium will be about 70:30 vegetable glycerol to propylene
glycol.
[0157] In any of the preferred embodiments, the humectant may
further comprise flavoring products. These flavorings may include
enhancers comprising cocoa solids, licorice, tobacco or botanical
extracts, and various sugars, to name but a few.
[0158] The tobacco or botanical may be heated in the oven up to its
pyrolytic temperature, which as noted previously is most commonly
measured in the range of 300-1000.degree. C.
[0159] In preferred embodiments, the tobacco or botanical is heated
to about 300.degree. C. at most. In other preferred embodiments,
the tobacco or botanical is heated to about 200.degree. C. at most.
In still other preferred embodiments, the tobacco or botanical is
heated to about 160.degree. C. at most. It should be noted that in
these lower temperature ranges (<300.degree. C.), pyrolysis of
tobacco or botanical does not typically occur, yet vapor formation
of the tobacco or botanical components and flavoring products does
occur. In addition, vapor formation of the components of the
humectant, mixed at various ratios will also occur, resulting in
nearly complete vaporization, depending on the temperature, since
propylene glycol has a boiling point of about
180.degree.-190.degree. C. and vegetable glycerin will boil at
approximately 280.degree.-290.degree. C.
[0160] In still other preferred embodiments, the aerosol produced
by said heated tobacco or botanical and humectant is mixed with air
provided through an aeration vent.
[0161] In still other preferred embodiments, the aerosol produced
by said heated tobacco or botanical and humectant mixed with air,
is cooled to a temperature of about 50.degree.-70.degree. C. at
most, and even as low as 35.degree. C. before exiting the
mouthpiece, depending on the air temperature being mixed into the
condensation chamber. In some embodiments, the temperature is
cooled to about 35.degree.-55.degree. C. at most, and may have a
fluctuating range of .+-. about 10.degree. C. or more within the
overall range of about 35.degree.-70.degree. C.
[0162] Also described herein are vaporization devices for
generating an inhalable aerosol comprising a unique oven
configuration, wherein said oven comprises an access lid and an
auxiliary aeration vent located within the airflow channel
immediately downstream of the oven and before the aeration chamber.
In this configuration, the user may directly access the oven by
removing the access lid, providing the user with the ability to
recharge the device with vaporization material.
[0163] In addition, having the added aeration vent in the airflow
channel immediately after the oven and ahead of the vaporization
chamber provides the user with added control over the amount of air
entering the aeration chamber downstream and the cooling rate of
the aerosol before it enters the aeration chamber.
[0164] As noted in FIGS. 4A-4C, the device 400 may comprise a body
401, having an air inlet 421 allowing initial air for the heating
process into the oven region 404. After heating the tobacco or
botanical, and humectant (heater not shown), the gas phase
humectant vapor generated may travel down the airflow channel 423,
passing the added aeration vent 407 wherein the user may
selectively increase airflow into the heated vapor. The user may
selectively increase and/or decrease the airflow to the heated
vapor by controlling a valve in communication with the aeration
vent 407. In some cases, the device may not have an aeration vent.
Airflow into the heated vapor through the aeration vent may
decrease the vapor temperature before exiting the airflow channel
at the outlet 422, and increase the condensation rate and vapor
density by decreasing the diameter of the vapor particles within
the aeration chamber (not shown), thus producing a thicker, denser
vapor compared to the vapor generated by a device without the
aeration vent. The user may also access the oven chamber 404a to
recharge or reload the device 400, through an access lid 430
provided therein, making the device user serviceable. The access
lid may he provided on a device with or without an aeration
vent.
[0165] Provided herein is a method for generating an inhalable
aerosol, the method comprising: providing an vaporization device,
wherein said device produces a vapor comprising particle diameters
of average mass of about 1 micron or less, wherein the vapor is
formed by heating a vapor forming medium in an oven chamber of the
device to a first temperature below the pyrolytic temperature of
the vapor forming medium, and cooling the vapor in a condensation
chamber to a temperature below the first temperature, before
exiting an aerosol outlet of said device.
[0166] In some embodiments the vapor may be cooled by mixing
relatively cooler air with the vapor in the condensation chamber
during the condensation phase, after leaving the oven, where
condensation of the gas phase humectants occurs more rapidly due to
high saturation ratios being achieved at the moment of aeration,
producing a higher concentration of smaller particles, with fewer
by-products, in a denser aerosol, than would normally occur in a
standard vaporization or aerosol generating device.
[0167] In some embodiments, formation of an inhalable aerosol is a
two-step process. The first step occurs in the oven where the
tobacco or botanical and humectant blend is heated to an elevated
temperature. At the elevated temperature, evaporation happens
faster than at room temperature and the oven chamber fills with the
vapor phase of the humectants. The humectant will continue to
evaporate until the partial pressure of the humectant is equal to
the saturation pressure. At this point, the gas is said to have a
saturation ratio of 1 (S=Ppartial/Psat).
[0168] In the second step, the gas leaves the oven chamber, passes
to a condensation chamber in a condenser and begins to cool. As the
gas phase vapor cools, the saturation pressure also goes down,
causing the saturation ratio to rise, and the vapor to condensate,
forming droplets. When cooling air is introduced, the large
temperature gradient between the two fluids mixing in a confined
space leads to very rapid cooling, causing high saturation ratios,
small particles, and higher concentrations of smaller particles,
forming a thicker, denser vapor cloud.
[0169] Provided herein is a method for generating an inhalable
aerosol comprising: a vaporization device having a body with a
mouthpiece at one end, and an attached body at the other end
comprising; a condenser with a condensation chamber, a heater, an
oven with an oven chamber, and at least one aeration vent provided
in the body, downstream of the oven, and upstream of the
mouthpiece, wherein tobacco or botanical comprising a humectant is
heated in said oven chamber to produce a vapor comprising gas phase
humectants.
[0170] As previously described, a vaporization device having an
auxiliary aeration vent located in the condensation chamber capable
of supplying cool air (relative to the heated gas components) to
the gas phase vapors and tobacco or botanical components exiting
the oven region, may be utilized to provide a method for generating
a far denser, thicker aerosol comprising more particles than would
have otherwise been produced without the extra cooling air, with a
diameter of average mass of less than or equal to about 1
micron.
[0171] In another aspect, provided herein is a method for
generating an inhalable aerosol comprising: a vaporization device,
having a body with a mouthpiece at one end, and an attached body at
the other end comprising: a condenser with a condensation chamber,
a heater, an oven with an oven chamber, wherein said oven chamber
further comprises a first valve in the airflow path at the inlet
end of the oven chamber, and a second valve at the outlet end of
the oven chamber; and at least one aeration vent provided in said
body, downstream of the oven, and upstream of the mouthpiece
wherein tobacco or botanical comprising a humectant is heated in
said oven chamber to produce a vapor comprising gas phase
humectants.
[0172] As illustrated in exemplary FIG. 2, by sealing the oven
chamber 204a with a tobacco or botanical and humectant vapor
forming medium 206 therein, and applying heat with the heater 205
during the vaporization process, before inhalation and air is drawn
in through a primary air inlet 221, the pressure will build in the
oven chamber as heat is continually added with an electronic
heating circuit generated through the combination of the battery
211, printed circuit board 212, temperature regulator 213, and
operator controlled switches (not shown), to generate even greater
elevated temperature gas phase humectants (vapor) of the tobacco or
botanical and humectant vapor forming components. This heated
pressurization process generates even higher saturation ratios when
the valves 208, 209 are opened during inhalation, which cause
higher particle concentrations in the resultant aerosol, when the
vapor is drawn out of the oven region and into the condensation
chamber 203a, where they are again exposed to additional air
through an aeration vent 207, and the vapors begin to cool and
condense into droplets suspended in air, as described previously
before the aerosol is withdrawn through the mouthpiece 222. The
inventor also notes that this condensation process may be further
refined by adding an additional valve 210, to the aeration vent 207
to further control the air-vapor mixture process.
[0173] In some embodiments of any one of the inventive methods, the
first, second and/or third valve is a one-way valve, a check valve,
a clack valve, or a non-return valve. The first, second and/or
third valve may be mechanically actuated. The first, second and/or
third valve may be electronically actuated. The first, second
and/or third valve may be automatically actuated. The first, second
and/or third valve may be manually actuated either directly by a
user or indirectly in response to an input command from a user to a
control system that actuates the first, second and/or third
valve.
[0174] In other aspects of the inventive methods, said device
further comprises at least one of: a power source, a printed
circuit board, or a temperature regulator.
[0175] In any of the preceding aspects of the inventive method, one
skilled in the art will recognize after reading this disclosure
that this method may be modified in a way such that any one, or
each of these openings or vents could be configured to have a
different combination or variation of mechanisms or electronics as
described to control airflow, pressure and temperature of the vapor
created and aerosol being generated by these device configurations,
including a manually operated opening or vent with or without a
valve.
[0176] The possible variations and ranges of aerosol density are
great in that the possible number of temperature, pressure, tobacco
or botanical choices and humectant selections and combinations are
numerous. However, by excluding the tobacco or botanical choices
and limiting the temperatures to within the ranges and the
humectant ratios described herein, the inventor has demonstrated a
method for generating a far denser, thicker aerosol comprising more
particles than would have otherwise been produced without the extra
cooling air, with a diameter of average mass of less than or equal
to 1 micron.
[0177] In some embodiments of the inventive methods, the humectant
comprises a ratio of vegetable glycerol to propylene glycol as a
vapor-forming medium. The ranges of said ratio will vary between a
ratio of about 100:0 vegetable glycerol to propylene glycol and a
ratio of about 50:50 vegetable glycerol to propylene glycol. The
difference in preferred ratios within the above stated range may
vary by as little as 1, for example, said ratio may be about 99:1
vegetable glycerol to propylene glycol. However, more commonly said
ratios would vary in increments of 5, for example, about 95:5
vegetable glycerol to propylene glycol; or about 85:15 vegetable
glycerol to propylene glycol; or about 55:45 vegetable glycerol to
propylene glycol.
[0178] Because vegetable glycerol is less volatile than propylene
glycol, it will recondense in greater proportions. A humectant with
higher concentrations of glycerol will generate a thicker aerosol.
The addition of propylene glycol will lead to an aerosol with a
reduced concentration of condensed phase particles and an increased
concentration of vapor phase effluent. This vapor phase effluent is
often perceived as a tickle or harshness in the throat when the
aerosol is inhaled. To some consumers, varying degrees of this
sensation may be desirable. The ratio of vegetable glycerol to
propylene glycol may be manipulated to balance aerosol thickness
with the right amount of "throat tickle."
[0179] In a preferred embodiment of the method, the ratio for the
vapor forming medium will be between the ratios of about 80:20
vegetable glycerol to propylene glycol, and about 60:40 vegetable
glycerol to propylene glycol.
[0180] In a most preferred embodiment of the method, the ratio for
the vapor forming medium will be about 70:30 vegetable glycerol to
propylene glycol. On will envision that there will be blends with
varying ratios for consumers with varying preferences.
[0181] In any of the preferred embodiments of the method, the
humectant further comprises flavoring products. These flavorings
include enhancers such as cocoa solids, licorice, tobacco or
botanical extracts, and various sugars, to name a few.
[0182] In some embodiments of the method, the tobacco or botanical
is heated to its pyrolytic temperature.
[0183] In preferred embodiments of the method, the tobacco or
botanical is heated to about 300.degree. C. at most.
[0184] In other preferred embodiments of the method, the tobacco or
botanical is heated to about 200.degree. C. at most. In still other
embodiments of the method, the tobacco or botanical is heated to
about 160.degree. C. at most.
[0185] As noted previously, at these lower temperatures,
(<300.degree. C.), pyrolysis of tobacco or botanical does not
typically occur, yet vapor formation of the tobacco or botanical
components and flavoring products does occur. As may be inferred
from the data supplied by Baker et al., an aerosol produced at
these temperatures is also substantially free from Hoffman analytes
or at least 70% less Hoffman analytes than a common tobacco or
botanical cigarette and scores significantly better on the Ames
test than a substance generated by burning a common cigarette. In
addition, vapor formation of the components of the humectant, mixed
at various ratios will also occur, resulting in nearly complete
vaporization, depending on the temperature, since propylene glycol
has a boiling point of about 180.degree.-190.degree. C. and
vegetable glycerin will boil at approximately
280.degree.-290.degree. C.
[0186] In any one of the preceding methods, said inhalable aerosol
produced by tobacco or a botanical comprising a humectant and
heated in said oven produces an aerosol comprising gas phase
humectants is further mixed with air provided through an aeration
vent.
[0187] In any one of the preceding methods, said aerosol produced
by said heated tobacco or botanical and humectant mixed with air,
is cooled to a temperature of about 50.degree.-70.degree. C., and
even as low as 35.degree. C., before exiting the mouthpiece. In
some embodiments, the temperature is cooled to about
35.degree.-55.degree. C. at most, and may have a fluctuating range
of .+-. about 10.degree. C. or more within the overall range of
about 35.degree.-70.degree. C.
[0188] In some embodiments of the method, the vapor comprising gas
phase humectant may be mixed with air to produce an aerosol
comprising particle diameters of average mass of less than or equal
to about 1 micron.
[0189] In other embodiments of the method, each aerosol
configuration produced by mixing the gas phase vapors with the cool
air may comprise a different range of particles, for example; with
a diameter of average mass of less than or equal to about 0.9
micron; less than or equal to about 0.8 micron; less than or equal
to about 0.7 micron; less than or equal to about 0.6 micron; and
even an aerosol comprising particle diameters of average mass of
less than or equal to about 0.5 micron.
[0190] Cartridge Design and Vapor Generation from Material in
Cartridge
[0191] In some cases, a vaporization device may be configured to
generate an inhalable aerosol. A device may be a self-contained
vaporization device. The device may comprise an elongated body
which functions to complement aspects of a separable and recyclable
cartridge with air inlet channels, air passages, multiple
condensation chambers, flexible heater contacts, and multiple
aerosol outlets. Additionally, the cartridge may be configured for
ease of manufacture and assembly.
[0192] Provided herein is a vaporization device for generating an
inhalable aerosol. The device may comprise a device body, a
separable cartridge assembly further comprising a heater, at least
one condensation chamber, and a mouthpiece. The device provides for
compact assembly and disassembly of components with detachable
couplings; overheat shut-off protection for the resistive heating
element; an air inlet passage (an enclosed channel) formed by the
assembly of the device body and a separable cartridge; at least one
condensation chamber within the separable cartridge assembly;
heater contacts; and one or more refillable, reusable, and/or
recyclable components.
[0193] Provided herein is a device for generating an inhalable
aerosol comprising: a device body comprising a cartridge
receptacle; a cartridge comprising: a storage compartment, and a
channel integral to an exterior surface of the cartridge, and an
air inlet passage formed by the channel and an internal surface of
the cartridge receptacle when the cartridge is inserted into the
cartridge receptacle. The cartridge may be formed from a metal,
plastic, ceramic, and/or composite material. The storage
compartment may hold a vaporizable material. FIG. 7A shows an
example of a cartridge 30 for use in the device. The vaporizable
material may be a liquid at or near room temperature. In some cases
the vaporizable material may be a liquid below room temperature.
The channel may form a first side of the air inlet passage, and an
internal surface of the cartridge receptacle may form a second side
of the air inlet passage, as illustrated in various non-limiting
aspects of FIGS. 5-60, 7C, 8A, 8B, and 10A
[0194] Provided herein is a device for generating an inhalable
aerosol. The device may comprise a body that houses, contains, and
or integrates with one or more components of the device. The device
body may comprise a cartridge receptacle. The cartridge receptacle
may comprise a channel integral to an interior surface of the
cartridge receptacle; and an air inlet passage formed by the
channel and an external surface of the cartridge when the cartridge
is inserted into the cartridge receptacle. A cartridge may be
fitted and/or inserted into the cartridge receptacle. The cartridge
may have a fluid storage compartment. The channel may form a first
side of the air inlet passage, and an external surface of the
cartridge forms a second side of the air inlet passage. The channel
may comprise at least one of: a groove; a trough; a track; a
depression; a dent; a furrow; a trench; a crease; and a gutter. The
integral channel may comprise walls that are either recessed into
the surface or protrude from the surface where it is formed. The
internal side walls of the channel may form additional sides of the
air inlet passage. The channel may have a round, oval, square,
rectangular, or other shaped cross section. The channel may have a
closed cross section. The channel may be about 0.1 cm, 0.5 cm, 1
cm, 2 cm, or 5 cm wide. The channel may be about 0.1 mm, 0.5 mm, 1
mm, 2 mm, or 5 mm deep. The channel may be about 0.1 cm, 0.5 cm, 1
cm, 2 cm, or 5 cm long. There may be at least 1 channel.
[0195] In some embodiments, the cartridge may further comprise a
second air passage in fluid communication with the air inlet
passage to the fluid storage compartment, wherein the second air
passage is formed through the material of the cartridge.
[0196] FIGS. 5-7C show various views of a compact electronic device
assembly 10 for generating an inhalable aerosol. The compact
electronic device 10 may comprise a device body 20 with a cartridge
receptacle 21 for receiving a cartridge 30. The device body may
have a square or rectangular cross section. Alternatively, the
cross section of the body may be any other regular or irregular
shape. The cartridge receptacle may be shaped to receive an opened
cartridge 30a or "pod". The cartridge may be opened when a
protective cap is removed from a surface of the cartridge. In some
cases, the cartridge may be opened when a hole or opening is formed
on a surface of the cartridge. The pod 30a may be inserted into an
open end of the cartridge receptacle 21 so that an exposed first
heater contact tips 33a on the heater contacts 33 of the pod make
contact with the second heater contacts 22 of the device body, thus
forming the device assembly 10.
[0197] Referring to FIG. 14, it is apparent in the plan view that
when the pod 30a is inserted into the notched body of the cartridge
receptacle 21, the channel air inlet 50 is left exposed. The size
of the channel air inlet 50 may be varied by altering the
configuration of the notch in the cartridge receptacle 21.
[0198] The device body may further comprise a rechargeable battery,
a printed circuit board (PCB) 24 containing a microcontroller with
the operating logic and software instructions for the device, a
pressure switch 27 for sensing the user's puffing action to
activate the heater circuit, an indicator light 26, charging
contacts (not shown), and an optional charging magnet or magnetic
contact (not shown). The cartridge may further comprise a heater
36. The heater may be powered by the rechargeable battery. The
temperature of the heater may be controlled by the microcontroller.
The heater may be attached to a first end of the cartridge.
[0199] In some embodiments, the heater may comprise a heater
chamber 37, a first pair of heater contacts 33, 33', a fluid wick
34, and a resistive heating element 35 in contact with the wick.
The first pair of heater contacts may comprise thin plates affixed
about the sides of the heater chamber. The fluid wick and resistive
heating element may be suspended between the heater contacts.
[0200] In some embodiments, there may be two or more resistive
heating elements 35, 35' and two or more wicks 34, 34'. In some of
the embodiments, the heater contact 33 may comprise: a flat plate;
a male contact; a female receptacle, or both; a flexible contact
and/or copper alloy or another electrically conductive material.
The first pair of heater contacts may further comprise a formed
shape that may comprise a tab (e.g., flange) having a flexible
spring value that extends out of the heater to complete a circuit
with the device body. The first pair of heater contact may be a
heat sink that absorb and dissipate excessive heat produced by the
resistive heating element. Alternatively, the first pair of heater
contacts may be a heat shield that protects the heater chamber from
excessive heat produced by the resistive heating element. The first
pair of heater contacts may be press-fit to an attachment feature
on the exterior wall of the first end of the cartridge. The heater
may enclose a first end of the cartridge and a first end of the
fluid storage compartment.
[0201] As illustrated in the exploded assembly of FIG. 7B, a heater
enclosure may comprises two or more heater contacts 33, each
comprising a flat plate which may be machined or stamped from a
copper alloy or similar electrically conductive material. The
flexibility of the tip is provided by the cut-away clearance
feature 33b created below the male contact point tip 33a which
capitalizes on the inherent spring capacity of the metal sheet or
plate material. Another advantage and improvement of this type of
contact is the reduced space requirement, simplified construction
of a spring contact point (versus a pogo pin) and the easy of
assembly. The heater may comprise a first condensation chamber. The
heater may comprise more one or more additional condensation
chambers in addition to the first condensation chamber. The first
condensation chamber may be formed along an exterior wall of the
cartridge.
[0202] In some cases, the cartridge (e.g., pod) is configured for
ease of manufacturing and assembly. The cartridge may comprise an
enclosure. The enclosure may be a tank. The tank may comprise an
interior fluid storage compartment 32. The interior fluid storage
compartment 32 which is open at one or both ends and comprises
raised rails on the side edges 45b and 46b. The cartridge may be
formed from plastic, metal, composite, and/or a ceramic material.
The cartridge may be rigid or flexible.
[0203] The tank may further comprise a set of first heater contact
plates 33 formed from copper alloy or another electrically
conductive material, having a thin cut-out 33b below the contact
tips 33a (to create a flexible tab) which are affixed to the sides
of the first end of the tank and straddle the open-sided end 53 of
the tank. The plates may affix to pins, or posts as shown in FIG.
7B or 5, or may be attached by other common means such as
compression beneath the enclosure 36. A fluid wick 34 having a
resistive heating element 35 wrapped around it, is placed between
the first heater contact plates 33, and attached thereto. A heater
36, comprising raised internal edges on the internal end (not
shown), a thin mixing zone (not shown), and primary condensation
channel covers 45a that slide over the rails 45b on the sides of
the tank on the first half of the tank, creating a primary
condensation channel/chamber 45. In addition, a small male snap
feature 39b located at the end of the channel cover is configured
fall into a female snap feature 39a, located mid-body on the side
of the tank, creating a snap-fit assembly.
[0204] As will be further clarified below, the combination of the
open-sided end 53, the protruding tips 33a of the contact plates
33, the fluid wick 34 having a resistive heating element 35,
enclosed in the open end of the fluid storage tank, under the
heater 36, with a thin mixing zone therein, creates an efficient
heater system. In addition, the primary condensation channel covers
45a which slide over the rails 45b on the sides of the tank create
an integrated, easily assembled, primary condensation chamber 45,
all within the heater at the first end of the cartridge 30 or pod
30a.
[0205] In some embodiments of the device, as illustrated in FIG. 9,
the heater may encloses at least a first end of the cartridge. The
enclosed first end of the cartridge may include the heater and the
interior fluid storage compartment. In some embodiments, the heater
further comprises at least one first condensation chamber 45.
[0206] FIG. 9 shows diagramed steps that mat be performed to
assemble a cartomizer and/or mouthpiece. In A-B the fluid storage
compartment 32a may be oriented such that the heater inlet 53 faces
upward. The heater contacts 33 may be inserted into the fluid
storage compartment. Flexible tabs 33a may be inserted into the
heater contacts 33. In a step D the resistive heating clement 35
may be wound on to the wick 34. In step E the wick 34 and heater 35
may be placed on the fluid storage compartment. One or more free
ends of the heater may sit outside the heater contacts. The one or
more free ends may be soldered in place, rested in a groove, or
snapped into a fitted location. At least a fraction of the one or
more free ends may be in communication with the heater contacts 33.
In a step F the heater enclosure 36 may be snapped in place. The
heater enclosure 36 may be fitted on the fluid storage compartment.
Step G shows the heater enclosure 36 is in place on the fluid
storage compartment. In step H the fluid storage compartment can be
flipped over. In step I the mouthpiece 31 can be fitted on the
fluid storage compartment. Step J shows the mouthpiece 31 in place
on the fluid storage compartment. In step K an end 49 can be fitted
on the fluid storage compartment opposite the mouthpiece. Step L
shows a fully assembled cartridge 30. FIG. 7B shows an exploded
view of the assembled cartridge 30.
[0207] Depending on the size of the heater and/or heater chamber,
the heater may have more than one wick 34 and resistive heating
element 35.
[0208] In some embodiments, the first pair of heater contacts 33
further comprises a formed shape that comprises a tab 33a having a
flexible spring value that extends out of the heater. In some
embodiments, the cartridge 30 comprises heater contacts 33 which
are inserted into the cartridge receptacle 21 of the device body 20
wherein, the flexible tabs 33a insert into a second pair of heater
contacts 22 to complete a circuit with the device body. The first
pair of heater contacts 33 may be a heat sink that absorbs and
dissipates excessive heat produced by the resistive heating element
35. The first pair of heater contacts 33 may he a heat shield that
protects the heater chamber from excessive heat produced by the
resistive heating element 35. The first pair of heater contacts may
be press-fit to an attachment feature on the exterior wall of the
first end of the cartridge. The heater 36 may enclose a first end
of the cartridge and a first end of the fluid storage compartment
32a. The heater may comprise a first condensation chamber 45. The
heater may comprise at least one additional condensation chamber
45, 45', 45'', etc. The first condensation chamber may be formed
along an exterior wall of the cartridge.
[0209] In still other embodiments of the device, the cartridge may
further comprise a mouthpiece 31, wherein the mouthpiece comprises
at least one aerosol outlet channel/secondary condensation chamber
46; and at least one aerosol outlet 47.The mouthpiece may be
attached to a second end of the cartridge. The second end of the
cartridge with the mouthpiece may be exposed when the cartridge is
inserted in the device. The mouthpiece may comprise more than one
second condensation chamber 46, 46', 46'', etc. The second
condensation chamber is formed along an exterior wall of the
cartridge.
[0210] The mouthpiece 31 may enclose the second end of the
cartridge and interior fluid storage compartment. The partially
assembled (e.g., mouthpiece removed) unit may be inverted and
filled with a vaporizable fluid through the opposite, remaining
(second) open end. Once filled, a snap-on mouthpiece 31 that also
closes and seals the second end of the tank is inserted over the
end. It also comprises raised internal edges (not shown), and
aerosol outlet channel covers 46a that may slide over the rails 46b
located on the sides of the second half of the tank, creating
aerosol outlet channels/secondary condensation chambers 46. The
aerosol outlet channels/secondary condensation chambers 46 slide
over the end of primary condensation chamber 45, at a transition
area 57, to create a junction for the vapor leaving the primary
chamber and proceed out through the aerosol outlets 47, at the end
of the aerosol outlet channels 46 and user-end of the mouthpiece
31.
[0211] The cartridge may comprise a first condensation chamber and
a second condensation chamber 45, 46. The cartridge may comprise
more than one first condensation chamber and more than one second
condensation chamber 45, 46, 45', 46', etc.
[0212] In some embodiments of the device, a first condensation
chamber 45 may be formed along the outside of the cartridge fluid
storage compartment 31. In some embodiments of the device an
aerosol outlet 47 exists at the end of aerosol outlet chamber 46.
In some embodiments of the device, a first and second condensation
chamber 45, 46 may be formed along the outside of one side of the
cartridge fluid storage compartment 31. In some embodiments the
second condensation chamber may be an aerosol outlet chamber. In
some embodiments another pair of first and/or second condensation
chambers 45', 46' is formed along the outside of the cartridge
fluid storage compartment 31 on another side of the device. In some
embodiments another aerosol outlet 47' will also exist at the end
of the second pair of condensation chambers 45', 46'.
[0213] In any one of the embodiments, the first condensation
chamber and the second condensation chamber may be in fluid
communication as illustrated in FIG. 10C.
[0214] In some embodiments, the mouthpiece may comprise an aerosol
outlet 47 in fluid communication with the second condensation
chamber 46. The mouthpiece may comprise more than one aerosol
outlet 47, 47' in fluid communication with more than one the second
condensation chamber 46, 46'. The mouthpiece may enclose a second
end of the cartridge and a second end of the fluid storage
compartment.
[0215] In each of the embodiments described herein, the cartridge
may comprise an airflow path comprising: an air inlet passage; a
heater; at least a first condensation chamber; an aerosol outlet
chamber, and an outlet port. In some of the embodiments described
herein, the cartridge comprises an airflow path comprising: an air
inlet passage; a heater; a first condensation chamber; a secondary
condensation chamber; and an outlet port.
[0216] In still other embodiments described herein the cartridge
may comprise an airflow path comprising at least one air inlet
passage; a heater; at least one first condensation chamber; at
least one secondary condensation chamber; and at least one outlet
port.
[0217] As illustrated in FIGS. 10A-10C, an airflow path is created
when the user draws on the mouthpiece 31 to create a suction (e.g.,
a puff), which essentially pulls air through the channel air inlet
opening 50, through the air inlet passage 51, and into the heater
chamber 37 through the second air passage (tank air inlet hole) 41
at the tank air inlet 52, then into the heater inlet 53. At this
point, the pressure sensor has sensed the user's puff, and
activated the circuit to the resistive heating element 35, which in
turn, begins to generate vapor from the vapor fluid (e-juice). As
air enters the heater inlet 53, it begins to mix and circulate in a
narrow chamber above and around the wick 34 and between the heater
contacts 33, generating heat, and dense, concentrated vapor as it
mixes in the flow path 54 created by the sealing structure
obstacles 44. FIG. 8A shows a detailed view of the sealing
structure obstacles 44. Ultimately the vapor may be drawn, out of
the heater along an air path 55 near the shoulder of the heater and
into the primary condensation chamber 45 where the vapor expands
and begins to cool. As the expanding vapor moves along the airflow
path, it makes a transition from the primary condensation chamber
45 through a transition area 57, creating a junction for the vapor
leaving the primary chamber, and entering the second vapor chamber
46, and proceeds out through the aerosol outlets 47, at the end of
the mouthpiece 31 to the user.
[0218] As illustrated in FIGS. 10A-10C, the device may have a dual
set of air inlet passages 50-53, dual first condensation chambers
55/45, dual second condensation chambers and aeration channels
57/46, and/or dual aerosol outlet vents 47.
[0219] Alternatively, the device may have an airflow path
comprising: an air inlet passage 50, 51; a second air passage 41; a
heater chamber 37; a first condensation chamber 45; a second
condensation chamber 46; and/or an aerosol outlet 47.
[0220] In some cases, the devise may have an airflow path
comprising: more than one air inlet passage; more than one second
air passage; a heater chamber; more than one first condensation
chamber; more than one second condensation chamber; and more than
one aerosol outlet as clearly illustrated in FIGS. 10A-10C.
[0221] In any one of the embodiments described herein, the heater
36 may be in fluid communication with the internal fluid storage
compartment 32a.
[0222] In each of the embodiments described herein, the fluid
storage compartment 32 is in fluid communication with the heater
chamber 37, wherein the fluid storage compartment is capable of
retaining condensed aerosol fluid, as illustrated in FIGS. 10A, 10C
and 14.
[0223] In some embodiments of the device, the condensed aerosol
fluid may comprise a nicotine formulation. In some embodiments, the
condensed aerosol fluid may comprise a humectant. In some
embodiments, the humectant may comprise propylene glycol. In some
embodiments, the humectant may comprise vegetable glycerin.
[0224] In some cases, the cartridge may be detachable from the
device body. In some embodiments, the cartridge receptacle and the
detachable cartridge may form a separable coupling. In some
embodiments the separable coupling may comprise a friction
assembly. As illustrated in FIGS. 11-14, the device may have a
press-fit (friction) assembly between the cartridge pod 30a and the
device receptacle. Additionally, a dent/friction capture such as 43
may be utilized to capture the pod 30a to the device receptacle or
to hold a protective cap 38 on the pod, as further illustrated in
FIG. 8B.
[0225] In other embodiments, the separable coupling may comprise a
snap-fit or snap-lock assembly. In still other embodiments the
separable coupling may comprise a magnetic assembly.
[0226] In any one of the embodiments described herein, the
cartridge components may comprise a snap-fit or snap-lock assembly,
as illustrated in FIG. 5. In any one of the embodiments, the
cartridge components may be reusable, refillable, and/or
recyclable. The design of these cartridge components lend
themselves to the use of such recyclable plastic materials as
polypropylene, for the majority of components.
[0227] In some embodiments of the device 10, the cartridge 30 may
comprise: a fluid storage compartment 32; a heater 36 affixed to a
first end with a snap-fit coupling 39a, 39b; and a mouthpiece 31
affixed to a second end with a snap-fit coupling 39c, 39d (not
shown--but similar to 39a and 39b). The heater 36 may be in fluid
communication with the fluid storage compartment 32. The fluid
storage compartment may be capable of retaining condensed aerosol
fluid. The condensed aerosol fluid may comprise a nicotine
formulation. The condensed aerosol fluid may comprise a humectant.
The humectant may comprise propylene glycol and/or vegetable
glycerin.
[0228] Provided herein is a device for generating an inhalable
aerosol comprising: a device body 20 comprising a cartridge
receptacle 21 for receiving a cartridge 30; wherein an interior
surface of the cartridge receptacle forms a first side of an air
inlet passage 51 when a cartridge comprising a channel integral 40
to an exterior surface is inserted into the cartridge receptacle
21, and wherein the channel forms a second side of the air inlet
passage 51.
[0229] Provided herein is a device for generating an inhalable
aerosol comprising: a device body 20 comprising a cartridge
receptacle 21 for receiving a cartridge 30; wherein the cartridge
receptacle comprises a channel integral to an interior surface and
forms a first side of an air inlet passage when a cartridge is
inserted into the cartridge receptacle, and wherein an exterior
surface of the cartridge forms a second side of the air inlet
passage 51.
[0230] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising: a fluid storage
compartment 32; a channel integral 40 to an exterior surface,
wherein the channel forms a first side of an air inlet passage 51;
and wherein an internal surface of a cartridge receptacle 21 in the
device forms a second side of the air inlet passage 51 when the
cartridge is inserted into the cartridge receptacle.
[0231] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising a fluid storage
compartment 32, wherein an exterior surface of the cartridge forms
a first side of an air inlet channel 51 when inserted into a device
body 10 comprising a cartridge receptacle 21, and wherein the
cartridge receptacle further comprises a channel integral to an
interior surface, and wherein the channel forms a second side of
the air inlet passage 51.
[0232] In some embodiments, the cartridge further comprises a
second air passage 41 in fluid communication with the channel 40,
wherein the second air passage 41 is formed through the material of
the cartridge 32 from an exterior surface of the cartridge to the
internal fluid storage compartment 32a.
[0233] In some embodiments of the device body cartridge receptacle
21 or the cartridge 30, the integral channel 40 comprises at least
one of: a groove; a trough; a depression; a dent; a furrow; a
trench; a crease; and a gutter.
[0234] In some embodiments of the device body cartridge receptacle
21 or the cartridge 30, the integral channel 40 comprises walls
that are either recessed into the surface or protrude from the
surface where it is formed.
[0235] In some embodiments of the device body cartridge receptacle
21 or the cartridge 30, the internal side walls of the channel 40
form additional sides of the air inlet passage 51.
[0236] Provided herein is a device for generating an inhalable
aerosol comprising: a cartridge comprising; a fluid storage
compartment; a heater affixed to a first end comprising; a first
heater contact, a resistive heating element affixed to the first
heater contact; a device body comprising; a cartridge receptacle
for receiving the cartridge; a second heater contact adapted to
receive the first heater contact and to complete a circuit; a power
source connected to the second heater contact; a printed circuit
board (PCB) connected to the power source and the second heater
contact; wherein the PCB is configured to detect the absence of
fluid based on the measured resistance of the resistive heating
element, and turn off the device.
[0237] Referring now to FIGS. 13, 14, and 15, in some embodiments,
the device body further comprises at least one: second heater
contact 22 (best shown in FIG. 6C detail); a battery 23; a printed
circuit board 24; a pressure sensor 27; and an indicator light
26.
[0238] In some embodiments, the printed circuit board (PCB) further
comprises: a microcontroller; switches; circuitry comprising a
reference resister; and an algorithm comprising logic for control
parameters; wherein the microcontroller cycles the switches at
fixed intervals to measure the resistance of the resistive heating
element relative to the reference resistor, and applies the
algorithm control parameters to control the temperature of the
resistive heating element.
[0239] As illustrated in the basic block diagram of FIG. 17A, the
device utilizes a proportional-integral-derivative controller or
PID control law. A PID controller calculates an "error" value as
the difference between a measured process variable and a desired
SetPoint. When PID control is enabled, power to the coil is
monitored to determine whether or not acceptable vaporization is
occurring. With a given airflow over the coil, more power will be
required to hold the coil at a given temperature if the device is
producing vapor (heat is removed from the coil to form vapor). If
power required to keep the coil at the set temperature drops below
a threshold, the device indicates that it cannot currently produce
vapor. Under normal operating conditions, this indicates that there
is not enough liquid in the wick for normal vaporization to
occur.
[0240] In some embodiments, the micro-controller instructs the
device to turn itself off when the resistance exceeds the control
parameter threshold indicating that the resistive heating element
is dry.
[0241] In still other embodiments, the printed circuit board
further comprises logic capable of detecting the presence of
condensed aerosol fluid in the fluid storage compartment and is
capable of turning off power to the heating contact(s) when the
condensed aerosol fluid is not detected. When the microcontroller
is running the PID temperature control algorithm 70, the difference
between a set point and the coil temperature (error) is used to
control power to the coil so that the coil quickly reaches the set
point temperature, [between 200.degree. C. and 400.degree. C.].
When the over-temperature algorithm is used, power is constant
until the coil reaches an over-temperature threshold, [between
200.degree. C. and 400.degree. C.]; (FIG. 17 A applies: set point
temperature is over-temperature threshold; constant power until
error reaches 0).
[0242] The essential components of the device used to control the
resistive heating element coil temperature are further illustrated
in the circuit diagram of FIG. 17B. Wherein, BATT 23 is the
battery; MCU 72 is the microcontroller; Q1 (76) and Q2 (77) are
P-channel MOSFETs (switches); R_COIL 74 is the resistance of the
coil. R_REF 75 is a fixed reference resistor used to measure R_COIL
74 through a voltage divider 73.
[0243] The battery powers the microcontroller. The microcontroller
turns on Q2 for 1 ms every 100 ms so that the voltage between R_REF
and R_COIL (a voltage divider) may be measured by the MCU at
V_MEAS. When Q2 is off, the control law controls Q1 with PWM (pulse
width modulation) to power the coil (battery discharges through Q1
and R_COIL when Q1 is on).
[0244] In some embodiments of the device, the device body further
comprises at least one: second heater contact; a power switch; a
pressure sensor; and an indicator light.
[0245] In some embodiments of the device body, the second heater
contact 22 may comprise: a female receptacle; or a male contact, or
both, a flexible contact; or copper alloy or another electrically
conductive material.
[0246] In some embodiments of the device body, the battery supplies
power to the second heater contact, pressure sensor, indicator
light and the printed circuit board. In some embodiments, the
battery is rechargeable. In some embodiments, the indicator light
26 indicates the status of the device and/or the battery or
both.
[0247] In some embodiments of the device, the first heater contact
and the second heater contact complete a circuit that allows
current to flow through the heating contacts when the device body
and detachable cartridge are assembled, which may be controlled by
an on/off switch. Alternatively, the device can be turned on an off
by a puff sensor. The puff sensor may comprise a capacitive
membrane. The capacitive membrane may be similar to a capacitive
membrane used in a microphone.
[0248] In some embodiments of the device, there is also an
auxiliary charging unit for recharging the battery 23 in the device
body. As illustrated in FIGS. 16A-16C, the charging unit 60, may
comprise a USB device with a plug for a power source 63 and
protective cap 64, with a cradle 61 for capturing the device body
20 (with or without the cartridge installed). The cradle may
further comprise either a magnet or a magnetic contact 62 to
securely hold the device body in place during charging. As
illustrated in FIG. 6B, the device body further comprises a mating
charging contact 28 and a magnet or magnetic contact 29 for the
auxiliary charging unit. FIG. 16C is an illustrative example of the
device 20 being charged in a power source 65 (laptop computer or
tablet).
[0249] In some cases the microcontroller on the PCB may be
configured to monitor the temperature of the heater such that the
vaporizable material is heated to a prescribed temperature. The
prescribed temperature may be an input provided by the user. A
temperature sensor may be in communication with the microcontroller
to provide an input temperature to the microcontroller for
temperature regulation. A temperature sensor may be a thermistor,
thermocouple, thermometer, or any other temperature sensors. In
some cases, the heating element may simultaneously perform as both
a heater and a temperature sensor. The heating element may differ
from a thermistor by having a resistance with a relatively lower
dependence on temperature. The heating element may comprise a
resistance temperature detector.
[0250] The resistance of the heating element may be an input to the
microcontroller. In some cases, the resistance may be determined by
the microcontroller based on a measurement from a circuit with a
resistor with at least one known resistance, for example, a
Wheatstone bridge. Alternatively, the resistance of the heating
element may be measured with a resistive voltage divider in contact
with the heating element and a resistor with a known and
substantially constant resistance. The measurement of the
resistance of the heating element may be amplified by an amplifier.
The amplifier may be a standard op amp or instrumentation
amplifier. The amplified signal may be substantially free of noise.
In some cases, a charge time for a voltage divider between the
heating element and a capacitor may be determined to calculate the
resistance of the heating element. In some cases, the
microcontroller must deactivate the heating element during
resistance measurements. The resistance of the heating element may
be directly proportional to the temperature of the heating element
such that the temperature may be directly determine from the
resistance measurement. Determining the temperature directly from
the heating element resistance measurement rather than from an
additional temperature sensor may generate a more accurate
measurement because unknown contact thermal resistance between the
temperature sensor and the heating element is eliminated.
Additionally, the temperature measurement may be determined
directly and therefore faster and without a time lag associated
with attaining equilibrium between the heating element and a
temperature sensor in contact with the heating element.
[0251] Provided herein is a device for generating an inhalable
aerosol comprising: a cartridge comprising a first heater contact;
a device body comprising; a cartridge receptacle for receiving the
cartridge; a second heater contact adapted to receive the first
heater contact and to complete a circuit; a power source connected
to the second heater contact; a printed circuit board (PCB)
connected to the power source and the second heater contact; and a
single button interface; wherein the PCB is configured with
circuitry and an algorithm comprising logic for a child safety
feature.
[0252] In some embodiments, the algorithm requires a code provided
by the user to activate the device. In some embodiments; the code
is entered by the user with the single button interface. In still
further embodiments the single button interface is the also the
power switch.
[0253] Provided herein is a cartridge 30 for a device 10 for
generating an inhalable aerosol comprising: a fluid storage
compartment 32; a heater 36 affixed to a first end comprising: a
heater chamber 37, a first pair of heater contacts 33, a fluid wick
34, and a resistive heating element 35 in contact with the wick;
wherein the first pair of heater contacts 33 comprise thin plates
affixed about the sides of the heater chamber 37, and wherein the
fluid wick 34 and resistive heating element 35 are suspended there
between.
[0254] Depending on the size of the heater or heater chamber, the
heater may have more than one wick 34, 34' and resistive heating
element 35, 35'.
[0255] In some embodiments, the first pair of heater contacts
further comprise a formed shape that comprises a tab 33a having a
flexible spring value that extends out of the heater 36 to complete
a circuit with the device body 20.
[0256] In some embodiments, the heater contacts 33 are configured
to mate with a second pair of heater contacts 22 in a cartridge
receptacle 21 of the device body 20 to complete a circuit.
[0257] In some embodiments, the first pair of heater contacts is
also a heat sink that absorbs and dissipates excessive heat
produced by the resistive heating element.
[0258] In some embodiments, the first pair of heater contacts is a
heat shield that protects the heater chamber from excessive heat
produced by the resistive heating element.
[0259] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising: a heater 36
comprising; a heater chamber 37, a pair of thin plate heater
contacts 33 therein, a fluid wick 34 positioned between the heater
contacts 33, and a resistive heating element 35 in contact with the
wick; wherein the heater contacts 33 each comprise a fixation site
33c wherein the resistive heating element 35 is tensioned there
between.
[0260] As will be obvious to one skilled in the art after reviewing
the assembly method illustrated in FIG. 9, the heater contacts 33
simply snap or rest on locator pins on either side of the air inlet
53 on the first end of the cartridge interior fluid storage
compartment, creating a spacious vaporization chamber containing
the at least one wick 34 and at least one heating element 35.
[0261] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising a heater 36 attached
to a first end of the cartridge.
[0262] In some embodiments, the heater encloses a first end of the
cartridge and a first end of the fluid storage compartment 32,
32a.
[0263] In some embodiments, the heater comprises a first
condensation chamber 45.
[0264] In some embodiments, the heater comprises more than one
first condensation chamber 45, 45'.
[0265] In some embodiments, the condensation chamber is formed
along an exterior wall of the cartridge 45b.
[0266] As noted previously, and described in FIGS. 10A, 10B and
10C, the airflow path through the heater and heater chamber
generates vapor within the heater circulating air path 54, which
then exits through the heater exits 55 into a first (primary)
condensation chamber 45, which is formed by components of the tank
body comprising the primary condensation channel/chamber rails 45b,
the primary condensation channel cover 45a, (the outer side wall of
the heater enclosure).
[0267] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising a fluid storage
compartment 32 and a mouthpiece 31, wherein the mouthpiece is
attached to a second end of the cartridge and further comprises at
least one aerosol outlet 47.
[0268] In some embodiments, the mouthpiece 31 encloses a second end
of the cartridge 30 and a second end of the fluid storage
compartment 32, 32a.
[0269] Additionally, as clearly illustrated in FIG. 10C in some
embodiments the mouthpiece also contains a second condensation
chamber 46 prior to the aerosol outlet 47, which is formed by
components of the tank body 32 comprising the secondary
condensation channel/chamber rails 46b, the second condensation
channel cover 46a, (the outer side wall of the mouthpiece). Still
further, the mouthpiece may contain yet another aerosol outlet 47'
and another (second) condensation chamber 46' prior to the aerosol
outlet, on another side of the cartridge.
[0270] In other embodiments, the mouthpiece comprises more than one
second condensation chamber 46, 46'.
[0271] In some preferred embodiments, the second condensation
chamber is formed along an exterior wall of the cartridge 46b.
[0272] In each of the embodiments described herein, the cartridge
30 comprises an airflow path comprising: an air inlet channel and
passage 40, 41, 42; a heater chamber 37; at least a first
condensation chamber 45; and an outlet port 47. In some of the
embodiments described herein, the cartridge 30 comprises an airflow
path comprising: an air inlet channel and passage 40, 41, 42; a
heater chamber 37; a first condensation chamber 45; a second
condensation chamber 46; and an outlet port 47.
[0273] In still other embodiments described herein the cartridge 30
may comprise an airflow path comprising at least one air inlet
channel and passage 40, 41, 42; a heater chamber 37; at least one
first condensation chamber 45; at least one second condensation
chamber 46; and at least one outlet port 47.
[0274] In each of the embodiments described herein, the fluid
storage compartment 32 is in fluid communication with the heater
36, wherein the fluid storage compartment is capable of retaining
condensed aerosol fluid.
[0275] In some embodiments of the device, the condensed aerosol
fluid comprises a nicotine formulation. In some embodiments, the
condensed aerosol fluid comprises a humectant. In some embodiments,
the humectant comprises propylene glycol. In some embodiments, the
humectant comprises vegetable glycerin.
[0276] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 comprising: a fluid storage
compartment 32; a heater 36 affixed to a first end; and a
mouthpiece 31 affixed to a second end; wherein the heater comprises
a first condensation chamber 45 and the mouthpiece comprises a
second condensation chamber 46.
[0277] In some embodiments, the heater comprises more than one
first condensation chamber 45, 45' and the mouthpiece comprises
more than one second condensation chamber 46, 46'.
[0278] In some embodiments, the first condensation chamber and the
second condensation chamber are in fluid communication. As
illustrated in FIG. 10C, the first and second condensation chambers
have a common transition area 57, 57', for fluid communication.
[0279] In some embodiments, the mouthpiece comprises an aerosol
outlet 47 in fluid communication with the second condensation
chamber 46.
[0280] In some embodiments, the mouthpiece comprises two or more
aerosol outlets 47, 47'.
[0281] In some embodiments, the mouthpiece comprises two or more
aerosol outlets 47, 47' in fluid communication with the two or more
second condensation chambers 46, 46'.
[0282] In any one of the embodiments, the cartridge meets ISO
recycling standards.
[0283] In any one of the embodiments, the cartridge meets ISO
recycling standards for plastic waste.
[0284] And in still other embodiments, the plastic components of
the cartridge are composed of polylactic acid (PLA), wherein the
PLA components are compostable and or degradable.
[0285] Provided herein is a device for generating an inhalable
aerosol 10 comprising a device body 20 comprising a cartridge
receptacle 21; and a detachable cartridge 30; wherein the cartridge
receptacle and the detachable cartridge form a separable coupling,
and wherein the separable coupling comprises a friction assembly, a
snap-fit assembly or a magnetic assembly.
[0286] In other embodiments of the device, the cartridge is a
detachable assembly. In any one of the embodiments described
herein, the cartridge components may comprise a snap-lock assembly
such as illustrated by snap features 39a and 39b. In any one of the
embodiments, the cartridge components are recyclable.
[0287] Provided herein is a method of fabricating a device for
generating an inhalable aerosol comprising: providing a device body
comprising a cartridge receptacle; and providing a detachable
cartridge; wherein the cartridge receptacle and the detachable
cartridge form a separable coupling comprising a friction assembly,
a snap-fit assembly or a magnetic assembly when the cartridge is
inserted into the cartridge receptacle.
[0288] Provided herein is a method of making a device 10 for
generating an inhalable aerosol comprising: providing a device body
20 with a cartridge receptacle 21 comprising one or more interior
coupling surfaces 21a, 21b, 21c . . . ; and further providing a
cartridge 30 comprising: one or more exterior coupling surfaces
36a, 36b, 36c, . . . , a second end and a first end; a tank 32
comprising an interior fluid storage compartment 32a; at least one
channel 40 on at least one exterior coupling surface, wherein the
at least one channel forms one side of at least one air inlet
passage 51, and wherein at least one interior wall of the cartridge
receptacle forms at least one side one side of at least one air
inlet passage 51 when the detachable cartridge is inserted into the
cartridge receptacle.
[0289] FIG. 9 provides an illustrative example of a method of
assembling such a device.
[0290] In some embodiments of the method, the cartridge 30 is
assembled with a [protective] removable end cap 38 to protect the
exposed heater contact tabs 33a protruding from the heater 36.
[0291] Provided herein is a method of fabricating a cartridge for a
device for generating an inhalable aerosol comprising: providing a
fluid storage compartment; affixing a heater to a first end with a
snap-fit coupling; and affixing a mouthpiece to a second end with a
snap-fit coupling.
[0292] Provided herein is a cartridge 30 for a device for
generating an inhalable aerosol 10 with an airflow path comprising:
a channel 50 comprising a portion of an air inlet passage 51; a
second air passage 41 in fluid communication with the channel; a
heater chamber 37 in fluid communication with the second air
passage; a first condensation chamber 45 in fluid communication
with the heater chamber; a second condensation chamber 46 in fluid
communication with the first condensation chamber; and an aerosol
outlet 47 in fluid communication with second condensation
chamber.
[0293] Provided herein is a device 10 for generating an inhalable
aerosol adapted to receive a removable cartridge 30, wherein the
cartridge comprises a fluid storage compartment [or tank] 32; an
air inlet 41; a heater 36, a [protective] removable end cap 38, and
a mouthpiece 31.
[0294] Charging
[0295] In some cases, the vaporization device may comprise a power
source. The power source may be configured to provide power to a
control system, one or more heating elements, one or more sensors,
one or more lights, one or more indicators, and/or any other system
on the electronic cigarette that requires a power source. The power
source may be an energy storage device. The power source may be a
battery or a capacitor. In some cases, the power source may be a
rechargeable battery.
[0296] The battery may be contained within a housing of the device.
In some cases the battery may be removed from the housing for
charging. Alternatively, the battery may remain in the housing
while the battery is being charged. Two or more charge contact may
be provided on an exterior surface of the device housing. The two
or more charge contacts may be in electrical communication with the
battery such that the battery may be charged by applying a charging
source to the two or more charge contacts without removing the
battery from the housing.
[0297] FIG. 18 shows a device 1800 with charge contacts 1801. The
charge contacts 1801 may be accessible from an exterior surface of
a device housing 1802. The charge contacts 1801 may be in
electrical communication with an energy storage device (e.g.,
battery) inside of the device housing 1802. In some cases, the
device housing may not comprise an opening through which the user
may access components in the device housing. The user may not be
able to remove the battery and/or other energy storage device from
the housing. In order to open the device housing a user must
destroy or permanently disengage the charge contacts. In some
cases, the device may fail to function after a user breaks open the
housing.
[0298] FIG. 19 shows an exploded view of a charging assembly 1900
in an electronic vaporization device. The housing (not shown) has
been removed from the exploded view in FIG. 19. The charge contact
pins 1901 may be visible on the exterior of the housing. The charge
contact pins 1901 may be in electrical communication with a power
storage device of the electronic vaporization device. When the
device is connected to a power source (e.g., during charging of the
device) the charging pins may facilitate electrical communication
between the power storage device inside of the electronic
vaporization device and the power source outside of the housing of
the vaporization device. The charge contact pins 1901 may be held
in place by a retaining bezel 1902. The charge contact pins 1901
may be in electrical communication with a charger flex 1903. The
charging pins may contact the charger flex such that a need for
soldering of the charger pins to an electrical connection to be in
electrical communication with the power source may be eliminated.
The charger flex may be soldered to a printed circuit board (PCB).
The charger flex may be in electrical communication with the power
storage device through the PCB. The charger flex may be held in
place by a bent spring retainer 1904.
[0299] FIG. 20 shows the bent spring retainer in an initial
position 2001 and a deflected position 2002. The bent spring
retainer may hold the retaining bezel in a fixed location. The bent
spring retainer may deflect only in one direction when the charging
assembly is enclosed in the housing of the electronic vaporization
device.
[0300] FIG. 21 shows a location of the charger pins 2101 when the
electronic vaporization device is fully assembled with the charging
pins 2101 contact the charging flex 2102. When the device is fully
assembled at least a portion of the retaining bezel may be fitted
in an indentation 2103 on the inside of the housing 2104. In some
cases, disassembling the electronic vaporization device may destroy
the bezel such that the device cannot be reassembled after
disassembly.
[0301] A user may place the electronic smoking device in a charging
cradle. The charging cradle may be a holder with charging contact
configured to mate or couple with the charging pins on the
electronic smoking device to provide charge to the energy storage
device in the electronic vaporization device from a power source
(e.g., wall outlet, generator, and/or external power storage
device). FIG. 22 shows a device 2302 in a charging cradle 2301. The
charging cable may be connected to a wall outlet, USB, or any other
power source. The charging pins (not shown) on the device 2302 may
be connected to charging contacts (not shown) on the charging
cradle 2301. The device may be configured such that when the device
is placed in the cradle for charging a first charging pin on the
device may contact a first charging contact on the charging cradle
and a second charging pin on the device may contact a second
charging contact on the charging cradle or the first charging pin
on the device may contact a second charging contact on the charging
cradle and the second charging pin on the device may contact the
first charging contact on the charging cradle. The charging pins on
the device and the charging contacts on the cradle may be in
contact in any orientation. The charging pins on the device and the
charging contacts on the cradle may be agnostic as to whether they
are current inlets or outlets. Each of the charging pins on the
device and the charging contacts on the cradle may be negative or
positive. The charging pins on the device may be reversible.
[0302] FIG. 23 shows a circuit 2400 that may permit the charging
pins on the device to be reversible. The circuit 2400 may be
provided on a PCB in electrical communication with the charging
pins. The circuit 2400 may comprise a metal-oxide-semiconductor
field-effect transistor (MOSFET) H bridge. The MOSFET H bridge may
rectify a change in voltage across the charging pins when the
charging pins are reversed from a first configuration where in a
first configuration the device is placed in the cradle for charging
with the first charging pin on the device in contact with the first
charging contact on the charging cradle to a second charging pin on
the device in contact with the second charging contact on the
charging cradle to a second configuration where the first charging
pin on the device is in contact with the second charging contact on
the charging cradle and the second charging pin on the device is in
contact with the first charging contact on the charging cradle. The
MOSFET H bridge may rectify the change in voltage with an efficient
current path.
[0303] As shown in FIG. 23 the MOSFET H bridge may comprise two or
more n-channel MOSFETs and two or more p-channel MOSFETs. The
n-channel and p-channel MOSFETs may be arranged in an H bridge.
Sources of p-channels MOSFETs (Q1 and Q3) may be in electrical
communication. Similarly, sources of n-channel FETs (Q2 and Q4) may
be in electrical communication. Drains of pairs of n and p MOSFETs
(Q1 with Q2 and Q3 with Q4) may be in electrical communication. TA
common drain from one n and p pair may be in electrical
communication with one or more gates of the other n and p pair
and/or vice versa. Charge contacts (CH1 and CH2) may be in
electrical communication to common drains separately. A common
source of then MOSFETs may be in electrical communication to PCB
ground (GND). The common source of the p MOSFETs may be in
electrical communication with the PCB's charge controller input
voltage (CH+). When CH1 voltage is greater than CH2 voltage by the
MOSFET gate threshold voltages, Q1 and Q4 may be "on," connecting
CH1 to CH+ and CH2 to GND. When CH2 voltage is greater than CH1
voltage by the FET gate threshold voltages, Q2 and Q3 may be "on,"
connecting CH1 to GND and CH2 to CH+. For example, whether there is
9V or -9V across CH1 to CH2, CH+ will be 9V above GND.
Alternatively, a diode bridge could be used, however the MOSFET
bridge may be more efficient compared to the diode bridge.
[0304] In some cases the charging cradle may be configured to be a
smart charger. The smart charger may put the battery of the device
in series with a USB input to charge the device at a higher current
compared to a typical charging current. In some cases, the device
may charge at a rate up to about 2 amps (A), 4 A, 5 A, 6 A, 7 A, 10
A, or 15 A. In some cases, the smart charger may comprise a
battery, power from the battery may be used to charge the device
battery. When the battery in the smart charger has a charge below a
predetermined threshold charge, the smart charger may
simultaneously charge the battery in the smart charger and the
battery in the device.
[0305] Blow Discrimination
[0306] In any of the devices and system (e.g., vaporizers)
described herein, a pressure sensor may be used and configured to
detect blowing and to distinguish blowing from draw
(sucking/inhaling). For example, a modified electret microphone may
be used as a pressure sensor connected to the device's
microcontroller so that pressure-dependent measurements can be made
by the microcontroller. The microcontroller's draw detection
algorithm, which uses measurements of pressure sensor's capacitance
to determine the start and end of the draw, may be configured to
include blow detection and/or blow discrimination.
[0307] As mentioned above, other types of pressures sensors may be
used (e.g., MEMS pressure sensors or any other differential
pressure sensor). In such cases the output of the sensor (which may
be converted by the sensor and/or associated circuitry into a
pressure value (e.g., in mmHg, atm, etc.) or it may be a raw sensor
output or value (e.g., reading) such as a capacitance value in the
case of a pressure sensor using a capacitive membrane, electrical
value (resistive, voltage, etc.), digital value, force and/or
displacement value, etc. As described herein, this raw value may be
used in the controls described (e.g., microcontrollers) without
requiring conversion to an actual pressure reading. Although the
examples described herein refer to a capacitive pressure sensor
having a capacitive membrane (e.g., an electret microphone), any
other differential pressure sensor may be used instead with the
methods and apparatuses described herein, including controlling the
baseline during a putative blow and/or draw through the mouthpiece
as described in greater detail below.
[0308] Thus, any pressure sensor that can distinguish positive and
negative pressure may be used. For example a pressure sensor may
comprise an electrically conductive diaphragm held in close
proximity to a conductive static plate, forming an air capacitor,
with both conductors connected to pins or pads on a circuit (e.g.,
PCB) opposite the static plate side of the sensor. FIGS. 24A-24D
illustrate one example of a pressure sensor that is a capacitive
pressure sensor. In this example, the diaphragm 2404 (shown in FIG.
24D) is mounted to a rigid thin wall tube (case 2403) that is a
close fit within the outer conductive case 2407 of the sensor such
that air cannot flow through the sensor around the diaphragm. Holes
2411 in the static plate on one side of a gasket and holes 2413 in
the PCB 2401 on the opposite side of the diaphragm allow pressure
differences between the two sides of the sensor to been seen by the
diaphragm, which deflects with a pressure difference across it.
[0309] Within the vaporizer, the sensor may be included in a sealed
air path so as to distinguish a difference between internal
pressure and air pressure. In some variations, a gasket 2502 in the
device forms an air-tight seal around the sensor's case such that
the static plate side of the sensor sees gauge pressures in the
device's air path when a user draws from or blows into the device,
as shown in FIG. 25. Air flow restriction between the device's
nominal air inlet 2505 and the pressure sensor 2509 creates a
pressure that the static plate side of the pressure registers. The
PCB 2511 side of the pressure sensor stays at an external reference
(e.g., 0 gauge) pressure during a draw or blow as the PCB side of
the pressure sensor is not part of the air path and is not sealed
from ambient air. Pressure difference on either side of the sensor
resolve onto either side of the diaphragm; negative gauge pressure
in the air path from a draw pulls the diaphragm towards the static
plate, increasing the capacitance of the sensor, while positive
gauge pressures in the air path from a blow push the diaphragm away
from the static plate, decreasing the sensor's capacitance.
[0310] Differences between the pressure on either side of the
diaphragm 2404 and the back plate 2404 change the spacing between
the diaphragm and back plate and therefore the capacitance of the
sensor. This different separation may be read as the capacitance of
the sensor and compared to ambient. In some variations, capacitance
is measured with an oscillating circuit that sources and sinks
current to/from the sensor to charge and discharge the sensor
repeatedly. The device's microcontroller counts the number of times
the sensor's intrinsic capacitor is charged and discharged within a
fixed time period (e.g., 0.5 ms, 1 ms, 1.5 ms, 2 ms, etc.) and uses
this value in a draw detection algorithm. This measurement may be
inversely related to the capacitance of the sensor, since an
increase in capacitance will make the capacitor charge slower,
resulting in fewer charge and discharge cycles during the
measurement period. So an increase in capacitance from negative air
path gauge pressure, normally a draw, will result in a lower
reading than when the user is not drawing from the device. Blowing
into the nominal outlet of the air path will result in an increase
in this measured value. Actual capacitance and air path gauge
pressure are not needed by the draw detection algorithm, so they
are not calculated, though they could be approximated and used in a
similar draw detection algorithm.
[0311] In any of the apparatuses described herein, a capacitive
sensing module within the microcontroller may handle the
oscillation and current sourcing/sinking needed for the measurement
via a direct connection to the pressure sensor diaphragm. The
pressure sensor's case may be tied to PCB ground.
[0312] Because the ambient pressure around the device may change,
the `baseline` capacitance of the sensor may also change. This may
be incorporated into the control circuitry that determines draw
(and may determine or reject blow). For example, the draw detection
algorithm may respond to environmental changes (not including draw
or blow) that may change the nominal pressure measurement by using
a baseline pressure measurement value which normally follows live
pressure measurements using a software low-pass filter. With a
moving baseline, a threshold for detecting the start of a draw can
be kept very close to the baseline and live readings for consistent
sensitivity and maximum sensitivity without falsely detected draws.
The draw detection algorithm may therefore detect the start of a
draw when the live pressure measurement drops (indicating a
pressure drop in the air path) to some threshold below the baseline
value for some number of measurements. The algorithm detects end of
draw when live pressure measurements rise above some threshold
below the baseline. The baseline may he fixed during the draw so
that end of draw detection does not happen prematurely, and so that
subsequent draws don't require larger pressure drops for the
algorithm to detect the start of a draw.
[0313] For example, see FIG. 26, which graphically illustrates the
output of the pressure sensor over time and when draws are detected
by the microcontroller (which is performing the control logic as
described herein). In this example, the live reading is the
pressure output (converted capacitance measurement in this example)
from the sensor. The baseline is a low-pass filtered measure of the
live reading. This baseline is fixed during the two draw events.
Draw detection state is shown by the square wave, where the high
state corresponds to a draw currently being detected. A first
threshold is positioned at a fixed offset below the baseline; when
the live reading from the sensor (the pressure measurement) crosses
the threshold (e.g., exceeds this offset), it detects a draw event,
and can again detect the end of the draw event when the pressure
returns past the same threshold. These two thresholds may differ
from each other in the draw detection logic (algorithm). A similar
method may be applied to detect blowing; a second threshold or
second offset (blow threshold/offset) maybe represented as a line
on the opposite side of the baseline from the draw
threshold/offset. In this example, draws are detected as downward
pressure deflection and offset, whereas blowing is upward
deflection relative to the baseline; if the orientation of the
sensor is reversed, or if the raw sensor values, depending on the
type of sensor, are used, the direction of blow and draw relative
to the baseline may be different.
[0314] Blowing into the device may be detected and/or ignored using
this algorithm. For example, when the live pressure measurement
rises to values above the baseline value (e.g., in the more
positive direction in the configuration shown in FIGS. 25, 26 and
27), which is usually caused by the user blowing into the air path
outlet, the baseline may also stop following the live pressure
measurements (e.g., remain at the last value) until the sensor
output returns to below some threshold above the baseline value, as
shown in FIG. 27. Holding the baseline during a blowing event may
prevent the baseline from rising to a value at which draw start
would be detected at the end of the blow. With this feature, users
can hold the device with their lips and/or teeth without worrying
about the device heating when they didn't intend for it to heat.
Without this feature, it the device may apparently heat on its own.
Thus, preventing false draw may save, battery life and vaporizable
material by preventing detection of false draws which may occur,
for example if the baseline during a blow event were reset to
higher values so that the end of the blow would drop the sensor
signal to beyond the threshold (which is an offset of the
now-incorrect baseline) for detecting draw.
[0315] Thus, in general, the pressure sensor is configured to
detect draw by comparing the instantaneous sensor output ("live
reading" in FIGS. 26 and 27) to a baseline value which is a based
on a filtered (e.g., low pass filtered, averaged, windowed,
weighted averaged, etc.) version of the instantaneous sensor
output. Detection of draw is made more accurate by rejecting
changes to the baseline during blowing (e.g., "blow rejection" or
"blow discrimination"). This may be achieved by freezing the value
of the baseline when the instantaneous sensor output is greater
than the baseline or greater than some predetermined offset above
or below (whichever direction corresponds to blowing based on the
orientation of the sensor in the system) the baseline. The baseline
value may also be frozen when the instantaneous sensor crosses a
threshold for detection of draw (e.g., above or below this
threshold based on the orientation of the sensor in the
system).
[0316] In an alternative embodiment, an oscillating circuit
external to the microcontroller may be used to charge and discharge
the pressure sensor's intrinsic capacitor. This circuit could be a
multivibrator circuit, relaxation oscillator, or other oscillator
that is self-resonant or excited by the microcontroller. The
pressure sensor case may not be grounded. A microcontroller is
still used to count charge and discharge cycles within a fixed
interval.
[0317] In an alternative embodiment, a fixed resistance may be used
to charge the pressure sensor's intrinsic capacitor. Charge time up
to some voltage or discharge time down to some voltage is measured
using a comparator internal or external to the microcontroller. In
this case, readings will increase with increased sensor
capacitance, as opposed to oscillator charge count readings which
decrease with increased sensor capacitance, and the draw detection
algorithm may be modified accordingly, with increased readings
required for draw start detection and decreased readings required
for blow detection.
[0318] In an alternative embodiment, the diaphragm is in between
the static plate and the air path, such that negative pressure from
a draw would decrease the capacitance of the sensor. If the sensor
is still measured with an oscillator, the sensor output for reading
deviations from baseline required for draw start detection and blow
detection are switched.
[0319] In an alternative embodiment, the pressure sensor has solder
pads and/or lead wires instead of pins on its PCB.
[0320] In an alternative embodiment, the draw detection circuitry
(e.g., algorithm) may not detect a draw start unless it has a
"stable" baseline. When a blow is detected, a flag may be set that
indicates that the baseline is not stable. When the end of blow is
detected and pressure readings stabilize, the baseline is set
conservatively below live pressure readings and the flag for
unstable baseline is cleared, meaning drops in the reading will
again be detected as draw start event, similar to what is shown in
FIG. 27.
[0321] When a feature or element is herein referred to as being
"on" another feature or element, it can be directly on the other
feature or element or intervening features and/or elements may also
be present. In contrast, when a feature or element is referred to
as being "directly on" another feature or element, there are no
intervening features or elements present. It will also be
understood that, when a feature or element is referred to as being
"connected", "attached" or "coupled" to another feature or element,
it can be directly connected, attached or coupled to the other
feature or element or intervening features or elements may be
present. In contrast, when a feature or element is referred to as
being "directly connected", "directly attached" or "directly
coupled" to another feature or element, there are no intervening
features or elements present. Although described or shown with
respect to one embodiment, the features and elements so described
or shown can apply to other embodiments. It will also be
appreciated by those of skill in the art that references to a
structure or feature that is disposed "adjacent" another feature
may have portions that overlap or underlie the adjacent
feature.
[0322] Terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. For example, 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 "comprises" and/or "comprising," when
used in this specification, specify the presence of stated
features, steps, operations, elements, and/or components, but do
not preclude the presence or addition of one or more other
features, steps, operations, elements, components, and/or groups
thereof. As used herein, the term "and/or" includes any and all
combinations of one or more of the associated listed items and may
be abbreviated as "/".
[0323] Spatially relative terms, such as "under", "below", "lower",
"over", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will 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 a device in the figures is inverted, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus, the
exemplary term "under" can encompass both an orientation of over
and under. The device may be otherwise oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly. Similarly, the terms
"upwardly", "downwardly", "vertical", "horizontal" and the like are
used herein for the purpose of explanation only unless specifically
indicated otherwise.
[0324] Although the terms "first" and "second" may be used herein
to describe various features/elements (including steps), these
features/elements should not be limited by these terms, unless the
context indicates otherwise. These terms may be used to distinguish
one feature/element from another feature/element. Thus, a first
feature/element discussed below could be termed a second
feature/element, and similarly, a second feature/element discussed
below could be termed a first feature/element without departing
from the teachings of the present invention.
[0325] Throughout this specification and the claims which follow,
unless the context requires otherwise, the word "comprise", and
variations such as "comprises" and "comprising" means various
components can be co-jointly employed in the methods and articles
(e.g., compositions and apparatuses including device and methods).
For example, the term "comprising" will be understood to imply the
inclusion of any stated elements or steps but not the exclusion of
any other elements or steps.
[0326] As used herein in the specification and claims, including as
used in the examples and unless otherwise expressly specified, all
numbers may be read as if prefaced by the word "about" or
"approximately," even if the term does not expressly appear. The
phrase "about" or "approximately" may be used when describing
magnitude and/or position to indicate that the value and/or
position described is within a reasonable expected range of values
and/or positions. For example, a numeric value may have a value
that is +/-0.1% of the stated value (or range of values), +/-1% of
the stated value (or range of values), +/-2% of the stated value
(or range of values), +/-5% of the stated value (or range of
values), +/-10% of the stated value (or range of values), etc. Any
numerical values given herein should also be understood to include
about or approximately that value, unless the context indicates
otherwise. For example, if the value "10" is disclosed, then "about
10" is also disclosed. Any numerical range recited herein is
intended to include all sub-ranges subsumed therein. It is also
understood that when a value is disclosed that "less than or equal
to" the value, "greater than or equal to the value" and possible
ranges between values are also disclosed, as appropriately
understood by the skilled artisan. For example, if the value "X" is
disclosed the "less than or equal to X" as well as "greater than or
equal to X" (e.g., where X is a numerical value) is also disclosed.
It is also understood that the throughout the application, data is
provided in a number of different formats, and that this data,
represents endpoints and starting points, and ranges for any
combination of the data points. For example, if a particular data
point "10" and a particular data point "15" are disclosed, it is
understood that greater than, greater than or equal to, less than,
less than or equal to, and equal to 10 and 15 are considered
disclosed as well as between 10 and 15. It is also understood that
each unit between two particular units are also disclosed. For
example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are
also disclosed.
[0327] Although various illustrative embodiments are described
above, any of a number of changes may be made to various
embodiments without departing from the scope of the invention as
described by the claims. For example, the order in which various
described method steps are performed may often be changed in
alternative embodiments, and in other alternative embodiments one
or more method steps may be skipped altogether. Optional features
of various device and system embodiments may be included in some
embodiments and not in others. Therefore, the foregoing description
is provided primarily for exemplary purposes and should not be
interpreted to limit the scope of the invention as it is set forth
in the claims.
[0328] The examples and illustrations included herein show, by way
of illustration and not of limitation, specific embodiments in
which the subject matter may be practiced. As mentioned, other
embodiments may be utilized and derived there from, such that
structural and logical substitutions and changes may be made
without departing from the scope of this disclosure. Such
embodiments of the inventive subject matter may be referred to
herein individually or collectively by the term "invention" merely
for convenience and without intending to voluntarily limit the
scope of this application to any single invention or inventive
concept, if more than one is, in fact, disclosed. Thus, although
specific embodiments have been illustrated and described herein,
any arrangement calculated to achieve the same purpose may be
substituted for the specific embodiments shown. This disclosure is
intended to cover any and all adaptations or variations of various
embodiments. Combinations of the above embodiments, and other
embodiments not specifically described herein, will be apparent to
those of skill in the art upon reviewing the above description.
* * * * *