U.S. patent application number 17/136520 was filed with the patent office on 2021-07-22 for electronic cigarette with mass air flow sensor.
The applicant listed for this patent is FONTEM HOLDINGS 1 B.V.. Invention is credited to Ramon ALARCON, Adam HOFFMAN, Christopher MYLES, Michael STARMAN.
Application Number | 20210220581 17/136520 |
Document ID | / |
Family ID | 1000005504932 |
Filed Date | 2021-07-22 |
United States Patent
Application |
20210220581 |
Kind Code |
A1 |
ALARCON; Ramon ; et
al. |
July 22, 2021 |
ELECTRONIC CIGARETTE WITH MASS AIR FLOW SENSOR
Abstract
In accordance with one aspect of the present invention there is
provided an electronic smoking device comprising a flow channel and
an atomizer. The flow channel can comprise an incoming airflow
opening, an incoming airflow pathway, a sensor assembly, and an
outgoing airflow opening. The atomizer can be fluidly coupled to
the flow channel. The flow channel can be configured to direct an
airflow from the incoming airflow opening, through the incoming
airflow pathway, over the sensor assembly, and through the outgoing
airflow opening. The electronic smoking device can further be
configured to pass the airflow over the atomizer.
Inventors: |
ALARCON; Ramon; (Los Gatos,
CA) ; HOFFMAN; Adam; (Campbell, CA) ; STARMAN;
Michael; (Los Gatos, CA) ; MYLES; Christopher;
(San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FONTEM HOLDINGS 1 B.V. |
Amsterdam |
|
NL |
|
|
Family ID: |
1000005504932 |
Appl. No.: |
17/136520 |
Filed: |
December 29, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15930061 |
May 12, 2020 |
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17136520 |
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15219214 |
Jul 25, 2016 |
10757973 |
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15930061 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61M 11/042 20140204;
H05B 1/0244 20130101; A61M 15/06 20130101; A24F 40/51 20200101;
A61M 2206/11 20130101; A24F 40/50 20200101; A61M 11/005 20130101;
A61M 2016/0039 20130101; G01F 1/6888 20130101; A61M 15/0025
20140204; A24F 40/10 20200101; A61M 2016/0024 20130101; G01F 1/696
20130101; A61M 2205/587 20130101 |
International
Class: |
A61M 15/06 20060101
A61M015/06; H05B 1/02 20060101 H05B001/02; G01F 1/688 20060101
G01F001/688; G01F 1/696 20060101 G01F001/696; A24F 40/50 20060101
A24F040/50; A24F 40/51 20060101 A24F040/51 |
Claims
1. An electronic cigarette comprising: a power supply housing
having a first and second end, a subassembly housing holding a
battery; a first circuit board at the first end of the power supply
housing, the first circuit board having a plurality of LEDs, the
first circuit board connected to a second circuit board by an
electrical connection extending along a length of the battery; the
second circuit board at the second end of the power supply housing;
an air flow sensor on the second circuit board; and a light guide
at the first end of the power supply housing.
2. The electronic cigarette of claim 1 wherein the light guide
illuminates the power supply housing when the LEDs are on.
3. The electronic cigarette of claim 1 having five LEDs.
4. The electronic cigarette of claim 1 wherein LEDs provide a
plurality of visual indications by varying the brightness, color,
and on/off time of the LEDs.
5. The electronic cigarette of claim 4 wherein the indications
reflect a functional aspect of the electronic cigarette.
6. The electronic cigarette of claim 5 wherein the functional
aspect is one or more of remaining battery life, battery charging,
and/or sleep mode.
7. The electronic cigarette of claim 1 further including controller
circuitry on the second circuit board.
8. The electronic cigarette of claim 1 further including a tip
diffuser at the first end of the power supply housing.
9. The electronic cigarette of claim 1 further including a locking
element locking the subassembly housing with the power supply
housing.
10. The electronic cigarette of claim 1 further including one or
more keying features on the subassembly housing for preventing
rotation of the subassembly housing about a longitudinal axis.
11. The electronic cigarette of claim 1 wherein first circuit board
comprises is a printed flex circuit.
12. The electronic cigarette of claim 11 wherein printed flex
circuit extends over the battery and around an end of the
battery.
13. An electronic cigarette power supply assembly comprising: a
power supply housing having a first and second end, a subassembly
housing holding a battery a first printed circuit board positioned
at the first end of the power supply housing, the first printed
circuit board having a plurality of LEDs, the first printed circuit
board connected to a second printed circuit board by an electrical
connection extending alongside of the battery; the second printed
circuit board located at the second end of the power supply
housing; an air flow sensor attached to the second printed circuit
board; and a light guide at the second end of the power supply
housing.
14. The electronic cigarette power supply assembly of claim 13
further including a connector port in the power supply housing.
15. The electronic cigarette power supply assembly of claim 14
further including an airflow gasket in the connector port.
16. The electronic cigarette power supply assembly of claim 13
further including control circuitry on the second printed circuit
board.
17. The electronic cigarette power supply assembly of claim 16
further including contacts on the second printed circuit board
electrically coupled to the controller circuitry, the contacts
extending toward apertures within the upper sub-assembly housing.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/930,061, filed May 12, 2020, which is a
continuation of U.S. patent application Ser. No. 15/219,214, filed
Jul. 25, 2016, now U.S. Pat. No. 10,757,973, both of which are
incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates generally to electronic
smoking devices and in particular electronic cigarettes.
BACKGROUND OF THE INVENTION
[0003] An electronic smoking device, such as an electronic
cigarette (e-cigarette), typically has a housing accommodating an
electric power source (e.g., a single use or rechargeable battery,
electrical plug, or other power source), and an electrically
operable atomizer. The atomizer vaporizes or atomizes liquid
supplied from a reservoir and provides vaporized or atomized liquid
as an aerosol. Control electronics control the activation of the
atomizer. In some electronic cigarettes, an airflow sensor is
provided within the electronic smoking device, which detects a user
puffing on the device (e.g., by sensing an under-pressure or an
airflow pattern through the device). The airflow sensor indicates
or signals the puff to the control electronics to power up the
device and generate vapor. In other e-cigarettes, a switch is used
to power up the e-cigarette to generate a puff of vapor.
[0004] In prior art eCigs, the pressure sensor is configured to
sense a user's draw on the eCig and transmit an activation signal
to the heating coil to vaporize the liquid solution. However, these
pressure sensors can be large and costly.
SUMMARY OF THE INVENTION
[0005] In accordance with one aspect of the present invention there
is provided an electronic smoking device comprising a flow channel
and an atomizer. The flow channel can comprise an incoming airflow
opening, an incoming airflow pathway, a sensor assembly, and an
outgoing airflow opening. The atomizer can be fluidly coupled to
the flow channel. The flow channel can be configured to direct an
airflow from the incoming airflow opening, through the incoming
airflow pathway, over the sensor assembly, and through the outgoing
airflow opening. The electronic smoking device can further be
configured to pass the airflow, at least in part, over the
atomizer.
[0006] The characteristics, features and advantages of this
invention and the manner in which they are obtained as described
above, will become more apparent and be more clearly understood in
connection with the following description of exemplary embodiments,
which are explained with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings, the same element numbers indicate the same
elements in each of the views:
[0008] FIG. 1 is a schematic cross-sectional illustration of an
exemplary e-cigarette.
[0009] FIG. 2A is a partial exploded assembly view of an eCig
battery housing, consistent with various aspects of the present
disclosure.
[0010] FIG. 2B is a partial exploded assembly view of an eCig
battery housing, consistent with various aspects of the present
disclosure.
[0011] FIG. 3 is an example of a microcontroller that is
constructed according to an aspect of the disclosure.
[0012] FIG. 4 is an example of a flow sensor that is constructed
according to an aspect of the disclosure.
[0013] FIGS. 5A and 5B are examples of signal amplification and
filtering through a single amplifier or multiple amplifiers.
[0014] FIG. 6 is an electrical diagram of an eCig comprising a
first and second thermopile.
[0015] FIG. 7 is an electrical diagram of an eCig comprising one
thermopile.
[0016] FIGS. 8A and 8B are an example of a flow channel according
to the principles of the disclosure.
[0017] FIG. 9 is a side view of one embodiment of a sensor
assembly.
[0018] FIG. 10 is a schematic view of another embodiment of a
sensor assembly.
[0019] FIG. 11A is a schematic view of another embodiment of a
sensor assembly.
[0020] FIG. 11B is a schematic view of an embodiment of a
sensor.
[0021] FIGS. 12A-12C are schematics of several embodiments of flow
channels according to the disclosure.
[0022] FIG. 13 is a graph illustrating one embodiment of the power
delivered for various flow rates.
[0023] FIG. 14 is a graph illustrating several embodiments of
response signals for various flow rates.
[0024] FIG. 15 is a graph illustrating one embodiment of a flow
rate over time.
[0025] FIG. 16 is a graph illustrating several embodiments of
response signals for various flow rates.
[0026] FIG. 17 is a flowchart illustrating one embodiment of a
process for interpreting signals according to the disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Throughout the following, an electronic smoking device will
be exemplarily described with reference to an e-cigarette. As is
shown in FIG. 1, an e-cigarette 10 typically has a housing
comprising a cylindrical hollow tube having an end cap 12. The
cylindrical hollow tube may be a single-piece or a multiple-piece
tube. In FIG. 1, the cylindrical hollow tube is shown as a
two-piece structure having a power supply portion 14 and an
atomizer/liquid reservoir portion 16. Together the power supply
portion 14 and the atomizer/liquid reservoir portion 16 form a
cylindrical tube which can be approximately the same size and shape
as a conventional cigarette, typically about 100 mm with a 7.5 mm
diameter, although lengths may range from 70 to 150 or 180 mm, and
diameters from 5 to 28 mm.
[0028] The power supply portion 14 and atomizer/liquid reservoir
portion 16 are typically made of metal (e.g., steel or aluminum, or
of hardwearing plastic) and act together with the end cap 12 to
provide a housing to contain the components of the e-cigarette 10.
The power supply portion 14 and the atomizer/liquid reservoir
portion 16 may be configured to fit together by, for example, a
friction push fit, a snap fit, a bayonet attachment, a magnetic
fit, or screw threads. The end cap 12 is provided at the front end
of the power supply portion 14. The end cap 12 may be made from
translucent plastic or other translucent material to allow a
light-emitting diode (LED) 18 positioned near the end cap to emit
light through the end cap. Alternatively, the end cap may be made
of metal or other materials that do not allow light to pass.
[0029] An air inlet may be provided in the end cap, at the edge of
the inlet next to the cylindrical hollow tube, anywhere along the
length of the cylindrical hollow tube, or at the connection of the
power supply portion 14 and the atomizer/liquid reservoir portion
16. FIG. 1 shows a pair of air inlets 20 provided at the
intersection between the power supply portion 14 and the
atomizer/liquid reservoir portion 16.
[0030] A power supply, preferably a battery 22, the LED 18, control
electronics 24 and, optionally, an airflow sensor 26 are provided
within the cylindrical hollow tube power supply portion 14. The
battery 22 is electrically connected to the control electronics 24,
which are electrically connected to the LED 18 and the airflow
sensor 26. In this example, the LED 18 is at the front end of the
power supply portion 14, adjacent to the end cap 12; and the
control electronics 24 and airflow sensor 26 are provided in the
central cavity at the other end of the battery 22 adjacent the
atomizer/liquid reservoir portion 16.
[0031] The airflow sensor 26 acts as a puff detector, detecting a
user puffing or sucking on the atomizer/liquid reservoir portion 16
of the e-cigarette 10. The airflow sensor 26 can be any suitable
sensor for detecting changes in airflow or air pressure, such as a
microphone switch including a deformable membrane which is caused
to move by variations in air pressure. Alternatively, the sensor
may be, for example, a Hall element or an electro-mechanical
sensor.
[0032] The control electronics 24 are also connected to an atomizer
28. In the example shown, the atomizer 28 includes a heating coil
30 which is wrapped around a wick 32 extending across a central
passage 34 of the atomizer/liquid reservoir portion 16. The central
passage 34 may, for example, be defined by one or more walls of the
liquid reservoir and/or one or more walls of the atomizer/liquid
reservoir portion 16 of the e-cigarette 10. The coil 30 may be
positioned anywhere in the atomizer 28 and may be transverse or
parallel to a longitudinal axis of a cylindrical liquid reservoir
36. The wick 32 and heating coil 30 do not completely block the
central passage 34. Rather an air gap is provided on either side of
the heating coil 30 enabling air to flow past the heating coil 30
and the wick 32. The atomizer may alternatively use other forms of
heating elements, such as ceramic heaters, or fiber or mesh
material heaters. Nonresistance heating elements such as sonic,
piezo, and jet spray may also be used in the atomizer in place of
the heating coil.
[0033] The central passage 34 is surrounded by the cylindrical
liquid reservoir 36 with the ends of the wick 32 abutting or
extending into the liquid reservoir 36. The wick 32 may be a porous
material such as a bundle of fiberglass fibers or cotton or bamboo
yarn, with liquid in the liquid reservoir 36 drawn by capillary
action from the ends of the wick 32 towards the central portion of
the wick 32 encircled by the heating coil 30.
[0034] The liquid reservoir 36 may alternatively include wadding
(not shown in FIG. 1) soaked in liquid which encircles the central
passage 34 with the ends of the wick 32 abutting the wadding. In
other embodiments, the liquid reservoir may comprise a toroidal
cavity arranged to be filled with liquid and with the ends of the
wick 32 extending into the toroidal cavity.
[0035] An air inhalation port 38 is provided at the back end of the
atomizer/liquid reservoir portion 16 remote from the end cap 12.
The inhalation port 38 may be formed from the cylindrical hollow
tube atomizer/liquid reservoir portion 16 or may be formed in an
end cap.
[0036] In use, a user sucks on the e-cigarette 10. This causes air
to be drawn into the e-cigarette 10 via one or more air inlets,
such as air inlets 20, and to be drawn through the central passage
34 towards the air inhalation port 38. The change in air pressure
which arises is detected by the airflow sensor 26, which generates
an electrical signal that is passed to the control electronics 24.
In response to the signal, the control electronics 24 activate the
heating coil 30, which causes liquid present in the wick 32 to be
vaporized creating an aerosol (which may comprise gaseous and
liquid components) within the central passage 34. As the user
continues to suck on the e-cigarette 10, this aerosol is drawn
through the central passage 34 and inhaled by the user. At the same
time, the control electronics 24 also activate the LED 18 causing
the LED 18 to light up, which is visible via the translucent end
cap 12. Activation of the LED may mimic the appearance of a glowing
ember at the end of a conventional cigarette. As liquid present in
the wick 32 is converted into an aerosol, more liquid is drawn into
the wick 32 from the liquid reservoir 36 by capillary action and
thus is available to be converted into an aerosol through
subsequent activation of the heating coil 30.
[0037] Some e-cigarette are intended to be disposable and the
electric power in the battery 22 is intended to be sufficient to
vaporize the liquid contained within the liquid reservoir 36, after
which the e-cigarette 10 is thrown away. In other embodiments, the
battery 22 is rechargeable and the liquid reservoir 36 is
refillable. In the cases where the liquid reservoir 36 is a
toroidal cavity, this may be achieved by refilling the liquid
reservoir 36 via a refill port (not shown in FIG. 1). In other
embodiments, the atomizer/liquid reservoir portion 16 of the
e-cigarette 10 is detachable from the power supply portion 14 and a
new atomizer/liquid reservoir portion 16 can be fitted with a new
liquid reservoir 36 thereby replenishing the supply of liquid. In
some cases, replacing the liquid reservoir 36 may involve
replacement of the heating coil 30 and the wick 32 along with the
replacement of the liquid reservoir 36. A replaceable unit
comprising the atomizer 28 and the liquid reservoir 36 may be
referred to as a cartomizer.
[0038] The new liquid reservoir may be in the form of a cartridge
(not shown in FIG. 1) defining a passage (or multiple passages)
through which a user inhales aerosol. In other embodiments, the
aerosol may flow around the exterior of the cartridge to the air
inhalation port 38.
[0039] Of course, in addition to the above description of the
structure and function of a typical e-cigarette 10, variations also
exist. For example, the LED 18 may be omitted. The airflow sensor
26 may be placed, for example, adjacent to the end cap 12 rather
than in the middle of the e-cigarette. The airflow sensor 26 may be
replaced by, or supplemented with, a switch which enables a user to
activate the e-cigarette manually rather than in response to the
detection of a change in airflow or air pressure.
[0040] Different types of atomizers may be used. Thus, for example,
the atomizer may have a heating coil in a cavity in the interior of
a porous body soaked in liquid. In this design, aerosol is
generated by evaporating the liquid within the porous body either
by activation of the coil heating the porous body or alternatively
by the heated air passing over or through the porous body.
Alternatively the atomizer may use a piezoelectric atomizer to
create an aerosol either in combination or in the absence of a
heater.
[0041] FIG. 2A is a partial exploded assembly view of an eCig power
supply portion 212 (also referred to as a power supply portion),
consistent with various aspects of the present disclosure. The
power supply portion 212 houses a number of electrical components
that facilitate the re-charging and re-use of the power supply
portion 212 with disposable and refillable atomizer/liquid
reservoir portions (14 as shown in FIG. 1), which are also referred
to as atomizer/liquid reservoir portions. A battery 218 is
electrically coupled to controller circuitry 222 on a printed
circuit board. An airflow sensor 224 for determining one or more
characteristics of a user's draw from the eCig is also located on
the printed circuit board, and communicatively coupled to the
controller circuitry 222. In various embodiments consistent with
the present disclosure, the airflow sensor 224 may be a mass
airflow sensor, a pressure sensor, a velocity sensor, a heater coil
temperature sensor, or any other sensor that may capture relevant
draw characteristics (either directly or through indirect
correlations). In the present embodiment, the airflow sensor 224 is
a mass airflow sensor that determines the flow of air across the
airflow sensor 224. The measured flow of air is then drawn through
the atomizer/liquid reservoir portion, where heater coils atomize
eCig juice into the air, and into a user's mouth. Accordingly, by
measuring the mass flow rate of air through the power supply
portion 212, the controller circuitry 222 may adjust a heating
profile of a heating coil in a atomizer/liquid reservoir portion
(e.g., power, length of time, etc.), as well as provide a variable
indication of the strength of the draw--by way of LEDs 220.sub.A-E,
which may be independently addressed by the controller circuitry or
powered at varying intensities to indicate characteristics
indicative of the eCig's functionality. For example, varying the
illumination intensity based on the sensed mass airflow. In further
embodiments, the LEDs may also indicate other functional aspects of
the eCig, such as remaining battery life, charging, sleep mode,
among others.
[0042] In various embodiments of the present disclosure, electrical
pins extending from the printed circuit board may be electrically
coupled to a atomizer/liquid reservoir portion, and thereby allow
for both energy transfer and data communication between the power
supply portion 212 and the atomizer/liquid reservoir portion (not
shown). In various other embodiments, pins may extend from a
surface of the printed circuit board to an exterior of the power
supply portion to facilitate charging and data communication with
external circuitry.
[0043] To provide user indications of status, power remaining, use,
error messages, among other relevant information, a flexible
printed circuit board 221 is communicatively coupled to controller
circuitry 222 via wire leads 242.sub.A-B. The flexible circuit
board 221 may include one or more light sources. In the present
embodiment, the flexible circuit board 221 includes LEDs
220.sub.A-E. When assembled into the rest of the power supply
portion 212, the LEDs 220.sub.A-E both illuminate a circumferential
portion of light guide 216, and a tip diffuser 246 that illuminates
a distal end of the light guide 216. The tip diffuser 246 and the
light guide 216 together facilitate even illumination of the distal
end of the power supply portion 212 in response to the activation
of the LEDs 220.sub.A-E.
[0044] As shown in FIG. 2A, once electrically coupled to one
another (e.g., by solder), battery 218, flexible printed circuit
board 221, and a printed circuit board containing controller
circuitry 222 and airflow sensor 224 are encased by upper
sub-assembly housing 240 and lower sub-assembly housing 241. In one
embodiment, the upper sub-assembly housing 240 and the lower
sub-assembly housing 241 can create a flow channel. The flow
channel created by the upper sub-assembly housing 240 and the lower
sub-assembly housing 241 can direct airflow over the airflow
sensor. The sub-assembly housing portions positively locate the
various components with the sub-assembly. In many embodiments, the
sub-assembly housing portions utilize locating pins and integral
locking features to maintain the sub-assembly after assembly.
[0045] Once assembly is complete on the sub-assembly, the
sub-assembly may be slid into tube 245 from one end, and tip
diffuser 246 and circumferential light guide 216 may be inserted
from the opposite end of the tube to complete assembly of power
supply portion 212. By way of the distal tip of the circumferential
light guide 216 and etch pattern 248 in tube 245, LEDs 220.sub.A-E
may illuminate evenly around a distal circumferential portion of
the tube 245, and a distal tip of the power supply portion 212.
[0046] In various embodiments of the present disclosure, one or
more keying features may be present on an exterior surface of upper
and/or lower sub-assembly housing portions 240 and 241. When the
sub-assembly is inserted into tube 245, mating keying features
along an inner surface of the tube 245 rotationally align the tube
and the sub-assembly along a longitudinal axis and prevent the
sub-assembly from spinning therein.
[0047] The use of a sub-assembly during manufacturing helps
minimize assembly complexity, as well as reduce overall assembly
time. Moreover, the sub-assembly helps to mitigate scrap as the
sub-assembly allows for rapid re-work of a power supply portion
212, such as when electronic circuitry within the power supply
portion fails in testing. Moreover, the sub-assembly helps to
mitigate common failure modes of eCigs during its useful life by
reducing shock and vibration related damage to the sub-components.
Specifically, by positively locating controller circuitry 222 and
flexible circuit board 221 within the upper and lower sub-assembly
housing portions 240 and 241, wire leads 242.sub.A-B and bonding
pads electrically coupling the circuitry are less likely to
experience failure modes. For example, stress fractures at a solder
joint on a bonding pad.
[0048] In various embodiments of the present disclosure, pattern
248 on tube 245 may include various different patterns, shapes,
images and/or logos. In the present embodiment, the pattern 248 is
a plurality of triangles positioned in proximity to one another.
The pattern 248 may be laser etched onto a painted surface of the
tube 245, silk screened, drilled or otherwise cut into an outer
surface of the tube 245, and/or the tube itself can be translucent
or semi-translucent and the pattern may be disposed on an outer
surface 350 of circumferential light guide 316. The pattern 248 on
an outer surface of tube 245 allows controller circuitry 222 to
provide visual indications of the eCigs functionality via light
being emitted from LEDs 220.sub.A-E through circumferential light
guide 216. The eCig may provide a plurality of visual indications
by varying the brightness (e.g., LED duty cycle), color (e.g.,
output frequency and/or multi-diode LEDs), location, on/off time,
patterning, among other visually distinguishable
characteristics.
[0049] FIG. 2B is a partial exploded assembly view of an eCig power
supply portion sub-assembly 213, consistent with various aspects of
the present disclosure. As shown in FIG. 2B, flex circuit 221 and
battery 218 are electrically coupled to controller circuitry 222
via wire leads which are soldered on to the controller circuitry.
Contacts 225.sub.A-C (also referred to as electrical pins) are also
electrically coupled to the controller circuitry 222 and extend
toward apertures within the upper sub-assembly housing 240. The
contacts 225.sub.A-C facilitate electrical communication between
the controller circuitry 222 and an external circuit, as well as
charging the battery 218.
[0050] When assembled, flex circuit 221 extends over and around
battery 218. The battery being circumferentially enclosed by upper
and lower sub-assembly housing portions 240 and 241. Controller
circuitry 222 is sandwiched between spacer 229 and MAF gasket 228;
the spacer and MAF gasket contacting respective surfaces of upper
and lower sub-assembly housing portions 240 and 241 and thereby
positively locate the controller circuitry within the sub-assembly.
The spacer 229 includes an inner aperture that functions as a light
guide to deliver light from an LED on the controller circuitry 222
through an aperture within the lower sub-assembly housing 241. The
MAF gasket 228 facilitates an airflow passage between the
controller circuitry 222 and the upper sub-assembly housing 240.
The MAF gasket 228 both forms a seal between the controller
circuitry 222 and the upper sub-assembly housing to direct the
airflow past the airflow sensor 224 (as shown in FIG. 2A), as well
as to maintain a desired cross-sectional area of the airflow
passage in the vicinity of a mass airflow sensor.
[0051] Female connector port 258 mates to a male connector port on
a atomizer/liquid reservoir portion of the eCig, and provides a
flow of air via a fluid outlet, and power and data communication
signals via a plurality of electrical contacts that are
communicatively coupled to corresponding electrical contacts on the
male connector port (when the male and female connector ports are
mated to one another). In various embodiments of the present
disclosure, the male and female connector ports are hemicylindrical
in shape. As used herein, "hemicylindrical" describes parts having
the shape of a half a cylinder, as well as parts that include a
larger or smaller portion of a cylinder when cut by a plane that is
parallel to the longitudinal axis (or lengthwise) of the cylinder.
An airflow gasket 227 is inserted into the female connector port
258 and facilitates a fluid seal with the mating male connector
port. In one particular embodiment, airflow sensor 224 is a mass
airflow sensor that measures a flow of air through the eCig, the
airflow gasket 227 prevents additional air from entering the
airflow into the atomizer/liquid reservoir portion (or the escape
of air from the airflow) after the mass airflow sensor has measured
the airflow.
[0052] Once the sub-assembly 213 has been assembled and inserted
into an outer tube 245, a locking pin 226 is inserted through
corresponding apertures in the outer tube and the upper
sub-assembly housing 240 to axially and rotationally couple the
sub-assembly 213 within the power supply portion 212.
[0053] FIG. 3 shows an example of the microcontroller 320
constructed according to an aspect of the disclosure. The
microcontroller 320 comprises a microcomputer 326, a memory 324 and
an interface 328. The microcontroller 320 can include a driver 322
that drives an atomizer (not shown). The driver 322 can include,
e.g., a pulse-width modulator (PWM) or signal generator. The
microcomputer 320 is configured to execute a computer program,
which can be stored externally or in the memory 324, to control
operations of the eCig, including activation (and deactivation) of
the heating element. The memory 324 includes a computer-readable
medium that can store one or more segments or sections of computer
code to carry out the processes described in the instant
disclosure. Alternatively (or additionally) code segments or code
sections may be provide on an external computer-readable medium
(not shown) that may be accessed through the interface 328.
[0054] It is noted that the microcontroller 320 may include an
application specific integrated circuit (IC), or the like, in lieu
of the microcomputer 326, driver 322, memory 324, and/or interface
328.
[0055] The microcontroller may be configured to log medium flow
data, including mass flow, volume flow, velocity data, time data,
date data, flow duration data, and the like, that are associated
with the medium flow. The medium may comprise an aerosol, a gas
(e.g., air), a liquid, or the like. The microcontroller may be
configured not only to turn ON/OFF a heater based on such data, but
to also adjust control parameters such as heater PWM or amount of
liquid solution dispensed onto a heating surface. This control may
be done proportionally to the flow data or according to an
algorithm where flow data is a parameter. In addition, the
microcontroller may use flow data to determine flow direction and
restrict or limit false activation of the heater in case the user
accidentally blows into the eCig.
[0056] FIG. 4 shows an example of a flow sensor 330 that is
constructed according to an aspect of the disclosure. The flow
sensor 330 comprises a substrate 331 and a thermopile (e.g., two or
more thermocouples), including an upstream thermopile (or
thermocouple) 332 and a downstream thermopile (or thermocouple)
333. The substrate 331 may include a thermal isolation base. The
flow sensor 130 may comprise a heater element 334. The flow sensor
330 may comprise a reference element 335. The heater element 334
may include a heater resistor. The reference element 335 may
include a reference resistor.
[0057] As seen in FIG. 4, the thermopiles 332, 333 may be
symmetrically positioned upstream and downstream from the heater
element 334. The heater element 334 heats up the hot junctions of
the thermopiles 332, 333. In response, each of the thermopiles 332,
333 generates an output voltage that is proportional to the
temperature gradient between its hot and cold junctions (the
"Seebeck" effect). The hot junctions of the thermopiles 332, 333
and the heater element 334 may reside on the thermal isolation
base. Mass airflow sensor signal conditioning may be composed of
various forms of filters or gain amplifiers. Filters may be used to
eliminate noise before or after signal amplification, thereby
reducing sensitivity to unwanted environmental noises or pressure
changes. Filtering can be accomplished using low pass, high pass,
band pass, or a combination thereof. Signal gain amplification may
be accomplished by employing electronic amplification on the
upstream or downstream thermopile signals, or a combination
thereof. Amplification of upstream or downstream thermopile signals
may use a single state or multiple cascaded stages for each signal,
or combination of these signals to form a sum or difference. The
amplifier circuit may include means to introducing a signal offset.
The amplifier may include transistors, operational amplifiers, or
other integrated circuits.
[0058] FIGS. 5A and 5B illustrate an example of a single amplifier
with a filter 364 and a difference amplifier and filters for
upstream and downstream, with offset 380. As shown in the single
amplifier with a filter 364 in FIG. 5A, the airflow signal 360
passes through a filter 361 and a gain amplifier 362 before a
signal output 363 is transmitted. The difference amplifier and
filters for upstream and downstream, with offset 380 shown in FIG.
5B comprises an upstream airflow signal 370 and a downstream
airflow signal 371. The upstream airflow signal 370 passes through
a first filter 372 and the downstream airflow signal passes through
a second filter 373. The outputs of the first and second filters
371,372 then enter a difference amplifier 374. A signal is then
output from the difference amplifier 374 and enters a gain
amplifier 375 along with an offset 375. The gain amplifier 376 then
outputs a signal output 377.
[0059] FIG. 6 illustrates an electrical diagram of an embodiment of
the disclosure comprising a first thermopile 452 and a second
thermopile 453. The eCig depicted in FIG. 6 comprises a
microcontroller 440, a mass airflow sensor 450, an amplifier 449,
and a heater 456. The mass airflow sensor 450 comprises a mass
airflow heater 451, a first thermopile 452, and a second thermopile
453. The electrical diagram further illustrates the direction of
airflow 454 over the mass airflow heater 451 and the first and
second thermopiles 452, 453. The microcontroller 440 can comprise a
data acquisition circuit 441, and an analog-to-digital converter
442. The data acquisition circuit 441 can log and transmit data
such as temperature of the heater 456, the number of times the
heater 456 has been activated in a certain time, the length of time
the heater 456 had been activated, and other information. A more
detailed description of data acquisition and transmission can be
found in commonly assigned U.S. Provisional Application No.
61/907,239 filed 21 Nov. 2013, the entire disclosure of which is
hereby incorporated by reference as though fully set forth herein.
The analog-to-digital converter 442 can output information about
the eCig to the microcontroller 440, the data acquisition circuit
441, and other devices and sensors that may be present on the
microcontroller 440 or otherwise connected to the eCig.
[0060] FIG. 7 illustrates an electrical diagram of another
embodiment of the disclosure comprising one thermopile 552. The
eCig depicted in FIG. 7 comprises a microcontroller 540, a mass
airflow sensor 550, an amplifier 549, and a heater 556. The mass
airflow sensor 550 comprises a mass airflow heater 551 and a
thermopile 552. The electrical diagram further illustrates the
direction of airflow over the heater 554 and the thermopile 552.
The microcontroller 540 can comprise a data acquisition circuit
541, and an analog-to-digital converter 542. The data acquisition
circuit 541 can log and transmit data such as temperature of the
heater 556, the number of times the heater 556 has been activated
in a certain time, the length of time the heater 556 had been
activated, and other information. The analog-to-digital converter
542 can output information about the eCig to the microcontroller
540, the data acquisition circuit 541, and other devices and
sensors that may be present on the microcontroller 540 or otherwise
connected to the eCig. In one embodiment, the eCig can also
comprise feedback and gain resistors 557, 558. More information
regarding the airflow sensor can be found in PCT Publication no. WO
2014/205263, filed 19 Jun. 2014, which is incorporated by reference
herein as though set forth in its entirety.
[0061] FIGS. 8A and 8B show an example of a flow channel according
to the principles of the disclosure. As seen in FIGS. 8A and 8B,
the flow channel can be shaped in the vicinity of the sensor so as
to direct a majority of flow over the sensing surface, thus
increasing the sensitivity of the system. FIG. 8A depicts a top
down view of one embodiment of a flow channel 601. FIG. 8B depicts
an end view of the flow channel 601 shown in FIG. 8A. The flow
channel 601 comprises a first side wall 603, a second side wall
605, a top wall 623, a bottom wall 625, an incoming airflow opening
611, an incoming airflow pathway 607, a sensor assembly 615, an
outgoing airflow pathway 609, and an outgoing airflow opening 613.
The first side wall 603, the second side wall 605, the top wall
623, and the bottom wall 625 define the incoming airflow opening
611, the incoming airflow pathway 607, the outgoing airflow pathway
609, and the outgoing airflow opening 613. The incoming airflow
opening 611 can allow air to enter the flow channel 601. The
incoming airflow pathway 607 can extend along a longitudinal axis
of the flow channel 601. The incoming airflow pathway 607 can
extend a distance along the longitudinal axis and comprise enough
volume so that any air entering the flow channel 601 through the
incoming airflow opening 611 creates a laminar flow before passing
over the sensor assembly 615. In one embodiment, to achieve a
laminar flow over the sensor assembly, the incoming airflow pathway
can comprise a longitudinal length of 1.5-2 mm. In other
embodiments, the longitudinal length of the incoming airflow
pathway can be adjusted in response to different dimensions and
volumes of the flow channel. The sensitivity of the sensor assembly
615 can be increased by decreasing the volume of the flow channel
601. However, by decreasing the volume of the flow channel 601 a
draw resistance for a user is increased. As the volume of the flow
channel 601 increases the signal quality decreases, but the draw
resistance is decreased. After the air has passed over the sensor
assembly 615, the airflow can be turbulent as it passes through the
rest of the system. The sensor assembly 615 can comprise a sensor
617. The sensor 617 can detect an airflow over the sensor assembly
615 and can further detect a mass of airflow over the sensor
assembly 615 and passing through the flow channel 601. The airflow
can move over the sensor along the airflow path 619 In one
embodiment, the sensor can comprise a mass airflow sensor. In
another embodiment, the sensor can comprise a capacitive sensor.
After passing over the sensor assembly 615, an airflow through the
flow channel 601 can enter the outgoing airflow pathway 609 and
exit the flow channel 601 through the outgoing airflow opening 613.
After leaving the flow channel 601, the airflow can enter an
external airflow pathway 621. In one embodiment, the external
airflow pathway 621 can be sealed such that any air entering the
flow channel 601 and passing over the sensor assembly 615 can be
routed through the flow channel 601 and the external airflow
pathway 621 to an atomizer (not shown).
[0062] In other embodiments, a diverter can be present after the
airflow has passed over the sensor assembly such that a portion of
the air passes over the atomizer and a portion of the air diverts
around the atomizer. In these embodiments, the electronic smoking
device is configured to, at least in part, pass the airflow over
the atomizer. In one embodiment, the portion of air that passes
over the atomizer can be 50% or greater of the air that passes over
the sensor assembly. In another embodiment, the portion of air that
passes over the atomizer can be 50% or less of the air that passes
over the sensor assembly. By diverting a portion of the airflow
that passes over the sensor assembly, the amount of air that passes
over the atomizer can be controlled and the amount of aerosol or
vapor created by the atomizer can be regulated. In yet other
embodiments, an additional air inlet can be added downstream of the
sensor assembly, such that additional air can be added to the
airflow that has passed over the sensor assembly. In one
embodiment, adding an additional air inlet downstream of the sensor
assembly can decrease the sensitivity of the sensor signal, but can
further dilute the vapor stream. In yet other embodiments,
additional components can be added to divert or add airflow to the
airflow stream after it has passed the sensor assembly. The
additional components can be used to divert the airflow stream away
from the atomizer, add additional air to the airflow stream, or
impart additional airflow after the airflow stream has passed the
atomizer. In yet other embodiments, the airflow passing over the
sensor assembly can comprise a first portion of the airflow passing
through a downstream portion of the electronic smoking device. A
second portion of the airflow passing through an upstream portion
of the electronic smoking device can be diverted around the sensor
assembly. In one embodiment, the second portion of the airflow can
join with the first portion of the airflow after the first portion
of the airflow has passed over the sensor assembly. In one
embodiment, the atomizer can comprise a heater. In other
embodiments, the atomizer can comprise a mechanical or thermal
atomizer as would be known to one in the art. In one embodiment,
the flow channel can be defined by the foam and plastic portions of
the battery housing as illustrated in FIGS. 2A and 2B. In one
embodiment, the foam portion of the flow channel can comprise a
minimum compression ratio of 30%. When foam is used within the flow
channel, the foam can be compressed enough to keep the flow channel
sealed, but not compressed to an extent that the foam intrudes into
the channel. In one embodiment, the foam can comprise a micro
closed-seal foam.
[0063] FIG. 9 illustrates a side view of one embodiment of a sensor
assembly 651. The sensor assembly 651 can comprise a support
structure 653, a sensor 655, a first layer 659, and a second layer
661. The support structure 653 can comprise a PCB or other
component that can be electrically coupled to the sensor 655. The
sensor 655 can detect an airflow over the sensor assembly 651 and
can further detect a mass of airflow over the sensor assembly 651.
In one embodiment, the sensor can comprise a mass airflow sensor.
In another embodiment, the sensor can comprise a capacitive sensor.
The first layer 659 and the second layer 661 can be used to create
an upper surface 663 that extends along an incoming portion 665 of
the sensor assembly 651. The upper surface 663 can comprise a
height above the support structure 653 similar to the height the
sensor 655 extends above the support structure 653. The upper
surface 663 created by the first layer 659 and the second layer 661
can be used to minimize turbulence created by an airflow passing
through an airflow pathway 667 and over the sensor assembly 651.
The first layer 659 can comprise any one of a number of substances
that can be used during a PCB manufacturing process. In one
embodiment, the first layer 659 can comprise copper. In other
embodiments, the first layer 659 can comprise solder mask,
silkscreen, or any other material that can be deposited on a PCB or
other support structure. The second layer 661 can comprise any one
of a number of substances that can be used during a PCB
manufacturing process. In one embodiment, the second layer 661 can
comprise solder mask. In other embodiments, the second layer 661
can comprise copper, silkscreen, or any other material that can be
deposited on a PCB or other support structure. In one embodiment, a
silkscreen layer can be further deposited on top of the second
layer 661. These materials can be used during the manufacturing of
the sensor assembly 651. Using materials already present during the
manufacture of a PCB component, additional manufacturing costs can
be limited. In one embodiment, the sensor can be formed and then a
backgrinding process can be used to remove portions of the sensor
that are not integral to the sensor. By backgrinding the sensor,
the height of the sensor can be decreased, requiring less
additional material to be placed on the support structure. In one
embodiment, after undergoing the backgrinding process the sensor
can comprise a height of 0.1 mm. In another embodiment, after
undergoing the backgrinding process the sensor can comprise a
height of 0.2 mm.
[0064] FIG. 10 depicts a schematic view of another embodiment of a
sensor assembly 701. The sensor assembly 701 can comprise a support
structure 703, a sensor 705, a first structure component 707, and a
second structure component 709. The sensor 705 can be coupled to
the support structure 703. In one embodiment, the sensor 705 can be
electrically coupled to the support structure 703. The first
structure component 707 and the second structure component 709 can
be coupled to the support structure 703. The first structure
component 707 and the second structure component 709 can assist in
securing the sensor 705 to the support structure 703. In another
embodiment, the first structure component 707 and the second
structure component 709 can each comprise an upper surface adjacent
to an upper surface of the sensor 705. The first support structure
707 and the second support structure 709 can be used to assist in
directing an airflow over the sensor 705 and to minimize air
currents that could be disruptive or otherwise unwanted when air is
passed over the sensor 705.
[0065] FIG. 11A illustrates another embodiment of a sensor assembly
751. The sensor assembly 751 can comprise a support structure 753,
a sensor base portion 757, a sensor top portion 755, and a sensor
transition region 759. The support structure 753 can comprise a
depression sized and configured to house the sensor base portion
757. When the sensor base portion 757 is placed within the
depression of the support structure 753, the sensor top portion 755
can be above an upper portion of the support structure. The sensor
transition region 759 can be lined up with an upper surface of the
support structure 753. By securing the sensor base portion 757
within a depression of the support structure 753, the sensor top
portion 755 can minimize any effects of the sensor top portion 755
on airflow flowing past the sensor assembly 751. As stated above,
in other embodiments, additional material can be placed on the
support structure to further minimize any effects, turbulence or
otherwise, possibly caused on an airflow passing over the sensor
assembly 751.
[0066] FIG. 11B illustrates the sensor of FIG. 11A. The sensor
comprises the sensor base portion 757, the sensor top portion 755,
and the sensor transition region 759. As described above, the
sensor base portion 757 can be placed within a depression in a
support structure. In other embodiments, the sensor base portion
757 can be coupled to a top surface of a support structure. The
sensor top portion 755 can comprise the portion of the sensor that
is needed to interact with an airflow passing over the sensor to
measure an airflow rate. In one embodiment, the sensor transition
region 759 can be denoted as separating the portion of the sensor
that needs to be exposed to a passing airflow (the sensor top
portion 755) and the portion of the sensor that does not need to be
exposed to a passing airflow (the sensor bottom portion 757).
[0067] FIG. 12A depicts a schematic view of one embodiment of a
flow channel 801. The flow channel 801 can comprise an upper
housing 803, a support structure 805, a support depression 807, a
sensor 809, and an airflow pathway 811. The upper housing 803, the
support structure 805, and the sensor 809 can define the airflow
pathway 811. Air entering the flow channel 801 can pass over the
sensor 809 in the airflow direction 813. The support depression 807
can be sized and configured to house a lower portion of the sensor
809. When the lower portion of the sensor 809 is placed within the
support depression 807, an upper portion of the sensor 809 can be
above an upper surface of the support structure 805. By securing
the sensor 809 within the support depression 807, the sensor 809
can minimize any effects on airflow flowing past the sensor 809. As
stated above, in other embodiments, additional material can be
placed on the support structure to further minimize any effects,
turbulence or otherwise, possibly caused on an airflow passing over
the sensor 809. The upper housing can comprise a variety of
materials. In one embodiment, the upper housing can comprise
plastic. In another embodiment, the upper housing can comprise tape
placed over the flow channel. In yet other embodiments, the upper
housing can comprise any other material that can withstand
deformation from air flowing through the airflow pathway.
[0068] FIG. 12B depicts a schematic view of another embodiment of a
flow channel 831. The flow channel 831 can comprise an upper
housing 833, a support structure 835, a sensor 837, a first
structure component 841, a second structure component 839, and an
airflow pathway 843. The upper housing 833, the support structure
835, the first structure component 841, the second structure
component 839, and the sensor 837 can define the airflow pathway
843. Air entering the flow channel 831 can pass over the sensor 837
in the airflow direction 845. The sensor 837 can be coupled to the
support structure 835. In one embodiment, the sensor 837 can be
electrically coupled to the support structure 835. The first
structure component 841 and the second structure component 839 can
be coupled to the support structure 835. The first structure
component 841 and the second structure component 839 can assist in
securing the sensor 837 to the support structure 835. In another
embodiment, the first structure component 841 and the second
structure component 839 can each comprise an upper surface adjacent
to an upper surface of the sensor 837. The first support structure
841 and the second support structure 839 can be used to assist in
directing an airflow over the sensor 837 and to minimize air
currents that could be disruptive or otherwise unwanted when air is
passed over the sensor 837. The upper housing can comprise a
variety of materials. In one embodiment, the upper housing can
comprise plastic. In another embodiment, the upper housing can
comprise tape placed over the flow channel. In yet other
embodiments, the upper housing can comprise any other material that
can withstand deformation from air flowing through the airflow
pathway.
[0069] FIG. 12C depicts a schematic view of another embodiment of a
flow channel 861. The flow channel 861 can comprise an upper
housing 863, a first side support structure 865, a second side
support structure 879, a sensor support structure 867, a sensor
869, an airflow pathway 871, an airflow sensor entrance 875, and an
airflow sensor exit 877. The upper housing 863, the first side
support structure 865, the second side support structure 879, the
sensor support structure 867, and the sensor 869 can define the
airflow pathway 871. The first side support structure 865 and the
sensor support structure 867 can define an airflow sensor entrance
875. The sensor support structure 867 and the second side support
structure 879 can define an airflow sensor exit 877. Air entering
the flow channel 861 can enter through the airflow sensor entrance
875, can pass over the sensor 869, and can exit through the airflow
sensor exit 877 in the airflow direction 873. As described above,
the sensor 869 can be placed within a depression in the sensor
support structure 867. The upper housing can comprise a variety of
materials. In one embodiment, the upper housing can comprise
plastic. In another embodiment, the upper housing can comprise tape
placed over the flow channel. In yet other embodiments, the upper
housing can comprise any other material that can withstand
deformation from air flowing through the airflow pathway.
[0070] FIG. 13 depicts a graph illustrating one embodiment of the
power delivered for a given flow rate 901. The depicted graph
illustrates a response curve 903 showing a logarithmic graph with a
power level for a sensed airflow rate. As seen in in the
illustrated embodiment, a first position 905 on the graph comprises
a power level of 4 W that can be output to an atomizer at a first
flow rate. A second position 907 on the graph comprises a power
level of 10 W that can be output to an atomizer at a second flow
rate. The response curve comprises a logarithmic curve where the
power output is exponential in response to the flow rate. An
exponential increase in power output can be used as an atomizer may
not be properly heated with an increasing rate of airflow using a
linear response. In other embodiments, the power output can be
increased in an exponential fashion in response to an increased
airflow so that the atomizer can deliver a larger amount of aerosol
in response to a larger or faster rate of airflow over the sensor
and through the system as a whole. The larger amount of aerosol
produced by the atomizer can attempt to mimic the increased amount
of smoke that can be produced by a user who takes a deeper or
longer drag on a traditional cigarette. In another embodiment,
where an increase in aerosol is not desired, the power output can
comprise a linear increase as airflow is increased.
[0071] FIG. 14 depicts a graph illustrating several embodiments of
response to flow rate 921. The response illustrated in FIG. 14 is
the response from the airflow sensor for a given flow rate. The
graph illustrates a first response curve 923, a second response
curve 925, and a third response curve 927. Each of the first
response curve 923, the second response curve 925, and the third
response curve 927 illustrate a response from different individual
airflow sensors. The second response curve 925 further depicts a
plurality of response points 929. The plurality of response points
can each individually comprise a known response for a given flow
rate. In another embodiment, only a portion of the plurality of
response points 929 can be determined during testing and other of
the plurality of response points 929 can be determined by
calculating a curve to fit the determined response points. As shown
in FIG. 14, a first response flow rate 931 can comprise a 5 ml/s
flow rate and a second response flow rate 935 can comprise a 40
ml/s flow rate.
[0072] FIG. 15 depicts a graph illustrating one embodiment of a
flow v time output 941. The flow v time output 941 comprises a user
puff 943. The user puff 943 comprises a varying flow rate over
time. As shown in the depicted user puff 943, initially the flow
rate is negligible. At a later time, a user initiates the puff, and
the flow rate increases until it reaches a maximum flow rate. The
flow rate then slowly lowers over the course of time, until
dropping back to the initial negligible flow rate.
[0073] FIG. 16 depicts a graph illustrating several embodiments of
response to flow rate 961. As seen in FIG. 14, the response
illustrated is the response from the airflow sensor for a given
flow rate. The graph illustrates a first response curve 963, a
second response curve 965, a third response curve 967, and a fourth
response curve 969. Each of the first response curve 963, the
second response curve 965, the third response curve 967, and the
fourth response curve 969 illustrate a response from different
individual airflow sensors. As seen in the illustrated embodiments,
all of the sensors have different curves and different baseline
conditions. The signals from each sensor can then be driven higher
or lower to bring each sensor to a common baseline signal. Even
after a common baseline signal has been assigned, each sensor still
displays a different curve. The curve for each sensor can be
calculated by determining the response signal for a subset of
airflow rates. In one embodiment, three response signals can be
determined to calculate the response curve. In the illustrated
embodiment, the response signals can be determined at a first
response location 971, a second response location 973, and a third
response location 975. In one embodiment the three response signals
can be recorded at 15 ml/s, 25 ml/s, and 40 ml/s. The response
signal received at each of the three flow rates can be used to
calibrate the response curve. Each of the sensors comprises a
response curve that is logarithmic or exponential. The response
curve can be used to generate a table of points 979 that can be
looked up by the system. The number of points within the look up
table can vary. In one embodiment, the look up table can comprise
32 values. Other embodiments can have fewer or more points within
the look up table. In another embodiment, an equation can be used
to determine a flow rate for a specific signal. In another
embodiment, the look up table can be limited in maximum range to
what can be performed by a user using the device. In one
embodiment, that upper range can comprise 40 ml/s to 50 ml/s.
Further, the lowest airflow that an average user will be able to
sustain for a light puff is about 15 ml/s. As a result, the normal
range that can be used within the lookup table is 15 ml/s to 40
ml/s. In another embodiment, the normal range that can be used
within the lookup table is 15 ml/s to 50 ml/s. In yet another
embodiment, the normal range that can be used is 5 ml/s to 50 ml/s.
In yet other embodiments, other ranges can be used. In one
embodiment, the responsiveness can be scaled in terms of power
output within that range. In another embodiment, an airflow rate
above 35 ml/s will not increase a power output to the atomizer. In
yet another embodiment, an airflow rate below 15 ml/s will not
decrease the power output to the atomizer. Further, in one
embodiment, the values included in the look up table are not evenly
spread out. In this embodiment, the values above 35 ml/s can be
further apart than those below 35 ml/s. In another embodiment, a
threshold airflow rate of 5 ml/s can be used to start a puff event.
While 5 ml/s airflow rate can be used to start a puff event, the
coil does not energize until an airflow rate of 10 ml/s occurs. In
one embodiment, the baseline value ceases updating after the puff
event starts at 5 ml/s. Further, in another embodiment, the
atomizer starts energizing at 10 ml/s, and then once the airflow
rate decreases below 10 ml/s, the atomizer stops energizing.
Further, the puff event stops after the airflow rate drops below 5
ml/s. Further, in other embodiments, the energization and puff
event values can comprise different amounts than those listed
herein.
[0074] FIG. 17 illustrates a flow-chart of the process by which the
microcontroller or other component can interpret signals from the
mass airflow sensor or other device. In step 1000 a microcontroller
can monitor a sensor signal sent from the mass airflow sensor. When
the microcontroller monitors a change in the sensor signal that is
being monitored in step 1000, the microcontroller can determine if
the change in the sensor signal is below a programmed threshold
1001. If the change in the sensor signal over a length of time is
below the programmed threshold the microcontroller or other
component can alter a reference signal and a relation signal to a
predetermined baseline 1002. In one embodiment the reference signal
can be set to a baseline reading of 2.0 volts. The microcontroller
than continues to monitor the mass airflow sensor for a change in
the sensor signal 1000. If the change in the sensor signal over
time is above a programmed threshold 1001, then the microcontroller
or other component reads the difference between the reference
signal and the relation signal 1003. In step 1004, the
microcontroller or other component can operate a device, sensor, or
other component according to the difference between the reference
signal and the relation signal. The process then goes back to step
1000 and the microcontroller or other component continues to
monitor the mass airflow sensor for a change in the sensor signal
over time.
[0075] The sensor can drift as the temperature of the sensor
increases. The drift can comprise about 0.1% per degree Celsius.
While the drift can appear minimal, at higher end flow rates,
because of the low overall signal, the small difference can make a
big difference in the sensed airflow rate. To account for the
temperature drift error two approaches can be used. The first
approach is to add a thermistor to the sensor. This thermistor can
be powered through the offset and the resistance of the thermistor
can vary with temperature. The resistance can be sampled and the
temperature of the sensor can be determined. The second approach
can use the sensor itself and look at the value output by the
sensor when a puff event starts and use this signal as a baseline.
A baseline of when a puff event is not occurring and a signal
output by the sensor when a puff event occurs. The baseline signal
when a puff event is not occurring will tend to shift slightly.
This shift can be correlated to temperature. In one embodiment, a
look up table can be used to determine a temperature shift. In
another embodiment, an algorithm can be used to determine a
temperature shift. The temperature shift described herein can be
used for any airflow sensor, including mass airflow sensors,
capacitive sensors, or others as would be known to one of ordinary
skill in the art.
[0076] Various embodiments of the present disclosure are directed
to an electronic smoking device. The electronic smoking device can
comprise a flow channel and an atomizer. The flow channel can
comprise an incoming airflow opening, an incoming airflow pathway,
a sensor assembly, and an outgoing airflow opening. The atomizer
can be fluidly coupled to the flow channel. The flow channel can be
configured to direct an airflow from the incoming airflow opening,
through the incoming airflow pathway, over the sensor assembly, and
through the outgoing airflow opening. The electronic smoking device
can further be configured to pass the airflow, at least in part,
over the atomizer. In a more specific embodiment, the electronic
smoking device can further comprise an outgoing airflow pathway
between the sensor assembly and the outgoing airflow opening. In a
more specific embodiment, the electronic smoking device can further
comprise an external airflow pathway coupled to the flow channel,
wherein the external airflow pathway is configured to direct air
from the outgoing airflow opening to the atomizer.
[0077] In a more specific embodiment, the flow channel further
comprises a first side wall, a second side wall, a bottom wall, and
a top wall, and wherein the first side wall, the second side wall,
the bottom wall, and the top wall define the incoming airflow
opening. In a more specific embodiment, the flow channel is sized
and configured to create a laminar flow of air in the incoming
airflow pathway before the airflow reaches the sensor assembly. In
some embodiments, the sensor assembly comprises a support structure
and a sensor, and wherein the sensor is coupled to the support
structure. In other embodiments, the sensor assembly further
comprises a first layer and a second layer coupled to the support
structure. In yet other embodiments, the first layer and the second
layer create an upper surface. In other embodiments, the upper
surface comprises a height above the support structure similar to a
height of the sensor. In yet other embodiments, the upper surface
is configured to minimize turbulence of the airflow over the
sensor. In some embodiments, the first layer comprises copper. In
other embodiments, the second layer comprises solder mask. In yet
other embodiments, the sensor assembly further comprises a
silkscreen material deposited on top of the second layer.
[0078] In another embodiment, the support structure comprises a
PCB. In yet another embodiment, the support structure comprises a
support depression. In other embodiments, a lower portion of the
sensor is sized and configured to fit within the support
depression. In some embodiments, the sensor assembly further
comprises a sensor, and wherein the sensor comprises a height of no
more than 0.2 mm.
[0079] Other various embodiments consistent with the present
disclosure are directed to an electronic smoking device. The
electronic smoking device can comprise a flow channel. The flow
channel can comprise an incoming airflow opening, an incoming
airflow pathway, a sensor assembly, and an outgoing airflow
opening. The flow channel can be configured to direct an airflow
from the incoming airflow opening, through the incoming airflow
pathway, over the sensor assembly, and through the outgoing airflow
opening. In other various embodiments, the flow channel is sized
and configured to create a laminar flow of air in the incoming
airflow pathway before the airflow reaches the sensor assembly. In
yet other embodiments, the sensor assembly comprises a support
structure, a first layer, a second layer, and a sensor, and wherein
the sensor, the first layer, and the second layer are coupled to
the support structure.
[0080] It should be noted that the features illustrated in the
drawings are not necessarily drawn to scale, and features of one
embodiment may be employed with other embodiments as the skilled
artisan would recognize, even if not explicitly stated herein.
Descriptions of well-known components and processing techniques may
be omitted so as to not unnecessarily obscure the embodiments of
the disclosure. The examples used herein are intended merely to
facilitate an understanding of ways in which the disclosure may be
practiced and to further enable those of skill in the art to
practice the embodiments of the disclosure. Accordingly, the
examples and embodiments herein should not be construed as limiting
the scope of the disclosure. Moreover, it is noted that like
reference numerals represent similar parts throughout the several
views of the drawings.
[0081] The terms "including," "comprising" and variations thereof,
as used in this disclosure, mean "including, but not limited to,"
unless expressly specified otherwise.
[0082] The terms "a," "an," and "the," as used in this disclosure,
means "one or more," unless expressly specified otherwise.
[0083] Although process steps, method steps, algorithms, or the
like, may be described in a sequential order, such processes,
methods and algorithms may be configured to work in alternate
orders. In other words, any sequence or order of steps that may be
described does not necessarily indicate a requirement that the
steps be performed in that order. The steps of the processes,
methods or algorithms described herein may be performed in any
order practical. Further, some steps may be performed
simultaneously.
[0084] When a single device or article is described herein, it will
be readily apparent that more than one device or article may be
used in place of a single device or article. Similarly, where more
than one device or article is described herein, it will be readily
apparent that a single device or article may be used in place of
the more than one device or article. The functionality or the
features of a device may be alternatively embodied by one or more
other devices which are not explicitly described as having such
functionality or features.
[0085] Although several embodiments have been described above with
a certain degree of particularity, those skilled in the art could
make numerous alterations to the disclosed embodiments without
departing from the spirit of the present disclosure. It is intended
that all matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative only and
not limiting. Changes in detail or structure may be made without
departing from the present teachings. The foregoing description and
following claims are intended to cover all such modifications and
variations.
[0086] Various embodiments are described herein of various
apparatuses, systems, and methods. Numerous specific details are
set forth to provide a thorough understanding of the overall
structure, function, manufacture, and use of the embodiments as
described in the specification and illustrated in the accompanying
drawings. It will be understood by those skilled in the art,
however, that the embodiments may be practiced without such
specific details. In other instances, well-known operations,
components, and elements have not been described in detail so as
not to obscure the embodiments described in the specification.
Those of ordinary skill in the art will understand that the
embodiments described and illustrated herein are non-limiting
examples, and thus it can be appreciated that the specific
structural and functional details disclosed herein may be
representative and do not necessarily limit the scope of the
embodiments, the scope of which is defined solely by the appended
claims.
[0087] Reference throughout the specification to "various
embodiments," "some embodiments," "one embodiment," "an
embodiment," or the like, means that a particular feature,
structure, or characteristic described in connection with the
embodiment is included in at least one embodiment. Thus,
appearances of the phrases "in various embodiments," "in some
embodiments," "in one embodiment," "in an embodiment," or the like,
in places throughout the specification are not necessarily all
referring to the same embodiment. Furthermore, the particular
features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments. Thus, the particular
features, structures, or characteristics illustrated or described
in connection with one embodiment may be combined, in whole or in
part, with the features structures, or characteristics of one or
more other embodiments without limitation.
[0088] It will be appreciated that the terms "proximal" and
"distal" may be used throughout the specification with reference to
a clinician manipulating one end of an instrument used to treat a
patient. The term "proximal" refers to the portion of the
instrument closest to the clinician and the term "distal" refers to
the portion located furthest from the clinician. It will be further
appreciated that for conciseness and clarity, spatial terms such as
"vertical," "horizontal," "up," and "down" may be used herein with
respect to the illustrated embodiments. However, surgical
instruments may be used in many orientations and positions, and
these terms are not intended to be limiting and absolute.
[0089] Any patent, publication, or other disclosure material, in
whole or in part, that is said to be incorporated by reference
herein is incorporated herein only to the extent that the
incorporated materials does not conflict with existing definitions,
statements, or other disclosure material set forth in this
disclosure. As such, and to the extent necessary, the disclosure as
explicitly set forth herein supersedes any conflicting material
incorporated herein by reference. Any material, or portion thereof,
that is said to be incorporated by reference herein, but which
conflicts with existing definitions, statements, or other
disclosure material set forth herein will only be incorporated to
the extent that no conflict arises between that incorporated
material and the existing disclosure material.
[0090] While this invention has been described in connection with
what is presently considered to be practical exemplary embodiments,
it is to be understood that the invention is not limited to the
disclosed embodiments, but, on the contrary, is intended to cover
various modifications and equivalent arrangements included within
the scope of the appended claims.
LIST OF REFERENCE SIGNS
[0091] 10 electronic smoking device [0092] 12 end cap [0093] 14
power supply portion [0094] 16 atomizer/liquid reservoir portion
[0095] 18 light-emitting diode (LED) [0096] 20 air inlets [0097] 22
battery [0098] 24 control electronics [0099] 26 airflow sensor
[0100] 28 atomizer [0101] 30 heating coil [0102] 32 wick [0103] 34
central passage [0104] 36 liquid reservoir [0105] 38 air inhalation
port [0106] 212 power supply portion [0107] 213 power supply
portion sub-assembly [0108] 216 circumferential light guide [0109]
218 battery [0110] 220 LED [0111] 221 flexible printed circuit
board [0112] 222 controller circuitry [0113] 224 airflow sensor
[0114] 225 contacts [0115] 226 locking pin [0116] 227 airflow
gasket [0117] 228 MAF gasket [0118] 229 spacer [0119] 240 upper
sub-assembly housing [0120] 241 lower sub-assembly housing [0121]
242 wire lead [0122] 245 tube [0123] 246 tip diffuser [0124] 248
pattern [0125] 258 female connector port [0126] 320 microcontroller
[0127] 322 driver [0128] 324 memory [0129] 326 microcomputer [0130]
328 interface [0131] 330 flow sensor [0132] 331 substrate [0133]
332 upstream thermopile [0134] 333 downstream thermopile [0135] 334
heater element [0136] 335 reference element [0137] 360 airflow
signal [0138] 361 filter [0139] 362 gain amplifier [0140] 363
signal output [0141] 364 filter [0142] 370 upstream airflow signal
[0143] 371 downstream airflow signal [0144] 372 first filter [0145]
373 second filter [0146] 374 difference amplifier [0147] 375 gain
amplifier [0148] 376 offset [0149] 377 signal output [0150] 380
offset [0151] 440 microcontroller [0152] 441 data acquisition
circuit [0153] 442 analog-to-digital converter [0154] 449 amplifier
[0155] 450 mass airflow sensor [0156] 451 mass airflow heater
[0157] 452 first thermopile [0158] 453 second thermopile [0159] 454
direction of airflow [0160] 456 heater [0161] 540 microcontroller
[0162] 541 data acquisition circuit [0163] 542 analog-to-digital
converter [0164] 549 amplifier [0165] 550 mass airflow sensor
[0166] 551 mass airflow heater [0167] 552 thermopile [0168] 554
heater [0169] 556 heater [0170] 557 feedback resistor [0171] 558
gain resistor [0172] 601 flow channel [0173] 603 first side wall
[0174] 605 second side wall [0175] 607 incoming airflow pathway
[0176] 609 outgoing airflow pathway [0177] 611 incoming airflow
opening [0178] 613 outgoing airflow opening [0179] 615 sensor
assembly [0180] 617 sensor [0181] 619 airflow path [0182] 621
external airflow pathway [0183] 623 top wall [0184] 625 bottom wall
[0185] 651 sensor assembly [0186] 653 support structure [0187] 655
sensor [0188] 659 first layer [0189] 661 second layer [0190] 663
upper surface [0191] 665 incoming portion [0192] 667 airflow
pathway [0193] 701 sensor assembly [0194] 703 support structure
[0195] 705 sensor [0196] 707 first structure component [0197] 709
second structure component [0198] 751 sensor assembly [0199] 753
support structure [0200] 755 sensor top portion [0201] 757 sensor
base portion [0202] 759 sensor transition region [0203] 801 flow
channel [0204] 803 upper housing [0205] 805 support structure
[0206] 807 support depression [0207] 809 sensor [0208] 811 airflow
pathway [0209] 813 airflow direction [0210] 831 flow channel [0211]
833 upper housing [0212] 835 support structure [0213] 837 sensor
[0214] 839 second structure component [0215] 841 first structure
component [0216] 843 airflow pathway [0217] 845 airflow direction
[0218] 861 flow channel [0219] 863 upper housing [0220] 865 first
side support structure [0221] 867 sensor support structure [0222]
869 sensor [0223] 871 airflow pathway [0224] 873 airflow direction
[0225] 875 airflow sensor entrance [0226] 877 airflow sensor exit
[0227] 879 second side support structure [0228] 901 power delivered
for a given flow rate [0229] 903 response curve [0230] 905 first
position [0231] 907 second position [0232] 921 response to flow
rate [0233] 923 first response curve [0234] 925 second response
curve [0235] 927 third response curve [0236] 929 plurality of
response points [0237] 931 first response flow rate [0238] 935
second response flow rate [0239] 941 flow v time output [0240] 943
user puff [0241] 1000 microcontroller monitoring sensor [0242] 1001
change over time below threshold [0243] 1002 normalize reference
signal and relation signal [0244] 1003 read difference between
reference signal and relation signal [0245] 1004 operate device
* * * * *