Cartridge for evaporator device

Abstract

A magazine for use in an evaporator or evaporation device is disclosed herein. Also disclosed herein are vaporizers or vaporizing devices, atomizer components, and methods.

Description

[0001] This divisional patent application of the present invention is a divisional application of Chinese Patent Application No. CN 201980041546.2 (International Application No. PCT / US2019 / 036136) with the invention title "Cartridge for an Evaporator Device", which was filed on June 7, 2019.

[0002] Cross - reference to related applications

[0003] This application claims the priority of U.S. Provisional Patent Application No. 62 / 848,681 filed on May 16, 2019 and U.S. Provisional Patent Application No. 62 / 682,144 filed on June 7, 2018, each with the title "Porous Substrate Surface Heater", the disclosures of which are hereby incorporated by reference in their entireties. Background Art

[0004] Evaporation devices, including electronic evaporators or electro - evaporator devices, allow the delivery of vapors containing one or more active ingredients by inhaling the vapors. Electronic evaporator devices are increasingly widely used in aspects such as regulated medical use in drug delivery, and the consumption of nicotine, tobacco, other liquid - based substances, and other plant - based smokable substances, such as hemp crops, including solid (e.g., bulk leaves) materials, solid / liquid (e.g., suspensions, liquid coatings) materials, wax extracts, and pre - loaded pods (cartridges, packaged containers, etc.) of such materials. Electronic evaporator devices can be particularly portable, self - contained, and easy to use. Summary of the Invention

[0005] Aspects of the present subject matter relate to cartridges for evaporators or evaporation devices, evaporators or evaporation devices, atomizer components, and methods.

[0006] In one exemplary aspect, a cartridge may include: a reservoir housing including a reservoir chamber configured to selectively hold an evaporable material; and an atomizer in fluid communication with the reservoir chamber. The atomizer includes: a porous matrix configured to draw the evaporable material from the reservoir chamber; and at least one surface heater configured to heat at least a portion of the evaporable material drawn into the porous matrix into an evaporated evaporable material. The porous matrix includes at least one vent extending therethrough, the at least one vent being configured to allow air to enter the reservoir chamber in response to at least a portion of the evaporable material being drawn out of the reservoir chamber. The at least one surface heater includes at least one conductive layer deposited on a portion of the porous matrix.

[0007] The porous matrix can have various configurations. In some aspects, the porous matrix can extend from a first surface to a second surface opposite the first surface. The at least first surface can be located within the reservoir chamber, and the at least one conductive layer can be deposited on the second surface.

[0008] The at least one vent can have various configurations. In some aspects, the at least one vent can include a first portion having a first cross-sectional area and a second portion having a second cross-sectional area that is less than the first cross-sectional area. In these aspects, the first portion can be adjacent to the reservoir chamber, and the second portion can be located at a distal end of the reservoir chamber.

[0009] In another exemplary aspect, an evaporator device is disclosed. The evaporator device can include an evaporator body that includes a first airflow path; and a cartridge as described above. The cartridge is selectively coupled to the evaporator body, wherein at least a portion of the atomizer is exposed to the first airflow path, and the at least one vent is in fluid communication with the first airflow path.

[0010] In some aspects, the cartridge can include a second airflow path that is in fluid communication with the first airflow path.

[0011] In another exemplary aspect, the cartridge can include: a reservoir housing that includes a reservoir chamber configured to selectively hold an evaporable material; and an atomizer in fluid communication with the reservoir chamber. The atomizer includes a matrix that has a channel extending at least partially therethrough, the channel being configured to receive a predetermined volume of the evaporable material from the reservoir chamber at a predetermined rate. The atomizer further includes at least one surface heater configured to selectively heat at least a portion of the evaporable material received within the channel into an evaporated evaporable material.

[0012] The at least one surface heater can have various configurations. In some aspects, the at least one surface heater can include at least one conductive layer deposited on a portion of the matrix. In other aspects, the at least one surface heater can include a first surface heater located on a first portion of the matrix and a second surface heater located on a second portion of the matrix.

[0013] The matrix can have various configurations. In some aspects, the matrix can have at least two spaced-apart surfaces, each surface defining a boundary of the channel. The matrix can include a substrate extending between the at least two spaced-apart surfaces, wherein the substrate further defines a boundary of the channel. In these aspects, the matrix can be formed as a unitary structure.

[0014] In other aspects, the substrate can include a first sidewall and a second sidewall spaced apart from each other in a first direction. The first sidewall and the second sidewall can each extend from an inner surface to an outer surface, where each inner surface defines a boundary of the channel. In these aspects, the substrate can include a third sidewall and a fourth sidewall spaced apart from each other in a second direction opposite to the first direction. The third sidewall and the fourth sidewall can each extend from an inner surface to an outer surface, where each inner surface defines a boundary of the channel.

[0015] In some aspects, the substrate can include at least one vent extending from a first surface of the substrate to a second surface of the substrate, where the second surface is opposite to the first surface.

[0016] The at least one vent can have various configurations. In some aspects, the at least one vent can include a first portion having a first cross-sectional area and a second portion having a second cross-sectional area smaller than the first cross-sectional area. In these aspects, the first portion can be adjacent to the reservoir chamber, and the second portion can be located at a distal end of the reservoir chamber.

[0017] In another exemplary aspect, an evaporator device is disclosed. The evaporator device can include an evaporator body that includes a first airflow path, and a cartridge as described above. The cartridge is selectively coupled to the evaporator body, where at least a portion of the atomizer is exposed to the first airflow path.

[0018] In some aspects, the cartridge can include a second airflow path that can be in fluid communication with the first airflow path.

[0019] In another exemplary aspect, the cartridge can include a mouthpiece, a reservoir configured to hold an evaporable material, and an atomizer component. The atomizer component includes: a porous substrate configured to draw the evaporable material from the reservoir to an evaporation surface exposed to an air flow path; and a surface heater configured to heat the evaporable material. The porous substrate has a rigid, non-deformable form. The surface heater includes at least one conductive layer deposited on a portion of the porous substrate, where the evaporation surface includes that portion of the porous substrate.

[0020] The porous substrate can have various configurations. In some aspects, the porous substrate can be at least partially received within the reservoir. In other aspects, the porous substrate can be fully received within the reservoir, where the surface heater can be positioned away from the evaporable material in the reservoir.

[0021] In some aspects, the porous substrate can be in fluid communication with the reservoir on a surface other than the portion on which the surface heater is deposited. In some aspects, the porous substrate can include a plurality of voids distributed throughout the porous substrate.

[0022] In some aspects, the porous matrix can include a stacked configuration formed by stacking a plurality of separate matrices on top of each other. In these aspects, at least a portion of the surface heater can be disposed between two of the plurality of separate matrices.

[0023] In some aspects, the portion of the porous matrix on which the conductive layer is deposited can include a flat surface, a recessed surface, or a cylindrical surface.

[0024] The at least one conductive layer can have various configurations. In some aspects, the at least one conductive layer can include a trace pattern or a plate. In other aspects, the at least one conductive layer can include a microelectromechanical systems (MEMS) layer.

[0025] In some aspects, the at least one conductive layer can allow an evaporable material from a reservoir to pass therethrough. In some aspects, the at least one conductive layer can include one or more electrical contacts for interfacing with one or more corresponding pins. In these aspects, the one or more electrical contacts can be deposited on a surface of the porous matrix, and the remaining portion of the at least one conductive layer is not deposited on this surface.

[0026] The mouthpiece can have various configurations. In some aspects, the mouthpiece can be disposed at a first end of the cartridge body, and the heating element can be disposed at a second end of the body opposite the first end.

[0027] In some aspects, the cartridge can include an air intake passage configured to direct an air flow along an evaporation surface in an air flow path such that when the surface heater is activated, the evaporable material drawn by the porous matrix along the evaporation surface is evaporated into the air flow.

[0028] In another exemplary aspect, an evaporation device is disclosed. The evaporation device can include a reservoir configured to hold an evaporable material, and an atomizer component. The atomizer component includes: a porous matrix configured to draw the evaporable material from the reservoir to an evaporation surface exposed to an air flow path; and a surface heater configured to heat the evaporable material. The porous matrix has a rigid, non-deformable form. The surface heater includes at least one conductive layer deposited on a portion of the porous matrix, wherein the evaporation surface includes this portion of the porous matrix.

[0029] The porous matrix can have various configurations. In some aspects, the porous matrix can be at least partially received within the reservoir. In other aspects, the porous matrix can be fully received within the reservoir, wherein the surface heater can be positioned away from the evaporable material in the reservoir.

[0030] In some aspects, the porous matrix can be in fluid communication with the reservoir on surfaces other than the portion where the surface heater is deposited thereon. In some aspects, the porous matrix can include a plurality of voids distributed throughout the porous matrix.

[0031] In some aspects, the porous matrix can include a stacked structure formed by stacking a plurality of separate matrices on top of each other. In these aspects, at least a portion of the surface heater can be disposed between two of the plurality of separate matrices.

[0032] In some aspects, the portion of the porous matrix on which the conductive layer is deposited can include a flat surface, a concave surface, or a cylindrical surface.

[0033] The at least one conductive layer can have various configurations. In some aspects, the at least one conductive layer can include a trace pattern or a plate. In other aspects, the at least one conductive layer can include a microelectromechanical systems (MEMS) layer.

[0034] In some aspects, the at least one conductive layer can allow an evaporable material from the reservoir to pass therethrough. In some aspects, the at least one conductive layer can include one or more electrical contacts for interfacing with one or more corresponding styli. In these aspects, the one or more electrical contacts can be deposited on a surface of the porous matrix on which the remainder of the at least one conductive layer is not deposited.

[0035] In some aspects, the evaporation device can include an intake channel configured to direct an air flow along an evaporation surface in an air flow path such that when the surface heater is activated, the evaporable material drawn by the porous matrix along the evaporation surface can be evaporated into the air flow.

[0036] In another exemplary aspect, an atomizer component is disclosed. The atomizer component can include: a porous matrix configured to draw an evaporable material from a reservoir, wherein the porous matrix has a rigid, non-deformable form; and a surface heater configured to heat the evaporable material. The surface heater includes at least one conductive layer deposited on a portion of the porous matrix.

[0037] The porous matrix can have various configurations. In some aspects, the porous matrix can be at least partially housed within the reservoir. In other aspects, the porous matrix can be fully housed within the reservoir, wherein the surface heater can be positioned away from the evaporable material in the reservoir.

[0038] In some aspects, the porous matrix can be in fluid communication with the reservoir on surfaces other than the portion where the surface heater is deposited thereon. In some aspects, the porous matrix can include a plurality of voids distributed throughout the porous matrix.

[0039] In some aspects, the porous matrix can include a stacked configuration formed by stacking a plurality of discrete matrices on top of each other. In these aspects, at least a portion of the surface heater can be disposed between two of the plurality of discrete matrices.

[0040] In some aspects, the portion of the porous matrix on which the conductive layer is deposited can include a flat surface, a concave surface, or a cylindrical surface.

[0041] The at least one conductive layer can have various configurations. In some aspects, the at least one conductive layer can include a trace pattern or a plate. In other aspects, the at least one conductive layer can include a microelectromechanical systems (MEMS) layer.

[0042] In some aspects, the at least one conductive layer can allow an evaporable material from a reservoir to pass therethrough. In some aspects, the at least one conductive layer can include one or more electrical contacts connected to one or more respective stylus interfaces. In these aspects, the one or more electrical contacts can be deposited on a surface of the porous matrix on which the remainder of the at least one conductive layer is not deposited.

[0043] In some aspects, the porous matrix can be configured to draw an evaporable material from a reservoir to an evaporation surface exposed to an airflow path. In these aspects, the atomizer component can include an intake channel configured to direct an airflow along the evaporation surface in the airflow path such that when the surface heater is activated, the evaporable material drawn by the porous matrix along the evaporation surface can be evaporated into the airflow.

[0044] In another exemplary aspect, a method is disclosed. The method can include drawing an evaporable material from a reservoir of an evaporation device to an evaporation surface through a porous matrix, where the porous matrix has a rigid, non-deformable form on at least a portion of the surface on which a surface heater including at least one conductive layer is deposited. The porous matrix is in direct fluid communication with at least a portion of the reservoir, and the surface heater is not in direct fluid communication with the reservoir and is directly along the airflow path. The method further includes heating the evaporation surface with the surface heater to cause evaporation of the evaporable material and entraining the evaporated evaporable material in an airflow along the airflow path leading to a mouthpiece of the evaporation device.

[0045] The porous matrix can have various configurations. In some aspects, the porous matrix can be at least partially housed within the reservoir. In other aspects, the porous matrix can be fully housed within the reservoir, where the surface heater can be positioned away from the evaporable material in the reservoir.

[0046] In some aspects, the porous matrix can be in fluid communication with the reservoir on a surface other than the portion on which the surface heater is deposited. In some aspects, the porous matrix can include a plurality of voids distributed throughout the porous matrix.

[0047] In some aspects, the porous matrix may include a stacked configuration formed by stacking a plurality of separate matrices on top of each other. In these aspects, at least a portion of the surface heater may be disposed between two of the plurality of separate matrices.

[0048] In some aspects, the portion of the porous matrix on which the conductive layer is deposited may include a flat surface, a concave surface, or a cylindrical surface.

[0049] The at least one conductive layer may have various configurations. In some aspects, the at least one conductive layer may include a trace pattern or a plate. In other aspects, the at least one conductive layer may include a microelectromechanical systems (MEMS) layer.

[0050] In some aspects, the at least one conductive layer may allow an evaporable material from a reservoir to pass therethrough. In some aspects, the at least one conductive layer may include one or more electrical contacts for interfacing with one or more corresponding styli. In these aspects, the one or more electrical contacts may be deposited on a surface of the porous matrix on which the remainder of the at least one conductive layer is not deposited.

[0051] The mouthpiece may have various configurations. In some aspects, the mouthpiece may be disposed at a first end of the cartridge body, and the heating element may be disposed at a second end of the body opposite the first end.

[0052] Details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the following description. Other features and advantages of the subject matter described herein will be apparent from the specification and drawings and from the claims.

[0053] Details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the following description. Other features and advantages of the subject matter described herein will be apparent from the specification and drawings and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The drawings incorporated in and constituting a part of this specification illustrate specific aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed embodiments. In the drawings:

[0055] Figure 1 is a cross-sectional perspective view of an exemplary embodiment of a cartridge consistent with the present subject matter embodiment, in which a surface heater and a porous matrix are combined;

[0056] Figure 2A is a cross-sectional front view of another exemplary embodiment of a cartridge consistent with the present subject matter embodiment, in which a surface heater and a porous matrix are combined;

[0057] Figure 2B is a cross-sectional side view of the cartridge taken along 2B-2B; Figure 2A of the cartridge;

[0058] Figure 3A is a front cross-sectional view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, wherein a surface heater and a porous matrix are combined;

[0059] Figure 3B is Figure 3A a bottom view of the cartridge;

[0060] Figure 4A is a partially transparent perspective view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, the cartridge having a surface heater and a porous matrix and being connected to a stylus;

[0061] Figure 4B is taken at 4B Figure 4A an enlarged view of the cartridge;

[0062] Figure 5A is a partially transparent perspective view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, the cartridge having a surface heater and a porous matrix and being connected to a stylus;

[0063] Figure 5B is taken at 5B Figure 5A an enlarged view of the cartridge;

[0064] Figure 6A is a perspective view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, the cartridge having a surface heater and a porous matrix;

[0065] Figure 6B is a cross-sectional view of a portion of the cartridge taken along line 6B-6B; Figure 6A of the cartridge;

[0066] Figure 7A is a perspective view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, having a surface heater and a porous matrix;

[0067] Figure 7B is Figure 7A a perspective view of a portion of the cartridge;

[0068] Figure 8A is a perspective view of another exemplary embodiment of the cartridge consistent with the current subject matter embodiment, having a surface heater and a porous matrix;

[0069] Figure 8B is taken at 8B Figure 8A an enlarged view of the cartridge;

[0070] Figure 9A is a perspective view of another exemplary embodiment of a cartridge having a surface heater and a porous matrix consistent with embodiments of the present subject matter;

[0071] Figure 9B yes Figure 9A A perspective view of a surface heater and a porous substrate;

[0072] Figure 10 is a partial cross-sectional elevation view of an exemplary embodiment of an evaporator device consistent with embodiments of the present subject matter, the evaporator device including a cartridge integrated into an evaporator body;

[0073] Figure 11 is a partially transparent perspective view of another exemplary embodiment of an evaporator device consistent with embodiments of the present subject matter, the evaporator device including a cartridge coupled to an evaporator body;

[0074] Figure 12 A process flow diagram is shown that illustrates one exemplary embodiment of a method of pumping and evaporating a vaporizable material in an evaporation apparatus consistent with embodiments of the current subject matter;

[0075] Figure 13A is an elevation view of a portion of another exemplary embodiment of an evaporator device consistent with embodiments of the present subject matter, the evaporator device including an evaporator body, a heater integrated into the evaporator body, and a cartridge having a porous matrix incorporated therein, the elevation view showing the cartridge insertably received in the evaporator body;

[0076] Figure 13B yes Figure 13A A front view of an evaporator device with a front portion of the evaporator body removed, the front view showing the cartridge being inserted into the evaporator body;

[0077] Figure 13C yes Figure 13A A front view of the evaporator device with a front portion of the evaporator body removed, the front view showing the cartridge insertably received in the evaporator body;

[0078] Figure 14 is a cross-sectional elevation view of another exemplary embodiment of a cartridge for use in a vaporizer device consistent with embodiments of the present subject matter, the cartridge having a reservoir and an atomizer including a substrate having a passage defined therethrough and at least one surface heater;

[0079] Figure 15 It was taken along 15-15 Figure 14 A cross-sectional side view of a material box;

[0080] Figure 16 is Figure 15 an enlarged cross-sectional view of the atomizer of

[0081] Figure 17 is a partially transparent top view of another exemplary embodiment of an evaporator device, the evaporator device including an evaporator body and a cartridge having a reservoir chamber and an atomizer in accordance with an embodiment of the present subject matter, showing the evaporator body and the cartridge separated from each other;

[0082] Figure 18 is Figure 17 a partially transparent top view of the evaporator device of

[0083] Figure 19 is a cross-sectional view of an exemplary embodiment of a reservoir system configured for an evaporator cartridge and / or an evaporator device in accordance with an embodiment of the present subject matter;

[0084] Figure 20 is a cross-sectional view of another exemplary embodiment of a reservoir system configured for an evaporator cartridge and / or an evaporator device in accordance with an embodiment of the present subject matter;

[0085] Figure 21 is a front cross-sectional view of another exemplary embodiment of a cartridge for an evaporator device in accordance with an embodiment of the present subject matter, the cartridge having a reservoir and an atomizer, the atomizer including a porous matrix having at least one air vent extending therethrough and at least one surface heater;

[0086] Figure 22 is Figure 21 an enlarged cross-sectional view of the atomizer of

[0087] Figure 23 is Figure 22 an enlarged bottom view of the atomizer of

[0088] Figure 24 is a partially transparent top view of another exemplary embodiment of an exemplary embodiment of an evaporator device in accordance with an embodiment of the present subject matter, the evaporator device including an evaporator body and a cartridge having a reservoir chamber and an atomizer, showing the evaporator body and the cartridge separated from each other; and

[0089] Figure 25 is Figure 24 a partially transparent top view of the evaporator device of Detailed Description

[0090] Embodiments of the present subject matter include devices related to vaporizing one or more materials for inhalation by a user. The term "evaporator" is used frequently in the following description and refers to a vaporizer or vaporizing device. Examples of evaporators consistent with embodiments of the present subject matter include electronic vaporizers, electronic cigarettes, e-cigars, and the like. Generally, such evaporators are typically portable, frequently hand-held devices that heat a vaporizable material to provide an inhalable dose of the material.

[0091] Electronic vaporizers typically use a basic atomizer system that includes a wicking element (or wick) having a resistive heating element such as a coil (e.g., a nichrome coil) wound around or located within the hollow wicking element. As discussed further below, other wick configurations are possible. The wick can serve at least one or more purposes, including: drawing liquid from a reservoir into the atomizer where the liquid can be vaporized by the coil, allowing air to enter the reservoir to replace a removed volume of liquid, and other potential purposes. When a user draws on the vaporizer, the coil heater may be activated and incoming air flows over the saturated wick / coil assembly, stripping the vapor, which passes through the user's mouth and into the user's lungs. Upon exhalation and / or after exhalation, capillary action draws more liquid into the wick and air returns through the wick to the reservoir.

[0092] Traditionally, evaporator devices have utilized wicks typically formed from silica, cotton, or fiberglass materials. Conventional silica wick materials are formed by first bundling thin, continuous filaments of, for example, silica glass into strands and then bundling those strands together to form a cable or cord that serves as the wick. The cable can typically be defined by a nominal outer diameter, number of strands, and / or a value representing the linear density.

[0093] However, such traditional atomizer systems (where liquid is drawn into the wick from a reservoir) are limited because the liquid is drawn longitudinally at the endpoints of the cable (e.g., at the endpoints of the continuous silica filaments). During use of the evaporator device, as liquid evaporates from the heated region of the wick and more liquid is needed to travel along the length of the wick for replenishment, the liquid may not be replenished as quickly as desired by the user. An improved liquid delivery rate for such a design may be desired.

[0094] Traditional atomizer systems can have certain other problems. For example, traditional atomizer systems may have many components, be quite complex, and there may be significant variations in the manufacture and use of wick and coil components. Also, as described above, a wick formed by first bundling thin continuous filaments into strands and then tying these strands to form a cable or cord for the wick can be fragile, and its non-rigid structure may require precise and careful placement, thereby increasing the complexity of manufacture.

[0095] In other atomizer designs, traditional wick and coil designs have been modified to incorporate a cylindrical ceramic wick, thereby addressing the design challenges of having a non-rigid wick and the drawbacks due to longitudinal pumping of the liquid. However, such designs may have multiple parts, potentially leading to manufacturing complexity as well.

[0096] In another atomizer design, a chimney-shaped coil design has been implemented. This design utilizes a ceramic wick formed within a hollow tube, with a heating coil inside the hollow tube. Instead of drawing liquid from a reservoir along the axis of the wick, the liquid surrounds the perimeter of the chimney-shaped coil, resulting in a larger capillary action area and a shorter capillary action distance. However, this design still requires many parts, which may also lead to manufacturing complexity.

[0097] Each of the above atomizers may also include other challenges because the design is not compact in volume but tends to occupy a large portion of the evaporator device to which it is combined.

[0098] The atomizer component for an evaporator device consistent with one or more embodiments of the present subject matter can provide advantages and improvements over existing methods, while also introducing other benefits described herein. As used herein, "atomizer component" is used synonymously with "atomizer".

[0099] An evaporator consistent with an embodiment of the present subject matter can include an evaporator body or device and a cartridge (also referred to as a pod). The body / device can include a battery, a microcontroller, and an interface that is electromechanically connected to the cartridge. According to an embodiment of the present subject matter, the cartridge generally can include a reservoir or reservoir chamber, an air path, and an atomizer component. As used herein, "reservoir" is used synonymously with "reservoir chamber".

[0100] An atomizer component consistent with an embodiment of the present subject matter can be formed from a porous matrix having a surface heater on a matrix surface (referred to herein as a "heated surface"). The atomizer can also be integrated into the evaporator body, that is, without any cartridge, or alternatively as a heating plate that is part of the evaporator body and is positioned to receive the surface of the porous matrix that is part of the cartridge when the cartridge is coupled to the evaporator body.

[0101] In an atomizer design consistent with embodiments of the present subject matter, a flat wick design can be formed of silica, cotton, fiberglass, or other materials. Such a design can have favorable wicking characteristics based on varying geometries, which can also facilitate manufacturing (e.g., based on ease of insertion, Di-cut capabilities, etc.). In some embodiments, traces can be printed onto the wick. In other embodiments, coils or wires are wound around the wick.

[0102] Figure 1 A cartridge 100 consistent with some embodiments of the present subject matter is shown in cross-section, where a surface heater 110 and a porous matrix 120 can be incorporated.

[0103] The cartridge 100 can be used with an evaporator body / device (not shown) having a battery and control circuitry, configured together to produce inhalable vapor by heating an evaporable material before and / or as it enters the porous matrix 120 from which it can be evaporated.

[0104] In Figure 1 In the exemplary configuration shown, the cartridge 100 includes a reservoir (or tank) 105 for holding an evaporable material (such as nicotine e-liquid, or oil or some other fluid or liquid having a desired evaporable material), a proximal mouthpiece 109, and an atomizer component located within or in contact with the liquid contained within the reservoir 105. The atomizer component is an integral modular component formed by the porous matrix 120 and the surface heater 110, which together produce a heated surface portion 115 of the atomizer component when the surface heater 110 is activated. According to some aspects, the atomizer component is secured within the cartridge 100 by, for example but not limited to, insert molding, welding (such as ultrasonic welding, plastic-to-ceramic welding, radio frequency (RF) welding, etc.), snap-fit connections, press-fit connections, or any other securing connection method.

[0105] According to some aspects of the present subject matter, the porous matrix 120 is in fluid communication with the reservoir 105 on many, most, or even all unheated surfaces (e.g., surfaces other than the heated surface 115). That is, the porous matrix 120 can provide a capillary from the reservoir 105 to an electrical layer (the surface heater 110) that does not directly contact the reservoir 105.

[0106] In Figure 1An air path 130 is shown. Air can be inhaled from the bottom or base of the cartridge 100 and drawn along the side of the atomizer component, particularly alongside the surface heater 110. Then, the air passing through the air path 130 of the cartridge 100 passes alongside the reservoir 105 in the channel 140 between the outer wall of the reservoir 105 and the inner wall of the cartridge 100 and leads to the mouthpiece 109. Thus, the atomizer component is directly located in the vapor path or air path 130. Other air paths can also be provided to supply air along the surface heater 110.

[0107] Due to the porosity of the matrix 120 and the resulting capillary action, the porous matrix 120 draws the evaporable material from the reservoir 105. When the user sucks on the mouthpiece 109 of the cartridge 100, air flows into the inlet and along the air path 130. In relation to the user's suction, the surface heater 110 can be activated. For example, suction can be automatically detected by a pressure sensor, by detecting that the user presses a button, by detecting signals generated by a motion sensor, a flow sensor, a capacitive lip sensor, or other methods capable of detecting that the user is sucking or about to suck or other inhalation that causes air to enter the evaporator device and flow along the air path 130. When the surface heater 110 is activated, since an electric current flows through the surface heater 110 to generate heat, the temperature rises. The heat is transferred to a certain amount of evaporable material by conduction, convection, and / or radiative heat transfer, thereby causing at least a portion of the evaporable material to evaporate. Heat transfer can occur in the evaporable material in the reservoir and the evaporable material drawn into the porous matrix. For example, it may be necessary to preheat some of the evaporable material in the reservoir before sucking it through the porous matrix into the surface heater 110. The air entering the evaporator device flows along the air path 130 through the atomizer component and draws away the evaporated evaporable material from the porous matrix 120. Then, the evaporated evaporable material typically condenses due to cooling, pressure changes, etc., such that it is discharged as an aerosol from the mouthpiece 109 for the user to inhale.

[0108] The porous matrix 120 can be made of porous ceramic materials, sintered materials, other porous materials, such as high-temperature resistant materials, including, for example, but not limited to, metals, glasses, silicon, carbon, or high-temperature resistant plastic materials, such as, for example, but not limited to, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), or polyether ether ketone (PEEK). The porous matrix 120 can be characterized by having a plurality of voids or spaces to allow the absorption and transmission of liquid from the reservoir 105. The void size, particle size, or porosity of the porous matrix 120 can be selected based on various factors, for example, to achieve desired properties or due to specific parameters of the cartridge / device (such as, for example, the viscosity of the evaporable material and / or other design considerations). The plurality of voids or spaces can be an inherent property of the material (or materials), or can be formed by, for example, drilling (such as, laser drilling). The porous matrix 120 can also be characterized by having a rigid, non-deformable structure.

[0109] According to another embodiment of the present subject matter, a combination of two or more materials can be included in a monolithic porous matrix, and such combination can include a uniform distribution of two or more materials over the monolithic porous material, or other relative amounts of two or more materials in a spatially heterogeneous structure. For example, in one exemplary configuration, the porous matrix can have a stacked configuration, where different matrices are stacked one on top of the other (vertically or horizontally). The porosity of the stacked configuration can decrease from the top to the bottom within the cartridge (for example, having the most porous material at the top within the reservoir and one or more materials with a lower porosity outside the reservoir). This type of stacked configuration can provide effective absorption of the evaporable material in the porous matrix inside the reservoir. In various configurations, the porosity of the matrix can be designed such that each layer is specifically fabricated with a particular porosity.

[0110] One or more materials and the configuration (such as, multi-layer) of the porous matrix 120 can be selected based on various factors, for example, to achieve desired properties or due to specific parameters of the cartridge / device (such as, for example, the type of evaporable material, evaporation temperature, desired pumping jet volume, size of the porous matrix, and / or surface area of the surface heater). For example, in an embodiment of designing a cartridge to be used with a liquid evaporable material having a relatively high viscosity, the pores of the porous matrix can be relatively larger.

[0111] The porous matrix 120 can be in the shape of a rectangular block or a cube. In some embodiments, the porous matrix 120 is a thin rectangular block, where the surface heater 110 is included on the rectangular side having the largest surface area. Other shapes are also within the scope of the present subject matter, as further described below. The large surface area of the surface heater 110 is beneficial for heat distribution and faster heating.

[0112] The surface heater 110 may include one or more conductive layers located on or in contact with the porous matrix 120. In some examples, the one or more conductive layers may include a trace pattern deposited on the surface or at least a portion of the surface of the porous matrix 120. The trace pattern may be configured to achieve a desired and controlled resistance and may be uniform or non-uniform in terms of thickness or extent along the surface of the porous matrix 120. The particular shape, pattern, thickness, etc. of the surface heater 110 are advantageous for allowing control of heat transfer to the porous matrix 120 and for allowing liquid from the reservoir 105 to pass through. Alternatively, the conductive layer may be a plate or other continuous layer that covers the entire surface or a portion of the heated surface 115 of the matrix 120. Such a plate or other continuous layer may include features such as holes, micro-perforations, etc. to allow the evaporable material from the reservoir 105 to pass through the surface heater 110. The conductive layer may be made of any conductive material, such as, for example but not limited to, nichrome, stainless steel, nickel, platinum, gold, copper, or aluminum. The conductive layer may be a microelectromechanical systems (MEMS) layer. In this manner, or in other ways consistent with the current subject matter, the surface heater may be in contact with at least a portion of the surface of the porous matrix and may be at least a portion (e.g., included within) of the evaporation surface of the porous matrix.

[0113] The surface heater 110 may be adhered to the porous matrix 120 in a variety of ways, such as by pulsed laser deposition, physical vapor deposition, chemical vapor deposition, electroplating, electroless plating, screen printing, etc. In some variations of the current subject matter, the surface heater 110 may be a stamped component that is snapped onto the porous matrix 120 or otherwise mechanically held by the porous matrix 120. In other variations, the surface heater 110 may be a stamped component that is insert-molded within the porous matrix. In other variations, the surface heater 110 is fixed to the porous matrix 120 by any fixed attachment method.

[0114] In some variations of the current subject matter, the atomizer component may have a single heated surface (e.g., heated surface 115), while in other variations, there may be more than one heated surface.

[0115] According to an embodiment of the current subject matter, the surface heater 110 may have a low-resistance region that may be used as a contact for electrically connecting the cartridge 100 to the evaporator body / device ( Figure 1The electric contact 112) shown. The electric contact area may be located on a surface different from the heated surface 115, and in some variations, the electric contact area may be on the same surface as the heated surface 115. This configuration of the surface heater 110 with the electric contact 112 has manufacturing advantages because the contact does not require additional components and may not require bridging in the cartridge. Additionally, the rigidity of the porous matrix on which the electric contact is formed provides a solid contact surface for contact with a stylus (e.g., a telescoping probe or leaf spring probe of an evaporator body / device that needs to operate in contact with the electric contact of the cartridge, which will be further described below).

[0116] According to some embodiments of the present subject matter, the heated surface 115 (and other heated surfaces, if any) is located in the air path 130.

[0117] According to some embodiments of the present subject matter, the surface heater 110 may have one or more holes or openings aligned with one or more corresponding holes of the porous matrix 120.

[0118] Figure 2A and Figure 2B A cartridge 200 consistent with other embodiments of the present subject matter is shown in a cross-sectional front view and a side view, respectively, incorporating a surface heater 210 and a porous matrix 220.

[0119] In Figure 2A the example configuration shown, the cartridge 200 includes a reservoir (or storage tank) 205, a proximal mouthpiece 209, and an atomizer component partially located within the reservoir 205 and formed by a porous matrix 220 having a surface heater 210. As Figure 2B shown, the surface heater 210 may be located on two opposite sides of the porous matrix 220, thereby creating two heated surface portions 215 when the surface heater 210 is activated.

[0120] As Figure 2A and Figure 2B shown, a portion of the porous matrix 220 extends into the reservoir 205, and the surface heater 210 is attached to one or more sides of the porous matrix 220 that are not in direct fluid communication with the reservoir 205. A void 207 (as Figure 2B shown) is formed in the area of the matrix 220 / heater 210 in the reservoir where there is no evaporable material on either side. An electric contact 212 is also shown in Figure 2A . The electric contact 212 is positioned such that it is easily accessible for contact with a stylus (e.g., a telescoping probe or leaf spring probe of an evaporator body / device that needs to operate in contact with the electric contact of the cartridge).

[0121] In Figure 2AThe air path 230 is shown. Air can be inhaled from the bottom or base of the cartridge 200 and drawn across the surface heater 210 (through the void 207). Then, the air passing through the air path 230 of the cartridge 100 passes alongside the reservoir 205 through one or more channels 240 located between the outer wall of the reservoir 205 and the inner wall of the cartridge 200 and leads to the mouthpiece 209.

[0122] Figure 3A and Figure 3B The state of combination of the surface heater 310 and the porous matrix 320 in accordance with a further embodiment of the present subject matter is shown by a cross-sectional front view and a bottom view.

[0123] In Figure 3A the exemplary configuration shown, the cartridge 300 includes a reservoir (or storage tank) 305, a proximal mouthpiece 309, and an atomizer component located at the bottom of the reservoir 305 and formed by a porous matrix 320 having a surface heater 310. As Figure 3B shown, the surface heater 310 is located at the bottom of the porous matrix 320 opposite the reservoir chamber 305, so that when the surface heater 310 is activated, a heated surface portion 315 is formed on the bottom of the porous matrix 320. Figure 3B The electrical contact 312 is also shown. The electrical contact 312 is sized and shaped to connect with a stylus (e.g., a telescopic probe or a leaf spring probe of an evaporator body / device, which needs to contact and operate with the electrical contact 312 of the cartridge 300).

[0124] In Figure 3A the air path 330 is shown. Air can be inhaled from the bottom or base of the cartridge 300, contacting the bottom of the surface heater 310 and the porous matrix 320. Then, the air path 330 passing through the cartridge 300 passes alongside the reservoir 305 through a channel 340 located between the outer wall of the reservoir 305 and the inner wall of the cartridge 300 and leads to the mouthpiece 309. It will be apparent to those skilled in the art that the porous matrix 320 can be configured to completely fill the bottom of the reservoir 305, or can be a porous matrix of a smaller size that is housed within a larger frame of some non-porous material. For example, this can be done to appropriately adjust the amount of vaporized material inhaled by the user with each puff.

[0125] Figure 4A - 4B and Figure 5A - 5B The features of the cartridges 400, 500 are shown by various perspective views, including the connection with the styli 440, 540. The features of the cartridges 400 and 500 (and the porous matrix / surface heater) are similar to the features of the above-described cartridge 200 (and the porous matrix 220 / surface heater 210). The airflow through the cartridges 400 and 500 is similar to the airflow described with respect to the cartridge 200.

[0126] Cartridge 400 includes a reservoir (or storage tank) 405, a proximal mouthpiece 409, and an atomizer component partially located at the bottom of reservoir 405. The atomizer component is formed by a porous matrix 420 (having a similar structure and operation to the porous matrix in Figure 2A and Figure 2B ), with a surface heater 410. As shown, the upper portion of the porous matrix 420 is received within the reservoir 405, while the bottom portion, which houses the surface heater 410 and electrical contacts 412 (in an extension protrusion of the porous matrix 420), is located outside the reservoir 405. Void 407 (as Figure 4B shown) is formed in the reservoir 405 in regions on either side of the matrix 420 / heater 410 where there is no evaporable material. The electrical contacts 412 provide an electrical connection for the cartridge 400 and the evaporator body / device by contacting a stylus 440 having a leaf spring probe configuration. The rigidity of the porous matrix 420 on which the electrical contacts 412 are positioned provides a solid connection surface for connection with the stylus 440.

[0127] Cartridge 500 has a structure similar to that of cartridge 400: a reservoir (or storage tank) 505, a proximal mouthpiece 509, and an atomizer component partially located within the bottom of reservoir 505. The atomizer component is formed by a porous matrix 520 having a surface heater 510. As shown, the upper portion of the porous matrix 520 is received within the reservoir 505, while the bottom portion, which houses the surface heater 510, is located outside the reservoir 505. Void 507 (one such as Figure 5B shown) is formed in the reservoir 505 in regions on either side of the matrix 520 / heater 510 where there is no evaporable material. In this configuration, electrical contacts 512 extend from the surface heater 510 and pass through a support structure 550, with the bottom edge of the electrical contacts 512 exposed to and / or accessible near the bottom of the support structure 550. The electrical contacts 512 contact a stylus 540, which in this configuration can be in the form of a telescoping probe.

[0128] As described above, in some embodiments of the present subject matter, the porous matrix can have a geometry other than a flat surface. For example, the porous matrix can have one or more recessed or protruding regions (e.g., curved or triangular), on which the surface heater is positioned (e.g., deposited). One or more recessed regions can provide a larger surface area for the heated surface within a smaller footprint. Other surfaces of the porous matrix (e.g., sides other than one or more heated surfaces) can be flat, recessed, protruding, a combination of shapes, or other geometries. In Figure 6A and Figure 6BAn example of such a configuration is shown, where a cartridge 600 having a mouthpiece 609 includes a porous matrix 620 located within a reservoir 605. The porous matrix 620 has two recessed regions, and a surface heater 610 is located on the recessed regions. In some embodiments, the surface heater 610 may be formed on just one of the recessed regions. The surface heater 610 can be directly deposited onto each recessed side. The two recessed regions can be joined together to form an open cylindrical body. In some configurations, the two recessed regions can be completely separated and have no electrical connection. The bottom region of the porous matrix 620 (e.g., the bottom end of the open cylindrical body) is outside the reservoir 605 or otherwise positioned away from any liquid retained within the reservoir 605. Electrical contacts 612 can be formed on the bottom region of the porous matrix 620. Although the surface heater 610 is shown having electrical traces arranged in a horizontal configuration (e.g., the electrical traces are orthogonal to the airflow direction), other configurations such as a vertical orientation (e.g., parallel to the airflow direction), a helical configuration, a zigzag configuration, or other patterns or arrangements are also possible. The traces can be connected in series or in parallel.

[0129] In other configurations, according to embodiments of the present subject matter, in addition to one or more recessed regions forming an open cylindrical body, the porous matrix can be in the form of a half-tube configuration or the like, which can be formed by: a single matrix or joining two or more profiles together to form a half-tube. Such a configuration can be similar to Figure 6B the porous matrix shown. The porous matrix is placed such that the recessed regions on which the electrical traces are deposited are away from any evaporable material retained within the reservoir. For example, the porous matrix can be positioned at a corner of the reservoir in contact with the wall of the reservoir, away from the liquid retained therein (such as, for example Figure 1 the position of the porous matrix shown). In such a configuration, a cap, plug, plate, etc. can form a top seal.

[0130] In another embodiment, a half-tube-shaped chimney can be substantially centered within the reservoir (similar to Figure 6A the position of the porous matrix shown), but where the opposite sides of the recessed regions are not part of the porous matrix but are adhered or otherwise joined to the porous matrix to form a half-tube cylindrical body for the airflow path.

[0131] As described above, in some exemplary configurations, the porous matrix can be two or more layers stacked (vertically or horizontally) such that the heater is accommodated within the porous matrix between two of the layers. In other configurations, the surface heater can be embedded within a portion of the porous matrix. Figure 7A and Figure 7BShows a configuration in which a cartridge 700 with a mouthpiece 709 is shown. In this configuration, the top of the porous matrix 720 is received within the reservoir 705, while the bottom in which the surface heater 710 is embedded (or placed between stacked layers) is received outside the reservoir 705. Electrical contacts 712 extend from the surface heater 510 and through a support structure 750 to provide contact with a stylus.

[0132] Figure 8A and Figure 8B The features of a cartridge 800 with a mouthpiece 809 are shown in a perspective view. The mouthpiece 809 includes an insulating layer 860 that contacts or adheres to a portion of the porous matrix 820. In this configuration, the surface heater 810 is deposited on the outer surface of the insulating layer 860, on the side remote from fluid communication with the contents of the reservoir 805. Electrical contacts 812 are also provided. The insulating layer 860 serves to electrically isolate the surface heater 810 from the porous matrix 820, while also allowing, due to a certain degree of porosity, the evaporable material drawn into the porous matrix 820 from the reservoir 805 to pass through and be heated and condensed. The surface heater 810 can be adhered to the insulating layer 860 in the same manner as described above for adhering the surface heater to the porous matrix. In some embodiments, the insulating layer is deposited on the porous matrix, and the electrical layer (surface heater) is deposited on the insulating layer, where one or more portions of the insulating layer are ablated to provide or increase porosity.

[0133] According to an embodiment of the present subject matter, the porous matrix can be in the shape of a cylindrical body, where the surface heater is screen printed or otherwise deposited on the outside of the cylindrical body. Figure 9A and Figure 9B An example of the above structure is shown, where a cartridge 900 with a reservoir 905 includes a tubular porous matrix 920 having a surface heater 910 and electrical contacts 912 adhered (e.g., deposited) on the outside of the porous matrix 920. As shown, two end regions of the porous matrix 920 extend into the reservoir 905 to be in direct fluid communication with the evaporable material contained therein. The portion to which the surface heater 910 and electrical contacts 912 are adhered is not in direct fluid communication with the reservoir 905. Due to the porosity of the matrix 920 and the resulting capillary action, the porous matrix 920 draws the evaporable material from the reservoir 905. That is, the porous matrix 920 is a capillary in the reservoir 905, where the electrical layer (surface heater 910) is not in capillary communication with the reservoir 905.

[0134] Figure 10 Shows an exemplary evaporator device 1000 consistent with an embodiment of the present subject matter, which includes a cartridge 1002 integrated into an evaporator body 1004. The cartridge can be similar to Figures 2A to 2BThe cartridge shown, and thus common elements are not described again here. In the illustrated embodiment, the evaporator body 1004 includes a power supply 1050 connected to the surface heater 1010 via electrical contacts, and a controller 1060 for various operations such as heating and draw detection.

[0135] Figure 11 Features of the device 1100 are shown, where a cartridge 1102 (having a porous matrix surface heater 1120 and a mouthpiece 1109) is coupled to an evaporator body 1145 (having a power supply 1150 and a controller 1160). It shows how any cartridge described herein can be coupled to and / or inserted into the evaporator body. An airflow path 1130 is also shown, where airflow moves across one or more portions of the surface heater 1120.

[0136] According to embodiments of the present subject matter, a cartridge is insertably received in a cartridge seat within an evaporator body to construct an evaporator device for use. In Figures 13A to 13C an example of such a configuration is shown, where a cartridge 1302 having a reservoir 1305 includes a porous matrix 1320, and an evaporator body 1345 includes a cartridge seat 1304 and a surface heater 1310.

[0137] Figure 13A The view in shows an example of a cartridge 1302 that is insertably received in a cartridge seat within an evaporator body 1345 to construct an evaporator device 1300 for use.

[0138] Figure 13B and Figure 13C show features of an exemplary evaporator device 1300 consistent with embodiments of the present subject matter. The evaporator device 1300 may include an evaporator body 1345 and a cartridge 1302. The evaporator body 1345 may include a cartridge seat 1304 configured to mechanically connect the evaporator body 1345 to the cartridge 1302. The cartridge 1302 generally may include a reservoir (or tank) 1305, an air path, and a porous matrix 1320 consistent with embodiments of the present subject matter. The evaporator body 1345 may include a surface heater 1310 configured to couple with the porous matrix 1320 to create a heated surface portion when the cartridge 1302 is insertably received in the cartridge seat 1304.

[0139] In some embodiments, the cartridge may have one or more surfaces of the porous matrix (wick) exposed at the cartridge receiving end. The surface heater may be exposed such that when the cartridge is inserted into the cartridge holder, the surface heater is coupled to the wick. The surface heater may be configured to be flexible and may be bent from an upward arc to a flat or substantially flat surface, thereby providing additional tension / contact between the wick and the surface heater. Figure 13C An example of the above configuration is shown, where a porous matrix 1320 coupled to a surface heater 1310 is shown.

[0140] The various features of the above embodiments of the present subject matter may be combined. For example, an atomizer component according to an embodiment of the present subject matter may have some features of each of the above embodiments.

[0141] An atomizer component according to an embodiment of the present subject matter, due to the porosity of the porous matrix and the shape of the porous matrix, can cause improved aerosol production characteristics relative to a conventional wick, such as a wick formed of silica glass fiber yarns, by holding more liquid per unit volume very close to the evaporation surface.

[0142] An atomizer component consistent with an embodiment of the present subject matter may have an increased liquid carrying capacity, while also having thermal stability and having sufficient structural integrity to accommodate its use in an evaporator device. Additionally, the porous matrix according to the embodiments described herein is a robust and easily automatable manufacturing design. In particular, it allows for the direct printing of electrical traces in one way or another onto the evaporation surface of the porous matrix, thereby eliminating the need to fabricate separate electrical components and embed or attach them to the matrix.

[0143] According to some embodiments, the flat surface side of the porous matrix described herein provides an easily controllable heated surface. The flat design allows for the control of the heating area and the size of the surface heater (e.g., the conductive trace pattern) by, for example, adjusting the exact pattern of the electrical heater traces in different regions. Additionally, the flat surface side has an increased surface area compared to a conventional round wick.

[0144] Furthermore, the use of a conductive material for the surface heater (e.g., in the form of a trace pattern) allows for the control of the temperature of the surface heater using the correlation based on the temperature coefficient of resistance (TCR). Different conductive materials (e.g., nickel) can be selected and used to achieve a more stable TCR, thereby enabling precise temperature sensing / control.

[0145] Refer to Figure 12 , process flow Figure 12Illustrates the features of the method, which may optionally include some or all of the following. At 1204, a vaporizable material is provided in a reservoir of an evaporation device. At 1206, a mouthpiece is provided where a user can apply a negative pressure to cause an air flow to pass over an evaporation surface. At 1210, the vaporizable material is drawn from the reservoir of the evaporation device through a porous matrix to the evaporation surface, which includes a heated surface of the porous matrix on which a surface heater is disposed. At 1220, the evaporation surface is heated using a surface heater disposed near the evaporation surface. The heating causes the vaporizable material in the evaporation surface to evaporate. At 1230, the vaporized vaporizable material is entrained in an air flow leading to the mouthpiece of the evaporation device.

[0146] The following is a brief description of specific aspects of the present invention, which is not intended to be limiting.

[0147] In some aspects, a cartridge for an evaporator device includes a mouthpiece, a reservoir configured to hold a vaporizable material, and an atomizer component. The atomizer component includes: a porous matrix configured to draw the vaporizable material from the reservoir to an evaporation surface exposed to an air flow path; the porous matrix having a rigid, non-deformable form; and a surface heater configured to heat the vaporizable material, the surface heater including at least one conductive layer deposited on a portion of the porous matrix, the evaporation surface including the portion of the porous matrix.

[0148] According to some aspects, an evaporation device includes a reservoir configured to hold a vaporizable material and an atomizer component. The atomizer component includes: a porous matrix configured to draw the vaporizable material from the reservoir to an evaporation surface exposed to an air flow path; the porous matrix having a rigid, non-deformable form; and a surface heater configured to heat the vaporizable material, the surface heater including at least one conductive layer deposited on a portion of the porous matrix, the evaporation surface including the portion of the porous matrix.

[0149] In some aspects, a method includes drawing a vaporizable material from a reservoir of an evaporation device through a porous matrix having a rigid, non-deformable form to an evaporation surface, depositing a surface heater including at least one conductive layer on at least a portion of the porous matrix, where the porous matrix is in direct fluid communication with at least a portion of the reservoir and further, the surface heater is not in direct fluid communication with the reservoir but is directly along the air flow path; heating the evaporation surface with the surface heater to cause evaporation of the vaporizable material; and causing the vaporized vaporizable material to be entrained in an air flow along the air flow path leading to a mouthpiece of the evaporation device.

[0150] In some aspects, the atomizer component includes a porous matrix configured to draw an evaporable material from a reservoir, the porous matrix having a rigid, non-deformable form, and a surface heater configured to heat the evaporable material, the surface heater including at least one conductive layer deposited on a portion of the porous matrix.

[0151] According to some aspects, the porous matrix is at least partially received within the reservoir.

[0152] According to some aspects, the porous matrix is fully received within the reservoir, and the surface heater is positioned away from the evaporable material in the reservoir.

[0153] According to some aspects, the porous matrix is in fluid communication with the reservoir on a surface thereof other than the portion on which the surface heater is deposited.

[0154] In some aspects, the intake passage is configured to direct an air flow along an evaporation surface in an air flow path such that when the surface heater is activated, the evaporable material drawn by the porous matrix along the evaporation surface is evaporated into the air flow.

[0155] According to some aspects, the at least one conductive layer includes a trace pattern or a plate.

[0156] According to some aspects, the at least one conductive layer includes a microelectromechanical systems (MEMS) layer.

[0157] According to some aspects, the at least one conductive layer allows the evaporable material from the reservoir to pass therethrough.

[0158] In some aspects, the at least one conductive layer further includes one or more respective electrical contacts for interfacing with one or more styli. The one or more electrical contacts may be deposited on a surface of the porous matrix on which the remainder of the at least one conductive layer is not deposited.

[0159] In some aspects, a mouthpiece is provided at a first end of the cartridge body, and a heating element is provided at a second end of the body opposite the first end.

[0160] In some aspects, the porous matrix includes a plurality of voids distributed throughout the porous matrix.

[0161] In some aspects, the porous matrix includes a stacked structure formed by a plurality of separate substrates stacked one on top of another.

[0162] According to some aspects, at least a portion of the surface heater is disposed between two of the plurality of separate matrices.

[0163] According to some aspects, the portion of the porous matrix on which the conductive layer is deposited includes a flat surface, a recessed surface, or a cylindrical surface.

[0164] As described above, traditional evaporator devices have used atomizers that include a wicking element (or wick) that draws a quantity of evaporable material from a reservoir (reservoir chamber) into a portion of the atomizer that includes a heating element (e.g., conduction, convection, and / or radiation). Typically, in such cases, the heating element is in thermal communication with the wicking element, and the wicking element is at least partially disposed within a reservoir chamber that contains a large quantity of evaporable material. As a result, when the wicking element is heated to evaporate at least a portion of the evaporable material contained therein, a quantity of heat is lost to the large quantity of evaporable material. Thus, to ensure that a sufficient quantity of the evaporable material within the wicking element is evaporated, additional energy is supplied by the heating element. Additionally, due to insufficient thermal insulation of the atomizer, additional heat loss may occur, thereby requiring the provision of additional excess energy. This lack of thermal insulation can also cause at least a portion of the supplied energy to be dissipated to other areas of the evaporator device, which can lead to a loss of structural integrity of the device, damage to internal components, etc. Additionally, due to the microstructure of the wicking element, it may also be difficult to control the quantity and rate at which the evaporable material is drawn into the wicking element. Various features and devices for ameliorating or overcoming these problems are described below. For example, various features are described herein that allow for a more controlled delivery of the evaporable material to the heating region of the evaporator device, which provides advantages and improvements over existing methods, while also introducing additional benefits as described herein.

[0165] In some aspects, the evaporator cartridges described herein utilize an atomizer that is in fluid communication with a reservoir chamber configured to selectively hold an evaporable material. The atomizer includes a matrix having a channel that at least partially extends therethrough, and the channel allows for a more controlled delivery of the evaporable material to the heating region of the evaporator device. As an example, the structural dimensions (e.g., diameter, length, etc.) of the channel can be customized to control the quantity and / or rate at which the evaporable material (e.g., from a reservoir chamber containing a large quantity of evaporable material) is received into the atomizer for subsequent evaporation. In this way, the channel can be configured to receive a predetermined volume of the evaporable material from the reservoir chamber at a predetermined rate. The atomizer also includes at least one surface heater configured to selectively heat at least a portion of the evaporable material received within the channel into an evaporated evaporable material. The at least one surface heater can provide a smaller, defined heating region for the evaporable material. As discussed in more detail below, the atomizer allows the evaporable material to be drawn therein and thus separated from the remaining large quantity of evaporable material. When the evaporable material is evaporated within the atomizer, this can avoid unnecessary heating of the large quantity of evaporable material. Thus, thermal efficiency can be optimized.

[0166] The matrix can have various configurations. In some aspects, for example, the matrix can have at least two spaced-apart surfaces, each surface defining a boundary of the channel. In these aspects, the channel is open at its ends and thus extends completely through the thickness or depth of the matrix. For example, the matrix can include a first sidewall and a second sidewall spaced apart from each other in a first direction, wherein the first sidewall and the second sidewall each extend from an inner surface to an outer surface. The inner surface of the first sidewall and the inner surface of the second sidewall each define a boundary of the channel. The matrix can further include a third sidewall and a fourth sidewall spaced apart from each other in a second direction opposite to the first direction, wherein the third sidewall and the fourth sidewall each extend from the inner surface to the outer surface. The inner surface of the third sidewall and the inner surface of the fourth sidewall each define a boundary of the channel.

[0167] The size and shape of the channel can depend at least on the structural dimensions of the matrix. For example, two or more of the at least two spaced-apart surfaces (e.g., the inner surfaces of the first and second sidewalls or the inner surfaces of the third and fourth sidewalls) can optionally be parallel or at least approximately parallel. In certain aspects, one or more of the two or more spaced-apart surfaces can optionally be at least approximately flat. In other aspects, one or more of the two or more spaced-apart surfaces can be curved, undulating, ridged, or non-planar on at least some of the surfaces. Those skilled in the art will understand that the amount and / or rate of the evaporable material received within the channel can depend at least on the distance and length between the at least two spaced-apart surfaces. Thus, a predetermined volume of the evaporable material can enter the channel via capillary pressure and / or gravity.

[0168] In some cases where capillary pressure is generated within the channel to draw in the evaporable material, the diameter of the channel can be equal to the distance between the at least two spaced-apart surfaces, and / or its length can be equal to the length of one or more of the at least two spaced-apart surfaces. In other cases where capillary pressure draws the evaporable material into the channel, the diameter of the channel can be less than the distance between the at least two spaced-apart surfaces, and / or its length can be less than the length of one or more of the at least two spaced-apart surfaces.

[0169] The matrix may further include a substrate extending between at least two spaced-apart surfaces. The substrate may have various configurations. Generally, the substrate extends from a first surface (e.g., an inner surface) to a second surface (e.g., an outer surface) opposite the first surface, wherein the first surface further defines a boundary of the channel. In these aspects, the channel is end-closed and thus extends partially through the thickness or depth of the matrix. The size and shape of the substrate may depend at least on the structural dimensions of the at least two spaced-apart surfaces and the distance between them. For example, in various aspects, the first and second surfaces may optionally be parallel or at least approximately parallel. In other aspects, the first and second surfaces may have other relative orientations. In certain aspects, one or both of the first surface and the second surface may optionally be at least approximately flat. In other aspects, one or both of the first surface and the second surface may be curved, undulating, ridged, or otherwise non-planar on at least some surfaces.

[0170] The matrix may be formed of any suitable material(s). In some aspects, the matrix is formed of one material, while in other embodiments, the matrix is formed of two or more materials. For example, the matrix may include a first sidewall and a second sidewall each formed of one material (e.g., a conductive material) and a substrate formed of another material (e.g., a conductive material). In some aspects, the substrate may be formed as a one-piece structure.

[0171] In some aspects, the matrix may include at least one vent extending from a first surface of the matrix to a second surface of the matrix opposite the first surface. That is, the at least one vent completely penetrates the thickness or depth of the matrix. The at least one vent may be configured to allow air to flow into the reservoir chamber in response to at least a portion of the evaporable material being withdrawn from the reservoir chamber and into the channel of the matrix. The inflow of air may help to stabilize the hydrostatic offset generated within the cartridge when the evaporable material is drawn into the porous matrix.

[0172] The at least one vent may have various configurations. In some aspects, the at least one vent may have a varying cross-sectional area, while in other aspects, the at least one vent may have a constant cross-sectional area. For example, the at least one vent may include a first portion having a first cross-sectional area and a second portion having a second cross-sectional area that is less than the first cross-sectional area. In some aspects, the first portion may be closer to the reservoir chamber and the second portion may be located distal to the reservoir chamber.

[0173] In some aspects, at least one surface heater can be positioned and thus extend across two different portions of the substrate. In other aspects, at least one surface heater can include a first surface heater located on a first portion of the substrate and a second surface heater located on a second portion of the substrate. For example, the first surface heater can be located on the outer surface of the first sidewall of the substrate, and the second surface heater can be located on the outer surface of the second sidewall of the substrate. In some aspects, the first surface heater and the second surface heater can be electrically isolated from each other (e.g., no electrical connection). In other embodiments, the first surface heater and the second surface heater are electrically bridged together (e.g., electrically connected).

[0174] The at least one surface heater can have various configurations. For example, in certain aspects, the at least one surface heater can include at least one conductive layer located on or in contact with at least a portion of the substrate. The at least one conductive layer can include a trace pattern deposited on at least one surface of the substrate or at least a portion of at least one surface (e.g., the outer surface of the first or second sidewall, the outer surfaces of the first and second sidewalls, or the outer surfaces of the first and second sidewalls and the second surface of the substrate). The trace pattern can be configured to achieve a desired and controllable resistance and can be uniform or non-uniform in the direction along the thickness of the substrate or in the direction extending along the surface of the substrate. The particular shape, pattern, thickness, etc. of the surface heater can be advantageous in terms of allowing control of heat transfer to the substrate. Alternatively, the at least one conductive layer can be a plate or other continuous layer covering at least one entire surface of the substrate (e.g., the outer surface of the first or second sidewall, the outer surfaces of both the first and second sidewalls, or the outer surfaces of both the first and second sidewalls and the second surface of the substrate). The at least one conductive layer can be made of any conductive material, such as but not limited to nichrome, stainless steel, nickel, platinum, gold, copper, or aluminum. The at least one conductive layer can be a microelectromechanical systems (MEMS) layer. In this manner, or in other ways consistent with the present subject matter, the at least one surface heater can be in contact with at least a portion of the surface of the substrate.

[0175] The at least one surface heater can be adhered to the porous substrate in a variety of ways, such as by pulsed laser deposition, physical vapor deposition, chemical vapor deposition, electroplating, electroless plating, screen printing, etc. In some variations of the present subject matter, the at least one surface heater can be a stamping component that is snapped onto the substrate or otherwise mechanically held by the substrate. In other variations, the at least one surface heater can be a stamping component that is insert molded into the substrate. In other variations, the at least one surface heater is fixed to the porous substrate by any fixed attachment method.

[0176] At least one surface heater may have a low resistance region that can be used as a contact for electrically interfacing the cartridge with the evaporator body (e.g., connecting with a stylus of the evaporator body (e.g., a telescopic probe or a leaf spring probe of the evaporator body)).

[0177] Figure 14 and Figure 15 An exemplary cartridge 1400 for an evaporator device is shown. More specifically, the cartridge 1400 includes a reservoir housing 1402 and an atomizer 1404 in fluid communication with a reservoir chamber 1406. Figures 14 to 16 The atomizer 1404 shown includes a matrix 1408 having a channel 1410 extending partially therethrough and first and second surface heaters 1412, 1414. For simplicity purposes only, specific components of the cartridge 1400 are not shown.

[0178] The reservoir housing 1402 includes a reservoir chamber 1406. The reservoir chamber 1406 is configured to hold an evaporable material (not shown). Although the reservoir housing 1402 can have various sizes and shapes, as Figure 14 and Figure 15 shown, the reservoir housing 1402 is generally rectangular. The reservoir housing 1402 includes at least two sets of opposing sidewalls, where a first set of opposing sidewalls 1416a, 1416b extend generally perpendicular to a second set of opposing sidewalls 1418a, 1418b. As shown, these sidewalls 1416a, 1416b, 1418a, 1418b define at least a portion of the reservoir chamber 1406. Additionally, as Figure 15 shown, the reservoir housing includes a third set of opposing sidewalls 1419a, 1419b that extend generally perpendicular to the first and second sets of opposing sidewalls 1416a, 1416b, 1418a, 1418b.

[0179] Although the matrix 1408 can have various configurations, as Figures 14 to 16 shown, the matrix 1408 includes first and second opposing sidewalls 1420, 1422 and a base 1424 extending therebetween. The first and second opposing sidewalls 1420, 1422 are spaced apart from each other by a distance (D). Although the first and second opposing sidewalls 1420, 1422 and the base 1424 can have various shapes and sizes, as shown, the two opposing sidewalls 1420, 1422 and the base 1424 are each generally rectangular. As Figure 16Further shown, the first and second opposing sidewalls 1420, 1422 each extend from an inner surface 1420a, 1422a to an outer surface 1420b, 1422b, and the base 1424 extends from an inner surface 1424a to an outer surface 1424b. The inner surfaces 1420a, 1422a, 1424a define the boundaries of a channel 1410 that partially extends through the matrix 1408. As a result, in the illustrated embodiment, the first end 1410a of the channel 1410 is open and in fluid communication with the reservoir chamber 1406, and the second end 1410b of the channel is closed. Additionally, in the illustrated embodiment, the second end 1410b is defined by the inner surface 1424a of the base 1424.

[0180] In use, the channel 1410 receives at least a portion of an evaporable material (not shown) from the reservoir chamber 1406 through its first end 1410a toward its second end 1410b. As described above, the structural dimensions (diameter and length) of the channel 1410 can control the amount and / or flow rate of the evaporable material from the reservoir chamber 1406 and into the atomizer 1404. In the illustrated embodiment, the diameter (Dc) of the channel 1410 is equal to the distance (D) between the first and second opposing sidewalls 1420, 1422, and the length (Lc) of the channel 1410 is less than the lengths (L1, L2) of the first and second opposing sidewalls 1420. As a result, the amount and / or rate of the evaporable material received within the channel 1410 depends at least on the distance (D) between the first and second opposing sidewalls 1420, 1422 of the matrix 1408 and the lengths (L1, L2) of the first and second opposing sidewalls 1420, 1422. Thus, depending on at least the distance (D) and lengths (L1, L2), a predetermined volume of the evaporable material can enter the channel 1410 by capillary pressure and / or gravity to be evaporated by the first surface heater 1412 and / or the surface heater 1414.

[0181] Although the first and second surface heaters 1412, 1414 can each have various configurations, such as Figures 14 to 16 shown, the first and second surface heaters 1412, 1414 each include a conductive layer having a trace pattern. As shown, the first surface heater 1412 is deposited on a portion of the outer surface 1420b of the first opposing sidewall 1420, and the second surface heater 1414 is deposited on a portion of the outer surface 1422b of the second opposing sidewall 1422. Additionally, as Figure 14 shown, two electrical contacts 1426a, 1426b are located at opposite ends of the trace pattern of the conductive layer of the first surface heater 1412. Although not shown, two electrical contacts are also located at opposite ends of the trace pattern of the conductive layer of the second surface heater 1414. The size and shape of each electrical contact are configured to mate with an evaporator body such as Figure 17 andFigure 18 The pins (e.g., telescopic probes or leaf spring probes) of the evaporator body 1702 shown are connected for operation. In use, the first surface heater 1412 and / or the second surface heater 1414 are activated to generate heat, thereby evaporating at least a portion of the evaporable material within the channel 1410 and thus within the substrate 1408 into the evaporated evaporable material.

[0182] As Figure 14 Further shown, the cartridge 1400 also includes an internal channel 1428 extending from the inlet 1430 to the outlet 1432 of the cartridge 1400. The internal channel 1428 is configured to direct air and the evaporated evaporable material through the cartridge 1400 for inhalation by the user. Although the internal channel 1428 can have various configurations, as Figure 15 shown, the internal channel 1428 is at least defined by opposing first and second sidewalls 1434a, 1434b. Additionally, in the illustrated embodiment, the sidewall 1416b of the reservoir housing 1402 and the first sidewall 1434a of the internal channel 1428 are the same. In other embodiments, the size and shape of the internal channel 1428 can be different, including any other possible shape.

[0183] Furthermore, as Figure 14 shown, the cartridge 1400 also includes a set of coupling elements 1438a, 1438b that can be used to selectively couple the cartridge 1400 to the evaporator body, such as Figure 17 and Figure 18 the evaporator body 1702 shown. Although the set of coupling elements 1438a, 1438b can have various configurations, in the illustrated embodiment, each coupling element 1438a, 1438b includes a protrusion extending outward from the sidewall of the cartridge 1400. In particular, the protrusion of the first coupling element 1438a extends from the sidewall 1416a of the reservoir housing 1402, and the protrusion of the second coupling element 1438b extends from the second sidewall 1434b of the internal channel 1428 of the cartridge 1400. In other embodiments, the set of coupling elements 1438a, 1438b can have any other suitable configuration and can be used to selectively couple to corresponding features (e.g., channels, slots, holes, hooks, grooves, ratchets, etc.) in the evaporator body.

[0184] Figure 17 and Figure 18 An exemplary evaporator device 1700 is shown, which includes an evaporator body 1702 and a cartridge 1704. In Figure 17 it, the evaporator body 1702 and the cartridge 1704 are shown in a separated configuration, while in Figure 18 it, the evaporator body 1702 and the cartridge 1704 are shown in a coupled configuration. The cartridge 1704 is similar to Figure 14and Figure 15 the cartridge 1400 in, and thus will not be described in detail herein. For simplicity, in Figure 17 and Figure 18 the specific components of the evaporator device 1700 are not shown.

[0185] The evaporator body 1702 and the cartridge 1704 can be coupled to each other through corresponding coupling elements. For example, as Figure 17 and Figure 18 shown, the evaporator body 1702 includes a first set of coupling elements 1706a, 1706b, and the cartridge 1704 includes a second set of corresponding coupling elements 1708a, 1708b. Although the first and second sets of coupling elements can have various configurations, in the illustrated embodiment, the first set of coupling elements 1706a, 1706b includes two recessed holes extending inwardly into the evaporator body 1702, and the second set of coupling elements 1708a, 1708b includes two protrusions extending outwardly from two opposite side walls 1709a, 1709b of the cartridge 1704.

[0186] The evaporator body 1702 can have various configurations. As Figure 17 and Figure 18 shown, the evaporator body 1702 includes a sleeve 1710 extending from a proximal end 1710a to a distal end 1710b. The sleeve 1710 defines a cartridge seat 1712 within the evaporator body 1702, and the cartridge seat 1712 is configured to receive at least a portion of the cartridge 1704. The distal end 1710b of the sleeve 1710 is coupled to a bottom plate 1714, and the bottom plate 1714 is configured to accommodate at least a portion of additional components of the evaporator device 1700, such as a power supply, an input device, a sensor, an output device, a controller, communication hardware, a memory, etc. Once the cartridge 1704 is coupled to the evaporator body 1702, then as Figure 18 shown, a first airflow path 1720 is generated between the distal end 1710b of the sleeve 1710 and the distal end 1704d of the cartridge 1704 within the cartridge seat 1712.

[0187] Further, as Figure 17 and Figure 18As shown, the first air inlet 1718 extends through the wall 1711 of the sleeve 1710. The first air inlet 1718 is configured to allow at least a portion of the ambient air outside the evaporator body 1702 and thus outside the reservoir housing 1705 of the cartridge 1704 to enter the evaporator device 1700. In use, when the user sucks on the device, at least a portion of the ambient air enters the evaporator body 1702 and travels through the first airflow path 1720. As will be described in detail below, the vaporized vaporizable material is added to the first airflow path 1720 and combined with at least a portion of the air to form a mixture. The mixture travels through the remainder of the first airflow path 1720 and then through the second airflow path 1722, which extends through the internal passage 1724 of the cartridge 1704. Thus, the first and second airflow paths 1720, 1722 are in fluid communication with each other.

[0188] In use, once the cartridge 1704 is coupled to the evaporator body 1702, the first surface heater 1726 and / or the second surface heater (covered in Figure 17 and Figure 18 ) of the atomizer 1728 can be activated by the user sucking on the cartridge 1704, and at least a portion of the vaporizable material within the matrix 1730 of the atomizer 1728 is vaporized into the vaporized vaporizable material. This sucking also simultaneously draws ambient air through the first air inlet 1718 of the sleeve 1710 into the first airflow path. As a result, at least a portion of the vaporized vaporizable material combines with the air flowing along the first airflow path 1720. Subsequently, at least a portion of the combined vaporized vaporizable material and air continues to travel through the evaporator body 1702 and into the second airflow path 1722 of the cartridge 1704. When the combined vaporized vaporizable material and air travel through at least the second airflow path 1722 and thus through the internal passage 1724 of the cartridge 1704, they at least partially condense into an aerosol for the user to subsequently inhale.

[0189] As described above, sucking the vaporizable material from the reservoir chamber is at least partially due to the capillary action provided by the porous matrix. However, as the vaporizable material is drawn out of the reservoir chamber, the pressure inside the reservoir chamber decreases, creating a vacuum that opposes the capillary action. This reduces the efficiency of the porous matrix in drawing the vaporizable material out of the reservoir chamber, and thus reduces the efficiency of the evaporator in vaporizing the required amount of vaporizable material when, for example, the user sucks on the evaporator device. In addition, the vacuum created in the reservoir chamber may ultimately prevent all of the vaporizable material from being drawn out, wasting the vaporizable material. The various features and devices described below can ameliorate or overcome these problems. For example, various features for controlling the airflow in the evaporator device are described herein, which can provide advantages and improvements over existing methods while also introducing additional benefits described herein.

[0190] Figure 19 and Figure 20 respectively illustrate exemplary first and second embodiments of the reservoir systems 2000, 2100, which are configured for an evaporator cartridge and / or an evaporator device to improve the air flow in the evaporator device. More specifically, Figure 19 and Figure 20 the reservoir systems 2000, 2100 shown in improve the pressure regulation within the reservoir chambers 2006, 2106 such that the vacuum generated within the reservoir chambers 2006, 2106 is released after the user inhales on the evaporator device. This enables the capillary action of the porous matrix of the atomizer 2104 to continue to effectively draw the evaporable material from the reservoir chambers 2006, 2106 after each inhalation.

[0191] As Figure 19 and Figure 20 shown, the reservoir systems 2000, 2100 include reservoir chambers 2006, 2106 configured to contain the evaporable material. All sides of the reservoir chambers 2006, 2106 are sealed by reservoir housing walls 2002, 2102 except through the porous matrix of the atomizer 2104. The atomizers 2004, 2104 also include surface heaters deposited on the surface of the porous matrix. The porous matrix is configured to provide capillary action that attracts the evaporable material from the reservoir chambers 2006, 2106 towards the surface heater to be vaporized into an aerosol by the surface heater. The aerosol is then combined with the air flow 2020, 2120 traveling along the air flow channels 2024, 2124 of the evaporator device for inhalation by the user.

[0192] The reservoir systems 2000, 2100 also include air flow restrictors 2018, 2118 that, for example, restrict the air flow 2020, 2120 along the air flow channels 2024, 2124 of the evaporator device when the user inhales on the evaporator device. The restriction of the air flow 2020, 2120 caused by the air flow restrictors 2018, 2118 may allow a vacuum to form in a portion of the air flow channels 2024, 2124 downstream of the air flow restrictors 2018, 2118. The vacuum generated along the air flow channels 2024, 2124 may assist in drawing the aerosol along the air flow channels 2024, 2124 for inhalation by the user. At least one air flow restrictor 2018, 2118 may be included in each of the reservoir systems 2000, 2100, and the air flow restrictors 2018, 2118 may include any number of features for restricting the air flow along the air flow channels 2024, 2124.

[0193] As Figure 19 andFigure 20 As shown, each memory system 2000, 2100 may also include vents 2010, 2110 configured to selectively allow air to enter the memory chambers 2006, 2106 to increase the pressure in the memory chambers 2006, 2106, e.g., to relieve the negative pressure (vacuum) in the memory chambers 2006, 2106 which, as discussed above, is created by the withdrawal of the evaporable material from the memory chambers 2006, 2106. At least one of the vents 2010, 2110 may be associated with the memory chambers 2006, 2106. The vents 2010, 2110 may be active or passive valves, and the vents 2010, 2110 may include any number of features to allow air to enter the memory chambers 2006, 2106 to relieve the negative pressure created in the memory chambers 2006, 2106. Various embodiments of the vents and vent configurations (e.g., embodiments including a porous matrix with one or more vents) are described in more detail below.

[0194] For example, as Figure 19 shown, an embodiment of the vent 2010 may include a passage extending between the memory chamber 2006 and the airflow channel 2024. In another embodiment, as Figure 20 shown, an embodiment of the vent 2110 may include a passage extending between the memory chamber 2106 and the ambient air outside the system 2100. In either case, the vents 2010, 2110 have a diameter sized such that when the pressure equilibrium is crossed through the vent 2010 (e.g., the pressure in the memory chamber 2006 is approximately the same as the pressure in the airflow channel 2024, or the pressure in the memory chamber 2106 is approximately the same as the pressure outside the system 2100), the surface tension of the evaporable material prevents the evaporable material from passing through the passage. However, the vent passage has a diameter sized such that the vacuum pressure created in the memory chambers 2006, 2106 breaks the surface tension of the evaporable material along the vent passage.

[0195] Accordingly, referring to Figure 19 , a volume of air can flow from the airflow channel 2024 to the memory chamber 2006 and relieve the vacuum pressure. Similarly, referring to Figure 20, a certain volume of air can be transported from the outside of the system 2100 to the reservoir chamber 2106 to relieve the vacuum pressure. Once this volume of air is added to the reservoir chambers 2006, 2106, the pressure on the vents 2010, 2110 is balanced again, allowing the surface tension of the evaporable material to prevent air from entering the reservoir chambers 2006, 2106 and preventing the evaporable material from leaking out of the reservoir chambers 2006, 2106 through the ventilation channels. Additionally, in addition to the diameter, the ventilation channels can also include a certain length that defines the volume of fluid that can pass through the vents when a pressure difference is experienced across the vents.

[0196] In one exemplary embodiment, the diameter dimension of the ventilation channels can include from about 0.3 mm to 0.6 mm and can also include a diameter having a dimension of from about 0.1 mm to 2 mm. The material of the ventilation channels can also assist in controlling ventilation, such as determining the contact angle between the walls of the ventilation channels and the evaporative material. The contact angle can affect the surface tension generated by the evaporative material and thus affect the threshold pressure difference generated across the vents before a certain volume of fluid passes through the vents, as described above. The ventilation channels can include various shapes / sizes and configurations within the scope of the present invention. Additionally, various embodiments of cartridges and cartridge parts including one or more various ventilation features are described in more detail below.

[0197] The positioning of the vents 2010, 2110 (e.g., passive vents) and the airflow restrictors 2018, 2118 relative to the atomizers 2004, 2104 contributes to the effective operation of the reservoir systems 2000, 2100. For example, improper positioning of the vents 2010, 2110 or the airflow restrictors 2018, 2118 can result in the accidental leakage of the evaporable material from the reservoir chambers 2006, 2106. The present invention addresses the effective positioning of the vents 2010, 2110 and the airflow restrictors 2018, 2118 relative to the atomizers 2004, 2014 (including the porous matrix). For example, a small or no pressure difference between the passive vents and the porous matrix can cause an effective reservoir system to relieve the vacuum pressure in the reservoir chamber and allow the porous matrix to perform effective capillary action while preventing leakage. The construction of a reservoir system in which the vents and the airflow restrictors are effectively positioned relative to the atomizer is described in more detail below.

[0198] As Figure 19As shown, the airflow restrictor 2018 can be positioned upstream of the atomizer 2004 along the airflow passage 2024, while the vent 2010 is positioned along the reservoir chamber 2006 such that it provides fluid communication between the reservoir chamber 2006 and a portion of the airflow passage 2024 downstream of the atomizer 2004. Thus, when the user sucks on the evaporator device, a negative pressure is generated downstream of the airflow restrictor 2018 such that the atomizer is subjected to the negative pressure. Similarly, the side of the vent 2010 that communicates with the airflow passage 2024 is also subjected to the negative pressure.

[0199] Thus, during a puff (e.g., when the user inhales or draws air from the evaporator device), a very small or no pressure differential is generated between the vent 2010 and the atomizer 2004. However, after the puff, capillary action of the porous matrix draws the evaporable material from the reservoir chamber 2006 to replenish the evaporable material that has been evaporated and inhaled due to the previous puff. As a result, a vacuum or negative pressure will be generated in the reservoir chamber 2006. Then, a pressure differential will occur between the reservoir chamber 2006 and the airflow passage 2024. As discussed above, the vent 2010 can be configured such that the pressure differential (e.g., a threshold pressure differential) between the reservoir chamber 2006 and the airflow passage 2024 allows a certain volume of air to enter the reservoir chamber 2006 from the airflow passage 2024, thereby relieving the vacuum in the reservoir chamber 2006 and restoring an equilibrium pressure across the vent 2010 and a stable reservoir system 2000.

[0200] In another embodiment, as Figure 20 shown, the airflow restrictor 2118 can be positioned downstream of the atomizer 2104 along the airflow passage 2124, while the vent 2110 is positioned along the reservoir chamber 2106 such that it provides fluid communication between the reservoir chamber 2106 and a portion of the airflow passage 2124 upstream of the atomizer 2104. Thus, when the user sucks on the evaporator device, the atomizer 2104 and the vent 2110 are subjected to very little or no suction or negative pressure caused by the suction, resulting in a very small or no pressure differential between the atomizer 2104 and the vent 2110. Similar to Figure 19 the situation, the pressure differential generated on the vent 2110 is the result of capillary action of the porous matrix drawing the evaporable material from the reservoir chamber 2106 after the puff. As a result, a vacuum or negative pressure will be generated in the reservoir chamber 2106. Then a pressure differential will occur across the vent 2110.

[0201] As described above, the vent openings 2010, 2110 can be configured such that a pressure difference (e.g., a threshold pressure difference) between the reservoir chambers 2006, 2106 and the airflow channel 2024 or the atmosphere (ambient air) allows a certain volume of air to enter the reservoir, thereby alleviating the vacuum in the reservoir chambers 2006, 2106. This balances the pressure across the vent openings 2010, 2110 and stabilizes the reservoir systems 19, 20. The vent openings 2010, 2110 can include various configurations and features and can be located at various positions along the cartridge to obtain various results. For example, one or more vent openings can be located near the atomizer or form part of the atomizer. In such a configuration, one or more vent openings can provide fluid (e.g., air) communication between the reservoir chamber and the atomizer (when the user draws on the evaporator, air flows through this channel and is thus part of the airflow path).

[0202] Similarly, as described above, vent openings located near the atomizer or forming part of the atomizer can allow air to travel through the vent opening into the reservoir chamber to increase the pressure inside the reservoir chamber, thereby effectively alleviating the vacuum pressure generated due to the inhalable material being drawn into the porous matrix of the atomizer. In this way, the alleviation of the vacuum pressure allows the inhalable material entering the atomizer via the porous matrix to continue to effectively capillary-act, thereby generating inhalable vapor during subsequent draws by the user on the evaporator device.

[0203] In some aspects, the evaporator cartridges described herein utilize an atomizer having a porous matrix configured to draw the inhalable material from the reservoir chamber, wherein the porous matrix has at least one vent opening extending therethrough, and the vent opening can be configured to allow air to pass into the reservoir chamber in response to at least a portion of the inhalable material being drawn out of the reservoir chamber (e.g., when the user draws on the cartridge or after). That is, at least one vent opening can be configured to selectively allow air to pass through and enter the reservoir chamber to increase the internal pressure within the reservoir chamber. This can alleviate the negative pressure (vacuum) in the reservoir chamber generated by the inhalable material being drawn out of the reservoir chamber and into the porous matrix. The atomizer also includes at least one surface heater configured to selectively heat at least a portion of the inhalable material drawn into the porous matrix.

[0204] The porous matrix can have various configurations. Generally, the porous matrix extends from a first surface to a second surface opposite the first surface. In some aspects, the first surface can be positioned within the reservoir chamber and thus be in direct contact with the evaporable material disposed therein. In this way, at least a portion of the porous matrix resides within the reservoir chamber. The porous matrix can have any suitable shape and size. In one aspect, the porous matrix is substantially rectangular. The size and shape of the porous matrix can depend at least on the other components of the cartridge and the structural dimensions of the cartridge itself. For example, in various aspects, the first and second surfaces can optionally be parallel or at least approximately parallel. In other aspects, the first and second surfaces can have other relative orientations. In certain aspects, one or both of the first and second surfaces can optionally be at least approximately flat. In certain aspects, one or both of the first and second surfaces can be curved, undulating, ridged, or otherwise non-planar on at least some of them.

[0205] The porous matrix can be made of porous ceramic materials, sintered materials, other porous materials, such as high-temperature resistant materials, which include, for example, but are not limited to metals, glass, silicon, carbon, or high-temperature resistant plastic materials, such as, for example, but are not limited to polyphenylene sulfide (PPS), liquid crystal polymer (LCP), or polyether ether ketone (PEEK). The porous matrix can be characterized by having a plurality of voids or spaces to allow absorption and conveyance of the evaporable material from the reservoir chamber. The void size, particle size, or porosity of the porous matrix can be selected based on, for example, various factors to achieve desired characteristics or due to specific parameters of the cartridge / device, such as, for example, the viscosity of the evaporable material and / or other design considerations. The plurality of voids or spaces can be an inherent property of the material (or materials), or can be formed by, for example, drilling (such as laser drilling). The porous matrix can also be characterized by having a rigid, non-deformable structure.

[0206] At least one vent can have various configurations. In some aspects, at least one vent can have a varying cross-sectional area, while in other aspects, at least one vent can have a constant cross-sectional area. For example, at least one vent can include a first portion having a first cross-sectional area and a second portion having a second cross-sectional area that is less than the first cross-sectional area. In some aspects, the first portion can be adjacent to the reservoir chamber, and the second portion can be at the distal end of the reservoir chamber. (It may be necessary to say that they can both be close to the reservoir chamber.) As a result, this cross-sectional area allows for a lower pressure at the interface between the evaporable material and the air flow entering the reservoir chamber, while the second cross-sectional area can allow for a higher pressure within a portion of the vent passage to prevent the evaporable material from passing therethrough and thus prevent leakage from the reservoir chamber.

[0207] By having different cross-sectional areas, this can allow for a lower air bubble pinch off resistance at the first end of the first portion of at least one vent in contact with the reservoir chamber, and a higher capillary pressure at the second end of the second portion of at least one vent, i.e., the opposite end of the first end, to counteract the static head of the evaporable material in the reservoir chamber. In some aspects, at least one vent can have a conical shape, while in other aspects, at least one vent can have any other possible shape.

[0208] The first portion can extend inwardly from the first surface of the porous matrix, and the second portion can extend inwardly from the second surface of the porous matrix. In other aspects, at least one vent can be located at the edge or end of the porous matrix, where at least one vent is partially defined by the inner surface of the reservoir housing. Those skilled in the art will understand that at least one vent can be provided at multiple locations along the length of the porous matrix (e.g., at the edge or end, in the middle, or any other possible location therebetween). In some aspects, at least one vent can have a conical shape, while in other aspects, at least one vent can have any other possible shape.

[0209] At least one surface heater can include one or more conductive layers located on or in contact with at least a portion of the porous matrix. In some examples, the one or more conductive layers can include a trace pattern deposited on the surface (e.g., the second surface) or at least a portion of the surface (e.g., the second surface) of the porous matrix. The trace pattern can be configured to achieve a desired and controlled resistance and can be uniform or non-uniform over a range extending along the thickness of the porous matrix or along the surface of the porous matrix. The specific shape, pattern, thickness, etc. of the surface heater can be advantageous in allowing control of heat transfer in the porous matrix and allowing the evaporable material from the reservoir chamber to pass through. Alternatively, the conductive layer can be a plate or other continuous layer covering the entire surface or a portion of the second surface of the matrix. Such a plate or other continuous layer can include features such as holes, micro-perforations, etc. to allow the evaporable material from the reservoir chamber to pass through the surface heater. The conductive layer can be made of any conductive material, such as, for example but not limited to, nichrome, stainless steel, nickel, platinum, gold, copper, or aluminum. The conductive layer can be a microelectromechanical systems (MEMS) layer. In this way, or by other methods consistent with the present subject matter, the surface heater can be in contact with at least a portion of the surface (e.g., the second surface) of the porous matrix.

[0210] At least one surface heater can be adhered to the porous matrix in a variety of ways, such as by pulsed laser deposition, physical vapor deposition, chemical vapor deposition, electroplating, electroless plating, screen printing, etc. In some variations of the present subject matter, at least one surface heater can be a stamping component that snaps onto the porous matrix or is otherwise mechanically held by the porous matrix. In other variations, at least one surface heater can be a stamping component that is insert molded into the porous matrix. In other variations, at least one surface heater is fixed to the porous matrix by any fixed attachment means.

[0211] At least one surface heater can have a low-resistance region that can be used as a contact (electrical contact) for electrically interfacing the cartridge with the evaporator body. The electrical contact region can be located on the second surface of the porous matrix, and in some variations, the electrical contact region can be on different surfaces of the porous matrix.

[0212] Figure 21 An exemplary cartridge 1900 for an evaporator device is shown. More specifically, the cartridge 1900 includes a reservoir housing 1902 and an atomizer 1904 that is in fluid communication with a reservoir chamber 1906. As Figure 21 and Figure 22 shown, the atomizer 1904 includes a porous matrix 1908 having at least one vent 1910 extending therethrough and a surface heater 1912. For simplicity purposes only, certain components of the cartridge 1900 are not shown.

[0213] The reservoir housing 1902 includes a reservoir chamber 1906. The reservoir chamber 1906 is configured to hold an evaporable material (not shown). Although the reservoir housing 1402 can have a variety of sizes and shapes, as Figure 21 shown, the reservoir housing 1902 is generally rectangular. The reservoir housing 1902 includes opposing first sidewalls 1916a and second sidewalls 1916b and a top wall 1918 extending therebetween. As shown, these walls 1916a, 1916b, 1918 define at least a portion of the reservoir chamber 1906.

[0214] Although the porous matrix 1908 can have various configurations, as Figures 21 to 23As shown, the porous matrix 1908 is generally rectangular. The porous matrix 1908 extends from a first surface 1908a to a second opposing surface 1908b. In the illustrated embodiment, the porous matrix 1908 at least partially resides within the reservoir chamber 1906. In particular, the first surface 1908a is located within the reservoir chamber 1906, and the second surface 1908b is flush with the reservoir housing 1902 and defines a portion of the distal end 1906a of the reservoir housing 1902. As a result, the first surface 1908a can be in direct contact with the evaporable material disposed within the reservoir chamber 1906. In other embodiments, the second surface 1908b can be positioned distally of the distal end 1906a of the reservoir housing 1902. Additionally, as Figure 21 shown, the first surface 1908a defines a portion of the reservoir chamber 1906. In use, when the reservoir chamber 1906 is filled with an evaporable material, the evaporable material is drawn into the porous matrix 1908 through the first surface 1908a towards the second surface 1908b for evaporation.

[0215] As Figures 21 to 23 further shown, at least one vent 1910 extends from the first surface 1908a of the porous matrix 1908 to the second surface 1908b. As described above, at least one vent 1910 is configured to allow air to enter the reservoir chamber 1906 in response to at least a portion of the evaporable material being drawn out of the reservoir chamber 1906 (e.g., when the user inhales on the cartridge 1900 during use or after inhalation). As a result, the internal pressure of the reservoir chamber 1906 can be balanced and thus substantially prevent the creation of a vacuum within the reservoir chamber 1906, which can prevent the evaporable material from being drawn out therefrom. Although the at least one vent 1910 can have various configurations, in the illustrated embodiment, the at least one vent includes a first portion 1907a having a first diameter (D1) and a second portion 1907b having a second diameter (D2), where the second diameter is less than the first diameter. Thus, the cross-sectional area of the first portion 1907a is greater than the cross-sectional area of the second portion 1907b. As shown, the first portion 1907a extends inwardly from the first surface 1908a of the porous matrix 1908, and the second portion 1907b extends inwardly from the second surface 1908b of the porous matrix 1908.

[0216] Although the surface heater 1912 can have various configurations, as Figure 21 shown, and as Figure 22 and Figure 23As shown in more detail in Figure 24 and Figure 25 , the surface heater 1912 includes a conductive layer having a trace pattern. The surface heater 1912 is deposited on a portion of the second surface 1908b of the porous matrix 1908. In addition, as shown, two electrical contacts 1920a, 1920b are located at opposite ends of the trace pattern of the conductive layer. The size and shape of each electrical contact 1920a, 1920b are designed to connect to a stylus (e.g., a telescopic probe or a leaf spring probe) of the evaporator body, such as

[0217] shown in Figure 21 the evaporator body 2102 for operation. In use, the surface heater 1912 is activated to generate heat, thereby evaporating at least a portion of the evaporable material within the porous matrix 1908 into an evaporated evaporable material.

[0218] Furthermore, as Figure 21 shown, the cartridge 1900 also includes an internal channel 1922 extending from an inlet 1924 of the cartridge 1900 to an outlet 1926. The internal channel 1922 is configured to direct air and the evaporated evaporable material through the cartridge 1900 for inhalation by a user. Although the internal channel 1922 can have various configurations, in the illustrated embodiment, the internal channel 1922 is defined by first and second opposing sidewalls 1928a, 1928b. In the illustrated embodiment, the sidewall 1916b of the reservoir housing 1902 and the first sidewall 1928a of the internal channel 1922 are the same. In other embodiments, the size and shape of the internal channel 1922 can be different, including any other possible shape.

[0218] In addition, as Figure 21 shown, the cartridge 1400 also includes a set of coupling elements 1932a, 1932b that can be used to selectively couple the cartridge 1900 to an evaporator body, such as Figure 24 and Figure 25 the evaporator body 2102 in

[0219] Figure 24 and Figure 25 Shown is an exemplary evaporator device 2200, which includes an evaporator body 2202 and a cartridge 2204. In Figure 24 , the evaporator body 2202 and the cartridge 2204 are shown in a separated configuration, while in Figure 25In [the figure], the evaporator body 2202 and the cartridge 2204 are shown in a coupled configuration. The cartridge 2204 is similar to Figure 21 the cartridge 1900 in [reference], and thus will not be described in detail here. For simplicity, specific components of the evaporator device 2200 are not shown in Figure 24 and Figure 25 .

[0220] The evaporator body 2202 and the cartridge 2204 can be coupled to each other through corresponding coupling elements. For example, as shown in Figure 24 and Figure 25 , the evaporator body 2202 includes a first set of coupling elements 2206a, 2206b, and the cartridge 2204 includes a second set of corresponding coupling elements 2208a, 2208b. Although the first and second sets of coupling elements can have various configurations, in the illustrated embodiment, the first set of coupling elements 2206a, 2206b includes two recessed holes extending inwardly into the evaporator body 2202, and the second set of coupling elements 2208a, 2208b includes two protrusions extending outwardly from two opposite side walls 2209a, 2209b of the cartridge 2204. In other embodiments, the first and second sets of coupling elements 2206a, 2206b, 2208a, 2208b can have any other suitable corresponding configurations (e.g., protrusions, channels, grooves, holes, hooks, recesses, pawls, etc.) for selectively coupling the cartridge 2204 to the evaporator body 2202.

[0221] The evaporator body 2202 can have various configurations. As shown in Figure 24 and Figure 25 , the evaporator body 2202 includes a sleeve 2210 extending from a proximal end 2210a to a distal end 2210b. The sleeve 2210 defines a cartridge seat 2212 within the evaporator body 2202, and the cartridge seat 2212 is configured to receive at least a portion of the cartridge 2204. The distal end 2210b of the sleeve 2210 is coupled to a bottom plate 2214, and the bottom plate 2214 is configured to accommodate at least a portion of other components of the evaporator device 22, such as, for example, a power supply, an input device, a sensor, an output device, a controller, communication hardware, a memory, etc. Once the cartridge 2204 is coupled to the evaporator body 2202, as shown in Figure 25 , a first airflow path 2220 is created between the distal end 2210b of the sleeve 2210 and the distal end 2204d of the cartridge 2204 within the cartridge seat 2212.

[0222] Further, as shown in Figure 24 and Figure 25As shown, the first air inlet 2218 extends through the wall 2211 of the sleeve 2210. The first air inlet 2218 is configured to allow ambient air outside at least a portion of the evaporator body 2202 and thus outside the reservoir housing 2205 of the cartridge 2204 to enter the evaporator device 2200. In use, when the user draws on the device, at least a portion of the ambient air enters the evaporator body 2202 and travels through the first airflow path 2220. As described in detail below, the vaporized vaporizable material joins the first airflow path 2220 and combines with at least a portion of the air to form a mixture. The mixture travels through the remainder of the first airflow path 2220 and then through the second airflow path 2222, which extends through the internal passage 2224 of the cartridge 2204. Thus, the first and second airflow paths 2220, 2222 are in fluid communication with each other.

[0223] In use, once the cartridge 2204 is coupled to the evaporator body 2202, the surface heater 2226 of the atomizer 2228 can be activated by the user drawing on the cartridge 2204, and at least a portion of the vaporizable material within the porous matrix 2230 of the atomizer 2228 is vaporized into the vaporized vaporizable material. This draw also simultaneously draws ambient air through the first air inlet 2218 of the sleeve 2210 into the first airflow path. As a result, at least a portion of the vaporized vaporizable material joins the air traveling along the first airflow path 2220. Subsequently, at least a portion of the added vaporized vaporizable material and air continue to travel through the evaporator body 2202 and into the second airflow path 2222 of the cartridge 2204. When the added vaporized vaporizable material and air travel through at least the second airflow path 2222 and thus through the internal passage 2224 of the cartridge 2204, they at least partially condense into an aerosol for the user to subsequently inhale.

[0224] In addition, during the draw, at least a portion of the ambient air 2232 drawn through the first air inlet 2218 of the sleeve 2210 enters the reservoir chamber 2234 of the cartridge 2204 through at least one vent 2236 in the porous matrix 2230 of the atomizer 2228. Thus, the negative pressure generated in the reservoir chamber 2234 due to the vaporizable material being drawn out therefrom can be reduced. That is, the ambient air flow 2232 flowing into the reservoir chamber 2234 replaces at least a portion of the volume of the vaporizable material drawn out of the reservoir chamber. As a result, the internal pressure of the reservoir chamber 2234 of the cartridge 2204 can be at least partially balanced.

[0225] When a feature or element is referred to herein 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. It should 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.

[0226] Although an embodiment has been described or illustrated, the features and elements so described or illustrated can be applied to other embodiments. Those skilled in the art will also understand that a structure or feature referred to as being "adjacent" to another feature can have portions that overlap or are beneath the adjacent feature.

[0227] The terms used herein are for the purpose of describing particular embodiments and implementations only and are not intended to be limiting. For example, as used herein, the singular forms "a", "an" and "the" are also intended to include the plural forms unless the context clearly indicates otherwise. It will also be understood that when the terms "comprises" and / or "comprising" are used in this specification, they specify the presence of the 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 can be abbreviated to " / ".

[0228] In the above description and claims, phrases such as "at least one" or "one or more" may appear, followed by a list of combinations of elements or features. The term "and / or" may also appear in a list of two or more elements or features. Unless implicit or clearly contradictory to the context in which it is used, this phrase is intended to mean any of the elements or features listed individually or any of the elements or features in combination with any other of the elements or features. For example, the phrases "at least one of A and B", "one or more of A and B", "A and / or B" respectively mean "a single A, a single B or A and B together". Similar interpretations are also intended for lists containing three or more items. For example, the phrases "at least one of A, B and C", "one or more of A, B and C" and "A, B and / or C" respectively are intended to mean "a single A, a single B, a single C, A and B together, A and C together, B and C together or A and B and C together". The use of the term "based on" in the above and the claims is intended to mean "at least partially based on", thus also allowing features or elements not recited.

[0229] For ease of description, spatial relative terms, such as "below", "beneath", "lower", "above", "upper", etc., may be used herein to describe the relationship of one element or feature shown in the drawings to another element or feature. It will be understood that the spatial relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is inverted, an element described as "below" or "beneath" another element or feature will then be oriented "above" the other element or feature. Thus, the exemplary term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatial relative descriptions used herein can be interpreted accordingly. Similarly, unless specifically stated otherwise, the terms "upwardly", "downwardly", "vertical", "horizontal", etc. are used herein for purposes of explanation only.

[0230] 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 otherwise indicates. These terms may be used to distinguish one feature / element from another. Thus, without departing from the teachings provided herein, the first feature / element discussed below may be referred to as the second feature / element, and similarly, the second feature / element discussed below may be referred to as the first feature / element.

[0231] As used herein in the specification and claims, including 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. When describing magnitudes and / or positions, the phrase "about" or "approximately" may be used to indicate that the described value and / or position is within a reasonable expectation range of the value and / or position. For example, the value of a numerical value may be + / -0.1% of a specified value (or range of values), + / -1% of a specified value (or range of values), + / -2% of a specified value (or range of values), + / -5% of a specified value (or range of values), + / -10% of a specified value (or range of values), etc. Any numerical value given herein should also be understood to include about or approximately that value, unless the context otherwise indicates. 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 should also be understood that, as would be understood by one of ordinary skill in the art, when a value "less than or equal to" that value is disclosed, "greater than or equal to that value" and the possible ranges between values are also disclosed. For example, if the value "X" is disclosed, then "less than or equal to X" and "greater than or equal to X" are also disclosed (e.g., where X is a numerical value). It should also be understood that throughout the application, the data is provided in a variety of different formats, and that this data represents ranges of endpoints and starting points and any combination of data points. For example, if a particular data point "10" and a particular data point "15" are disclosed, then it should be understood that greater than, greater than or equal to, less than, less than or equal to, and between 10 and 15 are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0232] Although the various illustrative embodiments have been described above, various changes among the various embodiments can be made without departing from the teachings herein. For example, in alternative embodiments, the order of performing the various method steps described can often be changed, and in other alternative embodiments, one or more method steps can be completely skipped. Optional features of the various apparatus and system embodiments can be included in some embodiments, while not included in other embodiments. Accordingly, the foregoing description has been provided primarily for exemplary purposes and should not be construed as limiting the scope of the claims.

[0233] The examples and illustrations included herein show, by way of illustration and not limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and other embodiments may be derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the invention. These embodiments of the subject matter of the invention may be referred to herein, individually or collectively, for convenience only, by the term "invention", and if more than one invention is disclosed, it is not intended to voluntarily limit the scope of this application to any single invention or inventive concept. 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. The invention is intended to cover any and all modifications or variations of various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those of ordinary skill in the art upon reading the foregoing description.

Claims

1. A cartridge for an evaporation device, the cartridge comprising: A mouthpiece; A reservoir configured to hold an evaporable material; And An atomizer component, the atomizer component comprising: A porous matrix configured to draw the evaporable material from the reservoir to an evaporation surface exposed to an airflow path, the porous matrix having a rigid, non-deformable form; And A surface heater configured to heat the evaporable material, the surface heater comprising at least one conductive layer deposited on a portion of the porous matrix, the evaporation surface comprising the portion of the porous matrix.

2. The cartridge according to claim 1, wherein, The porous matrix is at least partially received within the reservoir.

3. The cartridge according to claim 1, wherein, The porous matrix is fully received within the reservoir, and wherein the surface heater is positioned away from the evaporable material in the reservoir.

4. The cartridge according to any one of claims 1 to 3, wherein, The porous matrix is in fluid communication with the reservoir on a surface thereof other than the portion on which the surface heater is deposited.

5. The cartridge according to any one of claims 1 to 4, further comprising an air intake passage configured to direct an airflow along the evaporation surface in the airflow path such that when the surface heater is activated, the evaporable material drawn by the porous matrix along the evaporation surface is evaporated into the airflow.

6. The cartridge according to any one of claims 1 to 5, wherein, The at least one conductive layer comprises a trace pattern or a plate.

7. The cartridge according to any one of claims 1 to 5, wherein, The at least one conductive layer comprises a microelectromechanical systems (MEMS) layer.

8. The cartridge according to any one of claims 1 to 7, wherein, The at least one conductive layer allows the evaporable material from the reservoir to pass therethrough.

9. The cartridge according to any one of claims 1 to 8, wherein, The at least one conductive layer further comprises one or more electrical contacts for interfacing with one or more corresponding styluses.

10. The cartridge according to claim 9, wherein, The one or more electrical contacts are deposited on a surface of the porous matrix on which the remainder of the at least one conductive layer is not deposited.

11. The cartridge according to any one of claims 1 to 10, wherein, The mouthpiece is provided at a first end of the body of the cartridge, and the heating element is provided at a second end of the body opposite the first end.

12. The cartridge according to any one of claims 1 to 11, wherein, The porous matrix comprises a plurality of voids distributed throughout the porous matrix.

13. The cartridge according to any one of claims 1 to 12, wherein, The porous matrix comprises a stacked structure formed by stacking a plurality of separate matrices on top of each other.

14. The cartridge according to claim 13, wherein, At least a portion of the surface heater is provided between two of the plurality of separate matrices.

15. The cartridge according to any one of claims 1 to 14, wherein, The portion of the porous matrix on which the conductive layer is deposited comprises a flat surface, a recessed surface or a cylindrical surface.

16. An evaporator device, comprising: An evaporator body having a first airflow path; And The cartridge according to any one of claims 1 to 15, the cartridge being selectively coupled to the evaporator body.

17. A cartridge for an evaporator device, the cartridge comprising: A reservoir housing including a reservoir chamber configured to selectively hold an evaporable material; And An atomizer in fluid communication with the reservoir chamber, the atomizer comprising: A matrix having a channel extending at least partially therethrough, the channel configured to receive a predetermined volume of the evaporable material from the reservoir chamber at a predetermined rate, and At least one surface heater configured to selectively heat at least a portion of the evaporable material received in the channel into an evaporated evaporable material.

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