Nicotine pod assembly and nicotine e-vaping device

Abstract

To provide a nicotine e-vaping device.SOLUTION: A nicotine e-vaping device may include a nicotine pod assembly and a device body 100 defining a through hole 150 configured to receive the nicotine pod assembly. The nicotine pod assembly is configured to hold a nicotine pre-vapor formulation. The through hole of the device body includes at least one sidewall that is configured to deflect during an insertion of the nicotine pod assembly. One or more sidewalls of the through hole may include at least one protrusion 130b configured to engage with corresponding recesses of the nicotine pod assembly so as to retain the nicotine pod assembly within the through hole of the device body.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present disclosure relates to a nicotine electronic vaping (e-vaping) device.

Background Art

[0002] Some nicotine e-vaping devices include a first section coupled to a second section. The first section may include a core and a heater. The core is configured to move a nicotine pre-vapor formulation through capillary action and is positioned to extend into a reservoir and a vapor passage. The heater is in thermal contact with the core and is configured to vaporize the nicotine pre-vapor formulation drawn into the vapor passage through the core. The second section includes a power source configured to supply current to the heater during vaping. The initiation of operation of the nicotine e-vaping device can be achieved through manual and / or smoking activation.

Summary of the Invention

[0003] At least one embodiment relates to a nicotine e-vaping device.

[0004] In an exemplary embodiment, the nicotine e-cigarette device may include a nicotine pod assembly and a device body configured to receive the nicotine pod assembly. The nicotine pod assembly is configured to hold a nicotine pre-vapor formulation. The nicotine pod assembly has an upstream end and a downstream end. The upstream end may define at least one upstream recess. The downstream end may define at least one downstream recess. The device body defines a through-hole configured to receive the nicotine pod assembly. The through-hole may include an upstream sidewall and a downstream sidewall. At least one of the upstream sidewall or the downstream sidewall may be configured to flex during insertion of the nicotine pod assembly. The upstream sidewall may include at least one upstream protrusion, and the downstream sidewall may include at least one downstream protrusion. The at least one upstream protrusion and the at least one downstream protrusion may be configured to engage with the at least one upstream recess and the at least one downstream recess of the nicotine pod assembly, respectively, to hold the nicotine pod assembly within the through-hole of the device body.

[0005] At least one embodiment relates to a device body for a nicotine e-cigarette device.

[0006] In an exemplary embodiment, the device body may include a device housing that defines a through-hole configured to receive the nicotine pod assembly. The through-hole may include an upstream sidewall and a downstream sidewall. At least one of the upstream sidewall or the downstream sidewall is configured to flex during insertion of the nicotine pod assembly. The upstream sidewall includes at least one upstream protrusion, and the downstream sidewall includes at least one downstream protrusion. The at least one upstream protrusion and the at least one downstream protrusion are configured to engage with at least one upstream recess and at least one downstream recess of the nicotine pod assembly, respectively, to hold the nicotine pod assembly within the through-hole.

[0007] At least one embodiment relates to a nicotine pod assembly for a nicotine e-cigarette device.

[0008] In an exemplary embodiment, the nicotine pod assembly may include a pod body configured to hold a nicotine pre-vapor formulation. The pod body may have a front face, a rear face, a first side face, a second side face, an upstream end, and a downstream end. The upstream end may include at least one electrical contact and may define at least one upstream recess. The downstream end may define a pod outlet and at least one downstream recess.

[0009] The various features and advantages of the non-limiting embodiments of this specification should become more apparent when considered in conjunction with the detailed description and the accompanying drawings. The accompanying drawings are provided solely for purposes of illustration and should not be construed as limiting the claims. The accompanying drawings are not considered to be drawn to scale unless otherwise specified. For purposes of clarity, the various dimensions in the drawings may be exaggerated.

Brief Description of the Drawings

[0010]

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DETAILED DESCRIPTION OF THE INVENTION

[0011] Some detailed exemplary embodiments are disclosed herein. However, the details of the specific structural and functional aspects disclosed herein are merely exemplary for the purpose of describing the exemplary embodiments. However, the exemplary embodiments can be embodied in numerous alternative forms and should not be construed as limited to only the exemplary embodiments described herein.

[0012] Accordingly, while exemplary embodiments are capable of various modifications and alternative forms, the exemplary embodiments are shown by way of example in the drawings and are described in detail herein. However, it is understood that there is no intention to limit the exemplary embodiments to the particular forms disclosed, and on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives. Like numerals refer to like elements throughout the description of the figures.

[0013] Of course, when an element or layer is referred to as being “on,” “connected to,” “coupled to,” “attached to,” “adjacent to,” or “covering” another element or layer, this can mean directly on, directly connected to, directly coupled to, directly attached to, directly adjacent to, or directly covering the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, no intervening elements or layers are present. Like numerals refer to like elements throughout this specification. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0014] Of course, the terms first, second, third, etc. may be used herein to describe various elements, regions, layers, and / or sections, and these elements, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0015] Spatial relationship terms (e.g., "below", "beneath", "lower", "above", "upper", and the like) may be used herein to facilitate the description of the relationship between one element or feature and another element or feature when illustrated in a figure. It should be understood that spatial relationship terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figure. For example, if the device in the figure is turned over, an element described as "below" or "beneath" another element or feature will then be oriented "above" the other element or feature. Thus, the term "below" may sometimes encompass both upward and downward orientations. The device may be oriented in another way (rotated 90 degrees or in some other orientation), and the spatial relationship descriptors used herein are to be interpreted accordingly.

[0016] The terms used herein are for the purpose of describing various exemplary embodiments only and are not intended to limit the exemplary embodiments. The singular forms "a", "an", and "the" used herein are intended to include the plural forms as well, unless the context clearly indicates otherwise. When used herein, the terms "includes", "including", "comprises", and / or "comprising" identify the presence of the stated feature, integer, step, operation, and / or element, but it will be further understood that they do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0017] When the terms "same" or "identical" are used in the description of exemplary embodiments, there may of course be some degree of inaccuracy. Thus, when an element or value is referred to as being the same as another element or value, of course the element or value is the same as the other element or value within the manufacturing or operating tolerance range (e.g., ±10 percent).

[0018] The terms "about" or "substantially" are used herein in connection with numerical values, and of course, the accompanying numerical values include manufacturing or operating tolerances (e.g., ±10 percent) before and after the stated numerical values. Further, when the words "generally" and "substantially" are used in connection with geometric shapes, of course, the exactness of the geometric shapes is not required, but the allowable range of the shapes is within the scope of the present disclosure.

[0019] Unless defined otherwise, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments belong. Terms (including those defined in commonly used dictionaries) should be interpreted as having a meaning consistent with their meaning in the context of the relevant technical field and should not be interpreted in an idealized or overly formal sense, although it will be further understood that this is not the case if explicitly so defined herein.

[0020] Hardware may be implemented using processing or control circuitry including, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more system on chips (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs) or any other device having the ability to respond to and execute instructions in a defined manner.

[0021] FIG. 1 is a front view of a nicotine e-vaping device according to an exemplary embodiment. FIG. 2 is a side view of the nicotine e-vaping device of FIG. 1. FIG. 3 is a rear view of the nicotine e-vaping device of FIG. 1. Referring to FIGS. 1-3, the nicotine e-vaping device 500 includes a device body 100 configured to receive a nicotine pod assembly 300. The nicotine pod assembly 300 is a modular article configured to hold a nicotine pre-vapor formulation. The nicotine pre-vapor formulation is a material or combination of materials that can be transformed into a nicotine vapor. For example, the nicotine pre-vapor formulation can include liquid, solid, and / or gel formulations. These can include, for example, but not limited to, water, oil, emulsion, beads, solvents, active ingredients, ethanol, plant extracts, nicotine, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, and / or any other ingredients that may be suitable for vaping. During vaping, the nicotine e-vaping device 500 is configured to heat the nicotine pre-vapor formulation to generate a nicotine vapor. Nicotine vapor, nicotine aerosol, and nicotine dispersion are used interchangeably and refer to substances generated or output by the disclosed device, the claimed device, and / or their equivalents, and such substances contain nicotine. The nicotine e-vaping device 500 can be considered an electronic nicotine delivery system (ENDS).

[0022] As shown in FIGS. 1 and 3, the nicotine e - vaping device 500 extends in the long - axis direction and has a length greater than its width. Further, as shown in FIG. 2, the length of the nicotine e - vaping device 500 is also greater than its thickness. Further, the width of the nicotine e - vaping device 500 may be greater than its thickness. Assuming an x - y - z Cartesian coordinate system, the length of the nicotine e - vaping device 500 may be measured in the y - direction, the width may be measured in the x - direction, and the thickness may be measured in the z - direction. The nicotine e - vaping device 500 may have a substantially linear form with tapered and / or rounded ends based on its front view, side view, and rear view, but the exemplary embodiments are not limited thereto.

[0023] The device body 100 includes a front cover 104, a frame 106, and a rear cover 108. The front cover 104, the frame 106, and the rear cover 108 form a device housing that encloses mechanical components, electronic components, and / or circuits related to the operation of the nicotine e - vaping device 500. For example, the device housing of the device body 100 may enclose a power source configured to supply power to the nicotine e - vaping device 500, which may include supplying current to the nicotine pod assembly 300. Further, when assembled, the front cover 104, the frame 106, and the rear cover 108 may constitute most of the visible portion of the device body 100. The device housing may be regarded as including all components of the device body 100 except the mouthpiece 102. In other words, the mouthpiece 102 and the device housing may be considered to form the device body 100.

[0024] The front cover 104 (e.g., the first cover) defines a primary opening configured to accommodate the bezel structure 112. The primary opening may have a rounded rectangular shape, but other shapes are possible depending on the shape of the bezel structure 112. The bezel structure 112 defines a through - hole 150 configured to receive the nicotine pod assembly 300. The through - hole 150 is described in more detail herein, for example, in relation to FIG. 7.

[0025] The front cover 104 also defines a secondary opening configured to accommodate the light guide arrangement. The secondary opening may be similar to a slot, but other shapes are possible depending on the shape of the light guide arrangement. In an exemplary embodiment, the light guide arrangement includes a light guide housing 114 and a button housing 122. The light guide housing 114 is configured to expose a light guide lens 116. The button housing 122 may have an upstream portion structured as a first button 118 and a downstream portion structured as a second button 120. The button housing 122 may be in the form of a single structure or two separate structures. In the latter form, the first button 118 and the second button 120 can operate with a more independent feel when pressed.

[0026] The operation of the nicotine e-vaping device 500 may be controlled by the first button 118 and the second button 120. For example, the first button 118 may be a power button, and the second button 120 may be an intensity button. The two buttons are shown in the drawings in relation to the light guide arrangement, but of course, more (or fewer) buttons may be provided depending on the available features and the desired user interface.

[0027] Frame 106 (e.g., a base frame) is a central support structure of the device body 100 (and the entire nicotine vaping device 500). Frame 106 may be referred to as a chassis. Frame 106 includes a proximal end, a distal end, and a pair of side sections between the proximal end and the distal end. The proximal end and the distal end may also be referred to as the downstream end and the upstream end, respectively. As used herein, "proximal" (and conversely "distal") refers to that for an adult e-vaping device user during vaping, and the terms "downstream" (and conversely "upstream") refer to that for the flow of the nicotine vapor. A cross-linking section may be provided between the opposing inner surfaces of the side sections (e.g., substantially in the middle along the length of the frame 106) for additional strength and stability. Frame 106 may be integrally formed to be a monolithic structure.

[0028] Regarding the material of the structure, the frame 106 can be formed of an alloy or plastic. The alloy (e.g., die-cast grade, machinable grade) may be an aluminum (Al) alloy or a zinc (Zn) alloy. The plastic may be polycarbonate (PC), acrylonitrile butadiene styrene (ABS), or a combination thereof (PC / ABS). For example, the polycarbonate may be LUPOY SC1004A. Further, the frame 106 may be provided with a surface finish for functional and / or aesthetic reasons (e.g., to provide a premium appearance). In an exemplary embodiment, the frame 106 (e.g., when formed of an aluminum alloy) may be anodized. In another embodiment, the frame 106 (e.g., when formed of a zinc alloy) may be coated with a hard enamel or painted. In another embodiment, the frame 106 (e.g., when formed of polycarbonate) may be metallized. In yet another embodiment, the frame 106 (e.g., when formed of acrylonitrile butadiene styrene) may be electroplated. Of course, the material of the structure regarding the frame 106 may also apply to the front cover 104, the rear cover 108, and / or other suitable components of the nicotine e-vaping device 500.

[0029] The rear cover 108 (e.g., the second cover) also defines an opening configured to receive the bezel structure 112. The opening may have a rounded rectangular shape, but other shapes are possible depending on the shape of the bezel structure 112. In an exemplary embodiment, the opening of the rear cover 108 is smaller than the primary opening of the front cover 104. Further, although not shown, of course, a light guide arrangement (e.g., including buttons) may be provided on the back of the nicotine e-vaping device 500 in addition to (or instead of) the light guide arrangement on the front of the nicotine e-vaping device 500.

[0030] The front cover 104 and the rear cover 108 may be configured to engage with the frame 106 via a snap fit arrangement. For example, the front cover 104 and / or the rear cover 108 may include clips configured to interact with corresponding mating members of the frame 106. In a non-limiting embodiment, the clip may be in the form of a tab having an orifice configured to receive a corresponding mating member (e.g., a protrusion having an inclined edge) of the frame 106. As another method, the front cover 104 and / or the rear cover 108 may be configured to engage with the frame 106 via an interference fit (also referred to as a press fit or friction fit). However, of course, the front cover 104, the frame 106, and the rear cover 108 may be connected via other suitable arrangements and techniques.

[0031] The device body 100 may also include a mouthpiece 102. The mouthpiece 102 may be fixed to the proximal end of the frame 106. Further, as shown in FIG. 2, in an exemplary embodiment where the frame 106 is sandwiched between the front cover 104 and the rear cover 108, the mouthpiece 102 may abut against the front cover 104, the frame 106, and the rear cover 108. Further, in a non-limiting embodiment, the mouthpiece 102 may be coupled to the device housing via a bayonet connection.

[0032] Figure 4 is a proximal end view of the nicotine e-vaping device of FIG. 1. Referring to FIG. 4, the exit surface of the mouthpiece 102 defines a plurality of vapor exits. In a non-limiting embodiment, the exit surface of the mouthpiece 102 may be elliptical. Further, the exit surface of the mouthpiece 102 may include a first crossbar corresponding to the major axis of the elliptical exit surface and a second crossbar corresponding to the minor axis of the elliptical exit surface. Further, the first crossbar and the second crossbar may intersect at a right angle and may be an integrally formed part of the mouthpiece 102. The exit surface is shown as defining four vapor exits, but of course the exemplary embodiments are not limited to this. For example, the exit surface may define less than four (e.g., one, two) vapor exits, or more than four (e.g., six, eight) vapor exits.

[0033] Figure 5 is a distal end view of the nicotine e-vaping device of FIG. 1. Referring to FIG. 5, the distal end of the nicotine e-vaping device 500 includes a port 110. The port 110 is configured to receive current from an external power source (e.g., via a USB / mini-USB cable) to charge an internal power source within the nicotine e-vaping device 500. Further, the port 110 may also be configured to transmit and / or receive data (e.g., via a USB / mini-USB cable) between another nicotine e-vaping device or other electronic device (e.g., a phone, tablet, computer). Further, the nicotine e-vaping device 500 may be configured for wireless communication with another electronic device such as a phone via application software (app) installed on the electronic device. In such examples, an adult e-vaping device user may control or otherwise interface with the nicotine e-vaping device 500 through the app (e.g., identify the location of the nicotine e-vaping device, check usage information, change operating parameters).

[0034] FIG. 6 is a perspective view of the nicotine e-vaping device of FIG. 1. Referring to FIG. 6, and as briefly mentioned above, the nicotine e-vaping device 500 includes a nicotine pod assembly 300 configured to hold a nicotine pre-vapor formulation. The nicotine pod assembly 300 has an upstream end (facing the optical guide arrangement) and a downstream end (facing the mouthpiece 102). In non-limiting embodiments, the upstream end is the face of the nicotine pod assembly 300 that faces the downstream end of the nicotine pod assembly 300. The upstream end of the nicotine pod assembly 300 may define at least one upstream recess (e.g., the first upstream recess 312a and / or the second upstream recess 312b of FIG. 14), and the downstream end of the nicotine pod assembly 300 may define at least one downstream recess (e.g., the first downstream recess 306a and / or the second downstream recess 306b of FIG. 15). As described in more detail herein, the bezel structure 112 of the device body 100 can engage the upstream end (e.g., via at least one upstream recess) and the downstream end (e.g., via at least one downstream recess) of the nicotine pod assembly 300 when the nicotine pod assembly 300 is placed within the device body 100.

[0035] The device body 100 and the nicotine pod assembly 300 include mechanical, electronic, and / or circuit components related to the operation of the nicotine e-vaping device 500, which are described in more detail herein and / or incorporated herein by reference. For example, the nicotine pod assembly 300 may include mechanical components configured to release a nicotine pre-vapor formulation from a reservoir sealed therein when activated. The nicotine pod assembly 300 may also have mechanical aspects configured to engage with the device body 100 to facilitate insertion and placement of the nicotine pod assembly 300.

[0036] Furthermore, the nicotine pod assembly 300 may be a "smart pod" that includes electronic components and / or circuitry configured to store, receive, and / or transmit information to and from the device body 100. Such information may be used to authenticate the nicotine pod assembly 300 for use with the device body 100 (e.g., to prevent the use of unapproved / counterfeit nicotine pod assemblies). Additionally, the information may be used to identify the type of nicotine pod assembly 300, which may then be correlated with a vaping profile based on the identified type. The vaping profile may be designed to define general parameters for heating the nicotine pre-vapor formulation and may also be subject to adjustment, refinement, or other modification by an adult e-vaping device user before and / or during vaping.

[0037] The nicotine pod assembly 300 may also communicate other information related to the operation of the nicotine e-vaping device 500 to the device body 100. Examples of relevant information may include the level of nicotine pre-vapor formulation within the nicotine pod assembly 300 and / or the length of time elapsed since the nicotine pod assembly 300 was inserted and activated within the device body 100. For example, if the nicotine pod assembly 300 is inserted into the device body 100 and activated for a period longer than a particular duration (e.g., longer than six months ago), the nicotine e-vaping device 500 may disallow vaping, and the adult e-vaping device user may be prompted to replace the nicotine pod assembly with a new one, even if the nicotine pod assembly still contains an appropriate level of nicotine pre-vapor formulation.

[0038] As described above, and as will be described in more detail herein, the device body 100 may include mechanical components (e.g., complementary structures) configured to engage, hold, and / or activate the nicotine pod assembly 300. Further, the device body 100 may include electronic components and / or circuitry configured to receive current and charge an internal power source (e.g., a battery), which is then configured to supply power to the nicotine pod assembly 300 during vaping. Further, the device body 100 may include electronic components and / or circuitry configured to communicate with the nicotine pod assembly 300, different nicotine e-vaping devices, other electronic devices (e.g., phones, tablets, computers), and / or adult e-vaping device users. The information communicated may include pod-specific data, current vaping details, and / or past vaping patterns / history. Adult e-vaping device users may be notified about such communications using feedback that is tactile (e.g., vibration), auditory (e.g., beep sound), and / or visual (e.g., colored / flashing light). Charging and / or information communication may be performed using port 110 (e.g., via a USB / mini-USB cable).

[0039] FIG. 7 is a perspective view of the device body of the nicotine e-cigarette device of FIG. 6. FIG. 8 is an enlarged view of the bezel structure of FIG. 7. FIG. 9 is another enlarged view of the bezel structure of FIG. 7. Referring to FIGS. 7-9, the device body 100 defines a through hole 150 configured to receive the nicotine pod assembly 300. In an exemplary embodiment, the bezel structure 112 of the device body 100 defines the through hole. The through hole 150 may have a rectangular shape with rounded corners, but other shapes are possible depending on the configuration of the nicotine pod assembly 300. The bezel structure 112 may be integrally formed as a monolithic elastic article having at least one flexible portion (e.g., an upstream panel and / or a downstream panel having protrusions) configured to engage the nicotine pod assembly 300 when the nicotine pod assembly 300 is placed within the through hole 150. For example, the bezel structure 112 may be formed of plastic. Thus, the nicotine pod assembly 300 can be relatively easily positioned and securely held within the device body 100 in a cost-effective manner.

[0040] The bezel structure 112 has a length, a width, and a depth. The length of the bezel structure 112 may be in the long axis direction of the device body 100, the width of the bezel structure 112 may be in a transverse direction across the through hole 150 and may be perpendicular to the long axis direction of the device body 100. The depth of the bezel structure 112 may be in a vertical direction through the through hole 150 and may be perpendicular to both the long axis direction of the device body 100 and the transverse direction across the through hole 150. For example, assuming an x-y-z Cartesian coordinate system, the length of the bezel structure 112 may be measured in the y direction, the width may be measured in the x direction, and the depth may be measured in the z direction. The length of the bezel structure 112 may be greater than the width, and the width of the bezel structure 112 may be greater than the depth.

[0041] As shown in FIG. 8, the bezel structure 112 may include a first downstream corner defining a first downstream slit 154a and a second downstream corner defining a second downstream slit 154b. Further, as shown in FIG. 9, the bezel structure 112 may include a first upstream corner defining a first upstream slit 152a and a second upstream corner defining a second upstream slit 152b. As a result, in an exemplary embodiment where the bezel structure 112 has an upstream sidewall, an opposing downstream sidewall, and a pair of lateral sidewalls for defining a through-hole 150 therebetween, at least the upstream sidewall and / or the downstream sidewall may be configured to bend (by the slits) during insertion of the nicotine pod assembly 300. For example, the upstream and downstream sidewalls of the bezel structure 112 may be configured to bend away from each other during insertion of the nicotine pod assembly 300. Thus, the upstream and downstream sidewalls of the bezel structure 112 may be elastic sections configured to transition (e.g., reversibly) from an unloaded state to a loaded state when the nicotine pod assembly 300 is received by the device body 100.

[0042] In FIG. 8, a portion of the downstream sidewall between the first downstream slit 154a and the second downstream slit 154b may be the downstream engagement panel 158. Similarly, in FIG. 9, a portion of the upstream sidewall between the first upstream slit 152a and the second upstream slit 152b may be the upstream engagement panel 156. Each of the first upstream slit 152a, the second upstream slit 152b, the first downstream slit 154a, and the second downstream slit 154b may have a longest dimension (e.g., in the depth direction of the bezel structure) that is at least 30 percent (e.g., at least 40 percent) of the depth (e.g., average depth) of the bezel structure 112, although other dimensions are possible as long as the configuration allows for an elastic lever-like action by the upstream engagement panel 156 and the downstream engagement panel 158.

[0043] The upstream sidewall and / or the downstream sidewall of the bezel structure 112 may include at least one protrusion (e.g., a detent) configured to hold the nicotine pod assembly 300 within the through-hole 150 of the device body 100 (e.g., via engagement with one or more recesses of the nicotine pod assembly 300). For example, as shown in FIG. 8, the downstream engagement panel 158 of the downstream sidewall may include a first downstream protrusion 130a and a second downstream protrusion 130b. The first downstream protrusion 130a may be adjacent to the first downstream slit 154a of the device body 100 and the rear side (e.g., the rear cover 108), and the second downstream protrusion 130b may be adjacent to the second downstream slit 154b of the device body 100 and the rear side (e.g., the rear cover 108). Similarly, as shown in FIG. 9, the upstream engagement panel 156 of the upstream sidewall may include a first upstream protrusion 128a and a second upstream protrusion 128b. The first upstream protrusion 128a may be adjacent to the first upstream slit 152a of the device body 100 and the rear side (e.g., the rear cover 108), and the second upstream protrusion 128b may be adjacent to the second upstream slit 152b of the device body 100 and the rear side (e.g., the rear cover 108).

[0044] Although a pair of protrusions are illustrated in connection with each of the upstream and downstream sidewalls of the bezel structure 112, it will be appreciated that other quantities may be appropriate (e.g., one protrusion each, three protrusions each). Further, in an exemplary embodiment, each of the protrusions may be in the form of a spherical cap (e.g., a hemisphere). Alternatively, one or more of the protrusions may be in the form of an oval cap (e.g., a semi-ellipse), a raised portion (e.g., rounded, inclined), or other suitable mating structure for engaging a corresponding recess of the nicotine pod assembly 300. Further, the protrusions may be an integral part of the bezel structure 112.

[0045] The first upstream protrusions 128a and the second upstream protrusions 128b are biased (e.g., from an unloaded state) by the upstream engagement panel 156 of the upstream sidewall so as to interlock with corresponding upstream recesses of the nicotine pod assembly 300 during the loaded state. Similarly, the first downstream protrusions 130a and the second downstream protrusions 130b are biased (e.g., from an unloaded state) by the downstream engagement panel 158 of the downstream sidewall so as to interlock with corresponding downstream recesses of the nicotine pod assembly 300 during the loaded state. Thus, in an exemplary embodiment where the nicotine pod assembly 300 is placed within the through-hole 150 of the device body 100, the nicotine pod assembly 300 is held (e.g., compressed) therebetween by the upstream engagement panel 156 of the upstream sidewall and the downstream engagement panel 158 of the downstream sidewall.

[0046] When the nicotine pod assembly 300 is inserted into the through-hole 150 of the device body 100, the upstream pair of protrusions of the bezel structure 112 (e.g., the first upstream protrusion 128a and the second upstream protrusion 128b) may engage the upstream pair of corresponding recesses of the nicotine pod assembly 300 before the downstream pair of protrusions of the bezel structure 112 (e.g., the first downstream protrusion 130a and the second downstream protrusion 130b) engage the downstream pair of corresponding recesses of the nicotine pod assembly 300 (or vice versa). In another example, the upstream and downstream pairs of protrusions of the bezel structure 112 may engage the upstream and downstream pairs of corresponding recesses of the nicotine pod assembly 300 substantially simultaneously when the nicotine pod assembly 300 is inserted into the through-hole 150 of the device body 100. Additionally, the engagement of the protrusions of the bezel structure 112 with the corresponding recesses of the nicotine pod assembly 300 may generate an auditory feedback (e.g., an audible click) and / or a tactile feedback (e.g., a vibration) to notify the adult e-cigarette device user that the nicotine pod assembly 300 is properly placed within the through-hole 150 of the device body 100.

[0047] The downstream sidewall of the bezel structure 112 may define a downstream opening (e.g., the downstream opening 148 of FIG. 11). As a result, in the exemplary embodiments illustrated in FIGS. 7-8, the distal end of the mouthpiece 102 extends through the downstream opening of the bezel structure 112 and into the through-hole 150 (e.g., between the first downstream slit 154a and the second downstream slit 154b). The distal end of the mouthpiece 102 may be in the form of an annular elastic structure. Due to its elastic properties, the distal end of the mouthpiece 102 can be temporarily deformed to fit the insertion of the nicotine pod assembly 300 into the through-hole 150 of the device body 100. Further, the elasticity of the distal end of the mouthpiece 102 can help establish a vapor-tight seal with the pod outlet of the nicotine pod assembly 300.

[0048] The device electrical contacts of the device body 100 are configured to engage the pod electrical contacts of the nicotine pod assembly 300 when the nicotine pod assembly 300 is placed within the through-hole 150 of the device body 100. The device electrical contacts of the device body 100 include the device electrical connector 132. Referring to FIG. 9, the device electrical connector 132 of the device body 100 is disposed upstream of the through-hole 150. The device electrical connector 132 of the device body 100 is configured to electrically engage the nicotine pod assembly 300 placed within the through-hole 150. As a result, during vaping, power can be supplied from the device body 100 to the nicotine pod assembly 300 via the device electrical connector 132. Further, data can be transmitted and / or received between the device body 100 and the nicotine pod assembly 300 via the device electrical connector 132.

[0049] The device electrical connector 132 includes power contacts and data contacts. The power contacts of the device electrical connector 132 are configured to supply power from the device body 100 to the nicotine pod assembly 300. As shown, the power contacts of the device electrical connector 132 include a first power contact and a second power contact, which may be positioned closer to the rear cover 108 than the front cover 104 (or vice versa). The first power contact may be adjacent to the first upstream protrusion 128a, and the second power contact may be adjacent to the second upstream protrusion 128b. The first and second power contacts of the device electrical connector 132 are pullably attached and biased so as to extend into the through-hole 150 by default and to retract from the through-hole 150 (e.g., independently) when subjected to a force overcoming the bias.

[0050] The data contacts of the device electrical connector 132 are configured to transmit data between the nicotine pod assembly 300 and the device body 100. As shown, the data contacts of the device electrical connector 132 include six columns of protrusions, although exemplary embodiments are not limited thereto. The data contacts of the device electrical connector 132 may be positioned closer to the front cover 104 than the rear cover 108 (or vice versa). The data contacts of the device electrical connector 132 may be a separate structure that extends into the through-hole 150 when assembled. Also, the data contacts of the device electrical connector 132 are pullably attached and biased so as to extend into the through-hole 150 by default and to retract from the through-hole 150 (e.g., independently) when subjected to a force overcoming the bias.

[0051] For example, when the nicotine pod assembly 300 is inserted into the through hole 150 of the device body 100, the pod electrical contacts of the nicotine pod assembly 300 are pressed against the corresponding device electrical contacts of the device body 100. As a result, the power contacts and data contacts of the device electrical connector 132 retract (e.g., at least partially retract) into the device body 100, but due to their elastic arrangement, they continue to be pressed against the corresponding pod electrical contacts, thereby helping to ensure an appropriate electrical connection between the device body 100 and the nicotine pod assembly 300. Further, such a connection can also be mechanically secure and have a minimal contact resistance so that power and / or signals between the device body 100 and the nicotine pod assembly 300 can be reliably and accurately transmitted and / or communicated. Although various aspects have been described in relation to the device electrical contacts of the device body 100, it will be understood, of course, that the exemplary embodiments are not limited thereto and other configurations may be utilized.

[0052] FIG. 10 is a partial exploded view of the mouthpiece of FIG. 9. Referring to FIG. 10, the mouthpiece 102 extends through the frame 106 of the device housing and is configured to engage the bezel structure 112. As will be described in more detail herein, the mouthpiece 102 may be an assembly of several separate parts. Alternatively, the mouthpiece 102 may be a single, integrally formed structure. In the exemplary embodiment, the proximal end of the frame 106 and the proximal end of the bezel structure 112 are configured to receive the distal end of the mouthpiece 102. As illustrated, each of the proximal ends of the frame 106 and the bezel structure 112 may be female ends, and the distal end of the mouthpiece may be a male end.

[0053] For example, the mouthpiece 102 may be fixed, fitted, or coupled (e.g., reversibly coupled) to the bezel structure 112 using a bayonet connection. In such an example, the female end of the bezel structure 112 may define a pair of opposing L-shaped slots, and the male end of the mouthpiece 102 may have opposing radial members 134 (e.g., radial pins) configured to engage the L-shaped slots of the bezel structure 112. Each of the L-shaped slots of the bezel structure 112 may have a longitudinal portion and a circumferential portion. Optionally, the ends of the circumferential portion may have serrated portions that serve to reduce or prevent accidental disengagement of the radial members 134 of the mouthpiece 102.

[0054] In a non-limiting embodiment, the longitudinal portion of the L-shaped slot extends parallel to the longitudinal axis of the device body 100, and the circumferential portion of the L-shaped slot extends around the longitudinal axis (e.g., central axis) of the device body 100. As a result, to couple the mouthpiece 102 to the device housing, first rotate the mouthpiece 102 by 90 degrees to align the radial members 134 with the downstream opening at the proximal end of the frame 106 and the entrance to the longitudinal portion of the L-shaped slot of the bezel structure 112 (e.g., based on the figure in FIG. 10). Then, insert the mouthpiece 102 through the frame 106 into the bezel structure 112 such that the radial members 134 slide along the longitudinal portion of the L-shaped slot until they reach the junctions with each of the circumferential portions. At this point, then rotate the mouthpiece 102 to move it across the circumferential portions until the radial members 134 reach each end. If serrated portions are present at each end, tactile and / or auditory feedback (e.g., an audible click) may be generated to notify the adult e-cigarette device user that the mouthpiece 102 is properly coupled to the device housing. Although a pair of radial members 134 and corresponding L-shaped slots are described herein, of course, in some examples, one radial member 134 and a corresponding one L-shaped slot may be appropriate.

[0055] The mouthpiece 102 defines a vapor passage 136 through which nicotine vapor flows during vaping. The vapor passage 136 is in fluid communication with a through-hole 150 (where the nicotine pod assembly 300 is placed within the device body 100). The proximal end of the vapor passage 136 may include a flared portion. Further, the mouthpiece 102 may include an end cover 138. The end cover 138 may be tapered from its distal end to its proximal end. The exit surface of the end cover 138 defines a plurality of vapor outlets. Four vapor outlets are shown for the end cover 138, but of course, the exemplary embodiments are not limited to this.

[0056] FIG. 11 is a partial exploded view of the bezel structure according to the bezel structure of FIG. 9. FIG. 12 is an enlarged perspective view of the mouthpiece, holding structure, and bezel structure of FIG. 11. Referring to FIGS. 11-12, the bezel structure 112 includes an upstream side wall and a downstream side wall. The upstream side wall of the bezel structure 112 defines a connector opening 146. The connector opening 146 is configured to expose or receive the device electrical connector 132 of the device body 100. The downstream side wall of the bezel structure 112 defines a downstream opening 148. The downstream opening 148 of the bezel structure 112 is configured to receive the distal end of the mouthpiece 102.

[0057] To facilitate attachment to the device housing, the bezel structure 112 has an upstream pair of tabs and a downstream pair of tabs (e.g., external tabs). The upstream pair of tabs may be adjacent to the connector opening 146 (e.g., one tab on each side of the connector opening 146), and the downstream pair of tabs may be adjacent to the downstream opening 148 (e.g., one tab on each side of the downstream opening 148). Similarly, the frame 106 of the device housing has an upstream pair of tabs and a downstream pair of tabs (e.g., internal tabs) that respectively correspond to the upstream pair of tabs and the downstream pair of tabs of the bezel structure 112. The bezel structure 112 may be fixed to the frame 106 of the device housing via at least the holding structure 140 and the above-described tabs.

[0058] The retaining structure 140 may include a first fastener 142a, a second fastener 142b, and a catch mechanism (e.g., an intermediate connecting member). In an exemplary embodiment, the first fastener 142a and the second fastener 142b may be separate components (e.g., screws) that extend through openings at opposite ends of the catch mechanism. The downstream pair of tabs of the bezel structure 112 may be fixed to the corresponding downstream pair of tabs of the frame 106 using the first fastener 142a and the second fastener 142b of the retaining structure 140. Similarly, although not specifically disassembled for visibility in FIG. 11, the upstream pair of tabs of the bezel structure 112 may be fixed to the corresponding upstream pair of tabs of the frame 106 using upstream fasteners that are similar or identical to the first fastener 142a and the second fastener 142b.

[0059] As shown in FIG. 12, the proximal female end of the bezel structure 112 may be a cylindrical section that defines a downstream opening 148 and a pair of opposing L-shaped slots for establishing a bayonet connection with the opposing radial members 134 of the mouthpiece 102. In an exemplary embodiment, one of the circumferential portions of the L-shaped slot may be an open portion of the cylindrical section (e.g., the open portion on the lower side of the cylindrical section, based on the view of FIG. 12). In such an example, when the downstream pair of tabs of the bezel structure 112 are fixed to the corresponding downstream pair of tabs of the frame 106 by the retaining structure 140, the catch mechanism (which connects the first fastener 142a and the second fastener 142b) aligns with the open portion of the cylindrical section so as to define at least a portion of one of the circumferential portions of the L-shaped slot. The catch mechanism of the retaining structure 140 includes two angled fingers separated by a gap that substantially corresponds to the width of one of the radial members 134 of the mouthpiece 102. The two angled fingers of the catch mechanism are elastic and configured to bend when the mouthpiece 102 rotates (e.g., during assembly) to accommodate a corresponding circumferential movement of the radial member 134. When the corresponding radial member 134 reaches the gap between the two angled fingers of the catch mechanism (of the retaining structure 140), the two bent angled fingers rebound or spring back to their unloaded state so as to place the radial member 134 within the gap (e.g., catch it). In the placed position, the two angled fingers of the catch mechanism may abut or be adjacent to the side surface of the corresponding radial member 134 so as to resist further rotation of the mouthpiece 102. As a result, the bayonet connection between the mouthpiece 102 and the bezel structure 112 can be maintained in a relatively secure manner by the retaining structure 140.

[0060] During assembly, the bezel structure 112 may be fixed to the frame 106 (along with other mechanical, electronic, and / or circuit components) before the front cover 104 and the rear cover 108 are attached to the frame 106. For example, the bezel structure 112 may first be positioned relative to the frame 106 such that the downstream tab and the upstream tab of the bezel structure 112 are aligned with the downstream tab and the upstream tab of the frame 106, respectively. In an exemplary embodiment having an orifice (e.g., a pre-formed orifice) through which each of the tabs extends, the orifice in the downstream tab and the orifice in the upstream tab may be aligned and seated as a result. Once proper alignment is achieved, the first fastener 142a and the second fastener 142b are introduced through the downstream tab of the frame 106 and then through the downstream tab of the bezel structure 112 (e.g., via the underside of the tab, based on the view of FIG. 11). Similarly, the upstream fastener may be introduced in a similar manner through the upstream tab of the frame 106 and then through the upstream tab of the bezel structure 112. FIG. 11 shows the device housing as already assembled prior to the attachment of the bezel structure 112, but of course, this exploded view is only intended to show a particular part (e.g., the bezel structure 112) separately from the other parts of the device body 100 and thus does not necessarily represent the order of assembly of the device body 100.

[0061] FIG. 13 is an exploded partial view of the front cover, frame, and rear cover of FIG. 11. Referring to FIG. 13, various mechanical components, electronic components, and / or circuits related to the operation of the nicotine e-caping device 500 may be fixed to the frame 106. The front cover 104 and the rear cover 108 may be configured to engage with the frame 106 via a snap fit arrangement. In an exemplary embodiment, the front cover 104 and the rear cover 108 include clips configured to interact with corresponding mating members of the frame 106. The clips may be in the form of tabs having orifices configured to receive corresponding mating members of the frame 106 (e.g., protrusions having inclined edges). The front cover 104 may have two rows, each having four clips (a total of eight clips for the front cover 104). Similarly, the rear cover 108 may have two rows, each having four clips (a total of eight clips for the rear cover 108). The corresponding mating members of the frame 106 may be on the inner sidewalls of the frame 106. As a result, the engaged clips and mating members may be hidden from view when the front cover 104 and the rear cover 108 are snapped together. Alternatively, the front cover 104 and / or the rear cover 108 may be configured to engage with the frame 106 via an interference fit. However, of course, the front cover 104, the frame 106, and the rear cover 108 may be connected via other suitable arrangements and techniques.

[0062] FIG. 14 is a perspective view of the nicotine pod assembly of the nicotine vaping device of FIG. 6. FIG. 15 is another perspective view of the nicotine pod assembly of FIG. 14. Referring to FIGS. 14-15, the nicotine pod assembly 300 has a pod body including a front face, a rear face opposite the front face, a first side face between the front face and the rear face, a second side face opposite the first side face, an upstream end face, and a downstream end face opposite the upstream end face. The corners of the side faces and end faces (e.g., the corner of the first side face and the upstream end face, the corner of the upstream end face and the second side face, the corner of the second side face and the downstream end face, the corner of the downstream end face and the first side face) may be rounded. However, in some examples, the corners may have an angle. Further, the peripheral edge of the front face may be in the form of a ledge. The front face of the nicotine pod assembly 300 may be wider and longer than the rear face. In such examples, the first side face and the second side face may be angled inwardly towards each other. The upstream end face and the downstream end face may also be angled inwardly towards each other. Due to the angled faces, the insertion of the nicotine pod assembly ́300 is unidirectional (e.g., from the front side of the device body 100 (the side associated with the front cover 104)). As a result, the possibility of the nicotine pod assembly 300 being improperly inserted into the device body 100 can be reduced or prevented.

[0063] As shown in FIG. 14, the upstream end of the nicotine pod assembly 300 may include at least one electrical contact and may define at least one upstream recess (e.g., a first upstream recess 312a and / or a second upstream recess 312b). As shown in FIG. 15, the downstream end of the nicotine pod assembly 300 may define a pod outlet 304 and at least one downstream recess (e.g., a first downstream recess 306a and / or a second downstream recess 306b). The pod body of the nicotine pod assembly 300 may include a first housing section 302 and a second housing section 308. The first housing section 302 of the pod body may be configured to hold a nicotine pre-vapor formulation, and the second housing section 308 may be configured to receive a connector module 320 (e.g., FIG. 17).

[0064] In an exemplary embodiment, the upstream end of the second housing section 308 of the pod body defines a cavity, and the downstream end of the first housing section 302 of the pod body defines a pod outlet 304 that is in fluid communication with the cavity of the second housing section 308. As described in more detail herein, the connector module 320 (e.g., FIG. 17) is configured to be placed within the cavity of the second housing section 308 of the pod body. The connector module 320 includes an outer surface (e.g., having electrical contacts) and an adjacent side surface. When the nicotine pod assembly 300 is assembled, the outer surface of the connector module 320 forms the exterior of the nicotine pod assembly 300, and the adjacent side surface is hidden from view within the cavity of the second housing section 308. Thus, the outer surface of the connector module 320 may be a part of the upstream end face of the nicotine pod assembly 300.

[0065] The outer surface of the connector module 320 may include at least one electrical contact. The at least one electrical contact may include a plurality of power contacts. For example, the plurality of power contacts may include a first power contact 324a and a second power contact 324b. The first power contact 324a and the second power contact 324b are shown in FIG. 14 as extending horizontally outward, but of course, in further forms of the nicotine pod assembly 300, the first power contact 324a and the second power contact 324b may be folded upward to be adjacent to the data contact 326 with respect to the outer surface of the connector module 320. The first power contact 324a of the nicotine pod assembly 300 is configured to be electrically connected to the first power contact of the device electrical connector 132 of the device body 100 (for example, the power contact adjacent to the first upstream protrusion 128a in FIG. 9). Similarly, the second power contact 324b of the nicotine pod assembly 300 is configured to be electrically connected to the second power contact of the device electrical connector 132 of the device body 100 (for example, the power contact adjacent to the second upstream protrusion 128b in FIG. 9). Further, at least one electrical contact of the nicotine pod assembly 300 includes a plurality of data contacts 326. The plurality of data contacts 326 of the nicotine pod assembly 300 are configured to be electrically connected to the data contacts of the device electrical connector 132 (for example, the six columns of contacts in FIG. 9). Two power contacts and six data contacts are shown in relation to the nicotine pod assembly 300, but of course, other variations are possible depending on the design of the device body 100.

[0066] As described above, the pod body of the nicotine pod assembly 300 may include a first housing section 302 and a second housing section 308. The first housing section 302 has a downstream end that defines a pod outlet 304. The edge of the pod outlet 304 may optionally be a raised area. In such an example, when the downstream end face of the first housing section 302 is angled inwardly, the degree of protrusion of the edge of the pod outlet 304 may be greater towards the rear and smaller towards the front. Further, the side face facing the rear of the pod outlet 304 may have an inclination that slopes upwardly from the downstream end face to the edge. As a result, when the nicotine pod assembly 300 is inserted into the through hole 150 of the device body 100, the advancement of the pod outlet 304 to align with the distal end of the mouthpiece 102 can be facilitated by the inclination. In a non-limiting embodiment, the distal end of the mouthpiece 102 serves to accommodate the advancement of the nicotine pod assembly 300 into the through hole 150 of the device body 100 and may include (or be formed of) an elastic material that generates a seal around the pod outlet 304.

[0067] The downstream end of the first housing section 302 additionally defines at least one downstream recess. In an exemplary embodiment, the at least one downstream recess is in the form of a first downstream recess 306a and a second downstream recess 306b. The pod outlet 304 may be between the first downstream recess 306a and the second downstream recess 306b. The first downstream recess 306a and the second downstream recess 306b are configured to engage with a first downstream protrusion 130a and a second downstream protrusion 130b of the device body 100, respectively. The first downstream recess 306a and the second downstream recess 306b may each be in the form of a dimple. In such an example, each of the first downstream protrusion 130a and the second downstream protrusion 130b of the device body 100 may be in the form of a rounded structure (e.g., a spherical cap) configured to engage with a corresponding one of the first downstream recess 306a and the second downstream recess 306b.

[0068] Similarly, the upstream end of the second housing section 308 defines at least one upstream recess. In an exemplary embodiment, the at least one upstream recess is in the form of a first upstream recess 312a and a second upstream recess 312b. The first power contact 324a and the second power contact 324b of the connector module 320 may be between the first upstream recess 312a and the second upstream recess 312b. The first upstream recess 312a and the second upstream recess 312b are configured to engage with a first upstream protrusion 128a and a second upstream protrusion 128b of the device body 100, respectively. Also, the first upstream recess 312a and the second upstream recess 312b may each be in the form of a dimple. In such an example, each of the first upstream protrusion 128a and the second upstream protrusion 128b of the device body 100 may be in the form of a rounded structure (e.g., a spherical cap) configured to engage with a corresponding one of the first upstream recess 312a and the second upstream recess 312b.

[0069] The first housing section 302 may define therein a reservoir configured to hold a nicotine pre-vapor formulation. The reservoir may be configured to hermetically seal the nicotine pre-vapor formulation until activation of the nicotine pod assembly 300 for releasing the nicotine pre-vapor formulation from the reservoir. As a result of the seal, the nicotine pre-vapor formulation is separated from the environment and internal elements of the nicotine pod assembly 300 that may react with the nicotine pre-vapor formulation, thereby reducing or preventing the potential for adverse effects on the shelf life and / or sensory characteristics (e.g., flavor) of the nicotine pre-vapor formulation. The second housing section 308 may contain a structure configured to activate the nicotine pod assembly 300 and receive and heat the nicotine pre-vapor formulation released from the reservoir after activation.

[0070] The nicotine pod assembly 300 may be manually activated by an adult e-vaping device user before inserting the nicotine pod assembly 300 into the device body 100. As another method, the nicotine pod assembly 300 may be activated as part of the insertion of the nicotine pod assembly 300 into the device body 100. In an exemplary embodiment, the second housing section 308 of the pod body includes a perforator configured to release the nicotine pre-vapor formulation from the storage portion during activation of the nicotine pod assembly 300. The perforator may be in the form of a first activation pin 314a and a second activation pin 314b, which will be described in more detail herein.

[0071] To manually activate the nicotine pod assembly 300, an adult e-vaping device user may push the first activation pin 314a and the second activation pin 314b inwardly (e.g., simultaneously or sequentially) before inserting the nicotine pod assembly 300 through the through hole 150 into the device body 100. For example, the first activation pin 314a and the second activation pin 314b may be manually pushed until their ends are substantially flush with the upstream end face of the nicotine pod assembly 300. In an exemplary embodiment, the inward movement of the first activation pin 314a and the second activation pin 314b perforates or otherwise damages the seal of the storage portion so as to release the nicotine pre-vapor formulation therefrom.

[0072] As another way, to activate the nicotine pod assembly 300 as part of inserting the nicotine pod assembly 300 into the device body 100, the nicotine pod assembly 300 may first be positioned such that the first activation pin 314a and the second activation pin 314b contact the upstream sidewall of the through hole 150. Then, the upstream end of the nicotine pod assembly 300 is pushed (e.g., simultaneously) into the second housing section 308 by the first activation pin 314a and the second activation pin 314b, and thus can be biased toward the upstream sidewall of the through hole 150 so as to transition from the extended state to the retracted state and release the nicotine pre-vapor formulation from the storage portion. When the pod electrical contacts of the nicotine pod assembly 300 are adjacent to or in contact with the device electrical contacts of the device body 100, the downstream end of the nicotine pod assembly 300 can be manipulated (e.g., swiveled) into the through hole 150. As the nicotine pod assembly 300 advances into the through hole 150, after the recesses of the nicotine pod assembly 300 engage with the corresponding protrusions of the device body 100, the upstream engagement panel 156 and / or the downstream engagement panel 158 bend and then spring back.

[0073] In an exemplary embodiment, when the nicotine pod assembly 300 is placed within the device body 100, the first upstream recess 312a and the second upstream recess 312b of the nicotine pod assembly 300 engage (e.g., upstream engage) with the first upstream protrusion 128a and the second upstream protrusion 128b of the bezel structure 112, respectively. Similarly, the first downstream recess 306a and the second downstream recess 306b of the nicotine pod assembly 300 engage (e.g., downstream engage) with the first downstream protrusion 130a and the second downstream protrusion 130b of the bezel structure 112, respectively. The transition to upstream engagement and / or downstream engagement may generate an audible click and / or a tactile feedback indicating that the nicotine pod assembly 300 is properly placed within the through hole 150 of the device body 100.

[0074] When properly placed, the nicotine pod assembly 300 is mechanically, electrically, and fluidly connected to the device body 100. The upstream engagement of the nicotine pod assembly 300 can occur before the downstream engagement in some examples, although of course, alternatively, in other examples, the downstream engagement may occur before (or simultaneously with) the upstream engagement.

[0075] FIG. 16 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 14. Referring to FIG. 16, the first housing section 302 includes a vapor channel 316. The vapor channel 316 is configured to receive nicotine vapor (from the second housing section 308) and is in fluid communication with the pod outlet 304. In an exemplary embodiment, the vapor channel 316 may gradually increase in size (e.g., diameter) as it extends toward the pod outlet 304. Further, the vapor channel 316 may be integrally formed with the first housing section 302. The insert 342 and the seal 344 are disposed at the upstream end of the first housing section 302 to define a reservoir of the nicotine pod assembly 300. When assembled, the insert 342 may interact elastically with the outer sidewall of the vapor channel 316. Further, the seal 344 is attached to the upstream lip of the first housing section 302 and the upstream side of the insert 342 to provide a fluid-tight (e.g., liquid-tight and / or air-tight) containment within the reservoir of the nicotine pre-vapor formulation.

[0076] In an exemplary embodiment, the seal 344 is aligned with the vapor channel 316 and defines an opening (e.g., a central opening) configured to provide an associated gap for accommodating the downstream end of the vaporizer 336 (e.g., FIG. 17). In FIG. 16, it should be understood that the seal 344 is shown in a perforated state. In particular, when perforated by the first activation pin 314a and the second activation pin 314b of the nicotine pod assembly 300, the two perforated sections of the seal 344 are pushed into the reservoir as flaps (as shown in FIG. 16), and thus two perforated openings (e.g., one on each side of the central opening) are created within the seal 344. In contrast, in the non-perforated state, the seal 344 has a planar form and only one opening (e.g., a central opening). The seal 344 is designed to have sufficient strength to remain intact so as to avoid being prematurely / inadvertently torn during normal movement and / or handling of the nicotine pod assembly 300. For example, the seal 344 may be a coated foil (e.g., polyethylene terephthalate (PET) lined with aluminum).

[0077] FIG. 17 is a partial exploded view of a second housing section of the nicotine pod assembly of FIG. 14. Referring to FIG. 17, the second housing section 308 is structured to contain various components configured to release, receive, and heat a nicotine pre-vapor formulation. For example, the first activation pin 314a and the second activation pin 314b are configured to pierce a reservoir of the first housing section 302 to release a nicotine pre-vapor formulation. Each of the first activation pin 314a and the second activation pin 314b has a distal end that extends through a corresponding opening in the second housing section 308. In an exemplary embodiment, the distal ends of the first activation pin 314a and the second activation pin 314b are visible after assembly (e.g., FIG. 14), but the remaining portions of the first activation pin 314a and the second activation pin 314b are hidden from view within the nicotine pod assembly 300. Further, each of the first activation pin 314a and the second activation pin 314b has a proximal end positioned adjacent to and upstream of a seal 344 prior to activation of the nicotine pod assembly 300. When the first activation pin 314a and the second activation pin 314b are pushed into the second housing section 308 to activate the nicotine pod assembly 300, the proximal end of each of the first activation pin 314a and the second activation pin 314b advances, resulting in piercing of the seal 344 and thereby release of the nicotine pre-vapor formulation from the reservoir. Movement of the first activation pin 314a may be independent of movement of the second activation pin 314b (and vice versa). The first activation pin 314a and the second activation pin 314b are described in more detail herein.

[0078] In an exemplary embodiment, the back surface of the second housing section 308 defines a pod inlet (e.g., FIG. 3). The pod inlet (through which air enters during vaping) is in fluid communication with a pod outlet 304 (through which nicotine vapor is discharged during vaping). The pod inlet is located along the longitudinal axis of the nicotine pod assembly 300 (and the nicotine e-vaping device 500) and may be adjacent to the upstream end of the second housing section 308, although the exemplary embodiment is not limited thereto. Further, the pod inlet may be located between a pair of raised surfaces (e.g., ridges) on the back surface of the second housing section 308. As a result, the raised surfaces can help reduce or prevent occlusion of the pod inlet (e.g., inadvertent occlusion by the finger of an adult e-vaping device user during vaping). The pod inlet is shown as being in the form of a slot (e.g., FIG. 3). However, of course, the exemplary embodiment is not limited thereto and other forms are possible.

[0079] The upstream end of the second housing section 308 defines a cavity (e.g., the underside of the second housing section 308 based on the figure of FIG. 17). As described above, the cavity is configured to receive the connector module 320 (e.g., via interference fit). In an exemplary embodiment, the cavity is located between a first upstream recess 312a and a second upstream recess 312b and is also located between a first activation pin 314a and a second activation pin 314b. When the connector module 320 is absent, the upstream ends of the gasket 318 and the vaporizer 336 (extending through the gasket 318) may be visible through the cavity of the second housing section 308.

[0080] The vaporizer 336 is configured to receive and heat the nicotine pre-vapor formulation released from the storage portion within the first housing section 302. As will be described in more detail below, the vaporizer 336 may include a wick and / or a heater configured to receive and heat the nicotine pre-vapor formulation. Further, the vaporizer 336 may be considered to have an upstream end, an opposing downstream end, and an intermediate sector between the upstream and downstream ends. The upstream end of the vaporizer 336 extends through the second housing section 308 and the gasket 318 and is configured to engage with the connector module 320. For example, the upstream end of the vaporizer 336 may be placed within a corresponding socket of the connector module 320 (e.g., via an interference fit). On the other hand, the downstream end of the vaporizer 336 extends through the seal 344 and the insert 342 and is configured to engage with the vapor channel 316 of the first housing section 302. The intermediate sector of the vaporizer 336 defines an internal heating chamber, along with one or more openings configured to receive the nicotine pre-vapor formulation released from the storage portion of the first housing section 302 when the nicotine pod assembly 300 is activated.

[0081] In an exemplary embodiment, the intermediate sector of the vaporizer 336 defines a pair of openings upstream of the seal 344. The vaporizer 336 may include a wick extending within and / or through both of the openings of the intermediate sector. The wick has pores / gaps designed for capillary action. Further, the heater may be disposed within the heating chamber of the intermediate sector of the vaporizer 336 so as to be in thermal contact with the wick. As a result, the nicotine pre-vapor formulation released from the reservoir can be conveyed via the wick to the heater within the intermediate sector of the vaporizer 336. The heater is configured to heat the nicotine pre-vapor formulation during vaping to generate a nicotine vapor. The heater is electrically connected to at least one electrical contact of the connector module 320. For example, one end (e.g., the first end) of the heater may be connected to the first power contact 324a, and the other end (e.g., the second end) of the heater may be connected to the second power contact 324b. The heater may include a coiled heating element. In such examples, the wick may have a string-like form in which the heater is wound around at least a portion of its length (e.g., helically). Alternatively, the heater may include a folded heating element. In such examples, the wick may have a planar form (e.g., a fibrous pad) configured to be held by the folded heating element. Although various forms are described in relation to the heater and the wick, other configurations and combinations are of course possible.

[0082] The heater may be configured to receive Joule heating (also known as Ohmic / resistive heating) as current is applied. More specifically, the heater may be formed of one or more conductors (resistive materials) and configured to generate heat when current is passed therethrough. The current may be supplied from a power source (e.g., a battery) within the device body 100 and carried to the heater via the first power contact 324a or via the second power contact 324b. During vaping, the nicotine vapor generated by the heater travels from the heating chamber in the middle sector of the vaporizer 336, through the downstream end of the vaporizer 336, through the vapor channel 316 of the first housing section 302, out of the pod outlet 304 of the nicotine pod assembly 300, and through the vapor passage 136 of the mouthpiece 102 to the vapor outlet.

[0083] Conductors (resistive materials) suitable for the heater include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). Wires formed of such materials may be wound to provide a heater in a coiled configuration. In another example, the heater may be made from a conductive sheet (e.g., metal, alloy) that is stamped to cut a winding pattern therefrom. The winding pattern may have curved segments that are alternately disposed with horizontal segments such that the horizontal segments extend parallel to each other while zigzagging back and forth. Further, the width of each of the horizontal segments of the winding pattern may be substantially equal to the spacing between adjacent horizontal segments of the winding pattern, although exemplary embodiments are not limited thereto. To obtain a folded configuration for the heater, the winding pattern may be folded or folded onto itself (e.g., to provide a U-shaped cross-section configured to receive and grip a core). The heater and related structures are described in more detail in U.S. Patent Application No. 15 / 729,909, "Folded Heater For Electronic Vaping Devic", filed on October 11, 2017, the entire disclosure of which is incorporated herein by reference.

[0084] FIG. 18 is an exploded view of the activation pins of FIG. 17. Referring to FIG. 18, the activation pins may be in the form of a first activation pin 314a and a second activation pin 314b. Although two activation pins are shown and described in connection with non-limiting embodiments of the present specification, of course, alternatively, the nicotine pod assembly 300 may include only one activation pin. In FIG. 18, the first activation pin 314a may include a first blade 348a, a first actuator 350a, a first O-ring 352a, and a first cap 353a. Similarly, the second activation pin 314b may include a second blade 348b, a second actuator 350b, a second O-ring 352b, and a second cap 353b.

[0085] In an exemplary embodiment, the first blade 348a and the second blade 348b are each configured to be mounted or attached to an upper portion (e.g., proximal portion) of the first actuator 350a and the second actuator 350b. The mounting or attachment can be achieved via a snap-fit connection, an interference fit (e.g., friction fit) connection, an adhesive, or other suitable coupling techniques. Each upper portion of the first blade 348a and the second blade 348b may have one or more curved or concave edges that are tapered upwardly towards a pointed tip. For example, each of the first blade 348a and the second blade 348b may have two pointed tips with a concave edge therebetween, and curved edges adjacent to each of the pointed tips. The radius of curvature of the concave edge and the curved edge may be the same, and the arc lengths thereof may be different. The first blade 348a and the second blade 348b may be formed of sheet metal (e.g., stainless steel) that is cut or shaped to have a desired profile and bend into its final form. In another example, the first blade 348a and the second blade 348b may be formed of plastic.

[0086] Furthermore, as shown in FIG. 18, the first actuator 350a and the second actuator 350b may include protruding edges (e.g., curved inner lips facing each other) configured to push the two perforated sections of the seal 344 into the storage portion as the first blade 348a and the second blade 348b advance into the storage portion. In a non-limiting embodiment, when the first activation pin 314a and the second activation pin 314b are fully inserted into the nicotine pod assembly 300, two flaps (from the two perforated sections of the seal 344, as shown in FIG. 16) may be between the sidewall of the insert 342 and the protruding edges of the first actuator 350a and the second actuator 350b. As a result, the possibility that the two perforated openings of the seal 344 are obstructed (by the two flaps from the two perforated sections) can be reduced or prevented. Further, the first actuator 350a and the second actuator 350b may be configured to direct the nicotine pre-vapor formulation from the storage portion toward the opening of the vaporizer 336 (which leads to the internal heating chamber).

[0087] The lower portion (e.g., distal portion) of each of the first actuator 350a and the second actuator 350b is configured to extend through the bottom section (e.g., upstream end) of the second housing section 308. This rod-like portion of each of the first actuator 350a and the second actuator 350b may also be referred to as a shaft. The first O-ring 352a and the second O-ring 352b may be disposed on the respective shafts of the first actuator 350a and the second actuator 350b. In an exemplary embodiment, the first cap 353a may be used to help secure the first O-ring 352a against the concave surface of the shaft of the first actuator 350a. Similarly, the second cap 353b may be used to help secure the second O-ring 352b against the concave surface of the shaft of the second actuator 350b.

[0088] The first O-ring 352a and the second O-ring 352b are configured to engage the inner surfaces of the respective shafts of the first actuator 350a and the second actuator 350b, as well as the corresponding openings of the second housing section 308, in order to provide a fluid-tight seal. As a result, when the first activation pin 314a and the second activation pin 314b are pushed inward to activate the nicotine pod assembly 300, the first O-ring 352a and the second O-ring 352b move with the respective shafts of the first actuator 350a and the second actuator 350b within the corresponding openings of the second housing section 308 while maintaining their respective seals, thereby helping to reduce or prevent leakage of the nicotine pre-vapor formulation through the openings of the second housing section 308 to the first activation pin 314a and the second activation pin 314b. The first O-ring 352a and the second O-ring 352b may be formed of silicon.

[0089] FIG. 19 is an exploded view of the connector module of FIG. 17. Referring to FIG. 19, the module housing 354 and the faceplate 366 generally form the outer framework of the connector module 320. In particular, the connector module 320 can be considered to have a plurality of faces, including an outer face and adjacent side faces. In an exemplary embodiment, the outer face of the connector module 320 includes the upstream face of the faceplate 366 (e.g., the lower side of the faceplate 366 based on the view of FIG. 19). The side faces of the connector module 320 may be part of the module housing 354. Although hidden from view, the rear side face of the module housing 354 may define a module inlet (e.g., the side face of the module housing 354 angled toward the left rear based on the view of FIG. 19). The side faces may include rib structures (e.g., crush ribs) configured to facilitate interference fit when the connector module 320 is placed within the cavity of the second housing section 308. For example, each of the side faces may include a pair of rib structures that are tapered away from the faceplate 366. As a result, the module housing 354 will encounter increased resistance via the friction of the rib structures against the cavity walls when the connector module 320 is pushed into the cavity of the second housing section 308. When the connector module 320 is properly placed, the module inlet of the module housing 354 is aligned with the pod inlet of the second housing section 308.

[0090] Sensor 364, first power contact 324a, second power contact 324b, and printed circuit board (PCB) 362 are disposed within an external framework formed by module housing 354 and faceplate 366. In an exemplary embodiment, sensor 364 is configured to detect and / or measure the flow of air into nicotine pod assembly 300. For example, sensor 364 may be a hot wire anemometer positioned such that a wire portion extends across a module inlet of module housing 354. Faceplate 366 defines a plurality of contact openings. Data contacts 326 are configured to extend through corresponding contact openings of faceplate 366 and electrically connect to printed circuit board 362.

[0091] Each of the first power contact 324a and the second power contact 324b can be regarded as having a body portion, an arm portion, a finger portion, and a leg portion. When assembled, the body portions of the first power contact 324a and the second power contact 324b can be adjacent to the rear side surface of the module housing 354 (for example, the side surface of the module housing 354 angled towards the left rear based on the figure in FIG. 19). Further, the arm portions of the first power contact 324a and the second power contact 324b may be adjacent to the lateral side surfaces of the module housing 354 (for example, the two side surfaces extending from the rear side surface). The finger portions of the first power contact 324a and the second power contact 324b may be in the form of two fingers that are electrically connected (for example, via electrical lead wires) to the heater of the vaporizer 336 when the upstream end of the vaporizer 336 is placed in the corresponding socket defined by the module housing 354 of the connector module 320. When the face plate 366 is in place and engages with the module housing 354, the leg portions of the first power contact 324a and the second power contact 324b may bend towards the finger portions such that the leg portions are adjacent to or against the upstream surface of the face plate 366 (for example, the lower side of the face plate 366 based on the figure in FIG. 19). Thus, when assembled, the printed circuit board 362 can be regarded as being surrounded on at least four sides by the serpentine structure of the first power contact 324a and the second power contact 324b.

[0092] The draw resistance (RTD) of the nicotine vaping device 500 can be adjusted by changing the size of the module inlet (of the module housing 354), rather than changing the size of the pod inlet (of the second housing section 308). In an exemplary embodiment, the size of the module inlet can be selected to be between 25 and 100 millimeters of water column (e.g., between 30 and 50 millimeters of water column). For example, a 1.0 mm diameter of the module inlet can result in a draw resistance of 88.3 millimeters of water column. In another example, a 1.1 mm diameter of the module inlet can result in a draw resistance of 73.6 millimeters of water column. In another example, a 1.2 mm diameter of the module inlet can result in a draw resistance of 58.7 millimeters of water column. In yet another example, a 1.3 mm diameter of the module inlet can result in a draw resistance of about 40 - 43 millimeters of water column.

[0093] In an exemplary embodiment, the pod inlet of the second housing section 308 is larger than the module inlet of the module housing 354. In such examples, the module inlet within the module housing 354 can be a limiting factor for the flow of air into the nicotine pod assembly 300. As a result, the size of the module inlet can be adjusted for its internal arrangement without affecting the external aesthetics of the nicotine pod assembly 300, thereby enabling a more standardized product design for nicotine pod assemblies with various draw resistances (RTD), and at the same time, reducing the possibility of accidental blockage of the incoming air.

[0094] Although numerous exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not considered to depart from the spirit and scope of the present disclosure, and all such modifications that would be apparent to one of ordinary skill in the art are intended to be included within the scope of the following claims.

Claims

1. A nicotine pod assembly configured to hold a nicotine pre-vaporizer formulation, the nicotine pod assembly having an upstream end and a downstream end, the upstream end defining at least one upstream recess, and the downstream end defining at least one downstream recess, a nicotine pod assembly; An apparatus body defining a through-hole configured to receive the nicotine pod assembly, the through-hole including an upstream sidewall and a downstream sidewall, at least one of the upstream sidewall or the downstream sidewall being configured to flex during insertion of the nicotine pod assembly, the upstream sidewall including at least one upstream protrusion, the downstream sidewall including at least one downstream protrusion, the at least one upstream protrusion and the at least one downstream protrusion being configured to engage with the at least one upstream recess and the at least one downstream recess, respectively, to hold the nicotine pod assembly within the through-hole of the apparatus body, an apparatus body; comprising a nicotine e-vaping device.

2. The nicotine e-vaping device according to claim 1, wherein the upstream sidewall and the downstream sidewall of the apparatus body are configured to bend away from each other during the insertion of the nicotine pod assembly.

3. The nicotine e-vaping device according to claim 1 or 2, wherein the upstream sidewall and the downstream sidewall of the apparatus body are elastic sections configured to transition from an unloaded state to a loaded state when the nicotine pod assembly is received by the apparatus body.

4. The nicotine e-vaping device according to claim 3, wherein the at least one upstream protrusion is biased by the upstream sidewall of the apparatus body to interact with the at least one upstream recess of the nicotine pod assembly during the loaded state.

5. The nicotine e-vaping device according to claim 3 or 4, wherein the at least one downstream protrusion is biased by the downstream sidewall of the apparatus body to interact with the at least one downstream recess of the nicotine pod assembly during the loaded state.

6. The nicotine e-vaping device according to any one of claims 1 to 5, wherein the apparatus body includes a bezel structure defining the through-hole.

7. The nicotine e-vaping device according to claim 6, wherein the bezel structure is a monolithic article.

8. The nicotine e-vaping device according to claim 6 or 7, wherein the bezel structure includes a first upstream corner defining a first upstream slit, a second upstream corner defining a second upstream slit, a first downstream corner defining a first downstream slit, and a second downstream corner defining a second downstream slit.

9. The nicotine e-vaping device according to claim 8, wherein the upstream sidewall is between the first upstream slit and the second upstream slit, and the downstream sidewall is between the first downstream slit and the second downstream slit.

10. The nicotine e-vaping device according to claim 8 or 9, wherein the bezel structure has a length, a width, and a depth, and the width is greater than the depth.

11. The nicotine e-vaping device according to claim 10, wherein each of the first upstream slit, the second upstream slit, the first downstream slit, and the second downstream slit has a longest dimension that is at least 30 percent of the depth of the bezel structure.

12. The nicotine e-vaping device according to any one of claims 6 to 11, wherein the device body further includes a mouthpiece fixed to the bezel structure.

13. The nicotine e-vaping device according to claim 12, wherein the mouthpiece includes a male portion, the bezel structure includes a female portion, and the male portion of the mouthpiece and the female portion of the bezel structure are configured to fit as a bayonet connection.

14. The nicotine e-vaping device according to any one of claims 1 to 13, wherein the at least one upstream recess and the at least one downstream recess of the nicotine pod assembly are in the form of dimples.

15. The nicotine e-vaping device according to any one of claims 1 to 14, wherein the at least one upstream recess of the nicotine pod assembly includes two upstream recesses, and the at least one downstream recess of the nicotine pod assembly includes two downstream recesses.

16. The nicotine e-vaping device according to any one of claims 1 to 15, wherein the at least one upstream protrusion and the at least one downstream protrusion of the device body are in the form of spherical caps.

17. The nicotine e-vaping device according to any one of claims 1 to 16, wherein the at least one upstream protrusion of the device body includes two upstream protrusions, and the at least one downstream protrusion of the device body includes two downstream protrusions.

18. The nicotine e-vaping device according to any one of claims 1 to 17, wherein the device body is configured to generate at least one of an audible click or a tactile feedback in response to the nicotine pod assembly being placed within the through-hole of the device body.

19. A device housing defining a through-hole configured to receive a nicotine pod assembly, the through-hole including an upstream sidewall and a downstream sidewall, at least one of the upstream sidewall or the downstream sidewall being configured to flex during insertion of the nicotine pod assembly, the upstream sidewall including at least one upstream protrusion, the downstream sidewall including at least one downstream protrusion, the at least one upstream protrusion and the at least one downstream protrusion being configured to engage with at least one upstream recess and at least one downstream recess of the nicotine pod assembly, respectively, to hold the nicotine pod assembly within the through-hole. The device body for a nicotine e-vaping device comprises the device housing.

20. A pod body configured to hold a nicotine pre-vapor formulation, the pod body having a front surface, a rear surface, a first side surface, a second side surface, an upstream end, and a downstream end, the upstream end including at least one electrical contact and defining at least one upstream recess, the downstream end defining a pod outlet and at least one downstream recess. The nicotine pod assembly for a nicotine e-vaping device comprises the pod body.

21. The nicotine pod assembly according to claim 20, wherein the at least one upstream recess includes two upstream recesses, the at least one electrical contact is between the two upstream recesses, the at least one downstream recess includes two downstream recesses, and the pod outlet is between the two downstream recesses.

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