Nicotine pod assemblies and nicotine e-vaping devices

Abstract

To provide nicotine pod assemblies and nicotine e-vaping devices.SOLUTION: A nicotine pod assembly for a nicotine e-vaping device may include a first section and a second section connected to the first section. The first section may define a pod outlet and be configured to hold a nicotine pre-vapor formulation. The second section may define a pod inlet and be configured to heat the nicotine pre-vapor formulation. The pod inlet is in fluidic communication with the pod outlet via a flow path. The flow path may include a first diverged portion, a second diverged portion, and a converged portion. A nicotine e-vaping device may include a device body defining a through hole configured to receive the nicotine pod assembly such that a pod inlet for the air flow is exposed when the nicotine pod assembly is seated within the through hole.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present disclosure relates to nicotine electronic vaping (e-vaping) devices. [Background technology]

[0002] Some nicotine e-vapor devices include a first section connected to a second section. The first section may include a wick and a heater. The wick is configured to transfer the nicotine pre-vapor formulation via capillary action and is positioned to extend into the reservoir and the vapor passage. The heater is in thermal contact with the wick and configured to vaporize the nicotine pre-vapor formulation drawn into the vapor passage through the wick. The second section includes a power source configured to provide current to the heater during vaping. Initiation of operation of the nicotine e-vapor device may be achieved manually and / or through puff activation. Summary of the Invention

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

[0004] In an exemplary embodiment, the nicotine pod assembly may include a first section and a second section connected to the first section. The first section may define a pod outlet and be configured to hold a nicotine pre-vapor formulation. The second section may define a pod inlet and be configured to heat the nicotine pre-vapor formulation. The pod inlet is in fluid communication with the pod outlet via a flow path. The flow path may include a first branch portion, a second branch portion, and a confluence portion.

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

[0006] In an exemplary embodiment, the device body may include a device housing defining a throughbore configured to receive a nicotine pod assembly. The throughbore includes an upstream wall and a downstream wall. The upstream wall includes at least one upstream protrusion, and the downstream wall includes at least one downstream protrusion. The at least one downstream protrusion is retractable relative to an adjacent surface of the downstream wall and configured to engage with at least one downstream recess of the nicotine pod assembly to retain the nicotine pod assembly within the throughbore.

[0007] At least one embodiment relates to a nicotine e-vaping device.

[0008] In an exemplary embodiment, a nicotine e-vaping device may include a nicotine pod assembly and a device body configured to receive the nicotine pod assembly. The nicotine pod assembly may include a first section and a second section. The first section may be configured to hold a nicotine pre-vapor formulation. The second section may be configured to split and merge airflow entering the nicotine pod assembly before the airflow passes through the first section. The device body may define a through-hole configured to receive the nicotine pod assembly such that the pod inlet is exposed to the airflow when the nicotine pod assembly is placed within the through-hole.

[0009] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. The accompanying drawings are not intended to be drawn to scale unless expressly noted. Various dimensions of the drawings may be exaggerated for purposes of clarity. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a front view of a nicotine e-vaping device according to an exemplary embodiment. [Figure 2] FIG. 2 is a side view of the nicotine e-vaping device of FIG. [Figure 3] FIG. 3 is a rear view of the nicotine e-vaping device of FIG. [Figure 4] FIG. 4 is a proximal end view of the nicotine e-vaping device of FIG. [Figure 5] FIG. 5 is a distal end view of the nicotine e-vaping device of FIG. [Figure 6] FIG. 6 is a perspective view of the nicotine e-vaping device of FIG. [Figure 7] FIG. 7 is an enlarged view of the pod entrance of FIG. [Figure 8] FIG. 8 is a cross-sectional view of the nicotine e-vaping device of FIG. [Figure 9] FIG. 9 is a perspective view of the device body of the nicotine e-vaping device of FIG. [Figure 10] FIG. 10 is a front view of the device main body of FIG. [Figure 11] FIG. 11 is an enlarged perspective view of the through hole of FIG. [Figure 12] FIG. 12 is an enlarged perspective view of the electrical contacts of the device of FIG. [Figure 13] FIG. 13 is a partial exploded view of the mouthpiece of FIG. [Figure 14] FIG. 14 is a partial exploded view of the bezel structure of FIG. [Figure 15] 15 is an enlarged perspective view of the mouthpiece, spring, retaining structure, and bezel structure of FIG. 14. FIG. [Figure 16] FIG. 16 is a partial exploded view of the front cover, frame, and rear cover of FIG. [Figure 17] 17 is a perspective view of a nicotine pod assembly of the nicotine e-vaping device of FIG. 6. FIG. [Figure 18] 18 is another perspective view of the nicotine pod assembly of FIG. 17. FIG. [Figure 19] 19 is another perspective view of the nicotine pod assembly of FIG. 18. FIG. [Figure 20]FIG. 20 is a partially exploded view of the nicotine pod assembly of FIG. [Figure 21] 21 is a perspective view of the connector module of FIG. 20. FIG. [Figure 22] 22 is another perspective view of the connector module of FIG. 21. FIG. [Figure 23] FIG. 23 is an exploded view of the wick and heater of FIG. [Figure 24] 24 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 17. FIG. [Figure 25] 25 is a partially exploded view of the second housing section of the nicotine pod assembly of FIG. 17. FIG. [Figure 26] FIG. 26 is an exploded view of the upper hat holder of FIG. [Figure 27] FIG. 27 is an exploded view of the actuation pin of FIG. [Figure 28] FIG. 28 is a perspective view of the connector module of FIG. 22 without the wick and heater. [Figure 29] FIG. 29 is an exploded view of the connector module of FIG. [Figure 30] 30 is another exploded view of the connector module of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely exemplary for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments set forth herein.

[0012] Accordingly, while exemplary embodiments are susceptible to various modifications and alternative forms, such exemplary embodiments have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed; 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] It should be understood that when an element or layer is referred to as "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, this means that it is directly on, directly connected to, directly coupled to, directly attached to, directly adjacent to, or directly covering the other element or layer, or that intervening elements or layers may be present. In contrast, when an element is referred to as "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term "and / or" includes any or all combinations or subcombinations of one or more of the associated listed items.

[0014] It should be understood that terms such as first, second, third, etc. may be used herein to describe various elements, regions, layers, and / or sections, and that these elements, regions, layers, and / or sections should not be limited by these terms. These terms are used only 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 also be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

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

[0016] The terminology used herein is for the purpose of describing various exemplary embodiments only and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that as used herein, the terms "includes," "including," "comprises," and / or "comprising" specify the presence of stated features, integers, steps, operations, and / or elements, but 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 describing exemplary embodiments, it is understood that there may be some degree of imprecision. Thus, when one element or value is referred to as being the same as another element or value, it is understood that the element or value is the same as the other element or value within manufacturing or operating tolerances (e.g., ±10 percent).

[0018] The terms "about" or "substantially" are used herein in connection with numerical values, and it is understood that the accompanying numerical values include manufacturing or operating tolerances (e.g., ±10 percent) around the stated numerical value. Furthermore, when the words "generally" and "substantially" are used in connection with a geometric shape, it is understood that exactness of the geometric shape is not required, but a tolerance of the shape is within the scope of the present disclosure.

[0019] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments belong. It will be further understood that terms (including commonly used dictionary-defined terms) should be interpreted to have a meaning consistent with the meaning of those terms in the context of the relevant art, and not to be interpreted in an idealized or overly formal sense, except as expressly defined herein.

[0020] The 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 systems on a chip (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs), or any other device capable of responding to and executing instructions in a defined manner.

[0021] FIG. 1 is a front view of a nicotine e-vapor device according to an exemplary embodiment. FIG. 2 is a side view of the nicotine e-vapor device of FIG. 1. FIG. 3 is a rear view of the nicotine e-vapor device of FIG. 1. Referring to FIGS. 1-3, a nicotine e-vapor 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, nicotine pre-vapor formulations may include liquid, solid, and / or gel formulations. These may include, for example, but are not limited to, water, oil, emulsion, beads, solvent, active ingredient, ethanol, botanical extract, 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-vapor 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 devices, claimed devices, and / or equivalents thereof, which substances contain nicotine. The nicotine e-vapor device 500 may be considered an electronic nicotine delivery system (ENDS).

[0022] As shown in Figures 1 and 3, the nicotine e-vaporizing device 500 extends longitudinally and has a length that is greater than its width. Furthermore, as shown in Figure 2, the length of the nicotine e-vaporizing device 500 is also greater than its thickness. Furthermore, the width of the nicotine e-vaporizing device 500 may be greater than its thickness. Assuming an x-y-z Cartesian coordinate system, the length of the nicotine e-vaporizing 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. Based on its front, side, and rear views, the nicotine e-vaporizing device 500 may have a substantially linear configuration with tapered ends, although 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 circuitry related to the operation of the nicotine e-vaporizing device 500. For example, the device housing of the device body 100 may enclose a power source configured to power the nicotine e-vaporizing device 500, which may include providing current to the nicotine pod assembly 300. Furthermore, when assembled, the front cover 104, the frame 106, and the rear cover 108 may constitute the majority of the visible portion of the device body 100. The device housing may be considered to include all components of the device body 100, except for the mouthpiece 102. Stated another way, 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, although 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 connection with FIG. 9 .

[0025] Front cover 104 also defines a secondary opening configured to accommodate a light guide arrangement. The secondary opening may resemble a slot (e.g., a segmented slot), although 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 lens 116. Front cover 104 further defines a tertiary opening and a quaternary opening configured to accommodate first button 118 and second button 120. Each of the tertiary opening and the quaternary opening may resemble a rounded rectangle, although other shapes are possible depending on the shape of the buttons. First button housing 122 is configured to expose first button lens 124, and second button housing 123 is configured to expose second button lens 126.

[0026] Operation of the nicotine e-vaping device 500 may be controlled by a first button 118 and a second button 120. For example, the first button 118 may be a power button and the second button 120 may be an intensity button. Although two buttons are illustrated in the drawings, it will be appreciated that more (or fewer) buttons may be provided depending on the available features and desired user interface.

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

[0028] With regard to materials of construction, the frame 106 may 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. Additionally, 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 hard enamel or painted. In another embodiment, the frame 106 (e.g., when formed of a polycarbonate) may be metallized. In yet another embodiment, the frame 106 (e.g., when formed of an acrylonitrile butadiene styrene) may be electroplated. Of course, the materials of construction for the frame 106 may also apply to the front cover 104, the rear cover 108, and / or other suitable parts of the nicotine e-vaping device 500.

[0029] The rear cover 108 (e.g., the second cover) also defines an opening configured to accommodate the bezel structure 112. The opening may have a rounded rectangular shape, although other shapes are possible depending on the shape of the bezel structure 112. In the exemplary embodiment, the opening in the rear cover 108 is smaller than the primary opening in the front cover 104. Additionally, although not shown, it will be appreciated that a light guide arrangement and / or buttons may be provided on the rear of the nicotine e-vaping device 500 in addition to (or instead of) the light guide arrangement and buttons 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 interlock with corresponding mating members on the frame 106. In a non-limiting embodiment, the clips may be in the form of tabs having orifices configured to receive corresponding mating members on the frame 106 (e.g., protrusions with beveled edges). Alternatively, the front cover 104 and / or the rear cover 108 may be configured to engage with the frame 106 via an interference fit (which may also be referred to as a press fit or a friction fit). However, it will be appreciated that the front cover 104, the frame 106, and the rear cover 108 may be coupled via other suitable arrangements and techniques.

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

[0032] FIG. 4 is a proximal end view of the nicotine e-vaporizing device of FIG. 1. Referring to FIG. 4, the outlet surface of the mouthpiece 102 defines a plurality of vapor outlets. In a non-limiting embodiment, the outlet surface of the mouthpiece 102 may be elliptical. Further, the outlet surface of the mouthpiece 102 may include a first crossbar corresponding to the major axis of the elliptical outlet surface and a second crossbar corresponding to the minor axis of the elliptical outlet surface. Furthermore, the first crossbar and the second crossbar intersect at a right angle and may be an integrally formed part of the mouthpiece 102. While the outlet surface is shown as defining four vapor outlets, it should be understood that exemplary embodiments are not limited thereto. For example, the outlet surface may define fewer than four (e.g., one or two) vapor outlets or more than four (e.g., six or eight) vapor outlets.

[0033] FIG. 5 is a distal end view of the nicotine e-vaporizing device of FIG. 1. Referring to FIG. 5, the distal end of the nicotine e-vaporizing device 500 includes a port 110. The port 110 is configured to accept current from an external power source (e.g., via a USB / mini-USB cable) to charge an internal power source within the nicotine e-vaporizing device 500. Additionally, the port 110 may also be configured to transmit and / or receive data (e.g., via a USB / mini-USB cable) to and from another nicotine e-vaporizing device or other electronic device (e.g., a phone, tablet, computer). Furthermore, the nicotine e-vaporizing 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 an example, an adult e-vaporizing device user may control or otherwise interface with the nicotine e-vaporizing device 500 (e.g., locating the nicotine e-vaporizing device, checking usage information, changing operating parameters) through the app.

[0034] FIG. 6 is a perspective view of the nicotine e-vaporizing device of FIG. 1. FIG. 7 is an enlarged view of the pod inlet of FIG. 6. Referring to FIGS. 6-7, and as briefly mentioned above, the nicotine e-vaporizing 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 light guide arrangement) and a downstream end (facing the mouthpiece 102). In a non-limiting embodiment, the upstream end is the surface opposite the downstream end of the nicotine pod assembly 300. The upstream end of the nicotine pod assembly 300 defines a pod inlet 322. The device body 100 defines a through-hole (e.g., through-hole 150 of FIG. 9) 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 and includes an upstream edge. As shown particularly in FIG. 7, the upstream edge of the bezel structure 112 is angled (e.g., inwardly recessed) to expose the pod entrance 322 when the nicotine pod assembly 300 is placed within the through-hole of the device body 100.

[0035] For example, rather than following the contours of the front cover 104 (so as to be relatively flush with the front surface of the nicotine pod assembly 300 and thus overshadow the pod inlet 322), the upstream edge of the bezel structure 112 is in the form of a scoop configured to direct ambient air into the pod inlet 322. This angled / scooped configuration (which may be curved, for example) may help reduce or prevent blockage of the air inlet (e.g., the pod inlet 322) of the nicotine e-vaping device 500. The depth of the scoop may be such that less than half (e.g., less than a quarter) of the upstream end face of the nicotine pod assembly 300 is exposed. Furthermore, in a non-limiting embodiment, the pod inlet 322 is in the form of a slot. Furthermore, when the device body 100 is considered to extend in a first direction, the slot may be considered to extend in a second direction that is transverse to the first direction.

[0036] FIG. 8 is a cross-sectional view of the nicotine e-vapor device of FIG. 6. In FIG. 8, the cross-section is taken along the longitudinal axis of the nicotine e-vapor device 500. As shown, the device body 100 and the nicotine pod assembly 300 include mechanical components, electronic components, and / or circuitry associated with the operation of the nicotine e-vapor device 500, which are described in more detail herein and / or incorporated by reference herein. For example, the nicotine pod assembly 300 may include mechanical components configured to release a nicotine pre-vapor formulation from a reservoir sealed therein upon actuation. The nicotine pod assembly 300 may also have mechanical aspects configured to engage with the device body 100 to facilitate insertion and seating of the nicotine pod assembly 300.

[0037] Additionally, 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 unauthorized / counterfeit nicotine pod assemblies). Furthermore, the information may be used to identify the type of nicotine pod assembly 300, which is then 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 be subject to adjustment, refinement, or other adjustment by the adult e-vaping device user prior to and / or during vaping.

[0038] The nicotine pod assembly 300 may also communicate other information with the device body 100 that may be relevant to the operation of the nicotine e-vapor device 500. Examples of relevant information may include the level of nicotine pre-vapor formulation within the nicotine pod assembly 300 and / or the amount of time that has elapsed since the nicotine pod assembly 300 was inserted into the device body 100 and activated. For example, if the nicotine pod assembly 300 was inserted into the device body 100 and activated for more than a certain period of time (e.g., more than six months ago), the nicotine e-vapor device 500 may not allow vaping, and the adult e-vapor device user may be encouraged to replace the nicotine pod assembly 300 with a new nicotine pod assembly, even if the nicotine pod assembly 300 still contains an appropriate level of nicotine pre-vapor formulation.

[0039] The device body 100 may include mechanical components (e.g., complementary structures) configured to engage, retain, and / or activate the nicotine pod assembly 300. Additionally, the device body 100 may include electronic components and / or circuitry configured to receive electrical current to charge an internal power source (e.g., a battery), which in turn is configured to power the nicotine pod assembly 300 during vaping. Additionally, 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 communicated information may include pod-specific data, current vaping details, and / or past vaping patterns / history. The adult e-vaping device user may be notified of such communication using feedback that is tactile (e.g., vibration), auditory (e.g., beep), and / or visual (e.g., colored / flashing light). Charging and / or communication of information may be accomplished using port 110 (eg, via a USB / mini-USB cable).

[0040] FIG. 9 is a perspective view of the device body of the nicotine e-vaping device of FIG. 6. Referring to FIG. 9, the bezel structure 112 of the device body 100 defines a through-hole 150. The through-hole 150 is configured to receive the nicotine pod assembly 300. To facilitate insertion and seating of the nicotine pod assembly 300 into the through-hole 150, the upstream edge of the bezel structure 112 includes a first upstream protrusion 128a and a second upstream protrusion 128b. The through-hole 150 may have a rectangular shape with rounded corners. In the exemplary embodiment, the first upstream protrusion 128a and the second upstream protrusion 128b are integrally formed with the bezel structure 112 and are positioned at the two rounded corners of the upstream edge.

[0041] The downstream wall of the bezel structure 112 may define a first downstream opening, a second downstream opening, and a third downstream opening. The retention structure including the first downstream protrusion 130 a and the second downstream protrusion 130 b engages with the bezel structure 112 such that the first downstream protrusion 130 a and the second downstream protrusion 130 b protrude through the first downstream opening and the second downstream opening, respectively, of the bezel structure 112 and into the through-hole 150. Furthermore, the distal end of the mouthpiece 102 extends through the third downstream opening of the bezel structure 112 and into the through-hole 150 so as to be between the first downstream protrusion 130 a and the second downstream protrusion 130 b.

[0042] Figure 10 is a front view of the device body of Figure 9. Referring to Figure 10, the device body 100 includes a device electrical connector 132 disposed upstream of the through-hole 150. The device electrical connector 132 of the device body 100 is configured to electrically engage with the nicotine pod assembly 300 placed in 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. Furthermore, data can be transmitted and / or received between the device body 100 and the nicotine pod assembly 300 via the device electrical connector 132.

[0043] Figure 11 is an enlarged perspective view of the through-hole of Figure 10. Referring to Figure 11, the first upstream protrusion 128a, the second upstream protrusion 128b, the first downstream protrusion 130a, the second downstream protrusion 130b, and the distal end of the mouthpiece 102 protrude into the through-hole 150. In an exemplary embodiment, the first upstream protrusion 128a and the second upstream protrusion 128b are fixed structures (e.g., fixed pivots), and the first downstream protrusion 130a and the second downstream protrusion 130b are retractable structures (e.g., retractable members). For example, the first protrusion 130a and the second downstream protrusion 130b may be configured (e.g., spring-loaded) to be in an extended state by default, and may be configured to be temporarily retracted (and reversibly return to the extended state) to facilitate insertion of the nicotine pod assembly 300.

[0044] In particular, when the nicotine pod assembly 300 is inserted into the through-hole 150 of the device body 100, the recessed portions on the upstream end surface of the nicotine pod assembly 300 first engage with the first upstream protrusion 128 a and the second upstream protrusion 128 b, and then the nicotine pod assembly 300 is rotated (about the first upstream protrusion 128 a and the second upstream protrusion 128 b) until the recessed portions on the downstream end surface of the nicotine pod assembly 300 engage with the first downstream protrusion 130 a and the second downstream protrusion 130 b. In such an example, the axis of rotation of the nicotine pod assembly 300 (during rotation) may be perpendicular to the longitudinal axis of the device body 100. Furthermore, the first downstream protrusion 130a and the second downstream protrusion 130b, which may be retractably biased, may retract and elastically extend to engage with recesses in the downstream end surface of the nicotine pod assembly 300 when the nicotine pod assembly 300 is pivoted into the through-hole 150. Furthermore, the engagement of the first downstream protrusion 130a and the second downstream protrusion 130b with the recesses in the downstream end surface of the nicotine pod assembly 300 may generate tactile and / or auditory feedback (e.g., an audible click) to notify the adult e-vaping device user that the nicotine pod assembly 300 is properly placed in the through-hole 150 of the device body 100.

[0045] FIG. 12 is an enlarged perspective view of the device electrical contacts of FIG. 10 . The device electrical contacts of the device body 100 are configured to engage with the pod electrical contacts of the nicotine pod assembly 300 when the nicotine pod assembly 300 is placed in the through-hole 150 of the device body 100. Referring to FIG. 12 , the device electrical contacts of the device body 100 include a device electrical connector 132. 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 (positioned closer to the front cover 104 than to the rear cover 108). The first power contact (e.g., the power contact adjacent the first upstream protrusion 128a) may be a single, integral structure separate from the second power contact and includes a protrusion that extends into the through-hole 150 when assembled. Similarly, the second power contact (e.g., the power contact adjacent the second upstream protrusion 128b) may be a single, integral structure separate from the second power contact and include a protrusion that, when assembled, extends into the through-hole 150. The first and second power contacts of the device electrical connector 132 may be retractably mounted and biased to extend into the through-hole 150 by default and to retract (e.g., independently) from the through-hole 150 when subjected to an overcoming force.

[0046] 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 five rows of protrusions (positioned closer to the rear cover 108 than to the front cover 104). The data contacts of the device electrical connector 132 may be separate structures that extend into the through-holes 150 when assembled. The data contacts of the device electrical connector 132 may also be retractably mounted and biased (e.g., via a serpentine structure and / or with a spring) to extend into the through-holes 150 by default and to retract (e.g., independently) from the through-holes 150 when subjected to an overcoming force. 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 corresponding device electrical contacts of the device body 100. As a result, the power and data contacts of the device electrical connector 132 retract (e.g., at least partially retract) into the device body 100, but continue to press against the corresponding pod electrical contacts due to their resilient arrangement, thereby helping to ensure a proper electrical connection between the device body 100 and the nicotine pod assembly 300. Furthermore, such a connection may also be mechanically secure and have minimal contact resistance to allow power and / or signals between the device body 100 and the nicotine pod assembly 300 to be reliably and accurately transmitted and / or transferred. While various aspects have been described in connection with the device electrical contacts of the device body 100, it should be understood that example embodiments are not limited thereto and other configurations may be utilized.

[0047] FIG. 13 is a partially exploded view of the mouthpiece of FIG. 12. Referring to FIG. 13, mouthpiece 102 is configured to engage with the device housing via a retaining structure 140. In the exemplary embodiment, retaining structure 140 is located primarily between frame 106 and bezel structure 112. As shown, retaining structure 140 is positioned within the device housing such that the proximal end of retaining structure 140 extends through the proximal end of frame 106. Retaining structure 140 may extend slightly beyond or substantially evenly with the proximal end of frame 106. The proximal end of retaining structure 140 is configured to receive the distal end of mouthpiece 102. The proximal end of retaining structure 140 may be a female end, and the distal end of the mouthpiece may be a male end.

[0048] For example, the mouthpiece 102 may be coupled (e.g., reversibly coupled) to the retention structure 140 using a bayonet connection. In such an example, the female end of the retention structure 140 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 with the L-shaped slots of the retention structure 140. Each of the L-shaped slots of the retention structure 140 may have a longitudinal portion and a circumferential portion. Optionally, the ends of the circumferential portions may have serif portions that help reduce or prevent the likelihood of the radial members 134 of the mouthpiece 102 being inadvertently disengaged. In a non-limiting embodiment, the longitudinal portions of the L-shaped slots extend parallel to the longitudinal axis of the device body 100, and the circumferential portions of the L-shaped slots extend 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, the mouthpiece 102 shown in FIG. 13 is first rotated 90 degrees to align the radial member 134 with the entrance to the longitudinal portion of the L-shaped slot in the retaining structure 140. The mouthpiece 102 is then inserted into the retaining structure 140 such that the radial member 134 slides along the longitudinal portion of the L-shaped slot until it reaches a junction with each of the circumferential portions. At this point, the mouthpiece 102 is then rotated such that the radial member 134 moves across the circumferential portions until it reaches each end. If serif portions are present at each end, tactile and / or auditory feedback (e.g., an audible click) may be generated to notify the adult e-vaping device user that the mouthpiece 102 has been properly coupled to the device housing.

[0049] The mouthpiece 102 defines a vapor passageway 136 through which nicotine vapor flows during vaping. The vapor passageway 136 is in fluid communication with the through-hole 150 (where the nicotine pod assembly 300 is positioned within the device body 100). The proximal end of the vapor passageway 136 may include a flared portion. Additionally, 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 outlet surface of the end cover 138 defines a plurality of vapor outlets. While four vapor outlets are shown on the end cover 138, it should be understood that the illustrative embodiment is not so limited.

[0050] FIG. 14 is a partially exploded view of the bezel structure of FIG. 9. FIG. 15 is an enlarged perspective view of the mouthpiece, spring, retaining structure, and bezel structure of FIG. 14. Referring to FIGS. 14-15, bezel structure 112 includes an upstream wall and a downstream wall. The upstream wall of bezel structure 112 defines a connector opening 146. Connector opening 146 is configured to expose or receive device electrical connector 132 of device body 100. The downstream wall of bezel structure 112 defines a first downstream opening 148a, a second downstream opening 148b, and a third downstream opening 148c. First downstream opening 148a and second downstream opening 148b of bezel structure 112 are configured to receive first downstream protrusion 130a and second downstream protrusion 130b, respectively, of retaining structure 140. The third downstream opening 148c of the bezel structure 112 is configured to receive the distal end of the mouthpiece 102.

[0051] As shown in Figure 14, first downstream protrusion 130a and second downstream protrusion 130b are on the concave side of retention structure 140. As shown in Figure 15, first post 142a and second post 142b are on opposite convex sides of retention structure 140. First spring 144a and second spring 144b are disposed on first post 142a and second post 142b, respectively. First spring 144a and second spring 144b are configured to bias retention structure 140 against bezel structure 112.

[0052] When assembled, the bezel structure 112 may be secured to the frame 106 via a pair of posts adjacent to the connector opening 146 on the underside of the upstream edge of the bezel structure 112. Additionally, the retention structure 140 abuts the bezel structure 112 such that the first downstream protrusion 130a and the second downstream protrusion 130b extend through the first downstream opening 148a and the second downstream opening 148b, respectively. The mouthpiece 102 is coupled to the retention structure 140 such that the distal end of the mouthpiece 102 extends through the retention structure 140 and the third downstream opening 148c of the bezel structure 112. The first spring 144a and the second spring 144b are between the frame 106 and the retention structure 140.

[0053] When the nicotine pod assembly 300 is inserted into the through-hole 150 of the device body 100, the downstream end of the nicotine pod assembly 300 presses against the first downstream protrusion 130a and the second downstream protrusion 130b of the retaining structure 140. As a result, the first downstream protrusion 130a and the second downstream protrusion 130b of the retaining structure 140 elastically yield and retract from the through-hole 150 of the device body 100 (due to compression of the first spring 144a and the second spring 144b), thereby allowing for further insertion of the nicotine pod assembly 300. In an exemplary embodiment, when the first downstream protrusion 130a and the second downstream protrusion 130b are fully retracted from the through-hole 150 of the device body 100, displacement of the retaining structure 140 may cause the ends of the first post 142a and the second post 142b to contact the inner end surface of the frame 106. Furthermore, because mouthpiece 102 is coupled to retaining structure 140, the distal end of mouthpiece 102 retracts from through-hole 150, and therefore the proximal end of mouthpiece 102 (e.g., the visible portion including end cover 138) also shifts a corresponding distance away from the device housing.

[0054] When the nicotine pod assembly 300 is properly inserted such that the first and second downstream recesses of the nicotine pod assembly 300 reach a position that allows engagement with the first and second downstream protrusions 130a and 130b, respectively, the stored energy from the compression of the first and second springs 144a and 144b causes the first and second downstream protrusions 130a and 130b to elastically expand and engage with the first and second downstream recesses, respectively, of the nicotine pod assembly 300. Furthermore, the engagement may generate tactile and / or auditory feedback (e.g., an audible click) to notify the adult e-vaping device user that the nicotine pod assembly 300 is properly positioned within the through-hole 150 of the device body 100.

[0055] FIG. 16 is a partially exploded view of the front cover, frame, and rear cover of FIG. 14 . Referring to FIG. 16 , various mechanical components, electronic components, and / or circuitry associated with the operation of the nicotine e-vaping device 500 may be secured 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 interlock with corresponding mating members on the frame 106. The clips may be in the form of tabs having orifices configured to receive corresponding mating members (e.g., protrusions with beveled edges) on the frame 106. In FIG. 16 , the front cover 104 has two rows of four clips each (for a total of eight clips for the front cover 104). Similarly, the rear cover 108 has two rows of four clips each (for a total of eight clips for the rear cover 108). Corresponding mating members of the frame 106 may be on the inner sidewall of the frame 106. As a result, the engaged clips and mating members may be hidden from view when the front cover 104 and rear cover 108 are snapped together. Alternatively, the front cover 104 and / or rear cover 108 may be configured to engage with the frame 106 via an interference fit. However, it should be appreciated that the front cover 104, frame 106, and rear cover 108 may be coupled via other suitable arrangements and techniques.

[0056] FIG. 17 is a perspective view of the nicotine pod assembly of the nicotine e-vaporizing device of FIG. 6. FIG. 18 is another perspective view of the nicotine pod assembly of FIG. 17. FIG. 19 is another perspective view of the nicotine pod assembly of FIG. 18. Referring to FIGS. 17-19, a nicotine pod assembly 300 for a nicotine e-vaporizing device 500 includes a pod body configured to hold a nicotine pre-vapor formulation. The pod body has an upstream end and a downstream end. The upstream end of the pod body defines a pod inlet 322. The downstream end of the pod body defines a pod outlet 304 in fluid communication with the pod inlet 322 at the upstream end. During vaping, air enters the nicotine pod assembly 300 through the pod inlet 322, and nicotine vapor exits the nicotine pod assembly 300 through the pod outlet 304. The pod inlet 322 is shown in the drawings as being in the form of a slot. However, it should be understood that the exemplary embodiment is not so limited and other configurations are possible.

[0057] The nicotine pod assembly 300 includes a connector module 320 (e.g., FIG. 21 ) disposed within the pod body and exposed by an opening at the upstream end. The outer surface of the connector module 320 includes at least one electrical contact. The at least one electrical contact may include multiple power contacts. For example, the multiple power contacts may include a first power contact 324 a and a second power contact 324 b. The first power contact 324 a of the nicotine pod assembly 300 is configured to electrically connect with a first power contact of the device electrical connector 132 of the device body 100 (e.g., the power contact adjacent to the first upstream protrusion 128 a in FIG. 12 ). Similarly, the second power contact 324 b of the nicotine pod assembly 300 is configured to electrically connect with a second power contact of the device electrical connector 132 of the device body 100 (e.g., the power contact adjacent to the second upstream protrusion 128 b in FIG. 12 ). Additionally, the 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 electrically connect with the data contacts (e.g., the five rows of protrusions in FIG. 12 ) of the device electrical connector 132. While two power contacts and five data contacts are shown in connection with the nicotine pod assembly 300, it should be understood that other variations are possible depending on the design of the device body 100.

[0058] In the exemplary embodiment, the nicotine pod assembly 300 includes a front surface, a rear surface opposite the front surface, a first side surface between the front surface and the rear surface, a second side surface opposite the first side surface, an upstream end surface, and a downstream end surface opposite the upstream end surface. Corners of the side surfaces and end surfaces (e.g., corners of the first side surface and the upstream end surface, corners of the upstream end surface and the second side surface, corners of the second side surface and the downstream end surface, and corners of the downstream end surface and the first side surface) may be rounded. However, in some examples, the corners may be angled. Furthermore, the peripheral edge of the front surface may be in the form of a ledge. The outer surface of the connector module 320 (exposed by the pod body) may be considered to be part of the upstream end surface of the nicotine pod assembly 300. The front surface of the nicotine pod assembly 300 may be wider and longer than the rear surface. In such examples, the first side surface and the second side surface may be angled inward toward each other. The upstream end surface and the downstream end surface may also be angled inward toward each other. Due to the angled surface, 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 improper insertion of the nicotine pod assembly 300 into the device body 100 can be reduced or prevented.

[0059] As shown, the pod body of the nicotine pod assembly 300 includes 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 lip of the pod outlet 304 may optionally be a recessed or sunken region. In such an example, this region may resemble a cove, and the side of the lip adjacent to the rear surface of the nicotine pod assembly 300 may be open, while the side of the lip adjacent to the front surface may be surrounded by a raised portion at the downstream end of the first housing section 302. The raised portion may function as a stopper for the distal end of the mouthpiece 102. As a result, this configuration of the pod outlet 304 may facilitate receiving and aligning the distal end of the mouthpiece 102 (e.g., FIG. 11 ) via seating against the open side of the lip and the subsequent raised portion at the downstream end of the first housing section 302. In a non-limiting embodiment, the distal end of the mouthpiece 102 may also include (or be formed of) a resilient material that helps create a seal around the pod outlet 304 when the nicotine pod assembly 300 is properly inserted into the through-hole 150 of the device body 100.

[0060] The downstream end of the first housing section 302 additionally defines at least one downstream recess. In the 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 located 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 the first downstream protrusion 130a and the second downstream protrusion 130b, respectively, of the device body 100. As shown in FIG. 11 , the first downstream protrusion 130a and the second downstream protrusion 130b of the device body 100 may be disposed at adjacent corners of the downstream wall of the through-hole 150. The first downstream recess 306a and the second downstream recess 306b may each be in the form of a V-shaped notch. 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 wedge-shaped structure configured to engage with a corresponding V-shaped notch of the first downstream recess 306a and the second downstream recess 306b. The first downstream recess 306a may abut a corner of the downstream end face and the first side face, and the second downstream recess 306b may abut a corner of the downstream end face and the second side face. As a result, the edges of the first downstream recess 306a and the second downstream recess 306b adjacent to the first side face and the second side face, respectively, may be open. In such an example, as shown in FIG. 18 , each of the first downstream recess 306a and the second downstream recess 306b may be a three-sided recess.

[0061] The second housing section 308 has an upstream end that further defines (in addition to the pod entrance 322) a plurality of openings (e.g., a first power contact opening 325a, a second power contact opening 325b, and a data contact opening 327) configured to expose the connector module 320 (FIGS. 20-21) within the nicotine pod assembly 300. The upstream end of the second housing section 308 also defines at least one upstream recess. In the 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 pod entrance 322 may be located 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 the first upstream protrusion 128a and the second upstream protrusion 128b, respectively, of the device body 100. 12 , the first upstream protrusion 128a and the second upstream protrusion 128b of the device body 100 may be disposed at adjacent corners of the upstream wall of the through-hole 150. The depth of each of the first upstream recess 312a and the second upstream recess 312b may be greater than the depth of each of the first downstream recess 306a and the second downstream recess 306b. The ends of each of the first upstream recess 312a and the second upstream recess 312b may also be more rounded than the ends of each of the first downstream recess 306a and the second downstream recess 306b. For example, the first upstream recess 312a and the second upstream recess 312b may each be in the form of a U-shaped depression. 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 knob configured to engage with a corresponding U-shaped recess of the first upstream recess 312a and the second upstream recess 312b. The first upstream recess 312a may abut a corner of the upstream end face and a first side surface, and the second upstream recess 312b may abut a corner of the upstream end face and a second side surface. As a result, the edges of the first upstream recess 312a and the second upstream recess 312b adjacent to the first side surface and the second side surface, respectively, may be open.

[0062] The first housing section 302 may define a reservoir configured to hold a nicotine pre-vapor formulation. The reservoir may be configured to seal the nicotine pre-vapor formulation until activation of the nicotine pod assembly 300 to release the nicotine pre-vapor formulation from the reservoir. As a result of the airtight seal, the nicotine pre-vapor formulation is isolated 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 potential 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 structure configured to activate the nicotine pod assembly 300 and to receive and heat the nicotine pre-vapor formulation released from the reservoir after activation.

[0063] The nicotine pod assembly 300 may be manually activated by an adult e-vaping device user prior to inserting the nicotine pod assembly 300 into the device body 100. Alternatively, the nicotine pod assembly 300 may be activated as part of inserting 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 a reservoir within the first housing section 302 during activation of the nicotine pod assembly 300. The perforators may be in the form of a first activation pin 314 a and a second activation pin 314 b, which are described in more detail herein.

[0064] To manually activate the nicotine pod assembly 300, an adult e-vaping device user may first push the first activation pin 314a and the second activation pin 314b inward (e.g., simultaneously or sequentially) before inserting the nicotine pod assembly 300 into the through-hole 150 of 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 even with the upstream end surface 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 pierces or otherwise compromises the seal of the reservoir so as to release the nicotine pre-vapor formulation therefrom.

[0065] Alternatively, 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 is first positioned such that the first and second upstream recesses 312a, 312b engage with the first and second upstream protrusions 128a, 128b, respectively (e.g., upstream engagement). Each of the first and second upstream protrusions 128a, 128b of the device body 100 may be in the form of a rounded knob configured to engage with a corresponding U-shaped recess of the first and second upstream recesses 312a, 312b, so that the nicotine pod assembly 300 can then be relatively easily pivoted about the first and second upstream protrusions 128a, 128b into the through-hole 150 of the device body 100.

[0066] With respect to the pivoting of the nicotine pod assembly 300, the axis of rotation can be considered to extend through the first upstream protrusion 128a and the second upstream protrusion 128b and be oriented perpendicular to the longitudinal axis of the device body 100. During initial positioning and subsequent pivoting of the nicotine pod assembly 300, the first actuation pin 314a and the second actuation pin 314b contact the upstream wall of the through-hole 150 and transition from an extended state to a retracted state as the first actuation pin 314a and the second actuation pin 314b are pushed into the second housing section 308 (e.g., simultaneously) as the nicotine pod assembly 300 advances into the through-hole 150. When the downstream end of the nicotine pod assembly 300 reaches near the downstream wall of the through hole 150 and comes into contact with the first downstream protrusion 130a and the second downstream protrusion 130b, the first downstream protrusion 130a and the second downstream protrusion 130b retract and then elastically extend (e.g., downstream engagement) when the positioning of the nicotine pod assembly 300 allows the first downstream protrusion 130a and the second downstream protrusion 130b of the device body 100 to engage with the first downstream recess 306a and the second downstream recess 306b of the nicotine pod assembly 300, respectively.

[0067] As described above, according to the exemplary embodiment, the mouthpiece 102 is secured to the retention structure 140 (of which the first downstream protrusion 130a and the second downstream protrusion 130b are a part). In such an example, retraction of the first downstream protrusion 130a and the second downstream protrusion 130b from the through-hole 150 causes a simultaneous shift of the mouthpiece 102 a corresponding distance in the same direction (e.g., the downstream direction). Conversely, when the nicotine pod assembly 300 is fully inserted to facilitate downstream engagement, the mouthpiece 102 springs back simultaneously with the first downstream protrusion 130a and the second downstream protrusion 130b. In addition to the elastic engagement by the first downstream protrusion 130a and the second downstream protrusion 130b, the distal end of the mouthpiece 102 is also configured to be biased against the nicotine pod assembly 300 (and aligned with the pod outlet 304 to form a relatively vapor-tight seal) when the nicotine pod assembly 300 is properly placed within the through-hole 150 of the device body 100.

[0068] Additionally, the downstream engagement may produce an audible click and / or tactile feedback indicating that the nicotine pod assembly 300 is properly seated within the through-hole 150 of the device body 100. Once properly seated, the nicotine pod assembly 300 is mechanically, electrically, and fluidly connected to the device body 100. While the non-limiting embodiments herein describe upstream engagement of the nicotine pod assembly 300 occurring before downstream engagement, it should be appreciated that the associated mating, activation, and / or electrical arrangements may be reversed such that downstream engagement occurs before upstream engagement.

[0069] FIG. 20 is a partially exploded view of the nicotine pod assembly of FIG. 19. Referring to FIG. 20, the first housing section 302 includes a vapor channel 316. The vapor channel 316 is configured to receive nicotine vapor generated during vaping 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. Furthermore, the vapor channel 316 may be integrally formed with the first housing section 302. An insert 342 and a seal 344 are disposed at the upstream end of the first housing section 302 to define a reservoir of the nicotine pod assembly 300. For example, the insert 342 may be positioned within the first housing section 302 such that the peripheral surface of the insert 342 engages (e.g., via an interference fit) with the inner surface of the first housing section 302 along a lip such that the interface between the peripheral surface of the insert 342 and the inner surface of the first housing section 302 is fluid-tight (e.g., liquid-tight and / or air-tight). Additionally, a seal 344 may be attached to the upstream side of the insert 342 to seal the reservoir outlet of the insert 342, providing fluid-tight (e.g., liquid-tight and / or air-tight) containment of the nicotine pre-vapor formulation within the reservoir. The insert 342 and seal 344 are also illustrated, for example, in FIG. 24 and described in more detail herein.

[0070] The upstream end of the second housing section 308 defines a pod inlet 322, a first power contact opening 325a, a second power contact opening 325b, a data contact opening 327, a first upstream recess 312a, a second upstream recess 312b, a first pin opening 315a, and a second pin opening 315b. As described above, the pod inlet 322 allows air to enter the nicotine pod assembly 300 during vaping, and the first power contact opening 325a, the second power contact opening 325b, and the data contact opening 327 are configured to expose the first power contact 324a, the second power contact 324b, and the data contact 326, respectively, of the connector module 320. In the exemplary embodiment, the first power contact 324a and the second power contact 324b are mounted on a module housing 354 of the connector module 320. Further, the data contacts 326 may be disposed on a printed circuit board (PCB) 362. Further, the pod entrance 322 may be located between the first upstream recess 312a and the second upstream recess 312b, and the contact openings (e.g., the first power contact opening 325a, the second power contact opening 325b, the data contact opening 327) may be located between the first pin opening 315a and the second pin opening 315b. The first pin opening 315a and the second pin opening 315b are configured to accommodate the first activation pin 314a and the second activation pin 314b extending therethrough, respectively.

[0071] FIG. 21 is a perspective view of the connector module of FIG. 20. FIG. 22 is another perspective view of the connector module of FIG. 21. Referring to FIGS. 21-22, the general framework of the connector module 320 includes a module housing 354. Additionally, the connector module 320 has multiple surfaces, including an exterior surface and side surfaces adjacent the exterior surface. In the exemplary embodiment, the exterior surface of the connector module 320 is made up of the upstream surface of the module housing 354, the first power contact 324a, the second power contact 324b, the data contact 326, and a printed circuit board (PCB) 362. The side surfaces of the connector module 320 are integral parts of the module housing 354 and may be substantially perpendicular to the exterior surface.

[0072] The nicotine pod assembly 300 defines a flow path therein from the pod inlet 322 to the pod outlet 304. The flow path through the nicotine pod assembly 300 includes, among other things, a first branch portion, a second branch portion, and a confluence portion. The pod inlet 322 is upstream of the first branch portion and the second branch portion of the flow path. In particular, as shown in FIG. 21 , a side (e.g., an inlet side) of the module housing 354 (and connector module 320) above the first power contact 324a and the second power contact 324b is recessed to define a partition 329, along with initial segments of the first branch portion and the second branch portion of the flow path. In an exemplary embodiment in which the partition 329 is recessed from the outer surface of the module housing 354 (e.g., FIG. 21), the side of the module housing 354 above the first power contact 324a and the second power contact 324b can also be considered to define an inlet portion of the flow path downstream of the pod inlet 322 and upstream of the first and second branch portions of the flow path.

[0073] A pair of longer sides (e.g., vertical sides) of module housing 354 are also recessed to define subsequent segments of the first and second branched portions of the flow path. Herein, the pair of longer sides of module housing 354 may alternatively be referred to as lateral sides. The sector of module housing 354 (shown in FIG. 30 ) covered by printed circuit board (PCB) 362 of FIG. 21 defines, along with the converging portion of the flow path, further segments of the first and second branched portions. The further segments of the first and second branched portions include a first curved segment (e.g., first curved path 330 a) and a second curved segment (e.g., second curved path 330 b), respectively. As described in more detail herein, the first and second branched portions converge to form the converging portion of the flow path.

[0074] When the connector module 320 is placed within the receiving cavity downstream of the second housing section 308, the non-recessed side of the module housing 354 interfaces with the sidewall of the receiving cavity of the second housing section 308, and the recessed side of the module housing 354, together with the sidewall of the receiving cavity, define the first and second branch portions of the flow path. The seating of the connector module 320 within the receiving cavity of the second housing section 308 may be via a tight-fitting arrangement such that the connector module 320 remains essentially fixed within the nicotine pod assembly 300.

[0075] As shown in FIG. 22 , the connector module 320 includes a wick 338 configured to transfer the nicotine pre-vapor formulation to a heater 336. The heater 336 is configured to heat the nicotine pre-vapor formulation to generate a nicotine vapor during vaping. The heater 336 is electrically connected to at least one electrical contact of the connector module 320. For example, one end (e.g., a first end) of the heater 336 may be connected to the first power contact 324a, and the other end (e.g., a second end) of the heater 336 may be connected to the second power contact 324b. In an exemplary embodiment, the heater 336 includes a folded heating element. In such an example, the wick 338 may have a planar configuration configured to be held by the folded heating element. When the nicotine pod assembly 300 is assembled, the wick 338 is configured to be in fluid communication with the absorbent material 346 (e.g., FIG. 25) such that the nicotine pre-vapor formulation within the absorbent material 346 is transferred to the wick 338 via capillary action (when the nicotine pod assembly 300 is activated).

[0076] In the exemplary embodiment, the airflow entering the nicotine pod assembly 300 through the pod inlet 322 is directed by a partition 329 into a first branch portion and a second branch portion of the flow path. The partition 329 may be wedge-shaped and configured to split the incoming airflow in opposite directions (e.g., at least initially). The split airflow may include a first airflow (traveling through the first branch portion of the flow path) and a second airflow (traveling through the second branch portion of the flow path). After being split by the partition 329, the first airflow travels along the inlet side, around the corner, along the first lateral surface, and into a first curved path 330a. Similarly, the second airflow travels along the inlet side, around the corner, along the second lateral surface, and into a first curved path 330b (e.g., FIG. 30 ). The converging portions of the flow paths are downstream of the first branch portion and the second branch portion. The heater 336 and wick 338 are downstream of the converging portion of the flow paths. Thus, the first air stream joins with the second air stream at the converging portion of the flow paths (e.g., converging path 330c in FIG. 30) to form a combined flow before passing through module outlet 368 (e.g., as labeled in FIG. 28) of module housing 354 to the heater 336 and wick 338.

[0077] FIG. 23 is an exploded view of the wick and heater of FIG. 22. Referring to FIG. 23, the wick 338 may be a fibrous pad or other structure with pores / gaps designed for capillary action. Furthermore, the wick 338 may have a rectangular shape, although exemplary embodiments are not limited thereto. For example, the wick 338 may have an alternative shape of an irregular hexagon, with two of the sides angled inward toward the heater 336. The wick 338 may be fabricated into the desired shape or cut into such a shape from a larger sheet of material. If the lower section of the wick 338 tapers toward the wound section of the heater 336 (e.g., a hexagonal shape), the likelihood of the nicotine pre-vapor formulation becoming part of the wick 338 (due to its distance from the heater 336) and subsequently avoiding vaporization is reduced or avoided. Furthermore, as described above, the heater 336 may include a folded heating element configured to grip the wick 338. The folded heating element may also include at least one prong 337 configured to protrude into the core 338 .

[0078] In an exemplary embodiment, the heater 336 may be configured to undergo Joule heating (also known as ohmic / resistive heating) as an electric current is applied to it. More specifically, the heater 336 may be formed of one or more conductors (resistive materials) and configured to generate heat when an electric current is passed through it. The electric current may be supplied from a power source (e.g., a battery) within the device body 100 and delivered to the heater 336 via the first power contact 324 a or the second power contact 324 b.

[0079] Suitable conductors (resistive materials) for the heater 336 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). The heater 336 may be fabricated from a conductive sheet (e.g., metal, alloy) stamped to cut a winding pattern therefrom. The winding pattern may have curved segments alternating with horizontal segments such that the horizontal segments run parallel to one another while zigzagging back and forth. Furthermore, the width of each horizontal segment 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 the configuration of the heater 336 shown in the drawings, the winding pattern may be folded to grip the core 338. Furthermore, if prongs 337 are part of the heater 336, the protrusions corresponding to the prongs 337 are bent (e.g., inward and / or orthogonally) before the winding pattern is folded. As a result of the prongs 337, the possibility of the core 338 slipping out of the heater 336 is reduced or prevented. Heaters and related structures are described in more detail in U.S. Patent Application No. 15 / 729,909, filed October 11, 2017, entitled "Folded Heater For Electronic Vaping Device," which is incorporated herein by reference in its entirety.

[0080] FIG. 24 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 17. Referring to FIG. 24, the first housing section 302 includes a vapor channel 316. The vapor channel 316 is configured to receive nicotine vapor generated by the heater 336 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. Furthermore, the vapor channel 316 may be integrally formed with the first housing section 302. An insert 342 and a seal 344 are disposed at the upstream end of the first housing section 302 to define a reservoir of the nicotine pod assembly 300. For example, the insert 342 may be positioned within the first housing section 302 such that the peripheral surface of the insert 342 engages (e.g., via an interference fit) with the inner surface of the first housing section 302 along a lip such that the interface between the peripheral surface of the insert 342 and the inner surface of the first housing section 302 is fluid-tight (e.g., liquid-tight and / or air-tight). Additionally, the seal 344 may be attached to the upstream side of the insert 342 to seal the reservoir outlet of the insert 342, providing fluid-tight (e.g., liquid-tight and / or air-tight) containment of the nicotine pre-vapor formulation within the reservoir. Herein, the first housing section 302, the insert 342, and the seal 344 may be collectively referred to as a first section. As described in more detail herein, the first section is configured to seal the nicotine pre-vapor formulation until activation of the nicotine pod assembly 300.

[0081] In the exemplary embodiment, the insert 342 includes a holder portion (shown in FIG. 24 ) protruding from the upstream side and a connector portion (hidden in FIG. 24 ) protruding from the downstream side. The holder portion of the insert 342 is configured to hold an absorbent material 346 (e.g., FIG. 25 ), and the connector portion of the insert 342 is configured to engage with the vapor channel 316 of the first housing section 302. The connector portion of the insert 342 may be configured to be positioned within the vapor channel 316 and thus engage with the interior of the vapor channel 316. Alternatively, the connector portion of the insert 342 may be configured to receive the vapor channel 316 and thus engage with the exterior of the vapor channel 316. The insert 342 also defines a reservoir outlet through which the nicotine pre-vapor formulation flows when the seal 344 is pierced during activation of the nicotine pod assembly 300. The holder portion and connector portion of the insert 342 may be between the reservoir outlets (e.g., the first reservoir outlet and the second reservoir outlet), although example embodiments are not limited thereto. Additionally, the insert 342 defines a vapor conduit that extends through the holder portion and the connector portion. As a result, when the insert 342 is placed within the first housing section 302, the vapor conduit of the insert 342 is aligned with and in fluid communication with the vapor channel 316 such that a continuous pathway is formed through the reservoir and to the pod outlet 304 for nicotine vapor generated by the heater 336 during vaping.

[0082] The seal 344 is attached to the upstream side of the insert 342 so as to cover the reservoir outlet of the insert 342. In the exemplary embodiment, the seal 344 defines an opening (e.g., a central opening) configured to provide adequate clearance to accommodate the holder portion (protruding from the upstream side of the insert 342) when the seal 344 is attached to the insert 342. When the seal 344 is pierced by the first and second actuation pins 314a, 314b of the nicotine pod assembly 300, the two perforated sections of the seal 344 are pressed into the reservoir as flaps, thus creating two pierced openings in the seal 344 (e.g., one on each side of the central opening). The size and shape of the perforated openings in the seal 344 may correspond to the size and shape of the reservoir outlet of the insert 342. In contrast, when in an unpierced state as shown in FIG. 24 , the seal 344 has a planar configuration and only one opening (e.g., a central opening). The seal 344 is designed to be strong enough to remain intact to avoid premature / inadvertent tearing during normal movement and / or handling of the nicotine pod assembly 300. For example, the seal 344 may be a coated foil (e.g., aluminum-backed polyethylene terephthalate (PET)).

[0083] FIG. 25 is a partially exploded view of the second housing section of the nicotine pod assembly of FIG. 17. Referring to FIG. 25, the second housing section 308 is structured to contain various components configured to release, receive, and heat the nicotine pre-vapor formulation. For example, the first activation pin 314a and the second activation pin 314b are configured to pierce the reservoir of the first housing section 302 and release the nicotine pre-vapor formulation. The first activation pin 314a and the second activation pin 314b each have a distal end that extends through a corresponding one of the first pin opening 315a and the second pin opening 315b of the second housing section 308. In the exemplary embodiment, the distal end of the first activation pin 314a and the distal end of the second activation pin 314b are visible after assembly (e.g., FIG. 17), while the remainder of the first activation pin 314a and the second activation pin 314b are hidden from view within the nicotine pod assembly 300. Additionally, each of the first and second activation pins 314a, 314b has a proximal end positioned adjacent to and upstream of the seal 344 prior to activation of the nicotine pod assembly 300. When the first and second activation pins 314a, 314b are pressed into the second housing section 308 to activate the nicotine pod assembly 300, the proximal end of each of the first and second activation pins 314a, 314b advances through the insert 342, thereby piercing the seal 344 and releasing the nicotine pre-vapor formulation from the reservoir. The movement of the first activation pin 314a may be independent of the movement of the second activation pin 314b (or vice versa). The first and second activation pins 314a, 314b are described in more detail herein.

[0084] The absorbent material 346 may be placed in a holder (e.g., top hat holder 345). The absorbent material 346 is also downstream of and in fluid communication with the wick 338. Furthermore, as described above, the absorbent material 346 is configured to engage with the holder portion of the insert 342 (protruding from the upstream side of the insert 342, as shown in FIG. 24). The absorbent material 346 may have an annular shape, although exemplary embodiments are not limited thereto. As shown in FIG. 25, the absorbent material 346 may resemble a hollow cylindrical shape. In such an example, the outer diameter of the absorbent material 346 may be substantially equal to (or slightly greater than) the length of the wick 338. The inner diameter of the absorbent material 346 may be smaller than the average outer diameter of the holder portion of the insert 342 to provide an interference fit. The tip of the holder portion of the insert 342 may be tapered to facilitate engagement with the absorbent material 346. The absorbent material 346 is configured to receive and retain an amount of the nicotine pre-vapor formulation released from the reservoir when the nicotine pod assembly 300 is activated.

[0085] The wick 338 is positioned within the nicotine pod assembly 300 so as to be in fluid communication with the absorbent material 346 such that the nicotine pre-vapor formulation can be drawn from the absorbent material 346 to the heater 336 via capillary action. The wick 338 can be in physical contact with the upstream side of the absorbent material 346 (e.g., the bottom of the absorbent material 346 based on the illustration shown in FIG. 25 ). Additionally, the wick 338 can be aligned with the diameter of the absorbent material 346, although exemplary embodiments are not limited thereto.

[0086] As shown in FIG. 25 (as well as FIG. 23 above), the heater 336 may have a folded configuration to grip opposing surfaces of the wick 338 and establish thermal contact with the wick 338. The heater 336 is configured to heat the wick 338 to generate a nicotine vapor during vaping. To facilitate such heating, a first end of the heater 336 may be electrically connected to the first power contact 324a, and a second end of the heater 336 may be electrically connected to the second power contact 324b. As a result, electrical current may be supplied from a power source (e.g., a battery) within the device body 100 and conveyed to the heater 336 via the first power contact 324a or the second power contact 324b. Relevant details of other aspects of the connector module 320 already described above (e.g., in connection with FIGS. 21-22) will not be repeated in this section for the sake of brevity. In the exemplary embodiment, although hidden in FIG. 25, the second housing section 308 includes a receiving cavity for the connector module 320. The second housing section 308 and the above-described internal components may be collectively referred to as the second section. During vaping, nicotine vapor generated by the heater 336 is drawn through the vapor conduit of the insert 342, through the vapor channel 316 of the first housing section 302, out the pod outlet 304 of the nicotine pod assembly 300, and through the vapor passage 136 of the mouthpiece 102 to the vapor outlet.

[0087] FIG. 26 is an exploded view of the top hat holder of FIG. 25. Referring to FIG. 26, the top hat holder 345 includes a base portion 345a and a cylindrical portion 345b. In an exemplary embodiment, the base portion 345a and the cylindrical portion 345b are integrally formed. The cylindrical portion 345b defines a well configured to receive the absorbent material 346. Optionally, the inner lower surface of the well may include a ledge (or other protrusion) to support the absorbent material 346 so that the absorbent material 346 does not simply thread through or sag from the top hat holder 345 (e.g., when the absorbent material 346 becomes saturated with the nicotine pre-vapor formulation released from the reservoir). Additionally, the base portion 345a defines a groove configured to receive a gasket 345c. Additionally, a pair of integrally formed posts may extend from the base portion 345a and along the exterior of the cylindrical portion 345b so as to protrude beyond the edge of the cylindrical portion 345b. When the top hat holder 345 is assembled into the nicotine pod assembly 300, these pairs of integrally formed posts may abut the underside of the insert 342 with a portion of the seal 344 therebetween.

[0088] FIG. 27 is an exploded view of the actuation pin of FIG. 25. Referring to FIG. 27, the actuation pin may be in the form of a first actuation pin 314a and a second actuation pin 314b. While two actuation pins are shown and described in connection with the non-limiting embodiments herein, it will be appreciated that the nicotine pod assembly 300 may alternatively include only one actuation pin. In FIG. 27, the first actuation pin 314a may include a first blade 348a, a first actuator 350a, and a first O-ring 352a. Similarly, the second actuation pin 314b may include a second blade 348b, a second actuator 350b, and a second O-ring 352b.

[0089] In the exemplary embodiment, the first blade 348a and the second blade 348b are integrally formed with the first actuator 350a and the second actuator 350b, respectively. Alternatively, the first blade 348a and the second blade 348b may be configured to be mounted or attached to the upper portion (e.g., proximal portion) of the first actuator 350a and the second actuator 350b, respectively. The mounting or attachment may be achieved via a snap-fit connection, an interference fit (e.g., a friction fit) connection, adhesive, or other suitable connecting technique. The upper portion of each of the first blade 348a and the second blade 348b may have one or more curved or concave edges tapering upward to 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 a curved edge adjacent each pointed tip. The radii of curvature of the concave and curved edges may be the same, and their arc lengths may be different. First blade 348a and second blade 348b may be formed of sheet metal (e.g., stainless steel) that has a desired profile and is cut or shaped to bend into its final form. In another example, first blade 348a and second blade 348b may be formed of plastic (e.g., when integrally formed with first actuator 350a and second actuator 350b).

[0090] The size and shape of first blade 348a, second blade 348b, and first actuator 350a, 350b, based on a plan view to which they are integrally formed (or mounted), may correspond to the size and shape of the reservoir outlet of insert 342. Additionally, as shown in FIG. 27 , first actuation pin 314a, 314b may include protruding edges (e.g., curved inner lips facing each other) configured to push the two perforated sections of seal 344 into the reservoir as first blade 348a, 348b advance into the reservoir. 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, the two flaps (from the two perforated sections of the seal 344) may be between the curved sidewall of the reservoir outlet of the insert 342 and the corresponding curvature of the protruding edges of the first activation pin 314a and the second activation pin 314b. As a result, the possibility of the two perforated openings of the seal 344 being obstructed (by the two flaps from the two perforated sections) may be reduced or prevented. Furthermore, the first activation pin 314a and the second activation pin 314b may be configured to guide the nicotine pre-vapor formulation from the reservoir toward the absorbent material 346 in the top hat holder 345.

[0091] A lower portion (e.g., distal portion) of each of first actuator 350a and second actuator 350b is configured to extend through the bottom section (e.g., upstream end) of second housing section 308. This rod-like portion of each of first actuator 350a and second actuator 350b may also be referred to as a shaft. First O-ring 352a and second O-ring 352b may be disposed in annular grooves in the shafts of first actuator 350a and second actuator 350b, respectively. First O-ring 352a and second O-ring 352b are configured to engage with the shafts of first actuator 350a and second actuator 350b and the inner surfaces of corresponding openings in second housing section 308 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 shafts of the first actuator 350a and the second actuator 350b, respectively, within the corresponding openings in the second housing section 308 while maintaining their respective seals, which may help reduce or prevent leakage of the nicotine pre-vapor formulation through the openings in the second housing section 308 relative 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 silicone.

[0092] The perforators for the nicotine pod assembly 300 may include notches configured to engage with clips to prevent premature activation of the perforators. For example, the shafts of the first and second activation pins 314a and 314b may define first and second notches 351a and 351b, respectively, configured to engage with such clips. In an exemplary embodiment, the clip may be a planar structure defining first and second slots configured to engage with the first and second notches 351a and 351b, respectively. When engaged with the shafts of the first and second activation pins 314a and 314b (via the first and second notches 351a and 351b, respectively), the clip may abut the second housing section 308, thereby preventing the first and / or second activation pins 314a and 314b from being inadvertently pressed into the nicotine pod assembly 300. As a result, the first activation pin 314a and the second activation pin 314b may be appropriately restrained (e.g., during shipping and / or handling) to reduce or prevent the possibility of their premature activation. The clip may be removed (e.g., by an adult e-vaping device user) at the appropriate time when the nicotine pod assembly 300 is to be activated.

[0093] FIG. 28 is a perspective view of the connector module of FIG. 22 , excluding the wick and heater. FIG. 29 is an exploded view of the connector module of FIG. 28 . FIG. 30 is another exploded view of the connector module of FIG. 28 . Referring to FIGS. 28-30 , a module housing 354 forms the framework of the connector module 320. The module housing 354 defines, among other things, the partition 329 and a flow path for air drawn into the nicotine pod assembly 300. When assembled within the nicotine pod assembly 300, a downstream edge of the module housing 354 can be engaged with an upstream edge of the base portion 345 a of the top hat holder 345 (e.g., FIG. 26 ). As a result, the heater 336 and the wick 338 (e.g., FIG. 22 ) can be enclosed (at least partially) by the module housing 354 and the top hat holder 345. Additionally, the interior space defined by module housing 354 and top hat holder 345, when assembled (with heater 336 and wick 338 disposed therein), can be considered a heating chamber. The heating chamber is in fluid communication with the upstream flow path of module housing 354 via module outlet 368.

[0094] As described above, the flow path for air drawn into the nicotine pod assembly 300 includes a first branching portion, a second branching portion, and a converging portion defined by the module housing 354. In an exemplary embodiment, the first branching portion and the second branching portion are symmetrical portions bisected by an axis corresponding to the converging portion of the flow path. For example, as shown in FIG. 30 , the first branching portion, the second branching portion, and the converging portion may include a first curved path 330a, a second curved path 330b, and a converging path 330c, respectively. The first curved path 330a and the second curved path 330b may be substantially U-shaped paths, and the converging path 330c may be a substantially straight path. Based on the axis corresponding to the converging path 330c and aligned with the top of the partition 329, the first branching portion of the flow path may be a mirror image of the second branching portion of the flow path. During vaping, air drawn through the pod inlet 322 is divided by the divider 329, initially flowing in opposite directions away from the divider 329, then flowing in parallel before each airflow makes a U-turn (via first curved path 330a and second curved path 330b) and merges (via merged path 330c) for a combined flow traveling back toward the divider 329 before passing through the module outlet 368 and into the heating chamber. The heater 336 and wick 338 may be positioned so that both sides are substantially equally exposed to the airflow passing through the module outlet 368. During vaping, the generated nicotine vapor is entrained in the airflow traveling through the heating chamber and into the vapor channel 316.

[0095] A partition 370 may be disposed within the module outlet 368 to divide the flow of air entering the heating chamber. The heater 336 and wick 338 (e.g., FIG. 22) may be downstream of the module outlet 368 and oriented to align with the partition 370. As a result of the partition 370, the air flow may be divided relatively equally, with a first flow passing along a first side of the heater 336 (and wick 338) and a second flow passing along a second side of the heater 336 (and wick 338). In an exemplary embodiment, the magnitudes (e.g., velocity, volumetric flow rate, mass flow rate) of the first and second flows may be within ±10 percent of each other. For example, with respect to the air drawn into the heating chamber, 51 percent may be part of the first flow and 49 percent may be part of the second flow, although variations within the above ranges may, of course, occur. In addition to reducing flow imbalances through the heating chamber, the partition 370 may also be considered a flow straightener.

[0096] The partition 370 may be in the form of a bar extending across (e.g., bisecting) the module outlet 368. Dimensionally, the partition 370 may have a thickness of approximately 150 to 250 micrometers (e.g., 200 micrometers). The thickness of the partition 370 corresponds to the degree to which the module outlet 368 is obstructed by the partition 370. Consequently, the thickness of the partition 370 and / or the size of the module outlet 368 can be adjusted to provide a desired withdrawal resistance (e.g., 25 millimeters of water column) for the nicotine e-vaping device 500. Furthermore, the width of the partition 370 may be 525 to 875 micrometers (e.g., 700 micrometers). The width may be such that the partition 370 extends along most or all of the passage defined by the module outlet 368. Furthermore, assuming the module outlet 368 has a circular cross-section, the length of the partition 370 may correspond to the diameter of the module outlet 368. Alternatively, if the module outlet 368 has an oval cross-section, the length of the partition 370 may correspond to an axis (eg, minor axis, major axis) of the module outlet 368 .

[0097] As shown in FIGS. 29-30 , each of the first power contact 324a and the second power contact 324b may include a contact surface and contact legs. The contact legs (which may have an elongated configuration) may be oriented perpendicular to the contact surface (which may be square), although example embodiments are not limited thereto. The module housing 354 may define a pair of shallow recesses and a pair of openings to facilitate installation of the first power contact 324a and the second power contact 324b. During assembly, the contact surface of each of the first power contact 324a and the second power contact 324b may be positioned within a corresponding one of the pair of shallow recesses so as to be substantially flush with the outer surface of the module housing 354 (e.g., FIG. 21 ). Furthermore, the contact legs of each of the first power contact 324a and the second power contact 324b may extend through a corresponding one of the pair of openings to protrude from the downstream side of the module housing 354 (e.g., FIG. 28 ). The heater 336 may then be connected to the contact legs of each of the first and second power contacts 324a, 324b.

[0098] Printed circuit board (PCB) 362 includes a plurality of data contacts 326 (e.g., FIG. 30 ) on its upstream side and various electronic components (e.g., FIG. 29 ) on its downstream side, including sensor 364. Sensor 364 may be positioned on printed circuit board (PCB) 362 such that sensor 364 is within merged path 330 c defined by module housing 354. In an exemplary embodiment, printed circuit board (PCB) 362 (and associated components affixed thereto) is a free-standing structure that is initially inserted into a downstream receiving cavity of second housing section 308 such that data contacts 326 are exposed by data contact opening 327 in second housing section 308. Thereafter, the module housing 354 (with the first power contacts 324a, the second power contacts 324b, the heater 336, and the wick 338 attached thereto) may be inserted into the receiving cavity such that the first power contacts 324a and the second power contacts 324b are exposed by the first power contact openings 325a and the second power contact openings 325b, respectively, in the second housing section 308. Alternatively, to simplify the above two-step insertion process into a one-step insertion process, it should be understood that a printed circuit board (PCB) 362 (and associated components affixed thereto) may be affixed to the module housing 354 (e.g., to form a single, integrated structure) so as to cover the first curved path 330a, the second curved path 330b, the merging path 330c, and the module outlet 368.

[0099] As mentioned above, the module outlet 368 may be a resistance to withdrawal (RTD) port. In such a configuration, the withdrawal resistance of the nicotine e-vaping device 500 may be adjusted by changing the size of the module outlet 368 (rather than changing the size of the pod inlet 322). In an exemplary embodiment, the size of the module outlet 368 may be selected to provide a withdrawal resistance of 20 to 100 millimeters of water column (e.g., 25 to 50 millimeters of water column). For example, a 1.0 mm diameter of the module outlet 368 may provide a withdrawal resistance of 88.3 millimeters of water column. In another example, a 1.1 mm diameter of the module outlet 368 may provide a withdrawal resistance of 73.6 millimeters of water column. In another example, a 1.2 mm diameter of the module outlet 368 may provide a withdrawal resistance of 58.7 millimeters of water column. In yet another example, a 1.3 mm diameter of the module outlet 368 may provide a withdrawal resistance of 40 to 43 millimeters of water column. In particular, the size of the module outlet 368 may be adjusted for its internal arrangement without affecting the external aesthetics of the nicotine pod assembly 300, thereby allowing for a more standardized product design of nicotine pod assemblies having various resistance to withdrawal (RTD), while also reducing the possibility of inadvertent blockage of the incoming air.

[0100] While a number of exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications that would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. a first section defining a pod outlet and configured to hold a nicotine prevapor formulation; a second section connected to the first section, the second section defining a pod inlet and configured to heat the nicotine pre-vapor formulation, the pod inlet being in fluid communication with the pod outlet via a flow path, the flow path including a first branched portion, a second branched portion, and a confluence portion;

2. The nicotine pod assembly of claim 1 , wherein the first section is configured to seal the nicotine pre-vapor formulation until activation of the nicotine pod assembly.

3. 3. The nicotine pod assembly of claim 2, wherein the second section includes a perforator configured to release the nicotine pre-vapor formulation from the first section during the activation of the nicotine pod assembly.

4. The nicotine pod assembly of claim 3 , wherein the perforator includes a notch configured to engage a clip to prevent premature activation of the perforator.

5. The nicotine pod assembly according to any one of claims 1 to 4, wherein the pod inlet is located upstream of the first branched portion and the second branched portion of the flow path.

6. The nicotine pod assembly according to any one of claims 1 to 5, wherein the confluence portion of the flow path is downstream of the first branch portion and the second branch portion.

7. The nicotine pod assembly according to any one of claims 1 to 6, wherein the first branched portion and the second branched portion converge to form the convergent portion of the flow path.

8. A nicotine pod assembly according to any one of claims 1 to 7, wherein the second section includes a partition configured to direct incoming airflow into the first branched portion and the second branched portion of the flow path.

9. 9. The nicotine pod assembly of claim 8, wherein the divider is wedge-shaped and configured to split the incoming airflow in opposite directions.

10. The nicotine pod assembly according to any one of claims 1 to 9, wherein the first branched portion comprises a first curved segment.

11. The nicotine pod assembly according to any one of claims 1 to 10, wherein the second branched portion comprises a second curved segment.

12. A nicotine pod assembly according to any one of claims 1 to 11, wherein the first branched portion and the second branched portion are symmetrical portions bisected by an axis corresponding to the confluence portion of the flow path.

13. A nicotine pod assembly according to any preceding claim, wherein the second section comprises a heater and a wick downstream of the confluence of the flow paths.

14. The nicotine pod assembly of claim 13 , wherein the heater comprises a folded heating element configured to grip the wick.

15. The nicotine pod assembly of claim 14 , wherein the folded heating element includes at least one prong configured to protrude into the wick.

16. 15. The nicotine pod assembly of claim 13 or 14, wherein the second section further comprises an absorbent material disposed within a holder, the absorbent material being downstream of the wick and in fluid communication with the wick.

17. 17. The nicotine pod assembly of claim 16, wherein the absorbent material is configured to receive the nicotine pre-vapor formulation from the first section, and the wick is configured to transmit the nicotine pre-vapor formulation from the absorbent material to the heater.

18. 18. The nicotine pod assembly of claim 16 or 17, wherein the absorbent material has an annular shape and the core has a planar shape.

19. 19. The nicotine pod assembly of claim 16, 17 or 18, wherein the holder comprises a base portion and a cylindrical portion.

20. 1. A device body for a nicotine e-vaping device comprising: a device housing defining a through hole configured to receive a nicotine pod assembly, the through hole including an upstream wall and a downstream wall, the upstream wall including at least one upstream protrusion, the downstream wall including at least one downstream protrusion, the at least one downstream protrusion being retractable relative to an adjacent surface of the downstream wall and configured to engage with at least one downstream recess in the nicotine pod assembly to retain the nicotine pod assembly within the through hole.

21. a nicotine pod assembly including a first section and a second section, the first section configured to hold a nicotine pre-vapor formulation, and the second section configured to split and merge an airflow into the nicotine pod assembly before the airflow passes through the first section; a device body defining a through hole configured to receive the nicotine pod assembly such that a pod inlet is exposed to the airflow when the nicotine pod assembly is placed within the through hole.

Images