Nicotine e-vaping device including a reservoir assembly

Abstract

A reservoir assembly for a nicotine e-vaping device is provided. A reservoir assembly (204) for a nicotine e-vapor device (10) includes an outer shell (256), a wick (238), and a first membrane (264). The outer shell (256) includes a first opening (252), and the inner surface of the outer shell at least partially defines a reservoir (232) configured to hold a nicotine pre-vapor formulation. The wick (238) extends from the interior of the reservoir (232) to the exterior of the reservoir (232). The wick (238) is configured to draw the nicotine pre-vapor formulation held in the reservoir (232) to the exterior of the reservoir (232). The first membrane (264) covers the first opening (252). The first membrane (264) is one or more layers of fabric that are liquid-impermeable and air-permeable.

Description

[Technical Field]

[0001] Exemplary embodiments generally relate to a nicotine electronic vaping (e-vaping) device that includes a reservoir assembly. [Background technology]

[0002] The nicotine e-vaporizing device includes a heating element that vaporizes a nicotine pre-vapor formulation held within a reservoir to produce a nicotine vapor. Summary of the Invention

[0003] At least one exemplary embodiment relates to a reservoir assembly for a nicotine e-vapor device. The reservoir assembly includes an outer shell, a wick, and a membrane. The outer shell includes a first opening and an inner surface of the outer shell at least partially defining a reservoir configured to hold a nicotine pre-vapor formulation including nicotine. The wick extends from the interior of the reservoir to the exterior of the reservoir and is configured to draw the nicotine pre-vapor formulation held within the reservoir to the exterior of the reservoir. The first membrane covers the first opening. The first membrane includes one or more layers of fabric that are liquid-impermeable and air-permeable.

[0004] Another exemplary embodiment relates to a reservoir assembly for a nicotine e-vapor device. The reservoir assembly includes an outer shell, a plunger, and a wick. The outer shell extends in a first direction. The outer shell includes a first end and an inner surface. The inner surface of the outer shell at least partially defines the interior of the outer shell. The plunger extends through the interior of the outer shell in a second direction perpendicular to the first direction. The plunger includes a first surface and a second surface opposite the first surface. The first surface and a limited portion of the inner surface of the outer shell define a liquid containment region in a limited portion of the interior of the outer shell between the first surface of the plunger and the first end of the outer shell. The liquid containment region is a reservoir configured to hold a nicotine pre-vapor formulation. The plunger is configured to move in a first direction within the interior of the outer shell based on a first force applied to the first surface of the plunger by a volume of the nicotine pre-vapor formulation contained within the liquid containment region. The wick extends from the interior of the outer shell to the exterior of the liquid containment region.

[0005] Another exemplary embodiment relates to a method including providing an outer shell and a plunger, filling a liquid confinement region with a nicotine pre-vapor formulation, and disposing a portion of a wick within the liquid confinement region. The outer shell extends in a first direction. The outer shell includes a first end, an opening at the first end, and an inner surface. The inner surface of the outer shell partially defines an interior of the outer shell. The plunger extends through the interior of the outer shell in a second direction perpendicular to the first direction. The plunger includes a first surface and a second surface opposite the first surface. The first surface and a limited portion of the inner surface of the outer shell define a liquid confinement region in a limited portion of the interior of the outer shell between the first surface of the plunger and the first end of the outer shell. The liquid confinement region is a reservoir configured to hold the nicotine pre-vapor formulation. Filling the liquid containment region with the nicotine pre-vapor formulation is performed based on the nicotine pre-vapor formulation exerting a first force on a first surface of the plunger such that the nicotine pre-vapor formulation moves the plunger in a first direction away from the first end of the outer shell.

[0006] Various features and advantages of the non-limiting embodiments herein may become more apparent from a 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 to be considered as drawn to scale unless expressly noted. Various dimensions of the drawings may be exaggerated for clarity. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a side view of a nicotine electronic vaping (e-vaping) device according to at least one exemplary embodiment. [Figure 2] FIG. 2 is a cross-sectional view of an exemplary embodiment of the first section of the nicotine e-vaping device shown in FIG. 1 taken along line II-II'. [Figure 3]FIG. 3 is an exploded view of an exemplary embodiment of the first section shown in FIG. [Figure 4] FIG. 4 is a cross-sectional view of an exemplary embodiment of the second section of the nicotine e-vaping device shown in FIG. 1 taken along line II-II'. [Figure 5] FIG. 5 is an exploded view of an exemplary embodiment of the second section shown in FIG. [Figure 6] FIG. 6 is a cross-sectional view of the exemplary embodiment of the nicotine e-vaping device shown in FIG. 1 taken along line II-II'. [Figure 7] FIG. 7 is a cross-sectional view of an exemplary embodiment of a reservoir assembly. [Figure 8] FIG. 8 is a cross-sectional view of another exemplary embodiment of a reservoir assembly. [Figure 9] FIG. 9 is a cross-sectional view of another exemplary embodiment of a reservoir assembly. [Figure 10] FIG. 10 is a cross-sectional view of another exemplary embodiment of a reservoir assembly. [Figure 11] FIG. 11 is a flow diagram of a method for preparing a reservoir assembly. DETAILED DESCRIPTION OF THE INVENTION

[0008] Some detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing exemplary embodiments. However, exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments described herein.

[0009] As a result, while example embodiments are susceptible to various modifications and alternative forms, example embodiments thereof have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that there is no intention to limit the example embodiments to the particular forms disclosed, but on the contrary, the example embodiments encompass all modifications, equivalents, and alternatives falling within the scope of the example embodiments. Like numerals refer to like elements throughout the description of the figures.

[0010] It should be understood that when an element or layer is referred to as "on," "connected to," "coupled to," or "overlying" another element or layer, it may be directly on, directly connected to, directly bonded to, or directly overlying the other element or layer, or 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 and all combinations or subcombinations of one or more of the associated listed items.

[0011] Although terms such as first, second, and third may be used herein to describe various elements, regions, layers, and / or sections, it should be understood that these elements, regions, layers, and / or sections are not 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 described below would be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0012] 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. It should be understood that the spatial relationship terms are intended to encompass different orientations of the device during use or operation in addition to the orientation shown in the figures. For example, if the device in the figures were inverted, elements described as "below" or "below" other elements or features would, after inversion, be oriented "above" the other elements or features. Thus, the term "below" may encompass both an above and below orientation. The device may be oriented otherwise (rotated 90 degrees or at other orientations), and the spatial relationship descriptors used herein will be interpreted accordingly.

[0013] 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.

[0014] When the terms "about" or "substantially" are used herein in conjunction with a numerical value, it is intended that the associated numerical value include a manufacturing or operating tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the words "generally" and "substantially" are used in connection with a geometric shape, exactness of the geometric shape is not required, but a tolerance of the shape is intended to be within the scope of the present disclosure. Furthermore, regardless of whether a numerical value or shape is modified as "about" or "substantially," it will be understood that these values ​​and shapes should be interpreted as including a manufacturing or operating tolerance (e.g., ±10%) around the stated numerical value or shape.

[0015] 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.

[0016] 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 or devices capable of responding to and executing instructions in a defined manner.

[0017] 1 is a side view of a nicotine electronic vaping (e-vaping) device 10 according to at least one exemplary embodiment. The nicotine e-vaping device 10 may be considered an e-vaping nicotine delivery system (ENDS) device. In at least one exemplary embodiment, the nicotine e-vaping device 10 includes a replaceable cartridge (or first section) 105 and a reusable battery section (or second section) 110. The first section 105 and the second section 110 may be coupled together at a connector assembly 115 with an air inlet 145.

[0018] 1, the first section 105 includes a first housing 120 and the second section 110 includes a second housing 120′. The nicotine e-vaping device 10 includes a mouth-end insert 125 at the first end 130 and an end cap 135 at the second end 140.

[0019] According to at least one exemplary embodiment, first housing 120 and second housing 120' may have a generally cylindrical cross-section. In other exemplary embodiments, first and second housings 120 and 120' may have a generally triangular, rectangular, oval, square, or polygonal cross-section along one or more of first section 105 and second section 110. Furthermore, first and second housings 120 and 120' may have the same or different cross-sectional shapes or the same or different sizes. As discussed herein, first and second housings 120, 120' may also be referred to as outer or main housings.

[0020] Although the exemplary embodiments may be described in some instances with respect to a first section 105 coupled to a second section 110, the exemplary embodiments should not be limited to these examples.

[0021] Figure 2 is a cross-sectional view of the first section 105 of the nicotine e-vaping device 10 along line II-II in Figure 1. Figure 3 is an exploded view of an exemplary embodiment of the first section 105 shown in Figure 2.

[0022] 2 and 3, first housing 120 extends longitudinally. A central, longitudinal air passage 208 extends through a portion of first housing 120 and is in fluid communication with air tube 202 of reservoir assembly 204 to define an interior passageway (also referred to as a central channel or central interior passageway) 210.

[0023] First connector part 216 fits within a first end of first housing 120. First connector part 216 is part of connector assembly 115 (shown in FIG. 1).

[0024] In at least one exemplary embodiment, first connector part 216 is a hollow cylinder with internal threads on a portion of its inner surface. First connector part 216 is electrically conductive and may be formed of or coated with an electrically conductive material. The internal threads (or internally threaded section) may mate with the external threads (or externally threaded section) of second section 110 to connect first section 105 and second section 110. However, exemplary embodiments are not limited to this example. Rather, the connector may be, for example, a slip-fit ​​connector, a detent connector, a clamp connector, a clasp connector, or the like. Furthermore, the positions of the male and female connectors may be reversed, if desired, such that the male connector is part of first section 105.

[0025] The conductive post 218 nests within a hollow portion of the first connector part 216. The conductive post 218 may be formed from a conductive material (e.g., stainless steel, copper, etc.) and may function as the anode portion of the first connector part 216.

[0026] The conductive posts 218 define the central air passageway 214. The gasket insulator 220 holds the conductive posts 218 within the first connector part 216. The gasket insulator 220 also electrically insulates the conductive posts 218 from an outer portion 222 of the first connector part 216.

[0027] Outer portion 222 of first connector part 216 serves as the cathode connector of first connector part 216. Outer portion 222 may also be referred to herein as the cathode connector or cathode part. Outer portion 222 may be formed of an electrically conductive material (e.g., stainless steel, copper, etc.).

[0028] 2 and 3, the connection point 224 connects a central passageway 228 (or channel) disposed between the interior passageway 210 of the air tube 202 and the interior of the mouth-end insert 125. Nicotine vapor may flow from the interior passageway 210 through the central passageway 228 and into the cavity within the mouth-end insert 125. In at least one exemplary embodiment, the air tube 202 may have a diameter of approximately 4 mm.

[0029] The mouth-end insert 125 includes at least two outlets 230, which may be located off-axis relative to the longitudinal axis of the nicotine e-vapor device 10. The outlets 230 may be recessed or non-recessed and may be angled outward relative to the longitudinal axis of the nicotine e-vapor device 10. The outlets 230 may be substantially evenly distributed around the circumference of the mouth-end insert 125 to provide a substantially uniform distribution of the nicotine vapor.

[0030] First section 105 further includes a reservoir assembly 204. Reservoir assembly 204 includes a reservoir 232 that includes a reservoir housing 233 configured to store a nicotine pre-vapor formulation. First section 105 also includes a vaporizer 234. Vaporizer 234 includes a heating element 236 and a wick 238. In some exemplary embodiments, vaporizer 234 is included within reservoir assembly 204. Vaporizer 234 is configured to vaporize the nicotine pre-vapor formulation drawn from reservoir 232 to form a nicotine vapor. Nicotine vapor, nicotine aerosol, and nicotine dispersion are used interchangeably and refer to substances generated or output by any nicotine e-vaping device and / or elements of the disclosed and claimed devices containing nicotine, and / or equivalents thereof.

[0031] 2, in at least one exemplary embodiment, reservoir 232 surrounds interior passageway 210 and air tube 202. Heating element 236 may extend transversely across interior passageway 210 between opposing portions of reservoir 232. In at least some exemplary embodiments, heating element 236 may extend parallel to the longitudinal axis of interior passageway 210.

[0032] The reservoir 232 may be sized and configured to hold sufficient nicotine pre-vapor formulation so that the nicotine e-vapor device 10 may be configured for at least about 200 seconds of vaping. Additionally, the nicotine e-vapor device 10 may be configured to allow each puff to last up to about 5 seconds.

[0033] As described above, the vaporizer 234 includes a heating element 236 and a wick 238. The wick 238 may include at least a first end portion and a second end portion that may extend into opposite sides of the reservoir 232. The heating element 236 may at least partially surround a central portion of the wick 238.

[0034] The wick 238 may draw the nicotine pre-vapor formulation from the reservoir 232 (e.g., by capillary action), and the heating element 236 may heat the nicotine pre-vapor formulation in the central portion of the wick 238 to a temperature sufficient to vaporize the nicotine pre-vapor formulation, thereby generating a nicotine vapor.

[0035] In at least one exemplary embodiment, the nicotine pre-vapor formulation is a material or combination of materials that can be transformed into a nicotine vapor. For example, the nicotine pre-vapor formulation may be a liquid formulation, a solid formulation, and / or a gel formulation, including, but not limited to, water, beads, a solvent, an active ingredient, ethanol, a plant extract, a natural or artificial flavor, and / or a nicotine vapor former such as glycerin and propylene glycol. In some exemplary embodiments, the nicotine pre-vapor formulation may include tobacco and / or other plant materials, which may or may not be mixed with flavoring agents, nicotine vapor formers, fillers, binders, and / or polymers. The tobacco and / or other plant materials may be in the form of leaves, shreds, films, bits, particles, powders, beads, and combinations thereof.

[0036] In at least one exemplary embodiment, the wick 238 may include a filament (or thread) capable of drawing the nicotine pre-vapor formulation. For example, the wick 238 may be a bundle of glass (or ceramic) filaments, a bundle including a group of wound glass filaments, or the like, all of which arrangements may be capable of drawing the nicotine pre-vapor formulation by capillary action due to the gaps between the filaments. The filaments may be generally aligned perpendicular (transverse) to the longitudinal axis of the nicotine e-vapor device 10. In at least one exemplary embodiment, the wick 238 may include one to eight filament strands, each including multiple glass filaments twisted together. End portions of the wick 238 may be flexible and may be folded within the confines of the reservoir 232. The filaments may have a generally cross-shaped, clover-shaped, Y-shaped, or any other suitable cross-section.

[0037] In at least one exemplary embodiment, the wick 238 may comprise any suitable material or combination of materials. Examples of suitable materials may be, but are not limited to, glass, ceramic-based materials, or graphite-based materials. The wick 238 may have any suitable capillary drawing properties to accommodate nicotine pre-vapor formulations having different physical properties, such as density, viscosity, surface tension, and vapor pressure. The wick 238 may be non-conductive.

[0038] In at least one exemplary embodiment, the heating element 236 (or heater) may include a coil of wire (heater coil) that at least partially surrounds the wick 238. The wire used to form the coil of wire may be metallic. The heating element 236 may extend completely or partially along the length of the wick 238. The heating element 236 may further extend completely or partially around the circumference of the wick 238. In some exemplary embodiments, the heating element 236 may or may not be in contact (or direct contact) with the wick 238. The heating element 236 may be part of a vapor assembly. The vapor assembly may include the heating element 236, an air passageway, and any other portions of a nicotine e-vapor device that support the formation of a nicotine vapor from the nicotine pre-vapor formulation.

[0039] 2 and 3, the heating element 236 is electrically connected to the conductive post 218 by a first electrical lead 240 and to the outer portion 222 via a second electrical lead 240′. Thus, the outer portion 222 and the conductive post 218 each form an external electrical connection to the heating element 236.

[0040] In at least some other exemplary embodiments, the heating element 236 may be a planar body, a ceramic body, a single wire, a mesh, a cage of resistive wire, or any other suitable form. More generally, the heating element 236 may be any heater configured to vaporize a nicotine pre-vapor formulation.

[0041] In at least one exemplary embodiment, the heating element 236 may be formed of any suitable electrically resistive material. Examples of suitable electrically resistive materials may include, but are not limited to, copper, titanium, zirconium, tantalum, and metals from the platinum group. Examples of suitable metal alloys include, but are not limited to, stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-titanium-zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, and nickel-based, iron-based, cobalt-based, and stainless steel-based superalloys.

[0042] For example, the heating element 236 may be formed of nickel aluminide, a material with an alumina layer on its surface, iron aluminide, and other composite materials, and the electrically resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties. The heating element 236 may include at least one material selected from the group consisting of stainless steel, copper, copper alloy, nickel-chromium alloy, superalloy, and combinations thereof. In one exemplary embodiment, the heating element 236 may be formed of a nickel-chromium alloy or an iron-chromium alloy. In another exemplary embodiment, the heating element 236 may be a ceramic heater having an electrically resistive layer on its outer surface.

[0043] In at least one exemplary embodiment, the heating element 236 may heat the nicotine pre-vapor formulation within the wick 238 by thermal conduction. Alternatively, heat from the heating element 236 may be conducted to the nicotine pre-vapor formulation by a thermally conductive element, or the heating element 236 may transfer heat to the incoming ambient air drawn through the nicotine e-vapor device 10 during vaping, thereby heating the nicotine pre-vapor formulation by convection.

[0044] 2 , the reservoir assembly 204 is shown where the wick 238 passes through the air tube 202 and is adjacent to a first opening 252 at a first end 254 of an outer shell 256 of the reservoir assembly 204. A transfer material 258 may be adjacent to the wick 238. The reservoir 232 for the nicotine pre-vapor formulation may be defined by the interior surface of the outer shell 256 between the first end 254 of the outer shell 256 and a second end 260 of the outer shell 256. The transfer material 258 and the wick 238 may be configured to act together to wick the nicotine pre-vapor formulation out of the reservoir 232.

[0045] In some exemplary embodiments, the first opening 252 extends through a side of the air tube 202 (not shown). If the outer shell 256 is cylindrical, the reservoir 232 may be annularly spaced between the outer surface of the air tube 202 and the inner surface of the outer shell 256, and between the first end 254 and the second end 260 of the outer shell 256. The reservoir 232 may comprise a nicotine pre-vapor formulation. Although the exemplary embodiment is shown with the outer shell 256 having a cylindrical shape, the outer shell 256 may have a shape other than cylindrical, such as rectangular, square, oval, or any other shape.

[0046] In at least one exemplary embodiment, as shown in FIG. 2 , the reservoir assembly 204 can include a second opening 262 defined in the second end 260 of the outer shell 256. The second opening 262 can be covered by a membrane 264. The membrane 264 can be one or more layers of fabric. The fabric can be air permeable but water impermeable. For example, the fabric can be made from Gore-Tex or a fabric with woven hydrophobic fibers or a hydrophobic coating.

[0047] During transport, particularly by air, any air within reservoir 232 may expand due to a decrease in air pressure outside the reservoir. The expanding air can escape reservoir 232 through membrane 264. Thus, there may not be a pressure differential between the interior of the reservoir and the exterior of the reservoir. Providing a mechanism by which air within the reservoir can be removed from the reservoir reduces the likelihood of leakage of the nicotine pre-vapor formulation from reservoir 232 during transport, shipping, and use.

[0048] Figure 4 is a cross-sectional view of the second section of the exemplary embodiment of the nicotine e-vaping device 10 along line II-II' in Figure 1. Figure 5 is an exploded view of the exemplary embodiment of the second section 110 shown in Figure 4.

[0049] The second section 110 may be a reusable section of the nicotine e-vaping device 10, and the reusable section may be rechargeable by an external charging device. Alternatively, the second section 110 may be disposable. In this embodiment, the second section 110 may be used until the energy from the power source 402 is depleted (e.g., until the energy falls below a threshold level).

[0050] 4 and 5, according to at least this exemplary embodiment, the power supply 402 includes an anode connection 404 and a cathode connection 406. Each of the anode connection 404 and the cathode connection 406 may be in the form of one or more electrical leads or wires. The power supply 402 (or power source) may be a battery. For example, the power supply 402 may be a lithium ion battery or a variant of a lithium ion battery, such as a lithium ion polymer battery. The battery may be disposable or rechargeable. The power supply may be configured to provide power to the heating element 236.

[0051] Second section 110 further includes a connector piece 408 at a first end of second section 110. In the exemplary embodiment shown in FIG. 4, connector piece 408 is a male connector configured to connect to the female first connector piece 216 of first section 105. Alternatively, connector piece 408 may be a female connector configured to connect to the male connector of first section 105.

[0052] 4, connector part 408 includes threads 410 configured to mate with corresponding threads on first connector part 216 of first section 105. Although illustrated as a threaded connection, according to at least some other exemplary embodiments, connector part 408 may be, for example, a slip-fit ​​connector, a detent connector, a clamp connector, a clasp connector, or the like.

[0053] The negative connection (connector piece 408) of the power supply 402 terminates at and is electrically connected to a sensor assembly 424 located proximate the second end of the second section 110. The sensor assembly 424 is described in more detail below.

[0054] The anode connection 404 terminates in and is electrically connected to a conductive post 412. The conductive post 412 may function as the anode portion of the connector component 408. The conductive post 412 defines a central passageway 414 in fluid communication with one or more side vents 416. The side vents 416 may be perforated within the conductive post 412. The central passageway 414 and the one or more side vents 416 enable puff detection by a sensor assembly (e.g., a puff sensor assembly) 424 resulting from a change in pressure when air is drawn through the air inlet 145.

[0055] 4, exemplary embodiments should not be limited to this example. Rather, conductive post 412 may include any number of side vents 416 and connector component 408 may include any number of air inlets 145. For example, conductive post 412 may include four side vents 416 spaced equidistantly around conductive post 412. Similarly, connector component 408 may include four air inlets 145 spaced equidistantly around connector component 408.

[0056] The conductive post 412 further includes an upper portion 418 having a recess that allows air drawn through the air intake 145 to flow and / or communicate through the end of the second section 110 to the first section 105 when connected to the second section 110.

[0057] The conductive posts 412 may be formed from a conductive material (e.g., stainless steel, copper, etc.) and nested within the hollow portion of the connector piece 408. When the connector piece 408 of the second section 110 is coupled to the first connector piece 216 of the first section 105, the top portion 418 (and conductive posts 412) physically and electrically connects to the conductive posts 218 to enable the flow of electrical current from the power source 402 to the heating element 236. The electrical connection also enables electrical signal transmission between the first section 105 and the second section 110.

[0058] 4 and 5, gasket insulator 420 holds conductive post 412 within connector component 408. Gasket insulator 420 also electrically insulates conductive post 412 from an outer portion 422 of connector component 408. Outer portion 422 may be formed from a conductive material (e.g., stainless steel, copper, etc.) and may function as the cathode portion of connector component 408.

[0059] As mentioned above, the connector part 408 includes one or more air inlets 145 configured to communicate ambient air to the connector part 408. The air inlets 145 may also be referred to as vents or air holes.

[0060] Ambient air drawn into connector piece 408 may combine and / or mix with air flowing out of one or more side vents 416 and enter first section 105 when first section 105 is coupled to second section 110. In at least one exemplary embodiment, air inlet 145 may be drilled into connector piece 408 immediately below threads 410 at an angle perpendicular or substantially perpendicular to the longitudinal centerline of connector piece 408.

[0061] The sidewalls of the air inlet 145 may be rounded to slope the sidewalls inward (e.g., to "countersink" the sidewalls of the rim of the air inlet 145). By rounding the sidewalls of the rim of the air inlet 145 (as opposed to using a relatively sharp edge on the rim of the air inlet 145), the air inlet 145 may be less likely to become clogged or partially blocked (because the cross-sectional area of ​​the air inlet 145 near the rim of the air inlet 145 is effectively reduced). In at least one exemplary embodiment, the sidewalls of the rim of the air inlet 145 may be rounded (sloped) at approximately 38 degrees relative to the longitudinal length (or longitudinal centerline) of the connector component 408 and the housing 120' of the second section 110.

[0062] In at least one exemplary embodiment, the air inlet 145 may be sized and configured so that the nicotine e-vaping device 10 has a resistance to draw (RTD) within a range of about 60 millimeters of water column to about 150 millimeters of water column.

[0063] 4 and 5, as described above, second section 110 includes a sensor assembly (eg, a puff sensor assembly) 424.

[0064] 4, for example, sensor assembly 424 is electrically connected to and powered by power supply 402. In at least this exemplary embodiment, sensor assembly 424 includes a sensor (e.g., a puff sensor) 426 and control circuitry 428.

[0065] Control circuitry 428 is configured to provide electrical current and / or electrical signals to first section 105. To this end, control circuitry 428 is electrically connected to conductive post 412 (the anode portion of connector piece 408) via control circuitry wiring (or lead) 430 and to outer (cathode) portion 422 of connector piece 408 via control circuitry wiring (or lead) 432. In at least this example, control circuitry wiring 432 serves as the cathode for an electrical circuit that includes sensor assembly 424.

[0066] The sensor 426 may be a capacitance-type sensor capable of sensing an internal pressure drop within the second section 110. When coupled to the second section 110, the sensor 426 and the control circuit 428 may function together to open or close a heater control circuit (not shown) between the power supply 402 and the heating element 236 in the first section 105. In at least one exemplary embodiment, the sensor 426 is configured to generate an output indicative of the magnitude and direction of airflow through the nicotine e-vaping device 10. In this example, the control circuit 428 receives the output of the sensor 426 and determines (1) whether the direction of the airflow indicates the application of negative pressure (e.g., inhalation) to the mouth-end insert 125 (as compared to positive pressure or blowing), and (2) whether the magnitude of the applied negative pressure exceeds a threshold level. If these vaping conditions are met, the control circuit 428 electrically connects the power supply 402 to the heating element 236 to activate the heating element 236.

[0067] In one embodiment, the heater control circuit may include a heater power control transistor (not shown). The control circuit 428 may activate the heater power control transistor to electrically connect the power supply 402 to the heating element 236. In at least one embodiment, the heater power control transistor (or heater control circuit) may form part of the control circuit 428.

[0068] The control circuitry 428 and the sensor 426 may be separate components located on a printed circuit board and connected via electrical contacts. However, although discussed herein with respect to a capacitive sensor, the sensor 426 may be any suitable pressure sensor, for example, a microelectromechanical system (MEMS) including a piezoresistive or other pressure sensor.

[0069] The control circuitry 428 may include, among other things, a controller. According to one or more exemplary embodiments, the controller may be implemented using hardware, a combination of hardware and software, or storage medium stored software. 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 or devices capable of responding to and executing instructions in a defined manner.

[0070] In another exemplary embodiment, the control circuit 428 may include a manually operable switch for manually activating the heating element 236 .

[0071] In at least one exemplary embodiment, the control circuit 428 may include a time period limiter that limits the duration for which current is continuously supplied to the heating element 236. The time period may be set or preset depending on the amount of nicotine pre-vapor formulation desired to be vaporized. In one example, the duration for which current is continuously applied to the heating element 236 may be limited so that the heating element 236 heats a portion of the wick 238 for less than approximately 10 seconds. In another example, the duration for which current is continuously applied to the heating element 236 may be limited so that the heating element 236 heats a portion of the wick 238 for approximately 5 seconds.

[0072] 4 and 5, sensor assembly 424 is cradled within sensor holder 434 at the second end of second section 110. In at least one exemplary embodiment, sensor holder 434 may be part of a silicone or rubber gasket; however, exemplary embodiments should not be limited to this example.

[0073] A thermally activated light 436 may also be disposed at the second end of the second section 110. In the exemplary embodiment shown in FIG. 4, the thermally activated light 436 may be disposed within the end cap 135. The thermally activated light 436 may include one or more light emitting diodes (LEDs). The LEDs may include one or more colors (e.g., white, yellow, red, green, blue, etc.). Furthermore, the thermally activated light 436 may be configured to illuminate when the power source 402 supplies current to the heating element 236. The thermally activated light 436 may be utilized for diagnosing the nicotine e-vaping system or to indicate that a recharge of the power source 402 is in progress. The thermally activated light 436 may also be configured to be able to turn on or off for privacy purposes. The thermally activated light 436 may be part of or electrically connected to the sensor assembly 424.

[0074] FIG. 6 is a cross-sectional view of the exemplary embodiment of the nicotine e-vaping device shown in FIG. 1 taken along line II-II'.

[0075] In Figure 6, the first section 105 is shown coupled to the second section 110. The arrows in Figure 6 indicate an example of air flow through the nicotine e-vaping device 10.

[0076] Operation of the nicotine e-vaping device 10 to generate a nicotine vapor when the first section 105 is coupled to the second section 110 will now be described with reference to FIG.

[0077] Referring to FIG. 6, air is primarily drawn into the first section 105 through at least one air inlet 145 in response to the application of negative pressure to the mouth-end insert 125 .

[0078] When the control circuitry 428 detects the above-described vaping condition, the control circuitry 428 begins supplying power to the heating element 236 such that the heating element 236 heats the nicotine pre-vapor formulation in the wick 238 and generates a nicotine vapor.

[0079] Air drawn through air inlet 145 enters a cavity within connector piece 408 and passes through a recess in top portion 418 into central air passage 214. From central air passage 214, air flows through air passage 208 and then through interior passage 210.

[0080] Air flowing through the interior passageway 210 combines and / or mixes with the nicotine vapor generated by the heating element 236, and the air-nicotine vapor mixture passes from the interior passageway 210 into the central passageway 228 and then into the cavity within the mouth-end insert 125. From the cavity in the mouth-end insert 125, the air-nicotine vapor mixture flows out the outlet 230.

[0081] FIG. 7 is a cross-sectional view of an exemplary embodiment of a reservoir assembly 700 .

[0082] 7 is identical to reservoir assembly 204 of FIG. 2 except that reservoir assembly 700 includes a second opening 262 in the form of a slit in outer shell 256. The slit may extend from first end 254 of outer shell 256 to second end 260 of outer shell 256. Alternatively, the slit may extend for only a portion of the distance between first end 254 and second end 260 of outer shell 256.

[0083] In at least one exemplary embodiment, the reservoir assembly 200 can include multiple second openings 262 in the form of slits. Two of the second openings 262 can be slits on opposite sides of the outer shell 256. Having multiple slits allows multiple locations for air to escape from the reservoir 232 to equalize air pressure between the interior of the reservoir 232 and the exterior of the reservoir. For example, if only about one-tenth of the reservoir 232 contains air, the reservoir 232 can be positioned so that the air does not come into contact with the membrane 264 covering the second opening 262, preventing air from escaping if there is only one second opening 262. However, if there are multiple second openings 262, air can escape through one of the other second openings 262. The second openings 262 can extend in any direction along the outer shell 256. The second openings 262 can be covered by one or more membranes 264. For example, each second opening 262 can be covered by a respective membrane 264.

[0084] FIG. 8 is a cross-sectional view of another exemplary embodiment of a reservoir assembly 800 .

[0085] In at least one exemplary embodiment, as shown in Figure 8, reservoir assembly 800 is identical to reservoir assembly 204 of Figure 2, except that second openings 262 are in the form of pinholes. In at least one exemplary embodiment, reservoir assembly 800 can include multiple second openings 262 in the form of pinholes. The multiple second openings 262 can be covered by one or more membranes 264. For example, each second opening 262 can be covered by a respective membrane 264.

[0086] FIG. 9 is a cross-sectional view of another exemplary embodiment of a reservoir assembly 900 .

[0087] 9 , reservoir assembly 900 is the same as reservoir assembly 204 of FIG. 2 , except that reservoir assembly 900 includes a plunger 902 that extends across the interior of outer shell 256, forming a seal to prevent the nicotine pre-vapor formulation from passing under plunger 902. A first side of plunger 902 and a portion of outer shell 256 define a liquid confinement region 904 (or reservoir) for the nicotine pre-vapor formulation. If reservoir assembly 900 includes air tube 202, plunger 902 includes a hole such that plunger 902 fits around air tube 202 within outer shell 256. Plunger 902 can be configured to move based on the volume of nicotine pre-vapor formulation within liquid confinement region 904. For example, as the nicotine pre-vapor formulation is drawn through the wick 238 and transfer material 258 by wicking forces, the fluid pressure within the liquid confinement region 904 decreases, while the atmospheric pressure outside the liquid confinement region 904 remains the same. This change in pressure decreases the force on a first side of the plunger 902, while the atmospheric pressure on a second side of the plunger 902 opposite the first side of the plunger 902 remains the same. The force difference causes the plunger 902 to move in a first direction toward the first end 254 of the outer shell 256.

[0088] If the frictional force of plunger 902 against outer shell 256 and / or air tube 202 is greater than the force difference, plunger 902 will not move. An optional passive actuator 906 may apply a third force to the second side of plunger 902 to overcome the frictional force. The passive actuator 906 may be a spring inside outer shell 256 that pushes against second end 260 of outer shell 256 and the second side of plunger 902.

[0089] In at least one exemplary embodiment, reservoir assembly 900 can include multiple second openings 262 in the form of slits. Two of the second openings 262 can be slits on opposite sides of outer shell 256. Having multiple slits allows multiple locations for air to escape from reservoir 232 to equalize air pressure between the interior of reservoir 232 and the exterior of the reservoir.

[0090] FIG. 10 is a cross-sectional view of an exemplary embodiment of a reservoir assembly 1000 prior to filling the reservoir assembly 1000 with a nicotine pre-vapor formulation.

[0091] In at least one exemplary embodiment, the reservoir assembly 1000 may have an outer shell 256 having a first opening 252 (or openings) at a first end 254 of the outer shell 256. The plunger 1002 may include a first side of the plunger 1008 within the outer shell 256 that contacts the first end 254 of the outer shell 256, with the plunger 1008 extending across the interior of the outer shell 256. The first side of the plunger 1002 and a limited portion of the interior of the outer shell 256 define a liquid containment region for the nicotine pre-vapor formulation.

[0092] The liquid confinement region in Figure 10 has no volume. This is done so that there is no air in the liquid confinement region before the reservoir assembly is filled with the nicotine pre-vapor formulation. As previously mentioned, the plunger 1002 reduces and / or prevents air from being included in the nicotine pre-vapor formulation to reduce and / or prevent leakage during transportation, shipping, and / or vaping.

[0093] FIG. 11 is a flow diagram of a method for preparing a reservoir assembly.

[0094] 11, in S1110, a reservoir assembly 900 is provided with an outer shell 256 and a plunger 902. For example, a reservoir assembly may be provided as shown in FIG.

[0095] In S1120, the liquid confinement region is filled with a nicotine pre-vapor formulation. This may be accomplished by connecting the first opening 252 (or openings) to a filling device (not shown), which can supply the nicotine pre-vapor formulation to the first opening 252 and apply hydraulic pressure to the nicotine pre-vapor formulation to push the plunger 902 in a first direction from the first end 254 of the outer shell 256. As the plunger 902 moves in the first direction, the liquid confinement region increases in volume and fills with the nicotine pre-vapor formulation. A small amount of air, such as air that was in the first opening 252 before the filling device was connected to the first opening 252, may also enter the liquid confinement region 904. The plunger 902 may be moved until the second side of the plunger 902 contacts the second end 260 of the outer shell 256, or to any position between the first end 254 and the second end 260 of the outer shell 256 based on the amount of nicotine pre-vapor formulation delivered to the reservoir assembly 900.

[0096] In S1130, a portion of the wick 238 may be disposed within the liquid confinement region 904 through the first opening 252. The wick 238 may be a two-stage wick or a single-stage wick. When the wick 238 is inserted, the wick 238 may contain a small amount of air within the wick 238. The wick 238 absorbs a portion of the nicotine pre-vapor formulation and some or all of the air within the liquid confinement region via wicking. The wicking typically causes a substantial portion of the air contained within the liquid confinement region, as well as the air within the wick 238, to escape through the wick 238 and out of the liquid confinement region.

[0097] S1140 is optional. At S1140, if desired, a force may be applied to the second side of the plunger 902 to remove any air from the liquid confinement region 904. The force may be applied by hand or with some form or actuator, such as a tool, machine, or passive actuator 906. The force may be applied for a period of time or until the nicotine pre-vapor formulation begins to be forced from the wick out of the liquid confinement region 904. This action may not be necessary if a small amount of air has entered the liquid confinement region.

[0098] S1150 is also optional. In S1150, a passive actuator 906 may be coupled to a second side of the plunger 902 within the outer shell 256. The passive actuator 906 may be coupled to a second end of the outer shell 256. The passive actuator 906 may be a spring or other form of passive actuator that is inserted through the second opening 262. The passive actuator 906 may be inserted after the liquid confinement region 904 has been filled with the nicotine pre-vapor formulation.

[0099] 11 may have the advantage of not having air, or a negligible amount of air, within the liquid confinement region 904, such that the liquid confinement region does not include a plunger 902 or a passive actuator 906. Alternatively, the reservoir assembly may be similar to those of FIGS. 1, 6, 7, and 8, and include one or more openings 262 covered by a membrane 264 to accommodate removal of liquid from the reservoir.

[0100] Exemplary embodiments using nicotine prevapor formulations The nicotine prevapor formulation includes nicotine. In an exemplary embodiment, a flavoring agent (at least one flavoring agent) is included within the nicotine prevapor formulation. In an exemplary embodiment, the nicotine prevapor formulation is a liquid, solid, and / or gel formulation including, but not limited to, water, beads, a solvent, an active ingredient, ethanol, a botanical extract, a natural or artificial flavor, and / or at least one nicotine vapor former, such as glycerin and propylene glycol.

[0101] In exemplary embodiments, the at least one nicotine vapor former of the nicotine prevapor formulation includes a diol (such as propylene glycol and / or 1,3-propanediol), glycerin, and combinations or subcombinations thereof. Various amounts of the nicotine vapor former may be used. For example, in some exemplary embodiments, the at least one nicotine vapor former is included in an amount ranging from about 20 weight percent based on the weight of the nicotine prevapor formulation to about 90 weight percent based on the weight of the nicotine prevapor formulation (e.g., the nicotine vapor former is about 50 percent to about 80 percent, or about 55 percent to 75 percent, or about 60 percent to 70 percent). As another example, in exemplary embodiments, the nicotine prevapor formulation includes a weight ratio of diol to glycerin ranging from about 1:4 to 4:1, where the diol is propylene glycol, 1,3-propanediol, or a combination thereof. In exemplary embodiments, the ratio is about 3:2. Other amounts or ranges may be used.

[0102] In exemplary embodiments, the nicotine pre-vapor formulation includes water. Various amounts of water may be used. For example, in some exemplary embodiments, water may be included in an amount ranging from about 5 weight percent based on the weight of the nicotine pre-vapor formulation to about 40 weight percent based on the weight of the nicotine pre-vapor formulation, or from about 10 weight percent based on the weight of the nicotine pre-vapor formulation to about 15 weight percent based on the weight of the nicotine pre-vapor formulation. Other amounts or percentages may be used. For example, in exemplary embodiments, the remainder of the nicotine pre-vapor formulation that is not water (and not nicotine or flavorings) is a nicotine vapor former (described above), and the nicotine vapor former is 30 weight percent to 70 weight percent propylene glycol, with the remainder of the nicotine vapor former being glycerin. Other amounts or percentages may be used.

[0103] In exemplary embodiments, the nicotine prevapor formulation includes at least one flavorant in an amount ranging from about 0.2 percent to about 15 percent by weight (e.g., the flavorant can be in the range of about 1 percent to 12 percent, or about 2 percent to 10 percent, or about 5 percent to 8 percent). In exemplary embodiments, the at least one flavorant can be at least one of a natural flavorant, an artificial flavorant, or a combination of a natural flavorant and an artificial flavorant. For example, the at least one flavorant can include menthol, etc.

[0104] In exemplary embodiments, the nicotine pre-vapor formulation includes nicotine in an amount ranging from about 1 percent to about 10 percent by weight. For example, the nicotine ranges from about 2 percent to 9 percent, or from about 2 percent to 8 percent, or from about 2 percent to 6 percent. In exemplary embodiments, the portion of the nicotine pre-vapor formulation that is not nicotine and / or flavorings includes 10 to 15 percent water by weight, and the remainder of the nicotine pre-vapor formulation is a mixture of propylene glycol and a nicotine vapor former in a weight ratio ranging from 60:40 to 40:60. Other combinations, amounts, or ranges may be used.

[0105] While exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations should not be considered a departure from the 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. 1. A reservoir assembly for a nicotine e-vaping device, the reservoir assembly comprising: an outer shell including a first opening, an inner surface of the outer shell at least partially defining a reservoir configured to hold a nicotine pre-vapor formulation, the nicotine pre-vapor formulation including nicotine; a wick extending from an interior of the reservoir to an exterior of the reservoir, the wick configured to draw the nicotine pre-vapor formulation held within the reservoir to the exterior of the reservoir; A first film covering the first opening, the first film comprising: a first membrane comprising one or more layers of fabric that is liquid impervious and air permeable;

2. The reservoir assembly of claim 1 , wherein the fabric comprises woven hydrophobic fibers.

3. 3. The reservoir assembly of claim 1 or 2, wherein the first opening is a slit.

4. a plurality of openings including the first opening, each opening of the plurality of openings being a pinhole; 3. The reservoir assembly of claim 1, further comprising a plurality of membranes including the first membrane, each membrane of the plurality of membranes covering a respective opening of the plurality of openings.

5. the outer shell includes a second opening; the reservoir assembly includes a second membrane covering the second opening, the second membrane including one or more layers of a second fabric that is liquid impermeable and air permeable; The reservoir assembly of any preceding claim, wherein the second opening and the first opening are on opposite sides of the outer shell.

6. the outer shell includes a third opening; A reservoir assembly according to any preceding claim, wherein the wick extends through the third opening.

7. further comprising a conduit extending through the outer shell; the conduit and the outer shell collectively define the reservoir as a space between an outer surface of the conduit and the inner surface of the outer shell; A reservoir assembly according to any preceding claim, wherein the wick extends between the outer surface of the conduit and the inner surface of the outer shell.

8. A cartridge, A reservoir assembly according to any one of claims 1 to 7; a vaporizer assembly including a heater, the vaporizer assembly configured to generate a nicotine vapor based on heating the nicotine pre-vapor formulation drawn from the reservoir by the wick.

9. 1. A nicotine e-vaping device comprising: A cartridge according to claim 8; A nicotine e-vaping device comprising a power source configured to provide power to the vaporizer assembly.

10. 1. A reservoir assembly for a nicotine e-vaping device, the reservoir assembly comprising: an outer shell extending in a first direction, the outer shell including a first end and an inner surface, the inner surface of the outer shell defining an interior of the outer shell; a plunger extending through the interior of the outer shell in a second direction perpendicular to the first direction, the plunger including a first surface and a second surface opposite the first surface, a portion of the inner surface of the outer shell defining a liquid confinement region of a portion of the interior of the outer shell between the first surface of the plunger and the first end of the outer shell, the liquid confinement region being a reservoir configured to hold a nicotine pre-vapor formulation, the plunger configured to move in the first direction within the interior of the outer shell in response to a first force applied to the first surface of the plunger by a volume of the nicotine pre-vapor formulation contained within the liquid confinement region, the nicotine pre-vapor formulation comprising the nicotine; a wick extending from the interior of the outer shell to an exterior of the liquid containment region.

11. the outer shell is cylindrical; The reservoir assembly of claim 10 , wherein the first direction extends along a longitudinal axis of the outer shell.

12. further comprising a conduit extending in the first direction through the interior of the outer shell; 12. The reservoir assembly of claim 10 or 11, wherein the plunger includes an opening through which the conduit passes.

13. The reservoir assembly of claim 12 , wherein the wick extends through the opening in the conduit.

14. A reservoir assembly according to any one of claims 10 to 13, wherein the wick extends through an opening in the first end of the outer shell.

15. The reservoir assembly of any of claims 10 to 14, further comprising a passive actuator configured to continuously apply a second force to the second surface of the plunger.

16. 16. The reservoir assembly of claim 15, wherein the magnitude of the second force is less than the magnitude of the first force associated with passing the nicotine pre-vapor formulation through the wick from the liquid confinement region to the exterior of the outer shell.

17. 17. The reservoir assembly of claim 10, wherein the plunger is configured to move within the outer shell based solely on the first force applied on the first surface of the plunger by a volume of the nicotine pre-vapor formulation contained within the liquid confinement region and a third force applied on the second surface of the plunger by atmospheric pressure.

18. A cartridge, A reservoir assembly according to any one of claims 10 to 17; a vaporizer assembly including a heater configured to generate a nicotine vapor based on heating the nicotine pre-vapor formulation drawn by the wick from the interior of the liquid confinement region; and

19. 1. A nicotine e-vaping device comprising: a cartridge according to claim 18; a power source configured to provide power to the vaporizer assembly.

20. 1. A method of filling a nicotine e-vaping device, comprising: providing an outer shell and a plunger, the outer shell extending in a first direction, the outer shell including a first end, an opening at the first end, and an inner surface, the inner surface of the outer shell partially defining an interior of the outer shell, the plunger extending through the interior of the outer shell in a second direction perpendicular to the first direction, the plunger including a first surface and a second surface opposite the first surface, the first surface and a limited portion of the inner surface of the outer shell defining a liquid containment region in the limited portion of the interior of the outer shell between the first surface of the plunger and the first end of the outer shell, the liquid containment region being a reservoir configured to hold a nicotine pre-vapor formulation, the nicotine pre-vapor formulation including nicotine; filling the liquid confinement region with the nicotine pre-vapor formulation such that the nicotine pre-vapor formulation moves the plunger in the first direction away from the first end of the outer shell in response to the nicotine pre-vapor formulation applying a first force to the first surface of the plunger; and disposing a portion of a wick within said liquid containment region.

21. 21. The method of claim 20, further comprising applying a second force to the second surface of the plunger to remove any air from the liquid confinement region.

22. 22. The method of claim 20 or 21, further comprising coupling a passive actuator to the plunger within the outer shell such that the passive actuator is configured to continuously apply a second force on the second surface of the plunger.

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