Electronic vaping device including a bipartite rigid airway tube

Abstract

The electronic vaping device includes a heating base coupled to provide power to the electronic vaping device, a flexible seal, and a bipartite rigid airway tube coupled to the heating base by the flexible seal. The bipartite rigid airway tube forms an airway for providing an inhalable dispersion. The electronic vaping device further includes a heating assembly housed within the bipartite rigid airway tube. The heating assembly includes a wick in fluid communication with a reservoir holding a pre-vaporized formulation and a heating element configured to heat the pre-vaporized formulation in the wick to generate an inhalable dispersion.

Description

[Background technology]

[0001] This application claims priority under 35 U.S.C. 119(e). U.S. Provisional Application No. 63 / 487,169, entitled "Circuit Joining Method for Automated Assembly," filed February 27, 2023; U.S. Provisional Application No. 63 / 487,175, entitled "Stamping Sprayer Technology," filed February 27, 2023; and U.S. Provisional Application No. 63 / 487,180, entitled "Simplified Cartomizer Configuration," filed February 27, 2023, all of which are incorporated by reference herein for all purposes. [Technical Field]

[0002] The present disclosure relates to electronic vaping devices.

[0003] Electronic vaping ("e-vaping") devices typically include an on-board power source, such as a battery, electrically connected to a heating element that converts a pre-vaporized formulation stored in a cartridge into a vapor. The vapor is expelled from the electronic vaping device through a mouthpiece that includes at least one outlet. Electronic vaping devices are typically either entirely disposable (where the pre-vaporized formulation is contained within a disposable unit) or partially disposable (where a reusable battery section can be attached to a disposable cartridge that contains the pre-vaporized formulation). Summary of the Invention

[0004] Various exemplary embodiments herein disclose electronic vaping devices that use a bipartite rigid airway tube and a cylindrical absorber to improve device robustness and reduce process variability. Some exemplary embodiments of electronic vaping devices may increase total particulate matter (TPM) while reducing manufacturing time and waste rates. For example, using a cylindrical absorber may improve ease of manufacturing. Additionally, using a rigid atomizer holder and cover may better protect the fragile element / wick heating assembly during manufacturing and use. Furthermore, some exemplary embodiments may reduce overall part count and component count, allowing for higher manufacturing tolerances.

[0005] In various exemplary embodiments, an electronic vaping device includes a heating base coupled to provide power to the electronic vaping device, a flexible seal, and a bipartite rigid airway tube coupled to the heating base by the flexible seal. The bipartite rigid airway tube forms an airway for providing an inhalable dispersion. A heating assembly is housed within the bipartite rigid airway tube, the heating assembly including a wick in fluid communication with a reservoir holding a pre-vaporized formulation and a heating element configured to heat the pre-vaporized formulation in the wick to produce an inhalable dispersion. Optionally, a cylindrical absorber may be included surrounding at least a portion of the bipartite rigid airway tube, the cylindrical absorber holding the pre-vaporized formulation and providing the pre-vaporized formulation to the wick.

[0006] In one form of such an exemplary embodiment, the bipartite rigid airway tube includes a heating assembly cover and a heating assembly holder having a first end engaging the heating assembly cover and a second end distal to the first end engaging the flexible seal. The first end of the heating assembly holder has a first slot with a wick. The first end of the heating assembly holder can include a graduated adapter formed on an outer surface of the heating assembly holder.

[0007] In various exemplary embodiments, the heating assembly cover includes a flared mating end that engages with the heating assembly holder and a second slot in the flared mating end that aligns with the first slot in the heating assembly cover when the bipartite rigid airway tube is assembled. The heating assembly can include an elongated conductive leg that is long enough to extend from a bottom surface of the first slot at the first end of the heating assembly holder to a bottom surface of the flexible sealant.

[0008] In any or all of the above exemplary embodiments, the electronic vaping device may include a pressure sensor having electrical contacts mounted in a sensor cavity of the flexible seal. The pressure sensor triggers power to the electrical contacts in response to pressure changes indicative of a desired draw, and the elongated conductive legs are electrically connected to the electrical contacts included in the pressure sensor. In some exemplary embodiments, the electrical contacts included in the pressure sensor are disposed on an exposed surface of the pressure sensor, the elongated conductive legs of the heating assembly have a free end distal to the wick, and the free end of at least one elongated conductive leg has a 90-degree bend that extends onto the exposed surface of the pressure sensor and directly contacts at least one electrical contact on the exposed surface of the pressure sensor to establish a solderless connection.

[0009] In various exemplary embodiments, the electrical contacts included in the pressure sensor are disposed on the exposed surface of the pressure sensor, the elongated conductive legs of the heating assembly have free ends located away from the wick, and wires connected to the electrical contacts on the exposed surface of the pressure sensor are further connected to the free ends of the elongated conductive legs. The elongated conductive legs of the heating assembly may be formed as an integral part of the heating element included in the heating assembly, and in some exemplary embodiments, may be formed as a single piece by metal stamping.

[0010] In exemplary embodiments, the flexible seal includes a conductor passageway that holds the elongated conductive legs, allowing them to pass from the top of the seal to the bottom of the seal, and seals around the elongated conductive legs. In some exemplary embodiments, the flexible seal includes an air passageway that allows air to enter through the air passageway into the air path provided by the bipartite rigid airway tube. The flexible seal may include a sensor cavity in fluid communication with the air passageway, hold a pressure sensor, and include a first sealing surface that forms a first seal at the interface of the heated base and the flexible seal, a second sealing surface that forms a second seal at the interface of the bipartite rigid airway tube and the flexible seal, and a third sealing surface that forms a third seal at the interface of the air passageway included in the flexible seal and a pressure sensor inserted into the sensor cavity.

[0011] Any one or all of the above exemplary embodiments may include an outer housing encasing a heated base, a flexible seal, a two-piece rigid airway tube, and a cylindrical absorber, where the outer housing and the two-piece rigid airway tube form a pre-vaporized solution reservoir, and the flexible seal includes a plurality of resilient sealing ribs that seal against the pre-vaporized solution reservoir.

[0012] In various exemplary embodiments, an electronic vaping device includes a two-piece rigid airway tube including a heating assembly holder and a heating assembly cover, the two-piece rigid airway tube having slidingly engaged mating ends, the heating assembly housed within the two-piece rigid airway tube and located near the mating ends of the two-piece rigid airway tube.

[0013] In some exemplary embodiments, the electronic vaping device also includes a cylindrical absorber surrounding the bipartite rigid airway tube, the heating assembly including a heating element and a wick, and the heating assembly holder and heating assembly cover have slots at their mating ends, and when assembled, the slots in the heating assembly holder and heating assembly cover align to form the wick.

[0014] In some exemplary embodiments, the electronic vaping device includes a flexible seal attached to the bottom of the heating assembly holder. In some such embodiments, the heating element includes an elongated conductive leg extending from the wick opening to the bottom of the flexible seal. The elongated conductive leg may be integral with the heating element.

[0015] In various exemplary embodiments, electrical components of an electronic vaping device may be connected in a repeatable manner that eliminates and / or reduces the use of solder and / or manual manipulation when connecting the components. Various exemplary methods and devices may be used to achieve and maintain alignment and electrical connection properties during manufacturing and / or handling during product use. Various exemplary embodiments include lead-in alignment and snap-lock features.

[0016] It will be appreciated that in the presence of e-liquids, the materials used to make the electrical connections to the heating element are important. Various exemplary embodiments include devices, methods, and connectors with pressed and formed heating element and contact geometries that are easily guided and locked into place to form a robust electrical and mechanical connection without the use of soldering and / or resistance welding.

[0017] In various exemplary embodiments, an electronic vaping assembly includes a first electromechanical contact including a guide portion and a locking portion, and a second electromechanical contact including a complementary guide portion and a complementary locking portion, where the guide portion and the complementary guide portion cooperate to guide the first electromechanical contact into locking engagement with the second electromechanical contact, and the locking portion and the complementary locking portion form a solderless electromechanical connection that locks the first electromechanical contact in a fixed position relative to the second electromechanical contact.

[0018] In some such exemplary embodiments, a first electromechanical contact includes a first flat elongated end forming a V-shaped portion having two sides, at least one of the two sides including a guide opening, and a second electromechanical contact includes a second flat elongated end including a slot having a first complementary side, a back side, a second complementary side, and an opening side, wherein the first complementary side is tapered for sliding insertion into the guide opening of the first electromechanical contact.

[0019] In one exemplary embodiment, at least one of the two sides of the V-shaped portion is a free side, having an engagement length measured from the bottom of the V-shaped portion to the terminal end of the free side, and the V-shaped portion is resiliently compressible. The second complementary side includes a protrusion extending into the slot, the distance from the back of the slot to the protrusion matching the engagement length of the free side, and the protrusion snaps into engagement with the terminal end of the free side when the V-shaped portion is resiliently compressed in response to being guided into the slot by the guide opening that slides on the tapered first complementary side, and when the first electromechanical contact reaches a locking engagement position.

[0020] In another exemplary embodiment, the first electromechanical contact includes a sleeve including a resiliently compressible tab extending from an interior surface of the sleeve, and the second electromechanical contact includes a blade having a through hole formed therethrough, the blade being sized to fit snugly within the sleeve, and the resiliently compressible tab lockingly engaging the through hole in response to the first electromechanical contact reaching a locking engagement position.

[0021] The first electromechanical contact may be comprised of a first conductive material, and the second electromechanical contact is comprised of a second conductive material different from the first conductive material. In some exemplary embodiments, the first electromechanical contact is comprised of a nickel-chromium alloy, and the second electromechanical contact is comprised of gold-plated brass. The first electromechanical contact may be integral with a heating element included in the heating assembly, and the second electromechanical contact may be attached to a heating assembly holder.

[0022] In some exemplary embodiments, a method of assembling components of an electronic vaping device includes guiding a first electromechanical contact into locking engagement with a second electromechanical contact using a guide portion of the first electromechanical contact and a complementary guide portion of the second electromechanical contact, where the first electromechanical contact is integral to the first electronic vaping component and the second electromechanical contact is attached to the second electronic vaping component, and where a locking portion of the first electromechanical contact and a complementary locking portion of the second electromechanical contact are pressed into locking engagement.

[0023] In some exemplary embodiments, the guiding action includes guiding a tapered side of a slot formed in the elongated end of the second electromechanical contact into a guide opening in a side of the V-shaped portion of the first electromechanical contact. Various exemplary embodiments include forcing the V-shaped portion of the first electromechanical contact into the slot formed in the elongated end of the second electromechanical contact until a free side of the V-shaped portion snaps under a protrusion in the slot in response to the first electromechanical contact reaching the locking engagement position.

[0024] In some exemplary embodiments, a sleeve of the first electromechanical contact with a resiliently compressible tab extending from an inner surface of the sleeve is slid onto a blade sized to fit snugly within the sleeve, with the resiliently compressible tab spring-lockingly engaging an opening in the blade when the first electromechanical contact reaches a locking engagement position. Bringing the first electromechanical contact into locking engagement with the second electromechanical contact also includes connecting a heating element to the heating assembly holder.

[0025] In some exemplary embodiments, the electronic vaping device includes a heating element having a first electromechanical contact configured to generate an inhalable dispersion by heating a pre-vaporized formulation stored within the electronic vaping device using power received through the first electromechanical contact, a second electromechanical contact held by a heating assembly holder, the second electromechanical contact connected to a power source, and the first electromechanical contact locked to the second electromechanical contact to form a solderless electromechanical connection.

[0026] In various exemplary embodiments, the first electromechanical contact includes a guide portion and a locking portion, and the second electromechanical contact includes a complementary guide portion and a complementary locking portion, where the guide portion and the complementary guide portion cooperate to guide the first electromechanical contact into locking engagement with the second electromechanical contact, and the locking portion and the complementary locking portion cooperate to form a solderless electromechanical connection and lock the first electromechanical contact in a fixed position relative to the second electromechanical contact.

[0027] In some exemplary embodiments, the first electromechanical contact includes a first flattened elongated end forming a V-shaped portion having two sides, at least one of the two sides including a guide opening, and the second electromechanical contact includes a second flattened elongated end including a slot having a first complementary side, a back side, a second complementary side, and an open side, the first complementary side being tapered for sliding insertion into the guide opening of the first electromechanical contact.

[0028] In some or all of the exemplary embodiments described above, at least one of the two sides of the V-shaped portion is a free side having an engagement length measured from a bottom surface of the V-shaped portion to a terminal end of the free side, and the V-shaped portion is resiliently compressible. The second, complementary side includes a protrusion extending into the slot, the distance from the back surface of the slot to the protrusion corresponding to the engagement length of the free side. When the V-shaped portion resiliently compresses in response to being guided into the slot by the guide opening, the protrusion overcomes the terminal end of the free side and snaps into engagement in response to the first electromechanical contact reaching a locking engagement position.

[0029] In another exemplary embodiment, the first electromechanical contact includes a sleeve including a resiliently compressible tab extending from an interior surface of the sleeve, and the second electromechanical contact includes a blade having a through hole formed therethrough, the blade being sized to fit snugly within the sleeve, and the resiliently compressible tab lockingly engaging the through hole in response to the first electromechanical contact reaching a locking engagement position.

[0030] In any or all of the above exemplary embodiments, the first electromechanical contact is composed of a first conductive material and the second electromechanical contact is composed of a second conductive material different from the first conductive material. The first electromechanical contact may be composed of a nickel-chromium alloy and the second electromechanical contact may be composed of gold-plated brass. In various exemplary embodiments, the first electromechanical contact may be integral with the heating element. [Brief explanation of the drawings]

[0031] Various features and advantages of the non-limiting embodiments described herein will become more apparent from a consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes and should not be construed as limiting the scope of the claims. Unless explicitly stated, the accompanying drawings are not to be considered as drawn to scale. Various dimensions of the drawings may be exaggerated for clarity.

[0032] [Figure 1] FIG. 1 is an exploded view of an electronic vaping device according to various exemplary embodiments.

[0033] [Figure 2] FIG. 2 is a cross-sectional view of an electronic vaping device according to various exemplary embodiments.

[0034] [Figure 3] FIG. 3 is a perspective view of a portion of an electronic vaping device internal assembly according to various exemplary embodiments.

[0035] [Figure 4] FIG. 4 is an exploded view of a heating assembly connected without soldering to power contacts contained in a heating assembly holder, according to various exemplary embodiments.

[0036] [Figure 5] FIG. 5 is a perspective view of a portion of an alternative internal electronic vaping assembly according to various exemplary embodiments.

[0037] [Figure 6] FIG. 6 is an exploded view of a heating assembly connected without soldering to power contacts contained in a heating assembly holder, according to various exemplary embodiments.

[0038] [Figure 7] FIG. 7 is an exploded perspective view of another internal electronic vaping assembly according to various example embodiments.

[0039] [Figure 8] FIG. 8 is an exploded view of a heating assembly connected without soldering to power contacts contained in a heating assembly holder, according to various exemplary embodiments.

[0040] [Figure 9]FIG. 9 is an exploded perspective view of an internal electronic vaping assembly according to various exemplary embodiments.

[0041] [Figure 10] FIG. 10 is a perspective side view of an assembled electronic vaping device according to various exemplary embodiments.

[0042] [Figure 11] FIG. 11 is a perspective view of a portion of an internal electronic vaping assembly according to various exemplary embodiments.

[0043] [Figure 12] FIG. 12 is an exploded view of an upper electronic vaping assembly according to various exemplary embodiments.

[0044] [Figure 13A] FIG. 13A is a perspective view of an upper electronic vaping assembly according to various exemplary embodiments.

[0045] [Figure 13B] FIG. 13B is another perspective view of an upper electronic vaping assembly according to various exemplary embodiments.

[0046] [Figure 14] FIG. 14 is a perspective view of an electronic vaping device according to various exemplary embodiments.

[0047] [Figure 15] FIG. 15 is an exploded view of an upper electronic vaping assembly according to various exemplary embodiments.

[0048] [Figure 16] FIG. 16 is a perspective cross-sectional view of an electronic vaping device according to various exemplary embodiments.

[0049] [Figure 17A]FIG. 17A is a cross-sectional view of a seal portion of an electronic vaping device according to various exemplary embodiments.

[0050] [Figure 17B] FIG. 17B is a cross-sectional view of a seal portion of an electronic vaping device according to various exemplary embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0051] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative examples for describing the exemplary embodiments. 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.

[0052] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, such exemplary embodiments are illustrated in the drawings and will be described in detail herein. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Like numbers refer to like elements throughout the description of the drawings.

[0053] 1 , an electronic vaping device 100 will be discussed according to various exemplary embodiments. In various exemplary embodiments, the electronic vaping device 100 includes a rechargeable battery assembly 150 that includes a power connector / wire 153. The rechargeable battery assembly 150 may be housed within a heating base 139. The heating base 139 may also house a puff sensor 123 that detects negative pressure changes that occur when an adult electronic vaping consumer inhales through a heating assembly cover 140. In at least one exemplary embodiment, the puff sensor 123 is configured as described in U.S. Patent No. 9,072,321, issued July 7, 2015, to Liu, the entire contents of which are incorporated herein by reference.

[0054] In some exemplary embodiments, with the rechargeable battery assembly 150 and puff sensor 123 assembled within the heating base 139, the power connector / wire 153 may be connected to one or more puff sensor contacts 123a. The one or more puff sensor contacts 123a are also connected to power contacts 171 via conductors (not shown) included in the heating assembly holder 170. The heating assembly 130 is further electrically connected to the power contacts 171. The heating base 139 is matable with the heating assembly holder 170 via a seal 137, which seals the heating base 139 from a tank (not shown in this view) that stores the pre-vaporized formulation.

[0055] In various exemplary embodiments, the heating assembly holder 170 mates with the heating assembly cover 140 to form a two-part rigid airway tube in which the heating assembly 130 is housed. In some exemplary embodiments, the heating assembly 130 is connected to a puff sensor 123, which is connected to a rechargeable battery assembly 150 and functions as a switch that provides power to the heating assembly 130 when activated by inhalation or aspiration.

[0056] The heating base 139 may also include an air passageway 105. This air passageway forms part of the air path through which air drawn through one or more of the openings 103 in the outer housing 110 passes over the puff sensor 123 and through the bipartite rigid airway tube formed by the assembly holder 170 and the heating assembly cover 140. As air flows through the air path and around the heating assembly 130, the heating assembly 130 heats the pre-vaporized solution to produce an inhalable dispersion. This dispersion is entrained in the airflow and delivered to an adult consumer engaging in e-vaping via the mouth end 201. As used herein, the term "mouth end" refers to the end of a housing, cover, or the like through which an adult consumer draws in the inhalable dispersion. In contrast, a mouthpiece is fully integrated into a housing, cover, or the like, while a mouthpiece is a separately identifiable component that is part of an e-cigarette device.

[0057] In some exemplary embodiments, when the bipartite rigid airway tube and heating base 139 are placed within outer housing 110, a pre-vaporized solution reservoir is formed between the bipartite rigid airway tube and outer housing 110. Seal 137 prevents the liquid pre-vaporized formulation from exiting the reservoir or entering heating base 139. In various exemplary embodiments, the reservoir is filled with the pre-vaporized formulation, which is absorbed into heating assembly 130 and converted into an inhalable dispersion that is delivered through the bipartite rigid airway tube formed by assembly holder 170 and heating assembly cover 140. Optionally, various exemplary embodiments may include a cylindrical absorber 160 configured to be slidable onto the bipartite rigid airway tube and substantially fill the reservoir formed between the bipartite rigid airway tube and outer housing 110.

[0058] In at least one exemplary embodiment, the cylindrical absorber 160 may be a fibrous material including cotton, polyethylene, polyester, rayon, or a combination thereof. The fiber diameter ranges from about 6 microns to about 15 microns (e.g., about 8 microns to about 12 microns, or about 9 microns to about 11 microns). The storage medium may be a sintered, porous, or foam material. The fibers may also be sized to be non-respirable and may have a Y-shaped, cross-shaped, clover-shaped, or other suitable cross-section. In at least one exemplary embodiment, the reservoir 95 may not include any storage medium and may comprise a fill tank containing only the pre-vaporization formulation. U.S. Application Serial No. 18 / 411,538, filed January 1, 2024, entitled "Electronic Vaping Device Including a Transfer Pad with Oriented Fibers," describes various exemplary embodiments of an electronic vaping device, including a heating assembly, an absorbent material, and the like, and is incorporated herein by reference in its entirety.

[0059] Referring now to FIG. 2, an electronic vaping device 200 according to various exemplary embodiments will be described. The electronic vaping device 200 is an assembly view of the components shown in FIG. 1, and in various exemplary embodiments includes an outer housing 110, a cylindrical absorber 160 surrounding a two-piece rigid airway tube formed by a heating assembly holder 170 and a heating assembly cover 140. In at least some exemplary embodiments, the cylindrical absorber 160 substantially fills a reservoir 260 formed between the outer housing 110 and the two-piece rigid airway tube. The electronic vaping device 200 may further include a heating assembly 1030, a puff sensor 123, a seal 137, a puff sensor seal 241, and a rechargeable battery assembly 150.

[0060] In some exemplary embodiments, as shown by the white arrow in FIG. 2 , when an adult consumer inhales air through opening 201, the air is drawn into air inlet 203 in outer housing 110 and into channel 105 (not shown in this figure). Additionally and / or alternatively, in various exemplary embodiments, air inlet 203 is an example of opening 103 ( FIG. 1 ). The location of air inlet 203 can be varied, and the position, length, and size of channel 105 ( FIG. 1 ) can also be varied based on the location of air inlet 203. Channel 105 ( FIG. 1 ) directs air around and above puff sensor 123 and into cavity 105a, where negative pressure builds as air continues to be drawn into opening 105b in heating assembly holder 170. The membrane of puff sensor 123 deforms in response to negative pressure cavity 105a, activating a transistor or other switching element, which connects power from rechargeable battery assembly 150 to heating assembly 130. In at least one embodiment, the puff sensor 123 shuts off power when puffing is complete or after a maximum puffing time has elapsed.

[0061] In various exemplary embodiments, the pre-vaporized formulation may be stored in tank 260 and absorbed in cylindrical absorber 160. Heating assembly 130 draws the pre-vaporized formulation from tank 260 and / or cylindrical absorber 160, and when puff sensor 123 detects that power is connected to heating assembly 130, heats the drawn pre-vaporized formulation to produce an inhalable dispersion. The inhalable dispersion is drawn in through opening 105c in heating assembly cover 140 and discharged through opening 201 in outer housing 110.

[0062] Referring now to FIG. 3 , a portion of the internal electronic vaping assembly 300 will be described according to various exemplary embodiments. In some exemplary embodiments, the portion of the internal electronic vaping assembly 300 includes a rechargeable battery assembly 150. The rechargeable battery assembly 150 is configured to be housed within a heater base 139 and includes a puff sensor 123 connected between the rechargeable battery assembly 150 and the heater assembly 130. In some exemplary embodiments, the heater base 139 includes a channel 105 configured to direct air drawn into the electronic vaping assembly 300 through an air inlet 203 and / or other opening (not shown), past the puff sensor 123, and into the heater assembly 130. In various exemplary embodiments, the puff sensor 123 includes a membrane 123 b configured to deform in the presence of negative pressure generated when an adult electronic vaping consumer draws air through an air path including the channel 105 and the heater assembly holder 170. The heater assembly 130 is connected to power contacts attached to or otherwise contained within the heater assembly holder 170 without soldering. The solderless connection is shown in area 400 .

[0063] Referring now to Figure 4, a heating assembly 130 solderlessly connected to power contacts included in a heating assembly holder 170 will be described in accordance with various exemplary embodiments. Figure 4 is an expanded view of area 400 of Figure 3, showing the top of the heating assembly holder 170, including power contacts 440 solderlessly connected to connectors 477 of the heating assembly 130. The heating assembly 130 includes a wick 410 held within a heating element 420 and configured to wick a pre-vaporized formulation from a reservoir (not shown).

[0064] In at least one exemplary embodiment, the wick 410 can include one or more sheets of material, such as a sheet formed of borosilicate fibers. The sheets of material can be folded, braided, twisted, glued, etc., to form the wick 410. The sheets of material can include one or more layers of material. The sheets of material can be folded and / or twisted. When multiple layers of material are included, each layer can have the same or a different density from the other layers. The layers can have the same or different thicknesses. The wick 410 can have a thickness ranging from about 0.2 mm to about 2.0 mm (e.g., from about 0.5 mm to about 1.5 mm, or from about 0.75 mm to about 1.25 mm). In at least one exemplary embodiment, the wick 410 includes braided amorphous silica fibers.

[0065] In some exemplary embodiments, the heating element 420 and the integrated connector 477 are integrally formed as a single component. In various exemplary embodiments, the heating element 420 has a "taco shell" shape, including three sides that contact the wick 410. The three sides of the taco shell-shaped heating element may be formed from a single, continuous, serpentine wire made of a conductive material, such as a nickel-chromium alloy. Some exemplary embodiments may include a heating element as described in U.S. Patent No. 10,575,560 (issued March 3, 202, to Tucker et al.), the contents of which are incorporated herein by reference in their entirety. Other exemplary embodiments may include a heating element as described in U.S. Patent Application No. 15 / 729,909, filed October 11, 2017, and entitled "Collapsible Heater for Electronic Vaping Devices," by Holtz et al., the entire contents of which are incorporated herein by reference.

[0066] In at least one exemplary embodiment, the integrated connector 477 includes a sleeve-like guide portion, and the power contacts 440 include a complementary blade-like guide portion sized to fit snugly within the sleeve. The integrated connector 477 also includes a locking portion 478 in the form of a resiliently compressible tab extending from the interior surface of the sleeve, and the power contacts 440 include a complementary locking portion in the form of a through-hole formed in the blade. In various exemplary embodiments, the tab on the sleeve portion of the integrated connector 477 is biased toward the inside of the sleeve portion. This causes the tab to resiliently compress and move until it is positioned over the hole in the blade as the sleeve is slid over the blade. At this point, the tab returns to its original biased position, locking the sleeve to the blade.

[0067] In at least one exemplary embodiment, the guide portion and the complementary guide portion cooperate to guide the first electromechanical contact into locking engagement with the second electromechanical contact, and the lock portion and the complementary lock portion cooperate to form a solderless electromechanical connection that locks the first electromechanical contact in a fixed position relative to the second electromechanical contact.

[0068] In the illustrated exemplary embodiment, the sleeve and blade cooperate to guide the sleeve into position on the blade, and the resiliently compressible tab springs into locking engagement with the through hole in the blade upon the first electromechanical contact reaching the locking engagement position.

[0069] Referring now to FIG. 5 , portions of an alternative internal electronic vaping assembly are described in accordance with various exemplary embodiments. In some exemplary embodiments, portions of the alternative internal electronic vaping assembly 500 include a heater base 139, a heater assembly 530, and a heater assembly cover 140. The heater assembly 530 is connected, without soldering, to power contacts attached to or otherwise integrated into the heater assembly holder 170. When mated together, the heater assembly cover 140 and the heater assembly holder 170 form a two-part rigid airway tube that covers the heater assembly 530 and provides an airway pathway for the inhalable dispersion produced by the heater assembly 530 to be delivered to an adult consumer engaging in electronic vaping. The solderless connections are shown in area 600.

[0070] 6, various exemplary embodiments are described in which the heating element 620 of the heating assembly 530 is solderlessly connected to power contacts 640 included in the heating assembly holder 170 using an integrally formed connector on the heating element 623. In various exemplary embodiments, the heating element 620 has a "taco shell" shape with three sides formed from a continuous, single, serpentine-shaped wire made of a conductive material, such as a nickel-chromium alloy. The heating element 620 is similar to the heating element 420 (FIG. 4) except for the shape of the integral connector 677.

[0071] In at least one exemplary embodiment, integrated connector 677 includes a guide portion in the form of guide opening 610. In some exemplary embodiments, first flattened elongated end 611 of integrated connector 677 is formed to include a resiliently compressible V-shaped portion 613 having two sides 617 and 619, and the guide opening can be formed in at least one of the two sides. In some exemplary embodiments, power contact 640 includes a complementary guide portion in the form of a tapered side 651 of a slot 655 formed in flattened elongated end 669 of power contact 640.

[0072] The integrated connector 677 may also include a locking portion in the form of a free end 618 of a resiliently compressible V-shaped portion 613 of the integrated connector 677. The power contact 640 may include a complementary locking portion in the form of a protrusion 658 on a second side 653 of the slot 655. In some such embodiments, the V-shaped portion 613 is resiliently compressed in response to being guided into the slot 655 of the power contact 640 by the guide opening 610 and tapered side 651. The protrusion 658 snaps over the end of the free side 618 of the V-shaped portion 613 in response to the first integrated connector 677 reaching a locking engagement position.

[0073] In at least one exemplary embodiment, guide portion 610 and complementary guide portion 651 cooperate to guide a first electromechanical contact (e.g., integrated connector 677) into locking engagement with a second electromechanical contact (e.g., power contact 640), such as into a locking engagement position with power contact 640. Meanwhile, lock portion 617 and complementary lock portion 658 form a solderless electromechanical connection that locks the first electromechanical contact in a fixed position relative to the second electromechanical contact. Note that in at least some exemplary embodiments, guide portion 610 and complementary guide portion 651 provide locking engagement in addition to lock portion 617 and complementary lock portion 658.

[0074] 7, another internal electronic vaping assembly 700 will be described according to various exemplary embodiments. In some exemplary embodiments, the portions of the internal electronic vaping assembly 700 shown include a heater base 139, a heater assembly 730, and a heater assembly cover 140. The heater assembly 730 is solderlessly connected to power contacts 740 attached to or otherwise contained within a heater assembly holder 170. The solderless connection is shown in area 800.

[0075] FIG. 8 is an exploded view of the heating assembly 730. In various exemplary embodiments, the heating assembly 730 includes a wick 410 constructed from a fibrous water-absorbing material and a stamped nickel-chromium alloy heating element 720 that can be solderlessly connected to power contacts 740 included in the heating assembly holder 170 using slots 778 formed in an integrated connector 777. In various exemplary embodiments, the slots 778 can be formed in the same stamping process used to form the stamped nickel-chromium alloy heating element 720. In some exemplary embodiments, the slots 778 can be etched or cut into the integrated connector using a separate process. In some exemplary embodiments, the slots 778 can be straight, angled, diagonal, or other shapes other than the strictly rectangular shape shown. For example, the slots 778 can be star-shaped, round, or another shape corresponding to the shape of the power contacts 740 and designed to securely mate and lock with the power contacts 740 to form a secure, solderless electrical and mechanical connection. In at least one exemplary embodiment, when the integrated connector 777 slides over the power contacts 740, the power contacts 740 are received in the slots 778, providing a friction fit that secures the heating element 720 in place while providing electrical contact.

[0076] Referring now to FIG. 9 , an internal electronic vaping assembly 900 according to various exemplary embodiments will be described. In some exemplary embodiments, the internal electronic vaping assembly 900 includes a heater base 139, a heater assembly cover 140, and a heating assembly 930, where the heating assembly 930 includes a heating element 920 having an integral end 977 and a rolled wick 910. The rolled wick 910 is an alternative embodiment to the pillow-type or sandwich-type wick 410. In the exemplary embodiment shown, the heating element 920 is spirally wrapped around the rolled wick 910; however, similar to the heating elements described in other exemplary embodiments, the heating element 920 can also heat a pre-vaporized formulation absorbed in the rolled wick 910 to produce an inhalable dispersion.

[0077] In various exemplary embodiments, the integral end 970 may be frictionally connected to the power contact 940 contained within or attached to the heating assembly cover 140 without soldering. For example, the spacing between the power contact 940 and the molding of the heating assembly cover 140 may be sufficient to allow the integral end 970 to be pressed into the power contact 940 into a locked frictional engagement. In other exemplary embodiments, the power contact 940 includes an oval-shaped opening into which the integral end 970 is pressed, which deforms to securely secure the integral end, achieving a connection that does not require soldering. In some exemplary embodiments, the power contact 940 may include an earring-like post back that locks the integral end 970 in place once mated.

[0078] Referring now to FIG. 10 , a perspective side view of an assembled electronic vaping device according to various exemplary embodiments is described. In various exemplary embodiments, the electronic vaping device 1000 includes a battery assembly 1050, a flexible seal 1023, an outer housing 1010 with an air inlet 1024 and an inhalable dispersion outlet 1005 for inhalation by an adult electronic vaping consumer, and a cylindrical absorber 160 surrounding a bipartite rigid airway tube formed by a heating assembly holder 1070 and a heating assembly cover 1040. In at least some exemplary embodiments, the cylindrical absorber 160 substantially fills a reservoir or tank 1060 formed between the outer housing 1010 and the bipartite rigid airway tube. In some exemplary embodiments, an outlet seal 1026 is provided at the end of the tank 1060 opposite the seal 1023.

[0079] In various exemplary embodiments, the electronic vaping device 1000 further includes a heating assembly including a wick that passes through a wick opening 1030 formed by aligned slots in the heating assembly holder 1070 and the heating assembly cover 1040, thereby allowing the wick of the heating assembly to contact the cylindrical absorber 160 and absorb the pre-vaporized solution stored therein.

[0080] In various exemplary embodiments, power from the battery assembly 1050 is connected via a power bar 1053 to a puff sensor (not shown in this view) inserted into the battery end of the seal 1023, which in turn provides switching power to a heating assembly (not shown in this view) positioned near the wick opening 1030 via an elongated connector 1032 that passes through the seal 1023 and reaches contacts on the puff sensor. As indicated by the white arrows, in response to inhalation at the inhalable dispersion outlet 1005, air is drawn in through the air inlet 1024 of the outer housing 1010, through a channel (not visible in this view) in the seal 1023, through the internal passage of the heating assembly holder 1070, around the heating assembly near the wick opening 1030, and out the inhalable dispersion outlet 1005. The air entering through the air inlet 1024 creates a negative pressure on the sensing side of the puff sensor integrated into the seal 1023, which causes the puff sensor to power the heating assembly. When power is supplied to the heating assembly, the heating assembly heats the pre-vaporized solution held within the heating assembly wick, thereby generating an inhalable dispersion from the pre-vaporized solution. The inhalable dispersion is entrained in the airflow through an internal passageway in the heating assembly cover 1040 to the inhalable dispersion outlet 1005.

[0081] 11 , a portion of an internal electronic vaping assembly 1100 will be described according to various exemplary embodiments. In the illustrated exemplary embodiment, the portion of the internal electronic vaping assembly 1100 includes a replaceable battery assembly 1150, which includes a printed circuit board assembly (PCBA) 1130, battery contacts 1110 mounted to the PCBA 1130 and holding a replaceable battery 1120, and a flat power conductor 1132. In various exemplary embodiments, the replaceable battery assembly 1150 is an alternative exemplary embodiment of the battery assembly 1050 ( FIG. 10 ).

[0082] Although not shown, corresponding power conductors may be located on the back side of the replaceable battery assembly 1150. In some exemplary embodiments, the flat power conductor 1132 is connected to the positive side of the battery and the circular conductor 1133 is connected to the negative side of the battery 1120. In various exemplary embodiments, the circular conductor 1133 surrounds and engages the outer case of the puff sensor attached to the seal 1023 (not visible in this view) to provide a ground, while the flat power conductor 1132 is connected to the ungrounded terminal of the puff sensor.

[0083] In various exemplary embodiments, the PCBA 1130 is coupled to the heating assembly holder 1070 via a flexible seal 1023, which in at least some exemplary embodiments isolates the battery assembly 1150 from an air path that includes the heating assembly holder 1070. In various exemplary embodiments, the flexible seal 1023 includes a conductor passageway that allows the flat power conductor 1132 to reach and connect to the heating assembly while simultaneously forming a seal around the flat power conductor 1132. The flexible seal 1023 may further include a seal air inlet 1046, which allows outside air to be drawn into the air path that includes the heating assembly holder 1070 via an air inlet in the outer housing (not shown). In at least one exemplary embodiment, the heating assembly is connected to the flat power conductor 1132 without soldering.

[0084] 12 , an upper electronic vaping assembly 1200 according to various exemplary embodiments will be described. In various exemplary embodiments, the upper electronic vaping assembly 1200 includes a heating assembly holder 1070 including a seal engagement portion 1274 and a graduated adapter 1272. The graduated adapter 1272 can include a seal engagement slot 1290 that receives a seal tab 1291 and secures the seal 1023 in place. The heating assembly holder 1070 can further include a heating assembly cover mating end that includes a holder slot 1149 and a heating assembly cover 1140 having a flared mating end 1248 that includes a cover slot 1249. In various exemplary embodiments, when the heating assembly cover 1040 is mated with the heating assembly holder 1070, the holder slot 1149 and the cover slot 1249 align to form a wick opening.

[0085] In various exemplary embodiments, the flexible seal 1023 mates with the seal engagement portion 1274 of the heating assembly holder 1170 and houses the pressure / puff sensor 1223 within a sensor cavity of the flexible seal (not visible in this view). In various exemplary embodiments, the sensing membrane 1223b of the pressure / puff sensor 1223 faces toward the seal 1023. In some exemplary embodiments, the upper electronic vaping assembly 1200 also includes a cylindrical absorber 160 disposed around a two-piece rigid airway formed by the combination of the heating assembly holder 1070 and the heating assembly cover 1040.

[0086] In various exemplary embodiments, the upper electronic vaping assembly 1200 also includes a heating assembly including a wick 410 and a heating element 1220 with an integral elongated leg having a 90-degree "L-shaped" bend 1277.

[0087] 13A , an upper electronic vaping assembly 1300 according to various exemplary embodiments will be described. The upper electronic vaping assembly 1300 includes a flexible seal 1023 (including a seal air inlet 1046 and a seal tab 1141 locked to a heater assembly holder 1070) and a heater assembly cover 1040. The heater assembly holder 1070 and the heater assembly cover 1040 are connected to form a two-piece rigid airway tube 1390. As shown, the upper electronic vaping assembly 1300 further includes a flat conductor 1285, which in some exemplary embodiments may be an elongated conductive leg integrally formed with the heating element.

[0088] 13B, the upper electronic vaping assembly 1300 will be further described in accordance with various exemplary embodiments. The upper electronic vaping assembly 1300 includes a flexible seal 1023, a heater assembly holder 1070, and a heater assembly cover 1040, which are connected to form a two-piece rigid airway tube 1390. The airway tube is configured to provide an airway pathway for delivering an inhalable dispersion to an adult consumer engaging in electronic vaping. In various exemplary embodiments, the two-piece rigid airway tube 1190 can be coupled to a heater base (not shown) using the flexible seal 1023.

[0089] In various exemplary embodiments, the heating assembly holder 1070 includes a first end configured to engage the heating assembly cover 1170 and a second end distal to the first end configured to engage the flexible seal 1023. In some exemplary embodiments, the heating assembly holder includes a graduated adapter 1192 formed on an outer surface proximate the second end of the heating assembly holder, which adapter engages the flexible seal 1023.

[0090] In various exemplary embodiments, the heating assembly cover 1040 includes a mouthpiece end 1344, a body 1346, and a flared mating end 1248 configured to engage with the heating assembly holder 1070. The flared mating end 1248 can include a slot 1249. In some such exemplary embodiments, when the bipartite rigid airway tube 1390 is assembled, the slot in the heating assembly holder aligns with the slot included in the heating assembly cover.

[0091] In various exemplary embodiments, the upper electronic vaping assembly 1300 includes an elongated conductive leg 1285 integrally formed with a heating element included in a heating assembly housed within a two-piece rigid airway tube 1390. In the exemplary embodiment shown, the upper electronic vaping assembly 1300 also includes a pressure sensor 1223 (also referred to as a puff sensor) including a switching contact 1383S, a positive contact 1383P, and a ground contact 1383G. In various exemplary embodiments, a battery positive power source is connected to the positive contact 1383P, and the ground contact 1383G is connected to ground. The switching contacts allow power to flow from the positive contact 1383P to the switching contact 1383S in response to the detection of a puff. For example, the membrane 1223b (FIG. 12) of the pressure sensor 1223 can deform in response to negative pressure created by an adult consumer inhaling through the electronic vaping device, as discussed elsewhere herein. The deformation of membrane 1223b activates a switch, such as a power transistor, within pressure sensor 1223, electrically connecting positive contact 1383P and switch contact 1383S within pressure sensor 1223. This allows positive battery power to flow through switch contact 1383S. In the exemplary embodiment shown, elongated conductive leg 1285 includes a 90-degree bend 1277 that extends onto the exposed surface of pressure sensor 1223 and makes direct contact with switch contact 1383S and ground contact 1383G on the exposed surface of pressure sensor 1223, establishing a solderless connection. In operation, when pressure sensor 1223 detects a puff and connects positive contact 1383P to switch contact 1383S, positive battery power enters positive contact 1383P via an electrical connection (not shown in FIG. 13B ), flows through conductive leg 1285 connected to switching contact 1383S, passes through the heating element (not visible in this view), flows backward through the other conductive leg 1285, and returns to ground contact 1383G. In at least one exemplary embodiment, pressure sensor 1223 is supplied with operating power via positive contact 1383P and ground contact 1383G. In the exemplary embodiment shown, the pressure sensor's sensing membrane faces toward seal 1023 and is in fluid communication with seal air inlet 1046.

[0092] Referring now to FIG. 14 , an electronic vaping device 1400 according to various exemplary embodiments will be described. The electronic vaping device 1400 includes a battery assembly 1050 connected to provide battery power to a pressure sensor 1223. The pressure sensor 1223 provides switching power to an elongated conductive leg 1285 of a heating assembly (not shown), as described above with respect to FIG. 13B . In the illustrated embodiment, a power supply ground is connected to one of the elongated legs 1285 and to the ground contact 1383G of the pressure sensor 123 via electrical contact 1487, a positive battery power source is connected to the positive contact 1383P of the pressure sensor 123 via wire 1623RED, and a switched positive battery power source is connected to the other leg 1285 via the switched contact 1383S of the puff sensor 1223. In the illustrated exemplary embodiment, the elongated conductive leg 1285 includes a 90-degree bend 1277 that extends over the exposed surface of the pressure sensor 1223. Various exemplary embodiments also include a cylindrical absorber 160 that surrounds the heating assembly holder 1070, which defines the air passageway 1470. Note that the air inlet 1024 is located near the center of the seal 1023 when in the final assembled position and is capable of fluid communication with the seal air inlet 1046.

[0093] Referring now to Figure 15, an upper electronic vaping assembly according to various exemplary embodiments will be described. In various exemplary embodiments, the upper electronic vaping assembly 1500 includes elements that are the same as or similar to those described with respect to the upper electronic vaping assembly 1200 shown in Figure 12, except that the end 1577 of the integrally molded elongated leg 1285 does not have a 90-degree bend.

[0094] 16, an electronic vaping device will be described in accordance with various exemplary embodiments. The electronic vaping device 1600 includes a battery assembly 1050 that provides battery power to the pressure sensor 1223 via wire 1623 and to one of the elongated conductive legs 1577 of the heating assembly (not shown). In the exemplary embodiment shown, the elongated conductive leg 1577 is straight and does not extend onto the exposed surface of the pressure sensor 1180. A connection to ground is provided via electrical contact 1287, which is coupled to wire 1623BLA and one of the elongated conductive legs 1577. Wire 1623BLA is also connected to ground contact 1383G of the pressure sensor 1223. Wire 1623BLU is coupled between switched contact 1383S of pressure sensor 1223 and the other elongated conductive leg 1577, and wire 1623Red connects the positive battery power to positive contact 1383P.

[0095] Note that the rotational orientation of pressure sensor 1223 has been rotated compared to pressure sensor 1223 shown in FIG. 14. Specifically, the contacts have been rotated one position clockwise. Thus, for example, positive contact 1383P is located on the left side in the view of FIG. 16, whereas positive contact 1383P is located at the bottom in the view of FIG. 14. Power flow in FIG. 16 is the same as that described above, except that wires are used to connect elongated conductive leg 1577 to the contacts of pressure sensor 1223.

[0096] 17A and 17B, which illustrate different cross sections of an electronic vaping device seal 1023, according to various exemplary embodiments. In various exemplary embodiments, the flexible seal 1023 includes a sensor cavity 1710 that is in fluid communication with an air passageway 1720 via a negative pressure port 1702. A pressure sensor having a flexible membrane can be positioned with the membrane facing the negative pressure port 1702.

[0097] In various exemplary embodiments, the flexible seal 1023 includes a seal air inlet 1046. This air inlet communicates with the housing inlet and allows air to be drawn through the air passageway 1720 and into the passageway formed by the bipartite rigid airway tube 1390 when an adult consumer inhales. Air flowing through the seal air inlet 1046 and the air passageway 1720 creates a negative pressure that can be detected by a pressure sensor located in the sensor cavity 1710. In various exemplary embodiments, the shape of the sensor cavity 1710 can be adapted to the shape and form factor of the pressure sensor to be mounted therein. The pressure sensor included in the various exemplary embodiments described herein is cylindrical and conforms to the shape of the illustrated sensor cavity 1710.

[0098] The shape, size, configuration, and number of the seal air inlets 1046 may be adjusted in some exemplary embodiments to achieve a desired air resistance (e.g., resistance to suction), a desired air flow rate, and / or other design goals. In the exemplary embodiment shown, the seal 1023 is provided with two seal air inlets 1046. The air inlets in the exemplary embodiment shown are tapered, being wider at the ends of the seal 1023 and narrowing toward the center of the seal 1023. In other exemplary embodiments, the seal air inlets 1046 may have an oval shape, rounded edges, internal ribs, flaps, etc.

[0099] In some exemplary embodiments, the flexible seal 1023 includes a sealing surface 1779 that is used to form a seal at the interface of the heating base and the flexible seal 1023. In some exemplary embodiments, the flexible seal 1023 includes another sealing surface 1770 that is used to form a seal at the interface of the flexible seal with the bipartite rigid airway tube. In yet another exemplary embodiment, the flexible seal 1023 includes yet another sealing surface 1788 that forms a third seal at the interface of an air passage contained in the flexible seal and a pressure sensor inserted into the sensor cavity. As shown, a sealing tab 1141 may be located near the sealing surface 1770 to lock the seal to the bipartite rigid airway tube. In other exemplary embodiments, a sealing tab 1141 may additionally or alternatively be located near the sealing surface 1779.

[0100] In some exemplary embodiments, the flexible seal 1023 has a "dumbbell" shape and includes a plurality of resilient sealing ribs 1730 configured to seal against the pre-vaporized solution reservoir formed between the outer housing and the two-piece rigid airway tube. While three sealing ribs are shown, more or fewer sealing ribs of the same or different circumferences may be included. Additionally, the spacing between the ribs may be varied, as may the relative positions of the sealing ribs 1730, sealing air inlet 1046, and other openings.

[0101] In some exemplary embodiments, the flexible seal 1023 also includes conductor passages 1780 configured to accommodate elongated conductive legs or other conductors, allowing the conductors to pass through the seal 1023 while still providing a seal around the elongated conductive legs or other conductors. FIG. 17A shows the distal end of the conductor passages 1780, while FIG. 17B shows the full length of the conductor passages 1780. The shape, size, and number of the conductor passages can be varied in various exemplary embodiments to provide an adequate seal for conductors passing through the seal 1023 to reach a power source on the other side. The illustrated conductor passages 1780 can be used to allow the sealed passage of various shapes of elongated conductive legs used to provide power to the heating assembly in various exemplary embodiments.

[0102] It should be understood that the shape of the battery (or batteries) for the power source may vary. For example, the battery may be cylindrical, prismatic, disc-shaped, a pouch battery, or any other variation of a battery shape known in the art. It should also be understood that various types of batteries may be used. For example, in one embodiment, the battery may be a rechargeable battery (e.g., a lithium-ion battery). In another embodiment, the battery may be a non-rechargeable battery (e.g., an alkaline battery). In yet another embodiment, the battery may comprise silver oxide, carbon-zinc, cadmium, nickel, or other materials known in the art. Furthermore, the battery may comprise a primary battery and / or a secondary battery. Those skilled in the art will recognize that various changes in the form and details of the battery are possible without departing from the spirit and scope of the present invention.

[0103] As used herein, a pre-vaporization formulation, in various embodiments, refers to a substance (e.g., a liquid, wax, gel) that can be converted into vapor. For example, a pre-vaporization formulation may include, but is not limited to, water, a solvent, an active ingredient, ethanol, a botanical extract, a natural or artificial flavor, and a vapor former such as glycerin or propylene glycol.

[0104] It will be understood that plant extracts include not only active ingredients but also their supporting ingredients (e.g., compounds that aid in the absorption of the active ingredients). Active ingredients include, but are not limited to, nicotine (e.g., tobacco-derived nicotine, synthetic nicotine), caffeine, and / or any plant extract containing medicinal plants. Tobacco-derived nicotine can be obtained from one or more species of tobacco plants, such as any plant in the Nicotiana genus, e.g., Nicotiana rustica or Nicotiana tabacum, including blends of two or more different tobacco varieties. Examples of suitable tobacco materials that can be used include, but are not limited to, flue-cured tobacco, burley tobacco, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, and blends thereof. Medicinal plant extracts can be natural components or extracts of medicinal plants that have medically recognized physiological effects (e.g., therapeutic effects, preventative effects). For example, the medicinal plant can be a cannabis plant or a cannabinoid-like plant (i.e., a plant with pharmacological effects similar to those of cannabis). In the case of the cannabis plant, the compound can be a cannabinoid. Cannabinoids interact with receptors in the body, producing a wide range of effects. As a result, cannabinoids have been used for a variety of medicinal purposes (e.g., treating pain, nausea, epilepsy, and psychiatric disorders). In the case of cannabinoid-like plants, compounds may be cannabinoid-like substances. Cannabinoid-like substances interact with receptors in the body and produce pharmacological effects similar to cannabinoids.

[0105] Examples of cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerolic acid (CBG). Tetrahydrocannabinolic acid (THCA) is the precursor to tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is the precursor to cannabidiol (CBD).

[0106] In some exemplary embodiments, in addition to the active ingredient, the pre-vaporization formulation may include flavorings of natural and / or artificial origin, including botanical extracts (e.g., tobacco extracts, cannabis extracts, cannabimimetic extracts), menthol, mint, and / or vanilla.

[0107] When an element or layer is described as being "on," "connected," "coupled," "attached," "adjacent," or "overlying" another element or layer, it should be understood that this does not mean that the element or layer is directly on, connected, coupled, attached, adjacent, or overlying the element or layer, and that other elements or layers may be present. When used "adjacent" or "overlying," the element may be directly on, connected, coupled, attached, adjacent, or overlying the other element or layer, or intermediate elements or layers may be present. In contrast, when an element is described as being "directly on," "directly connected," or "directly coupled" to another element or layer, there are no intervening elements or layers. Like numbers refer to like components 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.

[0108] Terms such as "first," "second," and "third" may be used herein to describe various elements, regions, layers, and / or sections, but 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 may be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0109] Spatially relative terms (e.g., "beneath," "below," "above," "above," "upper," etc.) may be used herein for convenience of description to describe the relationship of one element or feature to other elements or features, as shown in the drawings. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown. For example, if a device in the figures were turned over, elements described as being "below" or "below" other elements or features would then be positioned "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. The device may be positioned in other orientations (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0110] The terminology used herein is for the purpose of describing various exemplary embodiments and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are to be construed as including the plural forms unless the context clearly indicates otherwise. Furthermore, it will be understood that the terms "comprise," "including," "comprises," and / or "comprises," as used herein, specify the presence of stated features, elements, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, elements, steps, operations, elements, and / or groups thereof.

[0111] While the terms "same" or "identical" are used in describing exemplary embodiments, it should be understood that there may be some imprecision. Thus, when an element is described as being identical to another element, it should be understood to mean that the element or value is identical to the other element within a given manufacturing or operating tolerance range (e.g., ±10%).

[0112] When the terms "about" or "substantially" are used in connection with numerical values ​​herein, it is intended that the associated numerical value include a manufacturing or operating tolerance (e.g., ±10%) around the stated numerical value. Furthermore, when the terms "approximately" and "substantially" are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required, but rather that a tolerance of the shape is within the scope of the disclosure. Furthermore, 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.

[0113] A controller may include processing circuitry, such as hardware including logic circuitry, a hardware / software combination, such as a processor executing software stored in memory, or a combination thereof. For example, processing circuitry may more specifically include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a system on a chip (SoC), a programmable logic unit, a microprocessor, an application specific integrated circuit (ASIC), etc.

[0114] 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. Furthermore, terms, including terms defined in commonly used dictionaries, should be interpreted to have a meaning consistent with the meaning in the context of the relevant technical field, and will not be interpreted in an idealized or overly formal sense unless expressly defined as such in this specification.

Claims

1. An electronic vaping device, comprising: A heating base; Flexible seal and a bipartite rigid airway tube; a heating assembly contained within the bipartite rigid airway tube; the heating base is coupled to provide power to an electronic vaping device; the bipartite rigid airway tube is connected to the heating base by the flexible seal to form an airway for providing an inhalable dispersion; The heating assembly includes a wick in fluid communication with a tank holding a pre-vaporized formulation, and a heating element configured to heat the pre-vaporized formulation in the wick to produce the inhalable dispersion.

2. 10. The electronic vaping device of claim 1, wherein the bipartite rigid airway tube comprises: a heating assembly cover; and a heating assembly holder; the heating assembly holder includes a first end that engages the heating assembly cover and a second end distal to the first end that engages the flexible seal; The first end of the heating assembly holder includes a first slot aligned with the wick.

3. 3. The electronic vaping device of claim 2, The first end of the heating assembly holder includes a graduated adapter formed on an outer surface of the heating assembly holder.

4. 3. The electronic vaping device of claim 2, the heating assembly cover includes a flared mating end that engages the heating assembly holder; the flared mating end defines a second slot; The second slot is aligned with the first slot included in the heating assembly cover.

5. 3. The electronic vaping device of claim 2, The heating assembly includes an elongated conductive leg of sufficient length to extend from a bottom of the first slot at the first end of the heating assembly holder to a bottom of the flexible seal.

6. 6. The electronic vaping device of claim 5, a pressure sensor having electrical contacts mounted within the sensor cavity of the flexible seal; the pressure sensor is configured to selectively provide power from a power source to the electrical contacts in response to a pressure change indicative of the requested suction; The elongated conductive leg is electrically connected to the electrical contact included in the pressure sensor.

7. 7. The electronic vaping device of claim 6, the electrical contacts included in the pressure sensor are located on an exposed surface of the pressure sensor; the elongated conductive leg of the heating assembly includes a free end distal from the wick; An electronic vaping device, wherein the free end of at least one of the elongated conductive legs includes a 90-degree bend that extends over the exposed surface of the pressure sensor and directly contacts at least one of the electrical contacts on the exposed surface to establish a solderless connection.

8. 7. The electronic vaping device of claim 6, the electrical contacts included in the pressure sensor are located on an exposed surface of the pressure sensor; the elongated conductive leg of the heating assembly includes a free end distal from the wick; An electronic vaping device, wherein a wire attached to the electrical contact on the exposed surface is further attached to the free end of the elongated conductive leg.

9. 6. The electronic vaping device of claim 5, An electronic vaping device, wherein the elongated conductive legs of the heating assembly are formed as an integral part of the heating element included in the heating assembly.

10. 10. The electronic vaping device of claim 9, The elongated conductive leg and the heating assembly are formed as the unitary part by metal stamping.

11. 6. The electronic vaping device of claim 5, The flexible seal holds the elongated conductive leg, allows the elongated conductive leg to pass from the top of the flexible seal to the bottom of the flexible seal, and defines a conductor passage that seals around the elongated conductive leg.

12. 10. The electronic vaping device of claim 1, The flexible seal defines an air passageway that allows air to flow through the air passageway and enter the air path provided by the bipartite rigid airway tube.

13. 13. The electronic vaping device of claim 12, the flexible seal defines a sensor cavity, a first sealing surface, a second sealing surface, and a third sealing surface; the sensor cavity is in fluid communication with the air passage and holds a pressure sensor; the first sealing surface forms a first seal at an interface between the heating base and the flexible seal; the second sealing surface forms a second seal at the interface of the bipartite rigid airway tube and the flexible seal; The third sealing surface forms a third seal at an interface between the air passage included in the flexible seal and a pressure sensor inserted into the sensor cavity.

14. 10. The electronic vaping device of claim 1, The electronic vaping device further includes an outer housing enclosing the heated base, the flexible seal, the two-piece rigid airway tube, and a cylindrical absorber, the outer housing and the two-piece rigid airway tube forming a pre-vaporized solution reservoir, and the flexible seal including a plurality of resilient sealing ribs that seal against the pre-vaporized solution reservoir.

15. An electronic vaping device, comprising: a two-piece rigid airway tube including a heating assembly holder and a heating assembly cover slidingly engaged at a mating end; and a heating assembly housed within the bipartite rigid airway tube and positioned proximate the mating end of the bipartite rigid airway tube.

16. 16. The electronic vaping device of claim 15, The electronic vaping device further comprises a cylindrical absorber surrounding the bipartite rigid airway tube.

17. 16. The electronic vaping device of claim 15, the heating assembly includes a heating element and a wick; The mating ends of the heating assembly holder and the heating assembly cover define a wick opening.

18. 18. The electronic vaping device of claim 17, The electronic vaping device further comprises a flexible seal coupled to a bottom of the heating assembly holder.

19. 20. The electronic vaping device of claim 18, The heating element includes an elongated conductive leg extending from the wick opening to a bottom of the flexible seal.

20. 20. The electronic vaping device of claim 19, The elongated conductive leg is integral with the heating element.

Images