Electronic cigarette devices and their parts

Abstract

To provide a novel electronic vaping (e-vaping) device.SOLUTION: An electronic vaping (e-vaping) device comprises a cartridge 70, and a power source unit 72 connectable to the cartridge 70. The cartridge 70 comprises a reservoir 22 configured to contain a to-be-vaporized formulation, a wick 28 positioned to receive the to-be-vaporized formulation, and a susceptor 14 configured to heat the to-be-vaporized formulation received by the wick 28. The power source unit 72 comprises an induction source 35 configured to generate an inductive field to heat the susceptor 14, control circuitry 16 configured to control the induction source 35, and a power supply 1 configured to supply power to the control circuitry 16.SELECTED DRAWING: Figure 1

Description

Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 61 / 946,376, filed February 28, 2014, the entire contents of which are incorporated herein by reference. [Technical field]

[0002] Exemplary embodiments relate generally to electronic cigarette devices. [Background technology]

[0003] Electronic vaping (e-vaping) devices are used to vaporize liquid materials in a vapor for adult vapers to inhale the vapor. These electronic cigarette devices can be referred to as e-vaping devices. E-vaping devices contain a heater that vaporizes the liquid material to produce vapor. E-vaping devices contain several e-vaping elements including a power source, and an e-vaping tank or cartridge that contains the heater, along with a reservoir that can hold the liquid material. Upon use of these devices, when the liquid in the cartridge is depleted, the adult vaper replaces it with a new cartridge containing fresh liquid to continue using the device. Summary of the Invention [Means for solving the problem]

[0004] At least one exemplary embodiment discloses a liquid reservoir component for an electronic cigarette (e-vaping) device, the liquid reservoir component including a longitudinally extending outer casing, an air inlet, a vapor outlet, an inner tube within the outer casing defining a central air passage communicating between the air inlet and the vapor outlet, a liquid reservoir configured to contain a liquid material within an annular space between the outer casing and the inner tube, a susceptor positioned adjacent to the central air passage, and a wick in communication with the liquid reservoir and extending across the central air passage. The wick is configured to be in thermal communication with the susceptor such that the susceptor is operable to heat the liquid material to a temperature that vaporizes the liquid material and form a vapor in the central air passage. The liquid reservoir component is configured to connect to a power supply component including a power source in electrical communication with an induction source. The induction source is axially spaced a distance from the susceptor when the liquid reservoir component is attached to the power supply component such that when powered by the power source, the induction source is operable to generate an induction field that heats the susceptor.

[0005] In an exemplary embodiment, the susceptor is wrapped around the wick and is a coil heater.

[0006] In an exemplary embodiment, the susceptor is wrapped around the wick, and the susceptor is a ribbon of mesh material, the mesh material being at least one of an electrically resistive material and a conductive material.

[0007] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is at least one conductive filament.

[0008] In an exemplary embodiment, the susceptor is integral with the wick, the susceptor being a conductive rod that extends through the filaments of the wick.

[0009] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is a conductive flake that is within the wick.

[0010] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is part of a conductive mesh in the induction field.

[0011] In an exemplary embodiment, the susceptor is a conductive plate that contacts a portion of the wick.

[0012] In an exemplary embodiment, the susceptor is a conductive mesh that contacts a portion of the wick.

[0013] In an exemplary embodiment, the susceptor comprises at least one material selected from stainless steel, copper, a copper alloy, a ceramic material coated with a film-resistant material, a nickel-chromium alloy, and combinations thereof.

[0014] In an exemplary embodiment, the susceptor is formed from a magnetic material.

[0015] In an exemplary embodiment, the wick is formed from a plurality of filaments.

[0016] In an exemplary embodiment, the wick is formed from a porous foam.

[0017] In an exemplary embodiment, the wick is formed from a glass, fiberglass, ceramic, metal, graphite, or polymeric material.

[0018] In an exemplary embodiment, the fluid reservoir comprises a gauze sealed with seals at its upstream and downstream ends.

[0019] In an exemplary embodiment, the e-vaping device has a uniform diameter of less than about 10 mm.

[0020] At least one exemplary embodiment discloses an electronic cigarette (e-vaping) device including a liquid reservoir component connectable to a power supply component. The liquid reservoir component includes a longitudinally extending outer casing, an air inlet, a vapor outlet, an inner tube within the outer casing defining a central air flow passage communicating the air inlet and the vapor outlet, a liquid reservoir in an annular space between the outer casing and the inner tube and configured to contain a liquid material, a susceptor positioned adjacent the central air flow passage, and a wick in communication with the liquid reservoir. The wick is configured to be in thermal communication with the susceptor such that the susceptor is operable to heat the liquid material to a temperature that vaporizes the liquid material. The power supply component includes a longitudinally extending outer casing including a power source in electrical communication with an induction source. The induction source is axially spaced a predetermined distance from the susceptor when the power supply component is coupled to the liquid reservoir component. As a result, when powered by the power supply, the induction source is operable to generate an induction field that heats the susceptor, which in turn heats the liquid material to a temperature that vaporizes the liquid material.

[0021] In an exemplary embodiment, the induction source includes an induction coil at a proximal end of the susceptor of the liquid reservoir component, the induction coil configured to generate an induction field to heat the susceptor.

[0022] In the exemplary embodiment, the induction coil extends in a helix along the length of the outer casing.

[0023] In an exemplary embodiment, the induction coil includes a planar coil.

[0024] In an exemplary embodiment, the induction coil extends helically transverse to the longitudinal extent of the outer casing.

[0025] In an exemplary embodiment, the induction source further includes a cylindrical core including a ferrite material, the induction coil being wound around the core, the core extending in one of a longitudinal direction of the outer casing and a transverse direction to the longitudinal direction of the outer casing.

[0026] In an exemplary embodiment, the susceptor is wrapped around the wick, and the susceptor is a coil heater.

[0027] In an exemplary embodiment, the susceptor is wrapped around the wick, and the susceptor is a ribbon of mesh material, the mesh material being at least one of an electrically resistive material and a conductive material.

[0028] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is at least one conductive filament.

[0029] In an exemplary embodiment, the susceptor is integral with the wick, the susceptor being a conductive rod that extends through the filaments of the wick.

[0030] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is a conductive flake that is within the wick.

[0031] In an exemplary embodiment, the susceptor is integral with the wick, and the susceptor is part of a conductive mesh in the induction field.

[0032] In an exemplary embodiment, the susceptor is a conductive plate that contacts a portion of the wick.

[0033] In an exemplary embodiment, the susceptor is a conductive mesh that contacts a portion of the wick.

[0034] In an exemplary embodiment, the susceptor comprises at least one of stainless steel, copper, a copper alloy, a ceramic material coated with a thin film resistive material, a nickel chromium alloy, and combinations thereof.

[0035] In an exemplary embodiment, the liquid reservoir component further includes a mouth end insert, the mouth end insert being in communication with the air inlet.

[0036] In an exemplary embodiment, when the liquid reservoir component is connected to the power supply component, the susceptor is spaced axially from the proximal end of the induction source by approximately 0.01 to 2 mm.

[0037] In an exemplary embodiment, when the power supply component and the liquid reservoir component are connected and the susceptor is axially spaced from the proximal end of the induction source, a portion of the power supply component is within the liquid reservoir component, or when the power supply component and the liquid reservoir component are connected and the susceptor is axially spaced from the proximal end of the induction source, a portion of the liquid reservoir component is within the power supply component.

[0038] In an exemplary embodiment, the power supply component further includes a control circuit including a puff sensor configured to sense air flow and initiate generation of an induction field from an induction source in electrical communication with the power source.

[0039] In an exemplary embodiment, the puff sensor is configured to generate a plurality of signals responsive to the magnitude of a puff or inhale of the e-vaping device, such that the control circuitry can distinguish between the signals to adjust the frequency, magnitude, and / or length of time of the power cycle in response to the signal received from the puff sensor.

[0040] In an exemplary embodiment, the control circuit is configured to control a variable power cycle from the power source to the induction source as a function of the output signal of the smoke puff sensor.

[0041] In an exemplary embodiment, at least one liquid reservoir component is connected to the power supply component by a mechanical or magnetic connection, and / or the liquid reservoir component is a disposable downstream component and the power supply component is a reusable upstream component.

[0042] In an exemplary embodiment, the susceptor is formed from a magnetic material.

[0043] In an exemplary embodiment, the wick is formed from a plurality of filaments.

[0044] In an exemplary embodiment, the wick is formed from a porous foam.

[0045] In an exemplary embodiment, the wick is formed from a glass, fiberglass, ceramic, metal, graphite, or polymeric material.

[0046] In an exemplary embodiment, the electronic article, including the e-vaping device, has a uniform diameter of about 10 mm or less. The power supply component includes a puff sensor configured to sense air flow and initiate generation of an induction field from an induction source in electrical communication with a power source, and a light emitting diode (LED) at a free end of the power supply component. The LED is configured to illuminate when the induction field is generated.

[0047] In at least one exemplary embodiment, a liquid reservoir component for an electronic cigarette (e-vaping) device is disclosed. The liquid reservoir component includes a longitudinally extending outer casing, an air inlet, a vapor outlet, the air inlet and the vapor outlet at least partially defining two air passages, a liquid reservoir within the outer casing and configured to contain a liquid material, the at least two air passages extending along an outer periphery of the liquid reservoir, a susceptor positioned adjacent each air passage, and a wick in communication with the liquid reservoir. The wick is configured in thermal communication with each susceptor such that the wick conveys the liquid material to the susceptor. Each susceptor is configured to heat the liquid material to a temperature that vaporizes the liquid material. The liquid reservoir component is configured to connect with a power supply component. The power supply component includes a power source in electrical communication with an induction source. When the liquid reservoir component is connected to the power supply component, the induction sources are axially spaced from the respective susceptors such that, when powered by the power source, the induction sources are configured to generate an induction field that heats the respective susceptors.

[0048] In an exemplary embodiment, the e-vaping device includes a liquid reservoir component having a uniform diameter of less than about 10 mm.

[0049] At least one exemplary embodiment discloses an electronic cigarette (e-vaping) device including a liquid reservoir component. The liquid reservoir component includes a longitudinally extending outer casing, an air inlet, a vapor outlet, an inner tube within the outer casing defining a central air flow passage communicating the air inlet and the vapor outlet, a liquid reservoir in an annular space between the outer casing and the inner tube and configured to contain a liquid material, and a susceptor positioned adjacent to the central air flow passage. The electronic cigarette device further includes a power supply component connectable to the liquid reservoir component. The power supply component includes a piezoelectric element including a delivery tube. When the power supply component is connected to the liquid reservoir component, the delivery tube is configured to enter the liquid reservoir. As a result, the delivery tube can deliver liquid to the piezoelectric element. The piezoelectric element is configured to deliver the liquid droplets to the susceptor such that the droplets are heated to a temperature at which the susceptor vaporizes the droplets. The power supply component further includes a longitudinally extending outer casing. The outer casing includes a power source in electrical communication with the induction source. When the power supply component is attached to the liquid reservoir component, the induction source is axially spaced from the susceptor. As a result, the induction source is configured to generate an induction field that heats the susceptor. This causes the susceptor to heat the droplets to a temperature that vaporizes the droplets.

[0050] In an exemplary embodiment, the piezoelectric element is configured to convey droplets laterally to the susceptor over an actuating surface of the susceptor, the actuating surface of the susceptor being at an angle relative to a longitudinal axis of the e-vaping device.

[0051] In an exemplary embodiment, the piezoelectric element and the working surface of the susceptor are at an angle with respect to a longitudinal axis of the e-vaporizing device, and the piezoelectric element is configured on the working surface to laterally convey droplets to the working surface of the susceptor.

[0052] In an exemplary embodiment, the e-vaping device has a uniform diameter of less than about 10 mm.

[0053] At least one exemplary embodiment discloses an electronic cigarette (e-vaping) device including a liquid reservoir component. The liquid reservoir component includes a longitudinally extending outer casing, an air inlet, a vapor outlet, an inner tube within the outer casing defining a central air passage communicating the air inlet and the vapor outlet, a liquid reservoir in an annular space between the outer casing and the inner tube and configured to contain a liquid material, and a susceptor located adjacent to the central air passage and in contact with a liquid supply medium. The liquid supply medium is configured to convey the liquid material from the liquid reservoir to the susceptor such that the susceptor heats the liquid material to a temperature at which the liquid material vaporizes. A portion of the liquid storage medium surrounds the susceptor. The electronic cigarette device also includes a power supply component connectable to the liquid reservoir component. The power supply component includes a longitudinally extending outer casing including a power source in electrical communication with an induction source. When the power supply component is attached to the liquid reservoir component, the induction source extends into the liquid reservoir component and is surrounded by the susceptor such that when powered by the power supply, the induction source is operable to generate an induction field to heat the susceptor, which in turn heats the liquid material to a temperature that vaporizes the liquid material.

[0054] In an exemplary embodiment, the susceptor is formed of a wicking material configured to wick liquid from a portion of the liquid supply medium toward the central air passage.

[0055] In an exemplary embodiment, the induction source includes an induction coil wound around a cylindrical core, the cylindrical core comprising a ferrite material, the induction coil and the cylindrical core extending longitudinally of the outer casing.

[0056] In an exemplary embodiment, the e-vaping device has a uniform diameter of less than about 10 mm.

[0057] At least one exemplary embodiment discloses a method of producing vapor from an electronic cigarette (e-vaping) device, the method including wicking a portion of a liquid material from a liquid reservoir to a location adjacent an inlet of an air passage adjacent a susceptor (adjacent to an induction source), generating a signal indicative of smoke to a puff sensor by conveying a draw on the e-vaping device, vaporizing at least a portion of the wick of the liquid material by applying an oscillating power cycle to the induction source in response to the generated signal to heat the susceptor to vaporize at least a portion of the wick of the liquid material, and withdrawing the vaporized material through the air passage and the e-vaping device.

[0058] In an exemplary embodiment, the removing step removes the vaporized material along a linear air path.

[0059] In an exemplary embodiment, an electronic cigarette (e-vaping) device includes a wick in communication with a liquid reservoir, the wick adjacent an inlet of an air passage upstream of a susceptor, the susceptor being positioned adjacent an induction source upstream of the wick, and the e-vaping device is operable to perform a method.

[0060] In an exemplary embodiment, the wick is in communication with a liquid reservoir, the wick is adjacent to an inlet of an air passage upstream of a susceptor, and the susceptor is positioned adjacent to an induction source upstream of the wick. The e-vaping device is operable to perform the method.

[0061] At least one exemplary embodiment discloses a liquid reservoir component for an electronic cigarette (e-vaping) device, the liquid reservoir component including an air inlet, an outlet downstream of the air inlet, a linear internal passageway having an inlet end and communicating the air inlet and the air outlet through the inlet end, a liquid reservoir, a wick including a heatable wick portion and a second wick portion, and a susceptor in proximate relationship to the heatable wick portion. The heatable wick portion is proximate to the inlet end of the linear internal passageway across at least a portion of the inlet end. The second wick portion is positioned to draw liquid from the liquid reservoir to the heatable wick portion. The susceptor is configured to generate heat in the presence of an active oscillating electromagnetic field to vaporize liquid from the heatable wick portion. Proximate the heatable wick portion to the inlet end of the linear internal passageway, the vaporized liquid is drawn directly to the inlet end of the linear internal passageway.

[0062] In an exemplary embodiment, the liquid reservoir component includes an outer casing having an outlet end and an opposite end, a connector at the opposite end, and a support. The connector is configured to releasably couple the liquid reservoir component to another electromagnetic energy source during sealing. The support is arranged to maintain a susceptor in a fixed relationship relative to the opposite end of the outer casing. When the connector is sealed, the susceptor is axially spaced a fixed distance from the other electromagnetic energy source.

[0063] In an exemplary embodiment, the wick is a filament wick. The susceptor is wrapped around a heatable wick portion and is a coil heater.

[0064] In an exemplary embodiment, the wick is a filament wick. The susceptor is a ribbon of electrically resistive / conductive mesh material wrapped around the heatable wick portion.

[0065] In an exemplary embodiment, the wick is a filament wick, and the susceptor is at least one conductive filament integral with the wick and intertwined with the filaments of the filament wick.

[0066] In an exemplary embodiment, the wick is a filament wick. The susceptor is a conductive rod that is integral with the wick and extends through the filaments of the wick.

[0067] In an exemplary embodiment, the susceptor is integral with the wick. The susceptor is a conductive flake. The conductive flake is within the wick.

[0068] In an exemplary embodiment, the susceptor and wick are integrated into a single wick / susceptor element.

[0069] In an exemplary embodiment, the susceptor and wick have a disk-like shape, with the susceptor in overlying relationship to the wick and the inlet end of the linear internal passage.

[0070] In an exemplary embodiment, the susceptor is a conductive mesh that contacts a portion of the wick.

[0071] In an exemplary embodiment, the wick is formed from a plurality of filaments.

[0072] In an exemplary embodiment, the wick is formed from a porous foam.

[0073] In an exemplary embodiment, the wick is formed from a glass, fiberglass, ceramic, metal, graphite, or polymeric material.

[0074] In an exemplary embodiment, the susceptor is formed in the shape of a disk. [Brief description of the drawings]

[0075] [Figure 1] FIG. 1 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0076] [Diagram 2] FIG. 2 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0077] [Diagram 3] FIG. 3 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0078] [Figure 4] FIG. 4 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0079] [Diagram 5] FIG. 5 is a cross-sectional view of an e-vaping device in an unplugged state according to an exemplary embodiment disclosed herein.

[0080] [Figure 6] FIG. 6 is a cross-sectional view of the e-vaping device of FIG. 5 in a connected state.

[0081] [Figure 7A] FIG. 7A is a partial cross-sectional view of a liquid reservoir component of an e-vaping device according to an exemplary embodiment disclosed herein.

[0082] [Figure 7B] FIG. 7B is an end view of the liquid reservoir component of FIG. 7A.

[0083] [Figure 8A] FIG. 8A is a partial cross-sectional view of a liquid reservoir component of an e-vaping device according to another exemplary embodiment disclosed herein.

[0084] [Figure 8B] FIG. 8B is an end view of the liquid reservoir component of FIG. 8A.

[0085] [Figure 9A] FIG. 9A is a partial cross-sectional view of a liquid reservoir component of an e-vaping device according to yet another exemplary embodiment disclosed herein.

[0086] [Figure 9B] FIG. 9B is an end view of the liquid reservoir component of FIG. 9A.

[0087] [Figure 10A] FIG. 10A is a partial cross-sectional view of a liquid reservoir component of an e-vaping device according to yet another exemplary embodiment disclosed herein.

[0088] [Figure 10B] FIG. 10B is an end view of the liquid reservoir component of FIG. 10A.

[0089] [Figure 11A] FIG. 11A is a partial cross-sectional view of a liquid reservoir component of another exemplary embodiment of an e-vaping device including an integrated susceptor and wick element.

[0090] [Figure 11B] FIG. 11B is an end view of the liquid reservoir component of FIG. 11A.

[0091] [Figure 11C] FIG. 11C is a detailed view of the integrated susceptor and wick element of the exemplary embodiment shown in FIGS. 11A and 11B.

[0092] [Figure 12]FIG. 12 is a detailed view of another exemplary embodiment of an integrated susceptor and wick element operable with a liquid reservoir component, such as that shown in FIGS. 11A and 11B.

[0093] [Figure 13] FIG. 13 is a detailed view of yet another exemplary embodiment of an integrated susceptor and wick element operable with a liquid reservoir component, such as that shown in FIGS. 11A and 11B.

[0094] [Figure 14] FIG. 14 is a detailed view of another exemplary embodiment of an integrated susceptor and wick element operable with a liquid reservoir component, such as that shown in FIGS. 11A and 11B.

[0095] [Figure 15] FIG. 15 is a cross-sectional view of an e-vaping device according to another exemplary embodiment disclosed herein.

[0096] [Figure 16] FIG. 16 is a cross-sectional view of an e-vaping device according to yet another exemplary embodiment disclosed herein.

[0097] [Figure 17] FIG. 17 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0098] [Figure 18A] FIG. 18A is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0099] [Figure 18B] FIG. 18B is a perspective view of a susceptor formed of conductive / resistive elements capable of wicking liquid material from a liquid reservoir.

[0100] [Figure 18C] FIG. 18C is a perspective view of a susceptor that has been combined with a wicking layer to form an integrated wick / susceptor.

[0101] [Figure 19] FIG. 19 is a cross-sectional view of an e-vaping device according to an exemplary embodiment disclosed herein.

[0102] [Figure 20] FIG. 20 is a perspective view of a liquid reservoir component of an e-vaping device according to an exemplary embodiment disclosed herein.

[0103] [Figure 21] FIG. 21 is a perspective view of a liquid reservoir component of an e-vaping device according to an exemplary embodiment disclosed herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0104] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely exemplary for the purpose of describing one embodiment of the present invention. The exemplary embodiments, however, may be implemented in many alternative forms and should not be construed as being limited to only the embodiments described herein.

[0105] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, embodiments thereof are 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 exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Reference numerals refer to the same elements throughout the description of the figures.

[0106] When an element or layer is referred to as "on," "connected," "coupled" or "covering" another element or layer, it may be directly on, connected, coupled or covering the other element or layer, or there may be intervening elements or layers present. In contrast, when an element is referred to as "directly on," "directly coupled" or "directly connected to" another element or layer, there are no intervening elements or layers present. Reference numbers refer to the same elements throughout the specification. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0107] Although the terms first, second, third, etc. are used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are merely used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section described below can be a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0108] Spatially relative terms (e.g., "lower," "below," "bottom," "upper," "top," etc.) are readily used herein to describe the relationship of one element or feature to another element or feature as shown in the figures. 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 in the figures. For example, if the device in the figures were turned over, elements described as "below" or "below" the other element or feature would then be oriented "above" the other element or feature. Thus, the term "below" encompasses both an orientation above and below. The device may be oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0109] The terminology used herein is for the purpose of describing various embodiments only and is not intended to limit the example embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. "Includes," "including," "comprises," and / or "comprising," as used herein, are understood to specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups.

[0110] Exemplary embodiments are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of exemplary embodiments. As such, variations from the shapes of the illustrations are expected as a result, for example, of manufacturing techniques and / or tolerances. Thus, the exemplary embodiments should not be construed as limited to the shapes of regions illustrated herein and may include deviations in shapes that result, for example, from manufacturing. As such, the illustrated regions are schematic in nature and their shapes are not intended to represent the actual shapes of regions of a device, nor are they intended to limit the scope of the exemplary embodiments.

[0111] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the exemplary embodiments belong. Terms, including words defined in commonly used dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art. And, unless defined herein, such terms should not be interpreted in an idealized or overly formal sense.

[0112] Disclosed herein is a novel exemplary embodiment of an electronic cigarette (e-vaping) device 60. Referring to FIG. 1, the e-vaping device 60 includes a liquid reservoir component (first or cartridge portion) 70 and a reusable power supply component (battery portion) 72. An induction source 35 and a susceptor 14 operate to heat the liquid and vaporize it from a wick 28. The wick draws liquid from the liquid reservoir 22 in the liquid reservoir component 70. The liquid reservoir component 70 can be connected to the power supply component 72 by a connector 205 (e.g., a threaded connection) or another convenient one such as a slip fit, detent, clamp, snap and / or magnetic connection. The connector 205 may be a single molded piece to achieve precise alignment of the liquid reservoir component 70 and the power supply component 72. When the connector 205 is sealed, the induction source 35 is axially spaced a predetermined and / or desired amount from the susceptor 14. As a result, the induction source 35 is operable to generate an oscillating electromagnetic field that superimposes on the susceptor 14 and causes the susceptor 14 to heat. The induction source 35 is axially spaced less than about 2 mm (more preferably less than about 1 mm) from the susceptor 14. Cartridge Part

[0113] 1, the liquid reservoir component or cartridge portion 70 includes an outer casing 6 (e.g., a cylindrical tube) extending longitudinally and including an air inlet 44. An inner tube 62 defines a linear central air passage 20 in communication with the air inlet 44 and the vapor outlet (mouth-end insertion outlet) 24. There are two air inlets 44 in communication with the central air passage 20. There may also be three, four, five or more air inlets 44. When there is more than one air inlet, the air inlets 44 may be located at different locations around the circumference and / or along the length of the e-vaping device 60. Varying the size and number of the air inlets 44 can also help establish a desired resistance to the draw sensation of the e-vaping device 60, reduce the occurrence of a whistling sound during the draw of the e-vaping device 60, and reduce Helmholtz resonance within the central air passage 20.

[0114] The liquid reservoir 22 is established in an annular space between the outer casing 6 and the inner tube 62. The annular space is sealed at an upstream end by an upstream seal 15 and at a downstream location by a downstream seal (or stopper) 10. The liquid reservoir 22 includes a liquid material and, if necessary, a liquid storage medium 21 (i.e., a fibrous medium) operable to disperse the liquid material in the liquid reservoir 22. For example, the liquid storage medium 21 can be a wrapping of gauze around the inner tube 62. The liquid storage medium 21 includes an outer wrapping of gauze surrounding an inner wrapping of gauze of the same or different material. In one exemplary embodiment, the liquid storage medium 21 of the liquid reservoir 22 is comprised of alumina ceramic in the form of loose particles, loose fibers, or woven or non-woven fibers. Alternatively, the liquid storage medium 21 is comprised of a cellulosic material (e.g., cotton or gauze material) or a polymeric material (e.g., polyethylene terephthalate). The cellulosic material may be in the form of a woven fabric, or the polymeric material may be in the form of loose fiber bundles.

[0115] The liquid storage medium 21 includes a fibrous material including cotton, polyethylene, polyester, rayon, and combinations thereof. The fibers have diameters in a size range of about 6 microns to about 15 microns (about 8 microns to 12 microns, or about 9 microns to about 11 microns). The liquid storage medium 21 may be a sintered, porous, or foamed material. The fibers may be sized to be non-inhalable and may have a Y-shaped, cross-shaped, clover-shaped, or any other suitable cross-section. Alternatively, the liquid reservoir 22 may include a liquid-filled tank without the liquid storage medium 21.

[0116] 1, the liquid reservoir component 70 includes a susceptor 14 positioned adjacent an upstream portion of the central air passage 20, and a wick 28 in liquid communication with the liquid material in the liquid reservoir 22 and in thermal communication with the susceptor 14. The wick 28 is operable to draw liquid material from the liquid reservoir 22 in proximate relationship with the susceptor 14 such that the susceptor 14, upon activation by an induction source 35, heats the liquid material adjacent the wick 28 to a temperature sufficient to vaporize the liquid material and produce a vapor. The susceptor 14 is positioned within the liquid reservoir component 70 overlying and proximate at least a portion of the inlet portion 230 of the central air passage 20.

[0117] With further reference to FIG. 1, the susceptor 14 may be in the form of a thin disk or foil of electrically conductive and electrically resistive material. The material may be metallic and, if desired, magnetic. Examples of suitable electrically resistive / conductive materials used to form the susceptor 14 include metals, alloys, and superalloys. For example, but not limited to, metals such as nickel, cobalt, chromium, aluminum, titanium, zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, iron, platinum, osmium, iridium, ruthenium, rhodium, palladium, copper, and alloys thereof may be used to form the susceptor 14. The susceptor 14 includes at least one material selected from the group consisting of stainless steel, copper alloys, nickel-chromium alloys, cobalt alloys, superalloys, and combinations thereof. In alternative exemplary embodiments, for example, the susceptor 14 may be formed of nickel aluminide, materials having a layer of alumina on the surface, iron aluminide, and other composite materials. The electrically resistive / conductive material may optionally be embedded within an insulating material encapsulated or covered, or vice versa, depending on the rate of energy transfer and the required external physicochemical properties.

[0118] In an exemplary embodiment, the susceptor 14 is formed of a nickel-chromium alloy, an iron-chromium alloy. In another exemplary embodiment, the susceptor 14 may be a ceramic composite susceptor having an electrically resistive / conductive layer on its outer surface. In another exemplary embodiment, the electrically resistive / conductive layer may be embedded in the ceramic susceptor.

[0119] In another exemplary embodiment, the susceptor 14 is constructed of an iron-aluminide (eg, FeAl or Fe3Al) such as disclosed in US Pat. No. 5,595,706 to Sikka et al., or a nickel aluminide (eg, Ni3Al).

[0120] When in the form of a metal disk or foil, the susceptor 14 may be approximately 3 to 8 millimeters (mm) thick, roughly the thickness of household aluminum foil.

[0121] 1, the wick 28 is comprised of a flexible filamentary material. The wick 28 includes multiple filaments with sufficient capillarity through the interstitial spaces between the filaments to draw liquid from the liquid reservoir 22. The wick 28 may include bundles of such glass, ceramic, or metal filaments and bundles of wound filaments wound into separate bundles or strands. The wick 28 includes multiple bundles, such as three or more bundles or strands of wound glass fiber filaments.

[0122] The wick 28 includes filaments having a cross section that is generally cross-shaped, cloverleaf-shaped, Y-shaped, or any other suitable shape.

[0123] The wick 28 may comprise any suitable material or combination of materials. Examples of suitable materials are glass filaments, glass fiber filaments, and ceramic, metal, or graphite based materials. Additionally, the wick 28 may have any suitable capillarity to contain vapor generating liquids having different liquid physical properties (e.g., density, viscosity, surface tension, and vapor pressure). The capillary properties of the wick 28 and the properties of the liquid are selected such that the wick 28 is constantly wet in the area adjacent to the susceptor 14 to prevent overheating of the septum 14 and / or the wick 28.

[0124] 1 and 5, the support 207 supports the susceptor 14 in the liquid reservoir component 70 in a fixed position relative to the wick 28 and / or the connector 205. In an exemplary embodiment, the wick 28 includes a heatable wick portion (lateral middle portion) 228 that extends across (adjacent to) the upstream (inlet) portion 230 of the central air passage 20 and the upstream seal 15. The wick 28 also includes a first end 29 and a second end 31 that extend longitudinally through the upstream seal 15 within the liquid reservoir portion 22 to contact the liquid in the liquid reservoir 22. Notches are provided at locations along the circumference of the upstream seal to accommodate the placement of the ends 29, 31 of the wick 28. The wick 28 may include only one end 29 in communication with the reservoir, so long as liquid is drawn from the liquid reservoir 22 in close proximity to the susceptor 14, wherever it is located. The routing and placement of portions of the wick 28 may be other than as specifically described.

[0125] The susceptor 14 is in thermal communication with the wick 28 and heats the liquid within the wick 28 via thermal conduction. Heat from the susceptor 14 is also transferred to the incoming flow of ambient air that is drawn through the e-vaping device 60 during use, which in turn heats the liquid material via convection.

[0126] The liquid reservoir component 70 (cartridge) further includes a mouth-end insert 8 having two or more off-axis diverging outlets 24 (e.g., four outlets). Alternatively, the mouth-end insert 8 can have a single outlet 24. The mouth-end insert 8 is in fluid communication with a central air passage 20 defined within the inner tube 62.

[0127] 1 and 5, locating the susceptor 14 adjacent the inlet portion 230 of the central passage 20 promotes more complete vapor formation by providing a generally straight flow path from the location of the susceptor 14 (where the vapor is initially formed) to the interior of the mouth end insert 8. Such an arrangement avoids abrupt changes in flow direction and associated losses due to sticking and other effects that would otherwise impede vapor growth and generation. The central air passage 20 also minimizes contact and heat transfer between the vapor and the walls of the liquid reservoir 22.

[0128] The liquid material in the liquid reservoir 22 has a suitable boiling point for use in the e-vaping device 60. If the boiling point is too high, the susceptor 14 will not be able to vaporize the liquid from the wick 28. However, if the boiling point is too low, the liquid will vaporize too quickly without the susceptor 14 activated.

[0129] The liquid material includes a tobacco-containing material that includes volatile tobacco flavor compounds that are released from the liquid when heated. The liquid may also be a tobacco flavor-containing material or a nicotine-containing material. Alternatively, or in addition, the liquid may include a non-tobacco material. For example, the liquid may include water, a solvent, ethanol, a plant extract, an amino acid, caffeine, and a natural or artificial flavoring. The liquid may further include a vapor-forming agent. Examples of suitable vapor-forming agents are glycerin and propylene glycol.

[0130] One advantage of the wick arrangement is that the liquid material in the liquid reservoir 22 is protected from oxygen (because oxygen generally cannot enter the liquid reservoir through the wick). As a result, the risk of degradation of the liquid material is greatly reduced. Furthermore, by using an opaque outer casing 6, the liquid reservoir 22 is protected from light. As a result, the risk of degradation of the liquid material is greatly reduced. Thus, storage time and cleanliness can be maintained at a high level.

[0131] 3, in an exemplary embodiment, the susceptor 14 includes a wire coil that at least partially surrounds the wick 28. The wire coil extends completely or partially around the circumference of the wick 28, with or without spacing between the turns of the coil. In another exemplary embodiment, the susceptor coil is adjacently positioned but is not wrapped around the wick 28. Additionally, the downstream gasket 10 is fitted to the downstream end of the inner tube 62. Battery section

[0132] 1 (and 5), the battery section 72 has a longitudinally extending outer casing 6 and includes a power source or battery 1 in electrical communication with the induction source 35 via control circuitry 16.

[0133] The battery or power source 1 is a lithium ion battery or any of its variants, such as a lithium ion polymer battery. Alternatively, the battery may be a nickel metal hydride battery, nickel cadmium battery, lithium manganese battery, lithium cobalt battery or a fuel cell. In this case, the e-vaping device 60 can be used by the adult vaper until the energy of the power source is consumed. Alternatively, the power source 1 is rechargeable and includes circuitry that allows the battery to be recharged by an external charger. In that case, the circuitry provides power for a certain number of smokes (puffs) upon charging. After that, the circuitry needs to be reconnected to the external charger.

[0134] The control circuit 16 includes an oscillator 18 operable to oscillate the power supplied to the induction source 35. As a result, the latter (the induction source 35) generates an oscillating induction field in a desired direction and at a desired time. Such an induction source 35 can cause the susceptor 14 to be heated to a predetermined and / or desired temperature and for a predetermined and / or desired period of time. The control circuit 16 includes a voltage regulator 19 so that the voltage across the induction source 35 is controlled. The induction source 35 is powered by the power supply 1 via the oscillator 18 at a frequency of about 100 kHz to 1 MHz. The frequency is selected based on the skin depth of the susceptor 14, the axial spacing between the susceptor 14 and the induction source 35, and the parameters of the induction source 35. In the case of a primary induction coil 36 as shown in FIG. 2, these parameters include the spacing between the turns and the number of turns. The frequency depends on the characteristics of the ferrite core 37 around which the induction coil 36 is wound. Details of the induction source and susceptor can be found in US Pat. No. 5,613,505, which is incorporated herein by reference in its entirety.

[0135] In an exemplary embodiment, as shown in Figure 2, for example, the axis of symmetry of the primary induction coil 36 and the ferrite core 37 extends in the longitudinal direction of the outer casing 6. In an alternative exemplary embodiment, as shown in Figure 4, for example, the axis of symmetry of the induction coil 36 and the ferrite core is oriented in the transverse direction.

[0136] 1 and 5, the control circuit 16 is in responsive communication with a puff sensor (pressure sensor) 17, which is located at the tip of the battery section 72. The puff sensor 17 is operable to generate a signal responsive to air being drawn from the e-vaping device 60 through the mouth-end insert 8. In response to the signal from the puff sensor 17, the control circuit 16 transmits an oscillating power cycle to the inductive source 35. The pressure drop of a puff (or puff) of the mouth-end insert 8 of the liquid reservoir component 70 is transmitted through openings 44B and 44C (FIGS. 5 and 6) (adjacent to the connector 205) in each of the components 70 and 72, respectively, through the space provided between the adjacent portion of the casing 6 and the battery 1, to the puff sensor 17. The puff sensor 17 is operable to generate a plurality of signals (e.g., a range of signals responsive to the magnitude of a puff or puff of the e-vaping device 60). As a result, the control circuit 16 can distinguish between signals to adjust the frequency, magnitude, and / or length of time of an instantaneous power cycle in response to a signal received from the puff sensor.

[0137] A bulkhead 61 is provided at or upstream of the puff sensor 17 separating the pressure relief 44a, which is located at the tip of the battery section 7. The pressure relief 44a serves to relieve pressure on the side of the puff sensor 17, which would otherwise prevent easy operation of the puff sensor 17. In an exemplary embodiment, the puff sensor 17 and the control circuit 16 can be a single chip, such as the MP909 chip from ChipTech. The MP909 chip is an integrated circuit with timing circuits, inputs and outputs, and resistors that can function to switch (i.e., provide power from a power source to an inductive source based on the puff sensor signal and other functions, and provide power to cause an LED to blink and other functions when the power drops).

[0138] 3, 5 and 6, the power source 1 includes a battery disposed in the e-vaping device 60. An anode connector of the battery connects one pole of the induction source 35 to the negative pole (anode) of the battery. And a cathode connector of the battery connects the other pole of the induction source 35 to the positive pole (cathode) of the battery. As a result, an induction field is generated. When the induction source 35 generates the induction field, the susceptor 14 is heated. The susceptor 14 is disposed within the induction field.

[0139] The control circuit 16 is configured to provide a power cycle, the elements of which provide for optimal increase in temperature of the susceptor 14 and maintenance of the operating temperature for a predetermined and / or desired period of time. For example, the power cycle is divided into two (or more) stages having respective periods of T1 and T2. In the first stage (T1), a higher frequency and / or magnitude of oscillation is used to induce rapid heating in the susceptor 14. In the second stage (T2), the control circuit 16 can provide a more moderate frequency and / or a more moderate magnitude of oscillation to the power cycle to achieve a stable heating effect throughout the second stage. Through testing, analysis and / or modeling, the desired power cycle is established. The power cycle includes multiple stages, including stages where only the amplitude or only the frequency is changed and no power and / or oscillation is directed to the induction source 35.

[0140] The control circuitry 16 can control the induction source 35 so that an alternate induction field is generated, or in an exemplary embodiment, the control circuitry 16 can pulse the induction source 35 between on and off states so that the generated induction field heats the susceptor 14. The pulsing can control the temperature of the susceptor 14 and steam generation.

[0141] The control circuit 16 is configured to adjust the duration and / or frequency and magnitude of its response to battery voltage readings to maintain consistent performance as the voltage level of the battery 1 drops during use.

[0142] The puff sensor 17 is operable to generate a number of signals (e.g., a range of signals depending on the magnitude of the inhale or puff on the mouth-end insert 8). As a result, the control circuit 16 can distinguish between signals that adjust the frequency, magnitude, and / or instantaneous power cycle depending on the signal it receives from the puff sensor 17. For example, a heavy draw will generate a first signal from the puff sensor 17. Similarly, the control circuit may extend the time of the responsive instantaneous power cycle or make some other adjustment in the power cycle to provide a greater production of vapor.

[0143] Upon activation, the susceptor 14 heats the portion of the wick 28 that is surrounded by the susceptor in less than about 10 seconds (preferably, less than about 7 seconds). Thus, the power cycle (or maximum puff length) can range from about 2 seconds to about 10 seconds in duration (e.g., from about 3 seconds to about 9 seconds, from about 4 seconds to about 8 seconds, or from about 5 seconds to about 7 seconds).

[0144] Alternatively, the control circuit 16 includes a manually operable switch for adult vapers to initiate a puff. The characteristics and duration of current supply to the induction source 35 are preset depending on the amount of desired liquid to be vaporized. The control circuit 16 may be preprogrammed or programmed for this purpose. Alternatively, the power circuit 16 provides power to the induction source 35 as long as the puff sensor 17 detects a pressure drop.

[0145] The control circuit 16 includes an LED 48 operable to glow when the susceptor 14 is activated. The LED 48 is at the upstream end of the e-vaping device 60 such that the LED 48 mimics the appearance of burning coals during a puff. The LED 48 is positioned to be visible to an adult vaper. Additionally, the LED 48 can be utilized for vaping system diagnostics. The LED 48 is configured to allow an adult vaper to activate and / or disable the LED 48 for privacy. As a result, the LED 48 is not activated during vaping, if desired.

[0146] 6, when the connector 205 is sealed, the induction source 35 is positioned at a predetermined and / or desired axial distance from the susceptor 14, the distance being less than 2 mm, and more preferably less than 1 mm. Reusable power supply components and replaceable fluid reservoir components

[0147] 3 and 13, another exemplary embodiment has the components and functions as described in connection with the exemplary embodiment described and shown with reference to Figures 1 and 5, except that the susceptor 14 can be in the form of a wire coil (or wire cage) 14 of conductive / resistive material disposed around the filaments of the wick 28 to establish an integrated wick / susceptor element 28 / 14. Optionally, the wire material may be a magnetic material.

[0148] Further exemplary embodiments are provided that include an integrated wick / susceptor element 28 / 14. With reference to Figures 11A and 11B and particularly to Figure 11(c), the susceptor 14 includes one or more inductively heatable wire filaments that are electrically resistive / conductive and intertwined (integrated) with the filaments of the wick 28 to form the integrated wick / susceptor element 28 / 14. With reference also to Figure 12, in addition to or as an alternative to the susceptor 14 being wrapped around the wick 28, the susceptor 14 is an inductively heatable ribbon of electrically resistive / conductive mesh material. The mesh material is intertwined between the wick filaments of the wick / susceptor 28 / 14. With reference to Figure 14, another exemplary embodiment includes an inductively heatable electrically resistive / conductive flake 14 of a thin foil or metal material. The flakes are positioned along the heatable portion of the wick 28 to establish another configuration of the integrated wick / susceptor assembly 28 / 14. The flakes 14 may be rectangular, triangular, or elliptical in shape or any combination thereof. Due to their small size (less than 1 mm in width, more preferably less than about 0.5 mm in width), the flakes 14 provide a faster response to inductive heating and a more efficient transfer of heat to the liquid adjacent to the heated flakes 14.

[0149] With particular reference to Figures 8A and 8B, in an alternative exemplary embodiment, the integrated wick / susceptor element 28 / 14 is formed from a conductive mesh capable of wicking liquid material from the liquid reservoir 22. The heatable portion 801 of the conductive mesh is disposed adjacent to the inlet 230 of the central air passage 20. The mesh-like wick / susceptor element 28 / 14 includes two or more layers of woven stainless steel yarn or mesh. The mesh material properties and number of layers are selected to achieve sufficient capillarity to wick liquid toward the heatable portion 801 of the integrated wick / susceptor element 28 / 14. The integrated wick / susceptor element 28 / 14 has a heatable (center) portion 801 that is different from the ends of the wicking element 28 / 14 in terms of density, fiber length, chemistry, number of layers, width, and other methods. As a result, the center portion is configured to optimize induction heating and / or heat transfer. And the ends of element 28 / 14 are optimized for wicking. Further Exemplary Embodiments

[0150] In a further exemplary embodiment of the e-vaping device 60, referring to Figs. 5 and 6, a liquid reservoir component 70 has an air inlet 44, an outlet 24 located downstream of the air inlet, and a linear internal passageway 20 having an inlet end 230. The linear internal passageway 20 communicates with the air inlet 44 and the air outlet 24 via the inlet end 230. The liquid reservoir component 70 has a liquid reservoir 22 and a wick 28. The wick 28 has a heatable wick portion 228, a first end 29, and a second end 31. The heatable wick portion 228 is disposed adjacent to and across at least a portion of the inlet end 230 of the linear internal passageway 20. The first end 29 and the second end 31 are disposed to wick liquid from the liquid reservoir 22 to the heatable wick portion 228. The susceptor 14 is in proximal relationship to the heatable wick 228. The susceptor 14 is adapted to generate heat in the presence of an energized oscillating electromagnetic field sufficient to vaporize liquid from the heatable wick 228. The energized oscillating electromagnetic field is generated by an electromagnetic field source 72 (e.g., a power supply component) separate from the liquid reservoir component 70. The presence of the heated wick proximal to the inlet end of the linear interior passage 20 is sufficient to vaporize liquid that is wicked directly to the inlet end 230 of the linear interior passage 20, with minimal degradation.

[0151] The liquid reservoir component 70 includes an outer casing 60 having a discharge end and an opposite end. A connector 205 is at the opposite end. When closed, the connector 205 is adapted to releasably couple the separate (separate) electromagnetic energy source 72 and the liquid reservoir component 70. A support 207 is positioned to maintain the susceptor 14 in fixed relationship to the opposite end of the outer casing 60 such that, when the connector 205 is closed, the susceptor 14 is axially spaced a predetermined and / or desired distance from the separate electromagnetic energy source 72.

[0152] Referring now specifically to FIG. 5, the battery portion 72 includes a seal 233 adjacent the coupling 205 to protect the electronic contents of the battery portion 72 from external elements.

[0153] 15, in an exemplary embodiment of an e-vaping device 60, the control circuit 16 is separate from the puff sensor 17 in the power supply component 72. The control circuit 16 is then located downstream of the power source 1. The puff sensor 17 may be at the tip of the power supply component 72. A bulkhead 61 isolates the downstream side of the puff sensor 17 from the remainder of the power supply component 72.

[0154] 7A and 7B, in an exemplary embodiment, the liquid reservoir component 70 includes a filament wick 28 that rests on the inlet end 230 of the central air passage 20. The susceptor 14 includes a flat screen of electrically conductive / resistive material, and is optionally air permeable. In this exemplary embodiment and other embodiments, the susceptor 14 is supported on an internal annular flange 41 of the liquid reservoir component 70. The susceptor 14 is secured to the flange 41 by any suitable means, such as a snap fit or a heat resistant adhesive. In this exemplary embodiment and other embodiments, the air inlets 744a, 744b include two or more converging oriented channels (channels that converge toward the mouth-end insert of the e-vaping device 60). They include a beveled rim on the outer surface of the casing 6 to minimize the generation of whistling sounds during drawing of the e-vaping device 60. The air inlets 744a, 744b emit air into the liquid reservoir component 70 at a location upstream of the flange 41. In the exemplary embodiment, the susceptor 14 comprises a foil disk or perforated foil. The air inlets 744a, 744b may alternatively be configured to emit air upstream of the flange 41.

[0155] 9A and 9B, in an exemplary embodiment, the air permeable susceptor 14 includes a screen or perforated foil disk located across the central air passage 20 downstream of and adjacent to the filamentary wick 28. The susceptor 14 is optionally supported from (or affixed to) the seal 15 with a thermally insulating gasket 33 interposed between the seal 15 and the susceptor 14 to protect the seal 15 from thermal decomposition.

[0156] 10A and 10B, in an exemplary embodiment, the upstream seal 15 of the inlet portion 230 of the central channel 20 includes a wick structure. The wick structure includes a first liquid-permeable porous toroidal layer 28a. The layer 28a covers the upstream inlet (end) portion 230 of the liquid reservoir 22 such that it surrounds but does not block the central air passage 20. The wick structure also includes a disk-shaped insulating second layer 28b. The layer 28b covers the first layer 28a and extends across the central air passage 20. The first layer 28a is composed of a sintered polymer (such as those used as wicks in ink markers) or a sintered porous metal. The second upstream layer 28b includes a mat or loose weave of glass fibers that has a greater degree of capillarity and air permeability than the first layer 28a. The wick layers 28a, 28b cooperate with the proximately located susceptor 14 as taught herein. The first layer 28a may be a disk of perforated material. The first layer 28a may draw liquid from the liquid reservoir 22. The liquid may be transferred from the first layer 28a to the second layer 28b. The second layer 28b may be a fiberglass cover held tightly against the first layer 28a. The fiberglass has a loose weave so that it is air permeable. The second layer 28b is also an air permeable material. The material has the ability to wick liquid so that liquid placed in thermal communication with the susceptor 14 can be vaporized (volatilized). The air permeable material forming the second layer 28b withstands temperatures up to 400°C. In this exemplary embodiment, the susceptor 14 includes a screen or foil disk held in adjacent relationship to a second wick layer 28a.

[0157] 16, in an exemplary embodiment, the susceptor 14 and the wick 28 are integral with each other to form the wick / susceptor 28 / 14. The wick / susceptor 28 / 14 is an electrically resistive / conductive mesh screen. It is capable of wicking (drawing up) liquid from the liquid reservoir 22 to its central region. When the liquid reservoir component 70 is connected to the power supply component 72 via the connector 205, the wick / susceptor 28 / 14 is axially spaced a predetermined and / or desired distance from the induction source 35. When the power supply 1 is powered, the induction source 35 in communication with the power supply 1 and the control circuit 16 (including the voltage regulator 19 and the oscillator 18) forms a resonant circuit that is entirely contained within the power supply component 72. In this manner, the induction source 35 is operable to generate an induction field that heats the wick / susceptor 28 / 14 and vaporize liquid in the central region of the wick / susceptor 28 / 14. Therefore, no electrical connection between the liquid reservoir component 70 and the power supply component 72 is required.

[0158] Referring to FIG. 17, in an exemplary embodiment, a disk-shaped wick 28 extends across the central air passage 20. A thermally transparent element 73 then transfers heat from a heater 27 to the wick 28. The heater 27 (e.g., a ceramic resistance heater or an inductively heated susceptor) is in contact with the thermal element 73. The heater 27 is then operable, via the control circuit 16, to transfer heat passed through the thermal element 73 and heat drawn by the wick 28 when powered by the power supply 1. This vaporizes the liquid to form water vapor. The thermally transparent element 73 may be in the form of a rod or the like (so that air is drawn around it) and is part of the liquid reservoir component 70. Air is thereby drawn through the air inlet 44, past the thermally transparent element 73, and into the central air passage 20. The thermally transparent element 73 also serves to maintain the spacing between the heater 27 and the wick 28 so as to prolong the cleanliness of the heater 27 .

[0159] 18A, in a further exemplary embodiment, the induction source 35 of the power supply component 72 is configured to extend to the area of ​​the liquid reservoir component 70. As a result, when the power supply component 72 is connected to the liquid reservoir component 70, the induction source 35 is at least partially surrounded by the susceptor 14. The susceptor, represented by feature A in FIG. 18A, is formed of a conductive / resistive element 14' having the ability to wick liquid material from the liquid reservoir 22 in the area of ​​the liquid reservoir 22 adjacent to the inlet portion 230 of the central channel 20 (see FIG. 18B). Alternatively, the susceptor is coupled with a wicking layer (28) to form an integrated wick / susceptor 28 / 14 in the area of ​​the liquid reservoir 22 adjacent to the inlet portion 230 of the central channel 20 (see FIG. 18C). The wick / susceptor 28 / 14 is in communication with a portion of the liquid storage medium 21 of the liquid reservoir 22. With such an arrangement, the wick / susceptor 28 / 14 wicks liquid material from the liquid storage medium 21. A portion of the liquid storage medium 21 may surround the susceptor 14 or may surround the wick / susceptor 28 / 14.

[0160] Still referring to FIG. 18A, in an alternative exemplary embodiment, the liquid storage medium 21 is configured to contact a susceptor, represented by feature A, which is an electrically resistive / conductive cylinder. When the susceptor is heated, it directly heats the liquid material in the liquid storage medium 21 such that the liquid vaporizes. The vaporized liquid is drawn through gaps or holes 319 provided in the susceptor into the central air passage 20 (see FIG. 18C). The induction source 35 includes an induction coil 36 wound around a cylindrical core 37 that includes a ferrite material. The induction coil 36 and the cylindrical core 37 extend in the longitudinal direction of the outer casing 6. The induction coil 36 may be wound in a spiral shape around the cylindrical core 37. However, in another exemplary embodiment, the induction coil 36 can be a planar coil. The planar coil may surround the cylindrical core 37.

[0161] 16-18A, the power supply component 72 is connected to the liquid reservoir component 70 with a threaded connector 205. An air inlet 44 is included in the liquid reservoir component 70. The air inlet 44 is adjacent to the threaded connection 44. Each air inlet 44 includes a chamfered entrance or an angled passage. In an exemplary embodiment, the e-vaping device 60 includes a pair of air inlets 44. Each air inlet 44 is angled toward the mouth-end insert 8 of the e-vaping device 60 at an angle ranging from about 35° to about 55° (more preferably, ranging from about 40° to about 50°, and most preferably about 45°) relative to the longitudinal axis of the article 60. Such an arrangement minimizes (dampens) "whistling" noises during a draw of the e-vaping device 60.

[0162] 19, in a further example embodiment, the battery portion 72 includes a piezoelectric element 76 including a capillary element (or needle) 78. The element 78 extends into the liquid reservoir 22 of the liquid reservoir component 70 upon sealing of the connector 205 between the cartridge component 70 and the battery portion 72. The piezoelectric element 76 is operable in response to a puff sensor 17 (as taught above). The piezoelectric element 76 conveys droplets from the outlet 77 to the adjacent susceptor 14 when the adult vaper inhales on the e-vaping device. The induction source 35 is also activated in response to the puff sensor 17 (as taught above). The susceptor 14 vaporizes the droplets shortly thereafter to form a vapor that is drawn through the central air passage 20. The output of the piezoelectric element 76 (droplets) is directed laterally onto the susceptor 14. The working surface is angled relative to the longitudinal axis of the e-vaping device 60 such that it passes through the stream of droplets produced by the piezoelectric element 76. The angular relationship can be reversed or both components can be angled. The wick 28 is positioned adjacent to the susceptor 14 such that the wick 28 receives the output of the piezoelectric element 76 instead of the susceptor 14. Such a wick 28 is made part of the cartridge part 70 such that it is replaced with each change of the cartridge part 70.

[0163] 20 and 21, in an exemplary embodiment, the liquid reservoir 22 is a self-supporting element and is formed to include an elongated groove (recess) along the wall of the liquid reservoir 22. As a result, an air channel 26 or multiple air channels 26 are defined between the reservoir wall and an adjacent portion of the casing 6. The arrangement of the wick 28 and susceptor 14 is adjacent to and extends across the inlet (end) portion 230 of each channel 26 in accordance with the teachings above. The liquid reservoir 22 is separated into a first liquid reservoir 22a and a second liquid reservoir 22b by an internal partition 237 (shown in dashed lines in FIG. 21). Each liquid reservoir 22a, 22b includes a respective channel 26a, 26b, and each liquid reservoir further includes a respective wick 28c, 28d. Each susceptor 14a, 14b is then operable to heat a respective wick 28c, 28d (see FIG. 21). In this exemplary embodiment, each liquid reservoir 22a, 22b contains a different liquid material. As a result, vapors formed from the liquid materials may be mixed in the e-vaping device 60. Alternatively, vapors formed by the different liquid materials may be mixed in the mouth of an adult vaper.

[0164] In some exemplary embodiments, the e-vaping device 60 is about 80 mm to about 110 mm long, preferably about 80 mm to about 100 mm long, and about 10 mm or less in diameter. For example, in an exemplary embodiment, the e-vaping device 60 is about 84 mm long and has a diameter of about 7.8 mm. In alternative exemplary embodiments, the e-vaping device 60 is larger. It may be cylindrical in cross section (e.g., having a square cross section), or of other shapes than a triangular or rectangular cross section.

[0165] The outer casing 6 and / or the inner tube 62 are formed of any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composites containing one or more of these materials, or thermoplastics. Thermoplastics are suitable for food or pharmaceutical applications, and include, for example, polypropylene, polyetheretherketone (PEEK), ceramic, and polyethylene. The materials are light and non-brittle.

[0166] Having the liquid reservoir component 70 and the power supply component 72 separately allows the susceptor 14, wick 28 and liquid reservoir 22 (which contact the liquid material) to be disposed of when the liquid reservoir component 70 is depleted, and the power supply component 72 is reusable. Thus, there is no cross-contamination when using different liquid materials, for example between different mouth-end inserts 8. Also, when the liquid reservoir component 70 is replaced at appropriate intervals, the liquid material is unlikely to clog the susceptor 14 and / or wick 28. Also, locating all electrical connections on the power supply component 72 (there are no wires connecting the power supply component 72 to the liquid reservoir component 70) reduces the manufacturing cost and simplifies assembly of the e-vaping device 60.

[0167] The teachings herein describe an exemplary embodiment of an e-vaping device 60. The device 60 includes a reservoir component 70 and a battery component 72. However, the e-vaping device 60 may be configured as a single-piece item 60 without the connector 205.

[0168] The exemplary embodiment is taught to be cylindrical, although other suitable shapes include right angle, triangular, elliptical, oval, or other cross sections.

[0169] When the term "about" is used herein in connection with a numerical value, it is intended that the associated numerical value includes a tolerance of ±10% of the stated numerical value. Furthermore, when reference is made to percentages herein, it is intended that the percentages are based on weight, i.e., weight percentages.

[0170] Additionally, when the terms "generally" and "substantially" are used in connection with geometric shapes, it is intended that precision in the geometric shapes is not required, but that freedom in the shapes is within the scope of the present disclosure.

[0171] It is apparent that a new, improved, and non-obvious e-vaping device has been described herein so as to be fully understood by those skilled in the art. It is also apparent to those skilled in the art that modifications, variations, substitutions, and equivalents exist in the function of the e-vaping device, which does not substantially depart from the spirit and scope of the exemplary embodiments disclosed herein. It is therefore expressly intended that all such modifications, variations, substitutions, and equivalents (which are within the spirit and scope of the invention as defined by the appended claims) be embraced in the appended claims.

Claims

1. A cartridge; and a power supply connectable to the cartridge, The cartridge comprises: a reservoir configured to contain a vapor pre-formulation; a wick positioned to receive the vapor pre-formulation; a susceptor configured to heat the vapor pre-formulation received by the wick; the wick and the susceptor are intertwined; The power supply unit includes: an induction source configured to generate an induction field that heats the susceptor; a control circuit configured to control the inductive source; and a power source configured to provide power to the control circuit.

2. the induction source includes an induction coil; The e-vaping device of claim 1 , wherein the induction coil is configured to generate the induction field to heat the susceptor.

3. The e-vaping device of claim 2 , wherein the induction coil extends helically in the longitudinal direction of the power supply unit.

4. The e-vaping device of claim 2 , wherein the induction coil comprises a planar coil.

5. The e-vaping device of claim 2 , wherein the induction coil extends helically transversely to the longitudinal direction of the power supply unit.

6. The induction source further includes a cylindrical core including a ferrite material; The induction coil is wound around the cylindrical core; The e-vaping device of claim 2 , wherein the cylindrical core extends in one of a longitudinal direction of the power supply unit and a transverse direction relative to the longitudinal direction of the power supply unit.

7. The e-vaping device of claim 1 , wherein the susceptor is a coil heater.

8. the susceptor is a ribbon of mesh material; The e-vaping device of claim 1 , wherein the mesh material is at least one of electrically resistive and conductive.

9. The e-vaping device of claim 1 , wherein the susceptor is at least one conductive filament.

10. The e-vaping device of claim 1 , wherein the susceptor is part of a conductive mesh in the induction field.

11. The e-vaping device of claim 1 , wherein the susceptor is a conductive mesh in contact with a portion of the wick.

12. 10. The e-vaping device of claim 1, wherein the susceptor comprises at least one of stainless steel, copper, a copper alloy, a ceramic material coated with a film resistive material, a nickel-chromium alloy, and combinations thereof.

13. The cartridge comprises: An outer casing; An air inlet; A steam outlet; an air flow passage in communication with the steam outlet and the air inlet; The e-vaping device of claim 1 , wherein the susceptor is within the air flow passage.

14. The e-vaping device of claim 1, wherein when the power supply and the cartridge are connected and the susceptor is axially spaced from the proximal end of the induction source, a portion of the power supply is within the cartridge.

15. The e-vaping device of claim 1, wherein when the power supply and the cartridge are connected and the susceptor is axially spaced from the proximal end of the induction source, a portion of the cartridge is within the power supply.

16. The cartridge further includes a smoke puff sensor; 2. The e-vaping device of claim 1, wherein the puff sensor is configured to sense air flow and initiate generation of the induction field from the induction source.

17. 17. The e-vaping device of claim 16, wherein the control circuit is configured to control a variable power cycle to the inductive source as a function of an output signal of the puff sensor.

18. The e-vaping device of claim 1 , wherein the wick comprises at least one of a glass, fiberglass, ceramic, metal, graphite, or polymer material.

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