Nicotine pod assemblies and nicotine e-vaping devices

Abstract

The nicotine e-vaporizing device includes a nicotine pod assembly and a device body (100) defining a throughbore (150) configured to receive the nicotine pod assembly. The nicotine pod assembly is configured to hold a nicotine pre-vapor formulation. The throughbore in the device body includes at least one sidewall configured to deflect during insertion of the nicotine pod assembly. One or more sidewalls of the throughbore may include at least one protrusion (130b) configured to engage a corresponding recess in the nicotine pod assembly to retain the nicotine pod assembly within the throughbore in the device body.

Description

[Technical field]

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

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

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

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

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

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

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

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

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

[0010] [Figure 1] FIG. 1 is a front view of a nicotine e-vaping device according to an exemplary embodiment. [Diagram 2] FIG. 2 is a side view of the nicotine e-vaping device of FIG. [Diagram 3] FIG. 3 is a rear view of the nicotine e-vaping device of FIG. [Figure 4] FIG. 4 is a proximal end view of the nicotine e-vaping device of FIG. [Diagram 5] FIG. 5 is a distal end view of the nicotine e-vaping device of FIG. [Figure 6] FIG. 6 is a perspective view of the nicotine e-vaping device of FIG. [Figure 7] FIG. 7 is a perspective view of the device body of the nicotine e-vaping device of FIG. [Figure 8] FIG. 8 is an enlarged view of the bezel structure of FIG. [Figure 9] FIG. 9 is another enlarged view of the bezel structure of FIG. [Figure 10]FIG. 10 is a partial exploded view of the mouthpiece of FIG. [Figure 11] FIG. 11 is a partial exploded view of the bezel structure of FIG. [Figure 12] 12 is an enlarged perspective view of the mouthpiece, retaining structure, and bezel structure of FIG. [Figure 13] FIG. 13 is a partial exploded view of the front cover, frame, and rear cover of FIG. [Figure 14] 14 is a perspective view of a nicotine pod assembly of the nicotine e-vaping device of FIG. 6. [Figure 15] 15 is another perspective view of the nicotine pod assembly of FIG. 14. FIG. [Figure 16] 16 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 14. FIG. [Figure 17] 17 is a partial exploded view of the second housing section of the nicotine pod assembly of FIG. 14. FIG. [Figure 18] FIG. 18 is an exploded view of the actuation pin of FIG. [Figure 19] 19 is an exploded view of the connector module of FIG. 17. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0012] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments have been shown by way of example in the drawings and are 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 are intended to cover all modifications, equivalents, and alternatives. Like numerals refer to like elements throughout the description of the figures.

[0013] It will be understood that when an element or layer is referred to as "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, this means that it is directly on, directly connected to, directly coupled to, directly attached to, directly adjacent to, or directly covering the other element or layer, or there may be intervening elements or layers present. In contrast, when an element is referred to as "directly on," "directly connected to," or "directly bonded to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term "and / or" includes any or all combinations or subcombinations of one or more of the associated listed items.

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

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

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

[0017] When the terms "same" or "identical" are used in describing exemplary embodiments, it is understood that there may be some degree of imprecision. Thus, when one element or value is referred to as being the same as another element or value, it is understood that the element or value is the same as the other element or value within manufacturing or operating tolerances (e.g., ±10 percent).

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

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

[0020] The hardware may be implemented using processing or control circuitry including, but not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field programmable gate arrays (FPGAs), one or more systems on a chip (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application specific integrated circuits (ASICs), or any other device capable of responding to and executing instructions in a defined manner.

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

[0022] As shown in Figures 1 and 3, the nicotine e-vaping device 500 extends in a longitudinal direction and has a length that is greater than its width. Additionally, as shown in Figure 2, the length of the nicotine e-vaping device 500 is also greater than its thickness. Additionally, the width of the nicotine e-vaping device 500 may be greater than its thickness. Assuming an xyz Cartesian coordinate system, the length of the nicotine e-vaping device 500 may be measured in the y direction, the width may be measured in the x direction, and the thickness may be measured in the z direction. Based on its front, side, and rear views, the nicotine e-vaping device 500 may have a substantially straight form with tapered and / or rounded ends, although exemplary embodiments are not limited thereto.

[0023] The device body 100 includes a front cover 104, a frame 106, and a rear cover 108. The front cover 104, the frame 106, and the rear cover 108 form a device housing that encloses mechanical components, electronic components, and / or circuitry associated with the operation of the nicotine e-vaping device 500. For example, the device housing of the device body 100 may enclose a power source configured to power the nicotine e-vaping device 500, which may include providing electrical current to the nicotine pod assembly 300. Furthermore, when assembled, the front cover 104, the frame 106, and the rear cover 108 may constitute a majority of the visible portion of the device body 100. The device housing may be considered to include all components of the device body 100, except for the mouthpiece 102. In other words, the mouthpiece 102 and the device housing may be considered to form the device body 100.

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

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

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

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

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

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

[0030] The front cover 104 and the rear cover 108 may be configured to engage with the frame 106 via a snap-fit ​​arrangement. For example, the front cover 104 and / or the rear cover 108 may include a clip configured to interlock with a corresponding mating member of the frame 106. In a non-limiting embodiment, the clip may be in the form of a tab having an orifice configured to receive a corresponding mating member of the frame 106 (e.g., a protrusion having a beveled edge). Alternatively, the front cover 104 and / or the rear cover 108 may be configured to engage with the frame 106 via an interference fit (which may also be referred to as a press fit or friction fit). However, it will be appreciated that the front cover 104, the frame 106, and the rear cover 108 may be coupled via other suitable arrangements and techniques.

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

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

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

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

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

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

[0037] The nicotine pod assembly 300 may also communicate other information with the device body 100 that may be relevant to the operation of the nicotine e-vapor device 500. Examples of relevant information may include the level of the nicotine pre-vapor formulation in the nicotine pod assembly 300 and / or the amount of time that has elapsed since the nicotine pod assembly 300 was inserted into the device body 100 and activated. For example, if the nicotine pod assembly 300 was inserted into the device body 100 and activated for longer than a certain period of time (e.g., longer than six months ago), the nicotine e-vapor device 500 may not permit vaping and the adult e-vapor device user may be prompted to replace the nicotine pod assembly 300 with a new nicotine pod assembly even if the nicotine pod assembly 300 still contains an appropriate level of the nicotine pre-vapor formulation.

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

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

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

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

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

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

[0044] Although a pair of protrusions are illustrated in association with each of the upstream and downstream walls of the bezel structure 112, it should be understood that other amounts may be appropriate (e.g., one protrusion each, three protrusions each). Additionally, in an exemplary embodiment, each of the protrusions may be in the form of a spherical cap (e.g., hemisphere). Alternatively, one or more of the protrusions may be in the form of an elliptical cap (e.g., semi-elliptical), a ridge (e.g., rounded, angled), or other suitable mating structure for engaging with a corresponding recess in the nicotine pod assembly 300. Additionally, the protrusions may be an integral part of the bezel structure 112.

[0045] The first upstream protrusion 128a and the second upstream protrusion 128b are biased by the upstream engagement panel 156 of the upstream wall to interlock with the corresponding upstream recess of the nicotine pod assembly 300 during the loaded state (e.g., from the unloaded state). Similarly, the first downstream protrusion 130a and the second downstream protrusion 130b are biased by the downstream engagement panel 158 of the downstream wall to interlock with the corresponding downstream recess of the nicotine pod assembly 300 during the loaded state (e.g., from the unloaded state). Thus, in an exemplary embodiment in which the nicotine pod assembly 300 is placed in the through-hole 150 of the device body 100, the nicotine pod assembly 300 is held (e.g., squeezed) between and by the upstream engagement panel 156 of the upstream wall and the downstream engagement panel 158 of the downstream wall.

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

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

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

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

[0050] The data contacts of the device electrical connector 132 are configured to transmit data between the nicotine pod assembly 300 and the device body 100. As shown, the data contacts of the device electrical connector 132 include six rows of protrusions, but the exemplary embodiment is not limited thereto. The data contacts of the device electrical connector 132 may be positioned closer to the front cover 104 than to the rear cover 108 (or vice versa). The data contacts of the device electrical connector 132 may be separate structures that extend into the through-holes 150 when assembled. The data contacts of the device electrical connector 132 may also be retractably mounted and biased to extend into the through-holes 150 as a default, and to retract (e.g., independently) from the through-holes 150 when subjected to a force that overcomes the bias.

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

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

[0053] For example, the mouthpiece 102 may be secured, mated, or coupled (e.g., reversibly coupled) to the bezel structure 112 using a bayonet connection. In such an example, the female end of the bezel structure 112 may define a pair of opposing L-shaped slots, and the male end of the mouthpiece 102 may have opposing radial members 134 (e.g., radial pins) configured to engage with the L-shaped slots of the bezel structure 112. Each of the L-shaped slots of the bezel structure 112 may have a longitudinal portion and a circumferential portion. Optionally, the ends of the circumferential portions may have serif portions that help reduce or prevent the possibility of the radial members 134 of the mouthpiece 102 being inadvertently disengaged.

[0054] In a non-limiting embodiment, the longitudinal portion of the L-shaped slot extends parallel along the longitudinal axis of the device body 100, and the circumferential portion of the L-shaped slot extends around the longitudinal axis (e.g., the central axis) of the device body 100. As a result, to couple the mouthpiece 102 to the device housing, the mouthpiece 102 is first rotated 90 degrees to align the radial member 134 with the downstream opening of the proximal end of the frame 106 and the entrance to the longitudinal portion of the L-shaped slot of the bezel structure 112 (e.g., based on the view of FIG. 10). The mouthpiece 102 is then inserted through the frame 106 and into the bezel structure 112 such that the radial member 134 slides along the longitudinal portion of the L-shaped slot until it reaches a junction with each of the circumferential portions. At this point, the mouthpiece 102 is then rotated to move the radial member 134 across the circumferential portions until it reaches each end. If serif portions are present at each end, tactile and / or auditory feedback (e.g., an audible click) may be generated to notify the adult e-vaping device user that the mouthpiece 102 is properly coupled to the device housing. Although a pair of radial members 134 and corresponding L-shaped slots are described herein, it will be appreciated that in some instances, a single radial member 134 and a single corresponding L-shaped slot will be appropriate.

[0055] The mouthpiece 102 defines a vapor passageway 136 through which the nicotine vapor flows during vaping. The vapor passageway 136 is in fluid communication with the through hole 150 (where the nicotine pod assembly 300 is placed within the device body 100). The proximal end of the vapor passageway 136 may include a flared portion. Additionally, the mouthpiece 102 may include an end cover 138. The end cover 138 may be tapered from its distal end to its proximal end. The outlet surface of the end cover 138 defines a plurality of vapor outlets. Although four vapor outlets are shown on the end cover 138, it should be understood that the exemplary embodiment is not so limited.

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

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

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

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

[0060] During assembly, the bezel structure 112 may be secured to the frame 106 (along with other mechanical components, electronic components, and / or circuitry) before the front cover 104 and rear cover 108 are attached to the frame 106. For example, the bezel structure 112 may first be positioned relative to the frame 106 such that the downstream and upstream tabs of the bezel structure 112 are aligned with the downstream and upstream tabs of the frame 106, respectively. In an exemplary embodiment in which each of the tabs has an orifice (e.g., a preformed orifice) extending therethrough, the orifice in the downstream tab and the orifice in the upstream tab may be positioned in alignment as a result. Once proper alignment is achieved, the first fastener 142a and the second fastener 142b are introduced through the downstream tab of the frame 106 and then through the downstream tab of the bezel structure 112 (e.g., through the underside of the tabs, based on the view of FIG. 11 ). Similarly, the upstream fastener may be introduced in a similar manner through an upstream tab on the frame 106 and then through an upstream tab on the bezel structure 112. Although Figure 11 shows the device housing as already assembled prior to attachment of the bezel structure 112, it will be appreciated that this partially exploded view is only intended to show certain portions (e.g., the bezel structure 112) separate from other portions of the device body 100, and thus does not necessarily represent the order of assembly of the device body 100.

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

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

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

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

[0065] The outer surface of the connector module 320 may include at least one electrical contact. The at least one electrical contact may include a plurality of power contacts. For example, the plurality of power contacts may include a first power contact 324a and a second power contact 324b. Although the first power contact 324a and the second power contact 324b are illustrated in FIG. 14 as extending horizontally outward, it will be appreciated that in further configurations of the nicotine pod assembly 300, the first power contact 324a and the second power contact 324b may be folded upwardly adjacent the data contact 326 relative to the outer surface of the connector module 320. The first power contact 324a of the nicotine pod assembly 300 is configured to electrically connect with a first power contact of the device electrical connector 132 of the device body 100 (e.g., a power contact adjacent the first upstream protrusion 128a in FIG. 9). Similarly, the second power contact 324b of the nicotine pod assembly 300 is configured to electrically connect with the second power contact of the device electrical connector 132 of the device body 100 (e.g., the power contact adjacent the second upstream protrusion 128b in FIG. 9). Furthermore, the at least one electrical contact of the nicotine pod assembly 300 includes a plurality of data contacts 326. The plurality of data contacts 326 of the nicotine pod assembly 300 is configured to electrically connect with the data contacts of the device electrical connector 132 (e.g., the six rows of contacts in FIG. 9). Although two power contacts and six data contacts are shown in connection with the nicotine pod assembly 300, it should be understood that other variations are possible depending on the design of the device body 100.

[0066] As described above, the pod body of the nicotine pod assembly 300 may include a first housing section 302 and a second housing section 308. The first housing section 302 has a downstream end that defines a pod outlet 304. The edge of the pod outlet 304 may optionally be a raised area. In such an example, if the downstream end face of the first housing section 302 is angled inwardly, the degree of protrusion of the edge of the pod outlet 304 may be greater toward the rear face and less toward the front face. Furthermore, the rear-facing side of the pod outlet 304 may have a slope that leads upward from the downstream end face to the edge. As a result, when the nicotine pod assembly 300 is inserted into the through-hole 150 of the device body 100, the slope may facilitate the advancement of the pod outlet 304 to align with the distal end of the mouthpiece 102. In a non-limiting embodiment, the distal end of the mouthpiece 102 may include (or be formed of) a resilient material that helps accommodate advancement of the nicotine pod assembly 300 into the through hole 150 of the device body 100 and creates a seal around the pod outlet 304.

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

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

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

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

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

[0072] Alternatively, to activate the nicotine pod assembly 300 as part of inserting the nicotine pod assembly 300 into the device body 100, the nicotine pod assembly 300 may first be positioned such that the first activation pin 314a and the second activation pin 314b contact the upstream wall of the through-hole 150. The upstream end of the nicotine pod assembly 300 may then be urged toward the upstream wall of the through-hole 150 such that the first activation pin 314a and the second activation pin 314b are (e.g., simultaneously) pressed into the second housing section 308, thus transitioning from an extended state to a retracted state and releasing the nicotine pre-vapor formulation from the reservoir. When the pod electrical contacts of the nicotine pod assembly 300 are adjacent to or in contact with the device electrical contacts of the device body 100, the downstream end of the nicotine pod assembly 300 may be manipulated (e.g., pivoted) into the through-hole 150. As the nicotine pod assembly 300 advances into the through-hole 150, the upstream engagement panel 156 and / or the downstream engagement panel 158 bend and then spring back after the recesses of the nicotine pod assembly 300 engage with the corresponding protrusions of the device body 100.

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

[0074] When properly placed, the nicotine pod assembly 300 is mechanically, electrically, and fluidically connected to the device body 100. While upstream engagement of the nicotine pod assembly 300 may occur before downstream engagement in some instances, it will be appreciated that alternatively, in other instances, downstream engagement may occur before (or simultaneously with) upstream engagement.

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

[0076] In an exemplary embodiment, the seal 344 defines an opening (e.g., a central opening) that is aligned with the vapor channel 316 and configured to provide an associated clearance for accommodating the downstream end of the vaporizer 336 (e.g., FIG. 17). It should be understood that in FIG. 16, the seal 344 is shown in a perforated state. In particular, when perforated by the first and second actuation pins 314a, 314b of the nicotine pod assembly 300, the two perforated sections of the seal 344 are forced into the reservoir as flaps (as shown in FIG. 16), thus creating two perforated openings (e.g., one on each side of the central opening) in the seal 344. In contrast, when in a non-perforated state, the seal 344 has a planar configuration and only one opening (e.g., a central opening). The seal 344 is designed to have sufficient strength to remain intact to avoid premature / inadvertent tearing during normal movement and / or handling of the nicotine pod assembly 300. For example, the seal 344 may be a coated foil (eg, aluminum-backed polyethylene terephthalate (PET)).

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

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

[0079] The upstream end of the second housing section 308 defines a cavity (e.g., an underside of the second housing section 308 based on the view of FIG. 17). As described above, the cavity is configured to receive the connector module 320 (e.g., via an interference fit). In the exemplary embodiment, the cavity is located between the first and second upstream recesses 312a and 312b, and also between the first and second actuation pins 314a and 314b. When the connector module 320 is not present, the gasket 318 and the upstream end of the carburetor 336 (which extends through the gasket 318) may be visible through the cavity of the second housing section 308.

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

[0081] In an exemplary embodiment, the middle sector of the vaporizer 336 defines a pair of openings upstream of the seal 344. The vaporizer 336 may include a wick extending into and / or through both of the openings of the middle sector. The wick has voids / gaps designed for capillary action. Additionally, a heater may be disposed in a heating chamber of the middle sector of the vaporizer 336 to be in thermal contact with the wick. As a result, the nicotine pre-vapor formulation released from the reservoir may be transported via the wick to the heater in the middle sector of the vaporizer 336. The heater is configured to heat the nicotine pre-vapor formulation during vaping to generate a nicotine vapor. The heater is electrically connected to at least one electrical contact of the connector module 320. For example, one end (e.g., a first end) of the heater may be connected to the first power contact 324a, and the other end (e.g., a second end) of the heater may be connected to the second power contact 324b. The heater may include a coil-shaped heating element. In such examples, the wick may have a string-like configuration with the heater wrapped (e.g., spirally) around at least a portion of its length. Alternatively, the heater may include a folded heating element. In such examples, the wick may have a planar configuration (e.g., a fibrous pad) configured to be held by the folded heating element. Although various configurations are described above in connection with the heater and wick, it will be appreciated that other configurations and combinations are possible.

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

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

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

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

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

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

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

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

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

[0091] Each of the first power contact 324a and the second power contact 324b may be considered to have a body portion, an arm portion, a finger portion, and a leg portion. When assembled, the body portions of the first power contact 324a and the second power contact 324b may be adjacent to the rear side of the module housing 354 (e.g., the side of the module housing 354 angled toward the left rear based on the view of FIG. 19). Additionally, the arm portions of the first power contact 324a and the second power contact 324b may be adjacent to the lateral sides of the module housing 354 (e.g., the two sides extending from the rear side). The finger portions of the first power contact 324a and the second power contact 324b may each be in the form of two fingers that are electrically connected (e.g., via electrical leads) to the heater of the vaporizer 336 when the upstream end of the vaporizer 336 is placed in a corresponding socket defined by the module housing 354 of the connector module 320. When the faceplate 366 is in place and engaged with the module housing 354, the leg portions of the first and second power contacts 324a, 324b may bend toward the finger portions such that the leg portions are adjacent to or against the upstream surface of the faceplate 366 (e.g., the underside of the faceplate 366 based on the illustration of FIG. 19 ). Thus, when assembled, the printed circuit board 362 may be considered to be surrounded on at least four sides by the serpentine structure of the first and second power contacts 324a, 324b.

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

[0093] In an exemplary embodiment, the pod inlet of the second housing section 308 is larger than the module inlet of the module housing 354. In such an example, the module inlet in the module housing 354 may be a limiting factor with respect to air flow into the nicotine pod assembly 300. As a result, the size of the module inlet may be adjusted for its internal arrangement without affecting the external aesthetics of the nicotine pod assembly 300, thereby allowing for a more standardized product design of nicotine pod assemblies having various resistance to withdrawal (RTD), while also reducing the possibility of inadvertent blockage of the incoming air.

[0094] While a number of exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as departing from the spirit and scope of the present disclosure, and all such modifications that would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. a nicotine pod assembly configured to hold a nicotine pre-vapor formulation, the nicotine pod assembly having an upstream end and a downstream end, the upstream end defining at least one upstream recess and the downstream end defining at least one downstream recess; a device body defining a through hole configured to receive the nicotine pod assembly, the through hole including an upstream wall and a downstream wall, at least one of the upstream wall or the downstream wall configured to deflect during insertion of the nicotine pod assembly, the upstream wall including at least one upstream protrusion, and the downstream wall including at least one downstream protrusion, the at least one upstream protrusion and the at least one downstream protrusion configured to engage with the at least one upstream recess and the at least one downstream recess, respectively, to retain the nicotine pod assembly within the through hole of the device body, A nicotine e-vaping device, wherein the device body includes a bezel structure defining the through hole, the bezel structure including a first upstream angle defining a first upstream slit, a second upstream angle defining a second upstream slit, a first downstream angle defining a first downstream slit, and a second downstream angle defining a second downstream slit.

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

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

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

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

6. A nicotine e-vaping device as described in any one of claims 1 to 5, wherein the bezel structure is a monolithic item.

7. The nicotine e-vaping device of any of claims 1 to 6, wherein the upstream wall is between the first upstream slit and the second upstream slit, and the downstream wall is between the first downstream slit and the second downstream slit.

8. The nicotine e-vaping device of any of claims 1 to 7, wherein the bezel structure has a length, a width and a depth, and the width is greater than the depth.

9. 9. The nicotine e-vaping device of claim 8, wherein each of the first upstream slit, the second upstream slit, the first downstream slit, and the second downstream slit has a longest dimension that is at least 30 percent of the depth of the bezel structure.

10. The nicotine e-vaping device of any one of claims 1 to 9, wherein the device body further comprises a mouthpiece secured to the bezel structure.

11. 11. The nicotine e-vaping device of claim 10, wherein the mouthpiece includes a male portion and the bezel structure includes a female portion, the male portion of the mouthpiece and the female portion of the bezel structure configured to mate as a bayonet connection.

12. The nicotine e-vaping device of any of claims 1 to 11, wherein the at least one upstream recess and the at least one downstream recess of the nicotine pod assembly are in the form of a dimple.

13. The nicotine e-vaping device of any one of claims 1 to 12, wherein the at least one upstream recess of the nicotine pod assembly includes two upstream recesses, and the at least one downstream recess of the nicotine pod assembly includes two downstream recesses.

14. The nicotine e-vaping device of any of claims 1 to 13, wherein the at least one upstream protrusion and the at least one downstream protrusion of the device body are in the form of a spherical cap.

15. A nicotine e-vaping device as described in any one of claims 1 to 14, wherein the at least one upstream protrusion of the device body includes two upstream protrusions, and the at least one downstream protrusion of the device body includes two downstream protrusions.

16. The nicotine e-vaping device of any of claims 1 to 15, wherein the device body is configured to generate at least one of an audible click or tactile feedback in response to the nicotine pod assembly being placed within the through-hole of the device body.

17. A device body for a nicotine e-vaping device, comprising:

1. A device housing defining a through hole configured to receive a nicotine pod assembly, the through hole including an upstream wall and a downstream wall, at least one of the upstream wall or the downstream wall configured to flex during insertion of the nicotine pod assembly, the upstream wall including at least one upstream protrusion, the downstream wall including at least one downstream protrusion, the at least one upstream protrusion and the at least one downstream protrusion configured to engage with at least one upstream recess and at least one downstream recess of the nicotine pod assembly, respectively, to retain the nicotine pod assembly within the through hole, the device body including a bezel structure defining the through hole, the bezel structure including a first upstream angle defining a first upstream slit, a second upstream angle defining a second upstream slit, a first downstream angle defining a first downstream slit, and a second downstream angle defining a second downstream slit.

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