Nicotine pod assemblies and nicotine e-vaping devices

Abstract

A nicotine pod assembly for a nicotine e-vaporizing device includes a first section and a second section connected to the first section. The first section defines a pod outlet and is configured to hold a nicotine pre-vapor formulation. The second section defines a pod inlet and is configured to heat the nicotine pre-vapor formulation. The pod inlet is in fluid communication with the pod outlet via a flow path. The flow path includes a first branched portion (330a), a second branched portion (330b), and a merging portion (330c). The nicotine e-vaporizing device includes a device body defining a through-hole configured to receive the nicotine pod assembly such that the pod inlet is exposed to airflow when the nicotine pod assembly is placed within the through-hole.

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 pod assembly for a nicotine e-vaping device.

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

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

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

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

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

[0009] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings, 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 an enlarged view of the pod inlet of FIG. [Figure 8] 8 is a cross-sectional view of the nicotine e-vaping device of FIG. [Figure 9] FIG. 9 is a perspective view of the device body of the nicotine e-vaping device of FIG. [Figure 10] FIG. 10 is a front view of the device body of FIG. [Figure 11] FIG. 11 is an enlarged perspective view of the through hole of FIG. [Figure 12] FIG. 12 is an enlarged perspective view of the electrical contacts of the device of FIG. [Figure 13] FIG. 13 is a partial exploded view of the mouthpiece of FIG. [Figure 14] FIG. 14 is a partial exploded view of the bezel structure of FIG. [Figure 15] 15 is an enlarged perspective view of the mouthpiece, spring, retaining structure, and bezel structure of FIG. [Figure 16] FIG. 16 is a partial exploded view of the front cover, frame, and rear cover of FIG. [Figure 17] 17 is a perspective view of a nicotine pod assembly of the nicotine e-vaping device of FIG. 6. [Figure 18] 18 is another perspective view of the nicotine pod assembly of FIG. 17. FIG. [Figure 19] 19 is another perspective view of the nicotine pod assembly of FIG. 18. FIG. [Figure 20]20 is a partially exploded view of the nicotine pod assembly of FIG. [Figure 21] FIG. 21 is a perspective view of the connector module of FIG. 20. FIG. [Figure 22] 22 is another perspective view of the connector module of FIG. 21. FIG. [Diagram 23] FIG. 23 is an exploded view of the wick and heater of FIG. [Figure 24] 24 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 17. FIG. [Diagram 25] 25 is a partially exploded view of the second housing section of the nicotine pod assembly of FIG. 17. FIG. [Figure 26] FIG. 26 is an exploded view of the upper hat holder of FIG. [Figure 27] FIG. 27 is an exploded view of the actuation pin of FIG. [Figure 28] FIG. 28 is a perspective view of the connector module of FIG. 22 without the wick and heater. [Figure 29] 29 is an exploded view of the connector module of FIG. 28. FIG. [Diagram 30] 30 is another exploded view of the connector module of 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 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 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 the majority of the visible portion of the device body 100. The device housing may be considered to include all components of the device body 100, except for the mouthpiece 102. 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. 9.

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

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

[0030] The front cover 104 and the rear cover 108 may be configured to engage with the frame 106 via a snap-fit ​​arrangement. For example, the front cover 104 and / or the rear cover 108 may include 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. FIG. 7 is a close-up view of the pod inlet of FIG. 6. With reference to FIGS. 6-7, and as briefly mentioned above, the nicotine e-vaporizing device 500 includes a nicotine pod assembly 300 configured to hold a nicotine pre-vapor formulation. The nicotine pod assembly 300 has an upstream end (facing the light guide arrangement) and a downstream end (facing the mouthpiece 102). In a non-limiting embodiment, the upstream end is the face opposite the downstream end of the nicotine pod assembly 300. The upstream end of the nicotine pod assembly 300 defines a pod inlet 322. The device body 100 defines a through hole (e.g., through hole 150 of FIG. 9) configured to receive the nicotine pod assembly 300. In an exemplary embodiment, the bezel structure 112 of the device body 100 defines the through hole and includes an upstream edge. As shown particularly in FIG. 7, the upstream edge of the bezel structure 112 is angled (e.g., sunken inward) to expose the pod inlet 322 when the nicotine pod assembly 300 is placed within the through-hole of the device body 100.

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

[0036] FIG. 8 is a cross-sectional view of the nicotine e-vaporizing device of FIG. 6. In FIG. 8, the cross-section is taken along the longitudinal axis of the nicotine e-vaporizing device 500. As shown, the device body 100 and the nicotine pod assembly 300 include mechanical components, electronic components, and / or circuitry associated with the operation of the nicotine e-vaporizing 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 the device body 100 to facilitate insertion and seating of the nicotine pod assembly 300.

[0037] 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.

[0038] The nicotine pod assembly 300 may also communicate other information with the device body 100 that may be relevant to the operation of the nicotine e-vapor device 500. Examples of relevant information may include the level of 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.

[0039] 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).

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

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

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

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

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

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

[0046] The data contacts of the device electrical connector 132 are configured to transmit data between the nicotine pod assembly 300 and the device body 100. As shown, the data contacts of the device electrical connector 132 include five rows of protrusions (positioned closer to the rear cover 108 than to the front cover 104). The data contacts of the device electrical connector 132 may be separate structures that extend into the through-hole 150 when assembled. The data contacts of the device electrical connector 132 may also be retractably attached and biased (e.g., via a serpentine structure and / or with a spring) to extend into the through-hole 150 as a default, and to retract (e.g., independently) from the through-hole 150 when subjected to a force that overcomes the bias. 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 and data contacts of the device electrical connector 132 retract (e.g., at least partially retract) into the device body 100, but continue to press against the corresponding pod electrical contacts due to their resilient arrangement, thereby helping to ensure a proper electrical connection between the device body 100 and the nicotine pod assembly 300. 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.

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

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

[0049] The mouthpiece 102 defines a vapor passageway 136 through which 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.

[0050] FIG. 14 is a partial exploded view of the bezel structure of FIG. 9. FIG. 15 is an enlarged perspective view of the mouthpiece, spring, retaining structure, and bezel structure of FIG. 14. Referring to FIGS. 14-15, 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 first downstream opening 148a, a second downstream opening 148b, and a third downstream opening 148c. The first downstream opening 148a and the second downstream opening 148b of the bezel structure 112 are configured to receive the first downstream protrusion 130a and the second downstream protrusion 130b of the retaining structure 140, respectively. The third downstream opening 148 c of the bezel structure 112 is configured to receive the distal end of the mouthpiece 102 .

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

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

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

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

[0055] FIG. 16 is a partial exploded view of the front cover, frame, and rear cover of FIG. 14. Referring to FIG. 16, 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). In FIG. 16, the front cover 104 has two rows of four clips each (a total of eight clips for the front cover 104). Similarly, the rear cover 108 has 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.

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

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

[0058] In an exemplary embodiment, the nicotine pod assembly 300 includes a front surface, a rear surface opposite the front surface, a first side surface between the front surface and the rear surface, a second side surface opposite the first side surface, an upstream end surface, and a downstream end surface opposite the upstream end surface. The 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 outer surface of the connector module 320 (exposed by the pod body) may be considered to be part of the upstream end surface of the nicotine pod assembly 300. The front surface of the nicotine pod assembly 300 may be wider and longer than the rear surface. In such examples, the first side surface and the second side surface may be angled inwardly toward one another. The upstream end surface and the downstream end surface may also be angled inwardly toward one another. Due to the angled surface, insertion of the nicotine pod assembly 300 is unidirectional (e.g., from the front side of the device body 100 (the side associated with the front cover 104)). As a result, the possibility of the nicotine pod assembly 300 being improperly inserted into the device body 100 can be reduced or prevented.

[0059] As shown, the pod body of the nicotine pod assembly 300 includes a first housing section 302 and a second housing section 308. The first housing section 302 has a downstream end that defines a pod outlet 304. The lip of the pod outlet 304 may optionally be a recessed or sunken region. In such an example, the region may resemble a cove, and the side of the lip adjacent the rear surface of the nicotine pod assembly 300 may be open, and the side of the lip adjacent the front surface may be surrounded by a raised portion of the downstream end of the first housing section 302. The raised portion may function as a stopper for the distal end of the mouthpiece 102. As a result, this configuration of the pod outlet 304 may facilitate receiving and aligning the distal end of the mouthpiece 102 (e.g., FIG. 11 ) via the open side of the lip and subsequent seating against the raised portion of the downstream end of the first housing section 302. In a non-limiting embodiment, the distal end of the mouthpiece 102 may also include (or be formed of) a resilient material that helps create a seal around the pod outlet 304 when the nicotine pod assembly 300 is properly inserted into the through hole 150 of the device body 100.

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

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

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

[0063] The nicotine pod assembly 300 may be manually activated by an adult e-vaping device user prior to inserting the nicotine pod assembly 300 into the device body 100. Alternatively, the nicotine pod assembly 300 may be activated as part of 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 a reservoir within the first housing section 302 during activation of the nicotine pod assembly 300. The perforator 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.

[0064] To manually activate the nicotine pod assembly 300, an adult e-vaping device user may first push the first activation pin 314a and the second activation pin 314b inward (e.g., simultaneously or sequentially) before inserting the nicotine pod assembly 300 into the through-hole 150 of the device body 100. For example, the first activation pin 314a and the second activation pin 314b may be manually pushed until their ends are substantially even with the upstream end surface of the nicotine pod assembly 300. In an exemplary embodiment, the inward movement of the first activation pin 314a and the second activation pin 314b pierces or otherwise compromises the seal of the reservoir so as to release the nicotine pre-vapor formulation therefrom.

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

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

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

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

[0069] FIG. 20 is a partially exploded view of the nicotine pod assembly of FIG. 19. Referring to FIG. 20, the first housing section 302 includes a vapor channel 316. The vapor channel 316 is configured to receive nicotine vapor generated during vaping and is in fluid communication with the pod outlet 304. In an exemplary embodiment, the vapor channel 316 may gradually increase in size (e.g., diameter) as it extends toward the pod outlet 304. Furthermore, the vapor channel 316 may be integrally formed with the first housing section 302. An insert 342 and a seal 344 are disposed at an upstream end of the first housing section 302 to define a reservoir of the nicotine pod assembly 300. For example, the insert 342 may be placed within the first housing section 302 such that a peripheral surface of the insert 342 engages (e.g., via an interference fit) with an inner surface of the first housing section 302 along an edge such that an interface between the peripheral surface of the insert 342 and the inner surface of the first housing section 302 is fluid-tight (e.g., liquid-tight and / or air-tight). Additionally, a seal 344 may be attached to an upstream side of the insert 342 to seal the reservoir outlet of the insert 342 to provide fluid-tight (e.g., liquid-tight and / or air-tight) containment of the nicotine pre-vapor formulation within the reservoir. The insert 342 and seal 344 are also illustrated, for example, in FIG. 24 and described in more detail herein.

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

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

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

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

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

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

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

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

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

[0079] Suitable conductors (resistive materials) for the heater 336 include iron-based alloys (e.g., stainless steel) and / or nickel-based alloys (e.g., nichrome). The heater 336 may be 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 the configuration of the heater 336 shown in the drawings, the winding pattern may be folded to grip the core 338. Additionally, if prongs 337 are part of the heater 336, the protrusions corresponding to the prongs 337 are bent (e.g., inwardly and / or orthogonally) before the winding pattern is folded. As a result of the prongs 337, the possibility of the core 338 slipping out of the heater 336 is reduced or prevented. Heaters and related structures are described in more detail in U.S. patent application Ser. No. 15 / 729,909, entitled "Folded Heater For Electronic Vaping Device," filed Oct. 11, 2017, the entirety of which is incorporated herein by reference.

[0080] FIG. 24 is an exploded view of the first housing section of the nicotine pod assembly of FIG. 17. Referring to FIG. 24, the first housing section 302 includes a vapor channel 316. The vapor channel 316 is configured to receive nicotine vapor generated by the heater 336 and is in fluid communication with the pod outlet 304. In an exemplary embodiment, the vapor channel 316 may gradually increase in size (e.g., diameter) as it extends toward the pod outlet 304. Furthermore, the vapor channel 316 may be integrally formed with the first housing section 302. An insert 342 and a seal 344 are disposed at an upstream end of the first housing section 302 to define a reservoir of the nicotine pod assembly 300. For example, the insert 342 may be placed within the first housing section 302 such that a peripheral surface of the insert 342 engages (e.g., via an interference fit) with an inner surface of the first housing section 302 along an edge such that an interface between the peripheral surface of the insert 342 and the inner surface of the first housing section 302 is fluid-tight (e.g., liquid-tight and / or air-tight). Additionally, the seal 344 may be attached to an upstream side of the insert 342 to seal the reservoir outlet of the insert 342 to provide a fluid-tight (e.g., liquid-tight and / or air-tight) containment of the nicotine pre-vapor formulation within the reservoir. Herein, the first housing section 302, the insert 342, and the seal 344 may be collectively referred to as a first section. As described in more detail herein, the first section is configured to seal the nicotine pre-vapor formulation until activation of the nicotine pod assembly 300.

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

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

[0083] FIG. 25 is a partially exploded view of the second housing section of the nicotine pod assembly of FIG. 17. Referring to FIG. 25, the second housing section 308 is structured to contain various components configured to release, receive, and heat the nicotine pre-vapor formulation. For example, the first activation pin 314a and the second activation pin 314b are configured to pierce the reservoir of the first housing section 302 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 one of the first pin opening 315a and the second pin opening 315b of 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. 17), 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 through the insert 342, 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.

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

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

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

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

[0088] FIG. 27 is an exploded view of the actuation pin of FIG. 25. Referring to FIG. 27, the actuation pin may be in the form of a first actuation pin 314a and a second actuation pin 314b. Although two actuation 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 actuation pin. In FIG. 27, the first actuation pin 314a may include a first blade 348a, a first actuator 350a, and a first O-ring 352a. Similarly, the second actuation pin 314b may include a second blade 348b, a second actuator 350b, and a second O-ring 352b.

[0089] In an exemplary embodiment, the first blade 348a and the second blade 348b are integrally formed with the first actuator 350a and the second actuator 350b, respectively. Alternatively, the first blade 348a and the second blade 348b may be configured to be mounted or attached to an upper portion (e.g., a 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 upper portion 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 and 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 has a desired profile and is cut or shaped to bend into its final form. In another example, the first and second blades 348a, 348b may be formed of plastic (e.g., when integrally formed with the first and second actuators 350a, 350b).

[0090] The size and shape of the first blade 348a, second blade 348b, and first and second actuators 350a, 350b, based on the plan view to which they are integrally formed (or mounted), may correspond to the size and shape of the reservoir outlet of the insert 342. Additionally, as shown in FIG 27, the first and second actuation pins 314a, 314b 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 and second blades 348a, 348b advance into the reservoir. In a non-limiting embodiment, when the first activation pin 314a and the second activation pin 314b are fully inserted into the nicotine pod assembly 300, the two flaps (from the two perforated sections of the seal 344) may be between the curved sidewall of the reservoir outlet of the insert 342 and the corresponding curvature of the protruding edges of the first activation pin 314a and the second activation pin 314b. As a result, the possibility 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. Furthermore, the first activation pin 314a and the second activation pin 314b may be configured to guide the nicotine pre-vapor formulation from the reservoir toward the absorbent material 346 in the top hat holder 345.

[0091] A lower portion (e.g., 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. The first O-ring 352a and the second O-ring 352b may be placed in annular grooves in the shafts of the first actuator 350a and the second actuator 350b, respectively. The first O-ring 352a and the second O-ring 352b are configured to engage the shafts of the first actuator 350a and the second actuator 350b and the inner surfaces of the corresponding openings in the second housing section 308 to provide a fluid-tight seal. As a result, when the first and second activation pins 314a, 314b are pressed inward to activate the nicotine pod assembly 300, the first and second O-rings 352a, 352b may move with the respective shafts of the first and second actuators 350a, 350b within the corresponding openings in 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 in the second housing section 308 relative to the first and second activation pins 314a, 314b. The first and second O-rings 352a, 352b may be formed of silicone.

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

[0093] FIG. 28 is a perspective view of the connector module of FIG. 22 without the wick and heater. FIG. 29 is an exploded view of the connector module of FIG. 28. FIG. 30 is another exploded view of the connector module of FIG. 28. Referring to FIGS. 28-30, a module housing 354 forms a framework of the connector module 320. The module housing 354 defines, among other things, the partition 329 and a flow path for air drawn into the nicotine pod assembly 300. When assembled within the nicotine pod assembly 300, a downstream edge of the module housing 354 can be engaged with an upstream edge of the base portion 345a of the top hat holder 345 (e.g., FIG. 26). As a result, the heater 336 and the wick 338 (e.g., FIG. 22) can be (at least partially) enclosed by the module housing 354 and the top hat holder 345. Additionally, the interior space defined by module housing 354 and top hat holder 345, when assembled (with heater 336 and wick 338 disposed therein), may be considered a heating chamber. The heating chamber is in fluid communication with the upstream flow path of module housing 354 via module outlet 368.

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

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

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

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

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

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

[0100] While a number of exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as 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 first section defining a pod outlet and configured to hold a nicotine prevapor formulation; a second section connected to the first section, the second section defining a pod inlet and configured to heat the nicotine pre-vapor formulation, the pod inlet being in fluid communication with the pod outlet via a flow path, the flow path including a first branching portion, a second branching portion, and a merging portion; A nicotine pod assembly for a nicotine e-vaping device, wherein the first branched portion includes a first curved segment, the second branched portion includes a second curved segment, and each of the first curved segment and the second curved segment is U-shaped.

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

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

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

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

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

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

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

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

10. A nicotine pod assembly according to any one of claims 1 to 9, wherein the first branched portion and the second branched portion are symmetrical portions bisected by an axis corresponding to the confluence portion of the flow path.

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

12. The nicotine pod assembly of claim 11 , wherein the heater includes a folded heating element configured to grip the wick.

13. The nicotine pod assembly of claim 12 , wherein the folded heating element includes at least one prong configured to protrude into the wick.

14. The nicotine pod assembly of claim 11 or 12, wherein the second section further comprises an absorbent material disposed within a holder, the absorbent material being downstream of the wick and in fluid communication with the wick.

15. The nicotine pod assembly of claim 14, wherein the absorbent material is configured to receive the nicotine pre-vapor formulation from the first section, and the wick is configured to transmit the nicotine pre-vapor formulation from the absorbent material to the heater.

16. 16. The nicotine pod assembly of claim 14 or 15, wherein the absorbent material has an annular configuration and the core has a planar configuration.

17. The nicotine pod assembly of claim 14, 15 or 16, wherein the holder comprises a base portion and a cylindrical portion.

18. a nicotine pod assembly including a first section and a second section, the first section configured to hold a nicotine pre-vapor formulation, the second section configured to branch and merge an airflow into the nicotine pod assembly before the airflow passes through the first section, the second section including a flow path including a first branching portion, a second branching portion, and a merging portion, the first branching portion including a first curved segment, the second branching portion including a second curved segment, each of the first curved segment and the second curved segment being U-shaped; a device body defining a through hole configured to receive the nicotine pod assembly such that a pod inlet is exposed to the airflow when the nicotine pod assembly is placed within the through hole.

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