Apparatus and method for assembling a heater assembly for a non-nicotine pod assembly

Abstract

An apparatus for assembling a heater assembly for a non-nicotine pod assembly includes a base, a wick supply, a slide, and a holder. The wick supply defines a channel extending toward the base and configured to receive a wick configured to draw a non-nicotine pre-vapor formulation by capillary action. The slide is configured to move along a plane on an upper surface of the base. The holder is disposed on the upper surface of the base.

Description

Technical Field

[0001] The present disclosure relates to an apparatus for preparing and assembling a heater assembly for a non-nicotine pod assembly.

Background Art

[0002] Non-nicotine electronic vaping or e-vaping devices include a heating element that vaporizes a non-nicotine pre-vaporizer formulation to produce a non-nicotine vapor.

[0003] Non-nicotine e-vaping devices include a power source, such as a rechargeable battery, disposed within the device. The power source is electrically connected to the heater. The power source supplies power to the heater to heat it to a temperature sufficient for the heater to convert the non-nicotine pre-vaporizer formulation into a non-nicotine vapor. The non-nicotine vapor exits the non-nicotine electronic vaping device through a mouthpiece that includes at least one outlet.

Summary of the Invention

[0004] This section describes a general overview of the present disclosure and does not disclose all of its entirety or all of its features.

Means for Solving the Problems

[0005] At least one exemplary embodiment relates to an apparatus for assembling a heater assembly for a non-nicotine pod assembly, comprising a base, a wick supply, a slide portion, and a holder portion. The wick supply extends towards the base and defines a channel configured to receive a wick, where the wick is structured to draw in a non-nicotine pre-vaporizer formulation by capillary action. The slide portion is configured to move along a plane on the upper surface of the base, and the holder portion is disposed on the upper surface of the base.

[0006] The device of this example further includes a wick holding part, and the wick holding part may extend parallel to and adjacent to the wick supply part so as to hold the wick in the channel.

[0007] The device of this example further includes a cutter part, the cutter part has a blade part, and the blade part may be configured to slide along the upper surface of the slide part to cut the wick.

[0008] The wick supply part in the device of this example may be configured to rotate with respect to the base.

[0009] The device of this example further includes a block part, and the block part may be fixed to the base. The wick supply part may be rotatably attached to the block part and supported by the block part.

[0010] The holder part in the device of this example is configured to receive the support of the heater assembly therein, and the holder part may be configured to fix the support to the base for inserting the wick.

[0011] The channel of the wick supply part in the device of this example may be configured to guide the wick to be aligned with the heater on the support.

[0012] The wick supply part in the device of this example may extend perpendicular to the base.

[0013] The holder part in the device of this example includes a locking finger part, and the locking finger part may be configured to engage with the support of the heater assembly and hold the support in the holder part.

[0014] The holder part in the device of this example may be configured to fix the support of the heater assembly. The slide part may include a front face orthogonal to the upper surface of the base. The slide part may be configured to contact the finger part of the heater on the support and move the finger part to a vertical position so as to compress the wick.

[0015] The wick supply part in the device of this example may include a plate part and a holding part. The plate part may be arranged orthogonal to the base and may define a channel. The holding part may be arranged adjacent to the plate part orthogonal to the base. The holding part and the plate part may define a slot part for guiding the wick.

[0016] The device of this example may further include a block part, and the block part may be fixed to the base. The plate part may be rotatably attached to and supported by the block part.

[0017] The holding part in the device of this example is fixed to the plate part, and the holding part and the plate part may be configured to rotate with respect to the base and the block part.

[0018] The holder part in the device of this example may be configured to fix the support of the heater assembly and lock the position of the support with respect to the base.

[0019] The holder part in the device of this example may include a locking finger part, and the locking finger part may be configured to engage with the support and hold the support within the holder.

[0020] The device of this example may further include a blade part, and the blade part may be configured to slide along the upper surface of the slide part.

[0021] At least one exemplary embodiment relates to a method for assembling a heater assembly for a non-nicotine pod assembly, the method including, at a holder portion, fixing a support of the heater assembly relative to a base; at a guide plate portion attached to the base, aligning a wick strip within a heater of the support, where the wick strip is structured to draw in a non-nicotine pre-vapor formulation by capillary action; at a blade portion configured to slide relative to the base, cutting a portion of the wick strip; at a slide portion configured to slide relative to the base, clamping a portion of the heater around a portion of the wick strip; and at the holder portion, releasing the support from the base.

[0022] Fixing the support relative to the base may include locking the support to the holder portion.

[0023] Aligning the wick strip within the heater of the support may include inserting the wick strip into a channel within the guide plate portion.

[0024] Aligning the wick strip within the heater of the support may include inserting the wick strip into a gap defined by a channel within the guide plate portion and a retaining plate portion fixed to the guide plate portion.

[0025] Further applicable areas will become apparent from the description provided herein. The description and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of the present disclosure.

[0026] The various features and advantages of the non-limiting embodiments of this specification will become more apparent by considering the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the claims. The accompanying drawings are not considered to be drawn to scale unless explicitly stated otherwise. For clarity, the various dimensions in the drawings may be exaggerated.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0063] [DETAILED DESCRIPTION] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of describing exemplary embodiments. However, the exemplary embodiments can be embodied in many alternative forms and should not be construed as limited to only the exemplary embodiments described herein.

[0064] Accordingly, the exemplary embodiments are capable of various changes and alternative forms, and the exemplary embodiments are shown by way of example in the drawings and will be described in detail herein. However, it is not intended to limit the exemplary embodiments to the specific forms disclosed, and on the contrary, the exemplary embodiments are to cover all changes, equivalents, and alternatives falling within the scope of the exemplary embodiments. Like numbers refer to like elements throughout the description of the figures.

[0065] A non-nicotine electronic vaping device, or non-nicotine e-vaping device, includes a heating element that vaporizes a non-nicotine pre-vaper formulation to produce a non-nicotine vapor. The non-nicotine pre-vaper formulation may be enclosed in a housing or non-nicotine pod assembly. The non-nicotine electronic vaping device includes a power source, such as a rechargeable battery, disposed within the device. The power source is electrically connected to a heater assembly of the non-nicotine pod assembly. The power source supplies power to the heater assembly such that the heater assembly heats the non-nicotine pre-vaper formulation within the non-nicotine pod assembly to a temperature sufficient to convert it to a non-nicotine vapor. The non-nicotine vapor exits the non-nicotine electronic vaping device through a mouthpiece that includes at least one outlet.

[0066] A non-nicotine pre-vaper formulation is a material or combination of materials that does not contain nicotine and can be converted into a non-nicotine vapor. For example, a non-nicotine pre-vaper formulation may include liquid, solid, and / or gel formulations. These may include, for example, water, oil, beads, solvents, active ingredients, ethanol, plant extracts, non-nicotine compounds, natural or artificial flavors, vapor-forming agents such as glycerin and propylene glycol, and / or solutions or suspensions (e.g., emulsions) containing other ingredients suitable for vaping, but are not limited thereto. During vaping, a non-nicotine e-vaping device is configured to heat the non-nicotine pre-vaper formulation to produce non-nicotine vapor. Non-nicotine vapor, non-nicotine aerosol, and non-nicotine dispersion are used interchangeably and refer to substances produced or output by the disclosed, claimed, and / or their equivalents, such substances lacking nicotine.

[0067] In an exemplary embodiment, the non-nicotine pre-vaper formulation does not contain tobacco and is not derived from tobacco. The non-nicotine compound of the non-nicotine pre-vaper formulation may be part of a liquid or partially liquid including extracts, oils, alcohols, tinctures, suspensions, dispersions, colloids, generally non-neutral (weakly acidic or weakly basic) solutions, or combinations thereof. During the preparation of the non-nicotine pre-vaper formulation, the non-nicotine compound may be injected, mixed, or otherwise combined with other components of the non-nicotine pre-vaper formulation.

[0068] In an exemplary embodiment, the non-nicotine compound undergoes a slow, natural decarboxylation process over a long period of time at a relatively low temperature, such as below room temperature (e.g., 72°F). Further, when the non-nicotine compound is exposed to a temperature in the range of about 175°F or higher for a certain period (several minutes or hours) at a high temperature, particularly under a relatively low pressure such as 1 atmosphere, it may undergo a significantly high decarboxylation process (e.g., 50% or more decarboxylation). At a high temperature of about 240°F or higher, rapid or instantaneous decarboxylation can occur at a relatively high decarboxylation rate, but further increasing the temperature may cause some or all of the chemical properties of the non-nicotine compound(s) to deteriorate.

[0069] In an exemplary embodiment, the non-nicotine compound may be derived from a medicinal plant (e.g., a naturally occurring component of a plant that provides a medically recognized therapeutic effect). The medicinal plant may be a cannabis plant, and the component may be at least one cannabis-derived component. Examples of cannabis-derived components include cannabinoids (e.g., phytocannabinoids) and terpenes. Cannabinoids interact with receptors in the body to produce various effects. As a result, cannabinoids are said to have various medicinal effects. Cannabis-derived materials include materials from the leaves and / or flowers of one or more cannabis plants, or extracts from one or more cannabis plants. For example, the one or more cannabis plants may include Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some exemplary embodiments, the non-nicotine pre-vaper formulation includes a mixture of cannabis and / or cannabis-derived components that are 60 - 80% (e.g., 70%) Cannabis sativa and 20 - 40% (e.g., 30%) Cannabis indica, or are derived therefrom.

[0070] Non-limiting examples of cannabis-derived cannabinoids include tetrahydrocannabinolic acid (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabinocyclol (CBL), cannabichromene (CBC), cannabigerol (CBG), and the like. Tetrahydrocannabinolic acid (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinolic acid (THCA) and cannabidiolic acid (CBDA) may be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, via heating. In an exemplary embodiment, heat from a heater may cause decarboxylation to convert tetrahydrocannabinolic acid (THCA) in a non-nicotine pre-vaporizer formulation to tetrahydrocannabinol (THC) and / or cause decarboxylation to convert cannabidiolic acid (CBDA) in a non-nicotine pre-vaporizer formulation to cannabidiol (CBD).

[0071] When both tetrahydrocannabinolic acid (THCA) and tetrahydrocannabinol (THC) are present in a non-nicotine pre-vaporizer formulation, decarboxylation and the resulting conversion cause a decrease in tetrahydrocannabinolic acid (THCA) and an increase in tetrahydrocannabinol (THC). At least 50% (e.g., at least 87%) of the tetrahydrocannabinolic acid (THCA) may be converted to tetrahydrocannabinol (THC) via a decarboxylation process during heating of the non-nicotine pre-vaporizer formulation for the purpose of vaporization. Similarly, in an example where both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in a non-nicotine pre-vaporizer formulation, decarboxylation and the resulting conversion cause a decrease in cannabidiolic acid (CBDA) and an increase in cannabidiol (CBD). At least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD) via a decarboxylation process during heating of the non-nicotine pre-vaporizer formulation for the purpose of vaporization.

[0072] The non-nicotine pre-vaporizer formulation may contain a non-nicotine compound that provides a medically recognized therapeutic effect (e.g., treatment of pain, nausea, epilepsy, mental disorders). Details of the treatment method are described in U.S. Application No. 15 / 845,501, filed on December 18, 2017, entitled "VAPORIZING DEVICES AND METHODS FOR DELIVER A COMPOUND USING THE SAME", the disclosure of which is hereby incorporated by reference in its entirety.

[0073] In an example of the embodiment, at least one flavorant is present in an amount in the range of about 0.2% to about 15% (e.g., about 1% to 12%, about 2% to 10%, or about 5% to 8%), based on the total weight of the non-nicotine pre-vapor formulation. The at least one flavorant may be at least one of a natural flavorant, an artificial flavorant, or a combination of a natural flavorant and an artificial flavorant. The at least one flavorant may contain a volatile cannabis flavor compound (flavonoid) or other flavor compound, instead of or in addition to the cannabis flavor compound. For example, the at least one flavorant may contain menthol, wintergreen, peppermint, cinnamon, clove, combinations thereof, and / or extracts thereof. Further, the flavorant may be provided to include other herb flavors, fruit flavors, nut flavors, liqueur flavors, roast flavors, mint flavors, celery flavors, combinations thereof, and other desired flavors.

[0074] Figures 1A and 1B are front and rear perspective views of an apparatus or fixture for assembling a heater assembly for a non-nicotine pod assembly according to at least one exemplary embodiment. This apparatus may be used, in at least one exemplary embodiment, with the cutter portion illustrated in FIG. 10 and the slicing guide portion and blade portion illustrated in FIGS. 13 and 14 to prepare and assemble a heater assembly for a non-nicotine pod assembly as described herein.

[0075] Referring to FIGS. 1A and 1B, in at least one exemplary embodiment, the apparatus or fixture 10 includes a base 14, a guide 18, a slide 22, a wick guide 26 (or non-nicotine wick guide), a holder 30, and a block 34.

[0076] In at least one exemplary embodiment, a detailed view of the base 14 is shown in FIG. 3. The base 14 may include a longitudinal channel 38 having side wall portions 42, 46. Each side wall portion may include step portions 50, 54 that increase the width of the longitudinal channel 38. The longitudinal channel 38 may have a first width W1 at the base or bottom 58 of the longitudinal channel 38 and a second width W2 at the upper portion 62 of the longitudinal channel 38 above the step portions 50, 54, and the second width W2 is greater than the first width W1.

[0077] In the exemplary embodiments shown in FIGS. 1A, 1B, and 3, for example, the base 14 may include a transverse channel 66 having side wall portions 70, 74 that define the transverse channel 66. The transverse channel 66 may extend orthogonally to and intersect the longitudinal channel 38. One of the side wall portions 70 of the transverse channel 66 may include a step portion 78, and the other of the side wall portions 74 may be flat. The step portion 78 may increase the width of the transverse channel 66. The transverse channel 66 may have a first width LW1 at the bottom or base 82 of the transverse channel 66 and a second width LW2 at the upper portion 86 of the transverse channel 66 above the step portion 78, and the second width LW2 is greater than the first width LW1.

[0078] The side wall portion 70 may include a notch 88 at the location of the holder portion 30. Thus, the notch 88 may separate the side wall portion 70 into two parts 70(a) and 70(b).

[0079] In the exemplary embodiments shown in FIGS. 1A, 1B, and 3, for example, the base 14 may include a plurality of openings 90, 94, 98 that extend orthogonally through the base 14. The opening 90 may receive a fastener (e.g., a bolt, screw, or other fastener) for fixing the guide part 18 on the upper surface part 100 of the base 14. The opening 94 may receive a fastener (e.g., a bolt, screw, or other fastener) for fixing the holder part 30 to the base 14. The opening 98 may receive a fastener (e.g., a bolt, screw, or other fastener) for fixing the block part 34 to the base 14. Also, the slot part 102 may be defined by the base 14 between the openings 98. The slot part 102 may receive a part of the block part 34.

[0080] The base 14 may additionally include a retaining notch 106 aligned with the longitudinal channel 38 and the opening 94 for receiving the holder part 30. The retaining notch 106 may correspond to the width of the holder part 30, thereby facilitating the assembly of the holder part 30 on the base 14.

[0081] At the intersection between the longitudinal channel 38 and the transverse channel 66, the support notch 110 may be defined by the base 14. The support notch 110 may provide a track or guide for inserting components of the heater assembly for the non-nicotine pod assembly into the holder part 30. The width of the support cutout SW may be smaller than the width W1 of the longitudinal channel 38 and the width HCW of the retaining notch. The support notch 110 may extend from the intersection between the longitudinal channel 38 and the transverse channel 66, beyond the plane of the side wall part 70, into the notch 88, and to the section of the base 14 having the retaining notch.

[0082] Figures 2A and 2B are perspective views of an exemplary embodiment of the assembled base 14 and guide 18 of the device, i.e., fixture 10, shown in Figure 1A. As described above, the guide 18 may be fixed to the base 14 at the opening 90 on the base 14. The guide 18 may be aligned with the opening 90 of the base 14 and include a corresponding first opening 114 for receiving a fastener for fixing the guide 18 to the base 14.

[0083] The guide 18 may include a second opening 118, a third opening 122, and a slot portion 126. The slot portion 126 may be longitudinally positioned along the center of the guide 18 above the channel portion 38 within the base 14. The second opening 118 may be positioned along each side surface portion 130, 134 and at the front end portion 138 of the slot portion 126. The second opening 118 may receive a pin, rod, or screw extending through the second opening 118 to apply a slight pressure to the slide portion 22 such that the movement of the slide portion 22 is controlled by the actuation of the pin 150. The third opening 122 may receive a pin, rod, or screw to set the functional movement distance of the slide portion 22, be disposed at the lateral center of the front surface portion 142 of the guide 18, and extend through to the front end portion 138 of the slot portion 126.

[0084] Figures 4A and 4B are perspective views of an exemplary embodiment of the assembled base 14 and slide portion 22 of the device, i.e., fixture 10, shown in Figure 1A. The slide portion 22 is slidable within the longitudinal channel 38. The slide portion 22 may include a plate portion 146 and a pin 150 extending from its upper surface portion 154. The plate portion 146 may rest on the upper surface portions 158, 162 of each step portion 50, 54 and be slidable. The front end portion 166 of the plate portion 146 may include a tab portion 170, i.e., a protrusion, having a front surface portion 174 slidable within the notch 88 of the base 14.

[0085] Pin 150 extends orthogonally to plate portion 146 and may be received within slot portion 126 in guide 18, as illustrated, for example, in FIGS. 1A and 1B. Slot portion 126 may function as a guide track portion and a stop portion for pin 150. In a fully forward position, pin 150 is adjacent to (e.g., in contact with) the front end portion 138 of slot portion 126, and a plane along front face portion 174 of tab portion 170 on slide portion 22 is aligned with a plane along side wall portion 70 of lateral channel 66. In a fully rearward position, pin 150 is adjacent to (e.g., in contact with) the rear end portion 178 of slot portion 126, and a plane along rear face portion 182 of plate portion 146 of slide portion 22 is aligned with a plane along rear face portion 186 of base 14.

[0086] Referring to FIG. 5, a perspective view of an exemplary embodiment of the apparatus, i.e., fixture 10, shown in FIG. 1A with the guide removed is shown. As shown in FIGS. 1A, 1B, and 5, for example, wick guide 26 may be fixed onto base 14 by block portion 34. As described above, block portion 34 may be fixed to base 14 by fasteners at openings 98 and at slot portions 102. Further, retraction spring 190 may be fixed to front face 194 outside block portion 34 and front face 198 of base 14, aligning a plane along front face 194 with a plane along front face 198 to limit movement of front face 194 of block portion 34 from protruding beyond front face 198 of base 14.

[0087] As shown, for example, in FIGS. 1A and 8A - 9B, the wick guide 26 may be fixed to the block portion 34 by a fastener 202 such as a shoulder screw. In some exemplary embodiments, the fastener 202 (FIG. 8C) may include a top portion 206 and a body portion 210 having a smooth portion 214 and a threaded portion 218. The threaded portion 218 may engage a screw within an opening 222 of the block portion 34 (FIG. 8B). The opening 222 may be a counter - sunk opening having a large - diameter portion 226 that mates with a portion of the smooth portion 214 of the fastener 202 and a small - diameter portion 230 that is threaded to mate with the threaded portion 218 of the fastener 202. The top portion 206 of the fastener 202 may be knurled, slotted, or both knurled and slotted to facilitate insertion and removal into the opening 222.

[0088] As shown in the exemplary embodiments of FIGS. 9A and 9B, the wick guide 26 may include a wick supply portion 234 (or non - nicotine wick supply portion) and a wick holding portion 238 (or non - nicotine wick holding portion). The wick supply portion 234 may be a plate portion having a channel portion 242, i.e., a slot portion, formed therein, or a plate portion having a channel portion. The channel portion 242 may extend across the width of the wick supply portion 234 and may be wide enough to accommodate a wick configured to draw out a non - nicotine pre - vapor formulation via capillary action (discussed in more detail below). For example, the channel portion 242 may have a width in the range of 0.0625 inches to 1 inch, more specifically, in the range of 0.125 inches to 0.5 inches. Although exemplary widths are provided, it will be understood that the width of the channel portion 242 may be sized differently to accommodate wicks of various sizes configured to draw in a non - nicotine pre - vapor formulation via capillary action.

[0089] The wick holding part 238 may be a flat plate that aligns with (and is fixed to) the wick supply part 234 to define a guide part or a track part 246 together with the channel part 242 in the wick supply part 234 into which the wick for non-nicotine wicking is inserted during assembly (discussed in more detail below). The wick holding part 238 may include an opening 250 that aligns with an opening 254 (FIG. 1B) in the wick supply part 234 that receives a fastener therein to fix the wick holding part 238 to the wick supply part 234. A fastener or pin extending through one of the openings 250 may extend beyond the wick supply part 234 and fit into the track part 258 of the block part 34, thereby enabling the wick supply part 234 to pivot relative to the block part 34. Further, the smooth part 214 of the fastener 202 is received within the opening of the wick guide part 26, providing a pivot about which the wick guide part 26 can rotate.

[0090] FIGS. 6-7F are detailed views of an exemplary embodiment of the holder part of the device shown in FIG. 1A, namely the fixture 10. The holder part 30 may include a base 262, a lock part 266, and an elastic member 270 (e.g., a spring). The base 262 may further include a slot part 274 for receiving one or more fingers of a heater assembly (described further below) for a non-nicotine pod assembly and / or a part of the lock part 266. The base 262 may include an opening 278 that aligns with the opening 94 of the base 14 and is configured to receive a fastener for fixing the holder part 30 to the base 14.

[0091] In some exemplary embodiments, the locking portion 266 may further include a toggle portion 282 and at least one locking finger portion 286. The locking portion 266 may be rotatably fixed to the base 262 at the opening 290 of the toggle portion 282. The opening 290 of the toggle portion 282 may be aligned with the opening 294 of the base 262 to receive a rod or pin therein. The rod or pin may provide a pivot point about which the toggle portion 282 can rotate. The toggle portion 282 may include a protrusion or lever portion 298 configured to be operated by an assembler to move the toggle portion 282 between a first forward position and a second rearward position. In the first forward position, the locking finger portion 286 may be in an open position, i.e., an unlocked position (described further below), and in the second rearward position, the locking finger portion 286 may be in a closed position, i.e., a locked position (described further below).

[0092] The locking finger portion 286 may be fixed to the front surface portion 302 of the toggle portion 282 and may rotate with the rotation of the toggle portion 282. In some exemplary embodiments, three locking finger portions 286 may be fixed to the toggle portion 282. However, it is understood that any number of locking finger portions 286 may be included. In some exemplary embodiments, each of the locking finger portions 286 may be a plate portion including a rectangular main body portion 306 and a hook portion 310 (FIG. 7F). The hook portion 310 may be defined by a dip portion 314 and a point portion 318.

[0093] The tab portion 322 on the side opposite to the front portion 302 of the toggle portion 282 contacts the elastic member 270. The elastic member 270 is a flat plate-shaped spring having a main body portion 326 and a tab portion 330 extending from the main body portion 326, that is, a protrusion. The main body portion 326 of the elastic member 270 is fixed to the base portion 262 at the opening 334 by a fastener (for example, only a screw or a bolt). The opening 334 is aligned with the opening 278 of the base portion 262 and is configured to receive the fastener. The tab portion 330 extends in the same manner as a cantilever beam and overlaps the tab portion 322 of the toggle portion 282. The tab portion 330 of the elastic member 270 applies a resistance force to the toggle portion 282 and biases the toggle portion 282 to a second rear position so that the lock finger portion 286 is biased to the locked closed position.

[0094] FIG. 10 is a perspective view of an exemplary embodiment of a cutter portion 338 that can be used with the apparatus shown in FIG. 1A, namely, the fixture 10. The cutter portion 338 includes a block portion 342 and a blade portion 346. The blade portion 346 may be disposed on the front surface portion 350 of the block portion 342. In some embodiments, the blade portion 346 may be fixed to the block portion 342 by one or more fasteners.

[0095] The cutter portion 338 may be slidable along the upper surface portion 154 of the slide portion 22 from a first position to a second position. In the first position, the cutter portion 338 may be disposed on the upper surface portion 154 of the slide portion 22 between the wick guide portion 26 and the guide portion 18. In the second position, the cutter portion 338 may be disposed on the upper surface portion 154 of the slide portion 22 with the blade portion 346 adjacent to the holder portion 30 and disposed below the wick guide portion 26.

[0096] Referring to the exemplary embodiments shown in FIGS. 1-10, the apparatus or fixture 10 and the cutter portion 338 may be used in a method 400 for preparing and assembling a heater assembly for a non-nicotine pod assembly. The method 400 may begin at 404. At step 408, the wick pad 500 (FIG. 12) is covered by a slicing guide 504 (FIG. 13). For example, the slicing guide 504 may be set on the wick pad 500.

[0097] In at least one exemplary embodiment, the wick pad 500 (or non-nicotine wick pad) may include filaments (or threads) having the ability to draw in a non-nicotine pre-vapor formulation via capillary action. For example, the wick pad 500 may be a sheet woven together with glass (or ceramic) fibers or filaments. In at least one exemplary embodiment, the wick pad 500 may include any suitable material or combination of materials. Examples of suitable materials may include, but are not limited to, glass, ceramic-based, or graphite-based materials.

[0098] The wick pad 500 can have any suitable capillary action to accommodate non-nicotine pre-vapor formulations having different physical properties such as density, viscosity, surface tension, and vapor pressure. Capillary action is the movement of a non-nicotine pre-vapor formulation (e.g., a liquid in which a non-nicotine substance is dissolved) within the pores of the porous wick pad 500 material due to the forces of adhesion, cohesion, and surface tension. Capillary action occurs when the molecules of a liquid are attracted to and adhere to the inner surface of a porous structure while remaining close to each other (cohesion). In particular, capillary action occurs when the adhesive force between the molecules of the liquid and the walls of the structure is stronger than the cohesive force between the molecules. Since non-nicotine pre-vapor formulations can contain various substances (e.g., but not limited to, water, oil, emulsion, beads, solvent, active ingredient, ethanol, plant or other extracts, non-nicotine compounds, natural or artificial flavors, vapor formers such as glycerin and propylene glycol, alcohol, tincture, suspension, dispersion, colloid, generally non-neutral slightly acidic or slightly basic solutions, cannabis-derived components, and / or any other ingredients suitable for vaping as described above), the wicking material for attracting the non-nicotine pre-vapor formulation may be designed according to a specific formulation. Thus, the material of the wick pad 500 may have different structures and / or compounds to promote capillary action for a specific non-nicotine pre-vapor formulation. For example, the diameter of the pores and / or the dimensions of the gaps in the material of the wick pad 500 may be appropriately sized to facilitate the drawing in of the non-nicotine pre-vapor formulation by capillary action based on the physical properties (e.g., surface tension) and material (e.g., hydrophilicity) of the formulation. For example, the size of the capillary space may need to increase as the density of the liquid increases. Further, in an exemplary embodiment, the wick pad 500 may be non-conductive.

[0099] The exemplary wick pad 500 is illustrated as a circular sheet in FIG. 12, but it is understood that the wick pad 500 can take any shape, including a rectangular sheet, a square sheet, or a sheet of any other shape.

[0100] As shown in FIG. 13, an exemplary slicing guide portion 504 may include one or more slots or channels 508 that penetrate its thickness. Each of the channels 508 may extend in the length direction of the slicing guide portion 504 and may be aligned in the width direction of the slicing guide portion 504. The channels 508 may spread evenly in the width direction such that strips of equal width are created when the wick pad 500 is cut or separated.

[0101] The openings 512 may be at one end of each channel 508. In some embodiments, the openings 512 may be at alternating ends of the channels 508. The openings 512 at the ends of the channels 508 may facilitate the insertion of the blade portion 516 (further described below). The openings 512 at the alternating ends of the channels 508 allow the blade portion 516 to be inserted into each channel in a more efficient manner and make slices.

[0102] In step 412, the blade portion 516, i.e., the razor, slices through each channel 508 of the slicing guide portion 504 to cut or separate the wick pad 500 into wick strips 520 (FIG. 16A). In the exemplary embodiment shown in FIG. 14, the blade portion 516 may include a cutting edge portion 522 and a grip portion 526. The cutting edge portion 522 may be a sharp blade used to cut or separate the wick pad 500 into wick strips 520 (or nicotine-free wick strips). The grip portion 526 may be, for example, a blunt edge of the blade portion 516 or a backing on the edge of the blade portion 516 opposite the cutting edge portion 522 to provide a portion of the blade portion 516 for the assembly technician to grip.

[0103] As shown in FIGS. 15A and 15B, the cutting edge portion 522 of the blade portion 516 is inserted into the opening 512 of each channel 508 of the slicing guide portion 504 and passes through, i.e., slices, in the longitudinal direction of the channel 508. This movement of the blade portion 516 cuts or separates the wick pad 500 disposed below the slicing guide portion 504. When slicing is performed in each channel 508 of the slicing guide portion 504, the blade portion 516 is moved to the next channel 508.

[0104] In step 416, the slicing guide portion 504 is removed and the wick strip 520 is separated from the wick pad 500. As shown in FIGS. 16A and 16B, when the slicing guide portion 504 is removed from the wick pad 500, the wick pad 500 is separated into a plurality of wick strips 520 corresponding to the positions of the channels 508. Each wick strip 520 may be separated from an adjacent strip 520.

[0105] In step 420, the wick strip 520 is inserted into the guide portion or the track portion 246 of the wick guide portion 26. As shown in FIG. 17A, the width of the channel portion 242 defining the guide portion or the track portion 246 is slightly larger than the width of the wick strip 520 in order to accommodate and guide the wick strip 520.

[0106] In step 424, the end portion of the wick strip 520 is removed using the cutter portion 338. As shown in FIGS. 17B and 18, the slide portion 22 of the device, i.e., the fixture 10, is moved to a position where it clamps the wick strip 520 against the holder portion 30 in order to suppress the movement of the wick strip 520 during cutting. The cutter portion 338 is moved from a position where it does not contact the wick strip 520 to a position where it contacts the wick strip 520. Specifically, the blade portion 346 of the cutter portion 338 is moved to a position where it slices the wick strip 520 and forms an edge extending parallel to the plane on the upper surface portion 154 of the slide portion 22.

[0107] In step 428, the wick guide 26 is rotated about the fastener 202. In at least one exemplary embodiment, the wick guide 26 is rotatably fixed to the block portion 34 by the fastener 202. The main body portion 210 of the fastener 202 extends through the wick holding portion 238, the wick plate portion 234, and the opening 222 of the block portion 34. A protrusion or other portion extending from the back surface of the wick plate portion 234 can slide within the track portion 258 of the block portion 34 when the wick guide 26 rotates relative to the block portion 34. As shown in FIG. 19, the wick guide 26 may be rotated from a position where the longitudinal axis A of the wick guide 26 is parallel to the plane on the upper surface portion 100 of the base 14 to a position where the longitudinal axis A of the wick guide 26 intersects the plane on the upper surface portion 100 of the base 14. In some embodiments, the wick guide 26 is rotated clockwise so that the longitudinal axis A forms an angle with the plane on the upper surface portion 100 of the base 14 within a range of 45° to 90°, more specifically within a range of 75° to 90°.

[0108] In step 432, the lever portion 298 on the toggle portion 282 of the lock portion 266 is engaged to move the lock finger portion 286 to the first position so that the finger is unlocked and in the open position. In some embodiments, the lock portion 266 may be rotatably fixed to the base portion 262 so as to rotate about a rod or pin within the opening 290 of the toggle portion 282. The lock finger portion 286 may rotate with the rotation of the toggle portion 282. In one embodiment, as shown in FIG. 20A, the lever portion 298 on the toggle portion 282 is pushed forward to move the lock finger portion 286 to the first position.

[0109] The tab portion 322 on the side opposite to the front portion 302 of the toggle portion 282 contacts the elastic member 270. The elastic member 270 is a flat plate-shaped spring having a main body portion 326 and a tab portion 330 extending from the main body portion 326, that is, a protrusion. The main body portion 326 of the elastic member 270 is fixed to the base portion 262. The tab portion 330 extends in the same manner as a cantilever beam and overlaps the tab portion 322 of the toggle portion 282. The tab portion 330 of the elastic member 270 applies a resistance force to the toggle portion 282 and biases the toggle portion 282 to a second rear position so that the lock finger portion 286 is biased to the closed position where it is locked.

[0110] Therefore, when the lever portion 298 on the toggle portion 282 of the lock portion 266 is engaged to move the lock finger portion 286 to the first position, a force is exerted on the elastic member 270 by the tab portion 322.

[0111] In step 436, a pre-heater arrangement 524 (or a pre-nicotine heater arrangement) for the non-nicotine pod assembly is inserted into the holder portion 30. As shown in FIGS. 20A and 20B, in at least one exemplary embodiment, the pre-heater arrangement 524 for the non-nicotine pod assembly may include a base 528 and a heating element 532 having a wire loop or a wire extending in a serpentine shape forming a coil 536. The wire used to form the coil may be a metal. The first set of wire loops 536a may extend perpendicular to the upper surface portion 540 of the base 528. The second set of wire loops 536b may extend obliquely with respect to the first set of wire loops 536a and the upper surface portion 540. As a single example, the second set of wire loops 536b may extend at an angle within the range of 30° to 60° with respect to the upper surface portion 540, and more specifically, may extend at an angle of 45° with respect to the upper surface portion 540.

[0112] The heating element 532 may extend completely or partially across the width of the base 528. In some exemplary embodiments, the heating element 532 may be in contact (e.g., direct contact) with an assembled wick (further described below).

[0113] The holder portion 30 is disposed in the retaining notch 106 of the base 14 such that the notch 88 is located between the holder portion 30 and the base 14 at a position above the support notch 110. Thus, when the pre - heater arrangement 524 for the non - nicotine pod assembly is inserted into the holder portion 30, the base 528 is inserted at least partially below the holder portion 30 and into the support notch 110 and the notch 88.

[0114] The pre - heater arrangement 524 for the non - nicotine pod assembly is inserted into the holder portion 30 until the first set of wire loops 536a contacts the holder portion 30 at a position near the slot portion 274 on the holder portion 30.

[0115] In step 440, the lever portion 298 of the toggle portion 282 is released so that the toggle portion 282 returns to the second position. The tab portion 330 of the elastic member 270 biases the toggle portion 282 to the second rearward position so as to provide a resistance force to the toggle portion 282 and bias the lock finger portion 286 to the locked closed position. As shown in FIG. 20B, when the toggle portion 282 moves to the second position, the lock finger portion 286 engages with the first set of wire loops 536a to hold the pre - heater arrangement 524 against the holder portion 30.

[0116] In step 444, the wick guide 26 is rotated counterclockwise to a position where the longitudinal axis A of the wick guide 26 is parallel to the plane on the upper surface portion 100 of the base 14. As described above, the wick guide 26 is rotatably fixed to the block portion 34 by the fastener 202. The main body portion 210 of the fastener 202 extends through the wick holding portion 238, the wick plate portion 234, and the opening 222 of the block portion 34. A protrusion or other portion extending from the back side of the wick plate portion 234 may slide within the track portion 258 in the block portion 34 when the wick guide 26 rotates with respect to the block portion 34. The wick guide 26 may be rotated from a position where the longitudinal axis A of the wick guide 26 intersects the plane on the upper surface portion 100 of the base 14 to a position where the longitudinal axis A of the wick guide 26 is parallel to the plane on the upper surface portion 100 of the base 14.

[0117] In step 448, the wick strip 520 is slid within the channel portion 242 in the wick guide 26 to a position where it contacts the upper surface portion 540 of the base 528 of the pre - heater arrangement 524 for the non - nicotine pod assembly. As shown in FIGS. 21A and 21B, the wick strip 520 includes an edge portion 544 that extends parallel to the plane on the upper surface portion 154 of the slide portion 22. The edge portion 544 is moved to a position where it contacts the upper surface portion 540 of the base 528 of the pre - heater arrangement 524. The wick strip 520 further contacts the first set of wire loops 536a.

[0118] In step 452, the pin 150 of the slide portion 22 is moved to a fully forward position, the pin 150 contacts the front end portion 138 of the slot portion 126, and the plane along the front surface portion 174 of the tab portion 170 on the slide portion 22 is aligned with the plane along the side wall portion 70 of the lateral channel 66.

[0119] As shown in FIGS. 21B and 21C, during the movement of the slide part 22 to the fully forward position, the front surface part 174 of the tab part 170 on the slide part 22 contacts the second set of wire loops 536b, and bends the second set of wire loops 536b from a position angled with respect to the first set of wire loops 536a and the upper surface part 540 to a position substantially parallel to the first set of wire loops 536a and contacting the wick strip 520. In the fully forward position, the front surface part 174 of the tab part 170 on the slide part 22 clamps the first set of wire loops 536a and the second set of wire loops 536b together, compresses the wick strip 520, fixes the wick strip 520 with respect to the pre - heater arrangement 524, and forms the heater assembly 524', that is, the heater wick assembly.

[0120] In step 456, the wick strip 520 is cut to create the wick 548 (or non - nicotine wick). In some embodiments, the ends of the wick strip 520 are removed using the cutter part 338. As shown in FIG. 21D, the cutter part 338 moves from a position not in contact with the wick strip 520 to a position in contact with the wick strip 520. Specifically, the blade part 346 of the cutter part 338 moves to a position where it slices the wick strip 520, forming an edge that extends parallel to the plane on the upper surface part 154 of the slide part 22. As a result, the cut part becomes the wick 548.

[0121] In step 460, the wick guide 26 is rotated clockwise. As shown in FIG. 22, the wick guide 26 is rotated about the fastener 202. The wick guide 26 may be rotated from a position where the longitudinal axis A of the wick guide 26 is parallel to the plane on the upper surface portion 100 of the base 14 to a position where the longitudinal axis A of the wick guide 26 intersects the plane on the upper surface portion 100 of the base 14. In some embodiments, the wick guide 26 may be rotated clockwise such that the longitudinal axis A forms an angle with the plane on the upper surface portion 100 of the base 14 within the range of 45° to 90°, more specifically within the range of 75° to 90°.

[0122] In step 464, the pin 150 of the slide portion 22 is moved to release the heater assembly 524' (or non-nicotine heater assembly) for the non-nicotine pod assembly. In some embodiments, the pin 150 moves to a fully rearward position as shown in FIG. 23. In the fully rearward position, the pin 150 may contact the rear end portion 178 of the slot portion 126, and the plane along the rear surface portion 182 of the plate portion 146 of the slide portion 22 may be aligned with the plane along the rear surface portion 186 of the base 14.

[0123] In step 468, the lever portion 298 of the toggle portion 282 is engaged to release the lock portion 266. The engagement of the lever portion 298 may move the lock finger portion 286 to a first position such that the finger is unlocked and in the open position. In some embodiments, the lock portion 266 may be rotatably fixed to the base 262 so as to rotate about a rod or pin within the opening 290 of the toggle portion 282. The lock finger portion 286 may rotate with the rotation of the toggle portion 282. In one embodiment, as shown in FIG. 20A, the lever portion 298 on the toggle portion 282 is pushed forward to move the lock finger portion 286 to the first position.

[0124] The tab portion 322 on the side opposite to the front portion 302 of the toggle portion 282 contacts the elastic member 270. The elastic member 270 extends similarly to a cantilever beam and overlaps on the tab portion 322 of the toggle portion 282. The elastic member 270 applies a resistance force to the toggle portion 282 and biases the toggle portion 282 to a second rear position so that the lock finger portion 286 is biased to the locked closed position. Therefore, when the lever portion 298 on the toggle portion 282 of the lock portion 266 is engaged to move the lock finger portion 286 to the first position, a force is exerted on the elastic member 270 by the tab portion 322.

[0125] In step 472, the heater assembly 524' for the non-nicotine pod assembly is removed from the holder portion 30. As shown in FIGS. 23 and 24, the heater assembly 524' is removed from the holder portion 30 by sliding the heater assembly 524' within the notch 88 and the support notch 110 away from the holder portion 30 until the heater assembly 524' passes through the edge of the holder portion 30. The heater assembly 524' for the non-nicotine pod assembly is then removed from the support notch 110.

[0126] In step 476, the lever portion 298 of the toggle portion 282 is released so that the toggle portion 282 returns to the second position. As described above, the tab portion 330 of the elastic member 270 applies a resistance force to the toggle portion 282, biases the toggle portion 282 to the second rear position, and biases the lock finger portion 286 to the locked closed position.

[0127] In step 480, the method 400 ends.

[0128] Referring now to FIG. 25, an embodiment of an assembled heater assembly 524' for a non-nicotine pod assembly is illustrated. Wick 548 is clamped between a first set of wire loops 536a and a second set of wire loops 536b such that the wick 548 is secured to the heater assembly 524'. An exemplary heater assembly is disclosed in U.S. Application No. 16 / 696,081, filed Nov. 26, 2019, entitled "NON-NICOTINE POD ASSEMBLIES AND NON-NICOTINE E-VAPING DEVICES", the disclosure of which is hereby incorporated by reference in its entirety.

[0129] When an element or layer is referred to as being "on," "connected to," "coupled to," or "covering" another element or layer, it can be directly on, connected to, or covering the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. In this specification, the same numbers refer to the same elements. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0130] In this specification, terms such as first, second, third, etc. may be used to describe various elements, components, regions, layers, and / or sections. However, it should be understood that these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Therefore, the first element, component, region, layer, or section described below can be referred to as the second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0131] In this specification, for ease of explanation, spatially relative terms (e.g., "beneath", "below", "lower", "above", "upper", etc.) are used to describe the relationship between an element or function and another element or function as shown in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures during use and operation. For example, if the device in the figure is turned over, an element described as "below" or "beneath" another element or feature will be oriented "above" the other element or feature. Therefore, the term "below" can potentially encompass both upward and downward orientations. Also, the device may be oriented in other directions (it may be rotated 90 degrees or oriented in other directions), and the spatially relative descriptors used in this specification are to be interpreted accordingly.

[0132] 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 forms as well, unless the context clearly indicates otherwise. The terms "includes", "including", "comprises", and / or "comprising" as used herein specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0133] Exemplary embodiments are described herein with reference to cross-sectional views that are schematic illustrations of idealized embodiments (and intermediate structures) of the exemplary embodiments. As such, for example, variations from the shapes of the figures as a result of manufacturing techniques and / or tolerances are to be expected. Accordingly, exemplary embodiments should not be construed as limited to the shapes of regions shown herein and should include, for example, departures in shapes resulting from manufacturing.

[0134] 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 illustrated embodiments belong. Further, terms defined in commonly used dictionaries, including those used herein, should be interpreted as having a meaning that coincides with the meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0135] Although exemplary embodiments have been disclosed herein, it should be understood that other variations are possible. Such variations should not be regarded as departing from the spirit and scope of the present disclosure, and all such changes that would be obvious to one of ordinary skill in the art are intended to be included within the scope of the following claims.

Claims

1. An apparatus for assembling a heater assembly for a non-nicotine pod assembly, comprising: a base, a wick supply portion, a slide portion, and a holder portion; the wick supply portion defines a channel extending toward the base and configured to receive a wick, where the wick is structured to draw a non-nicotine pre-vapor formulation by capillary action; the slide portion is configured to move along a plane on the upper surface of the base; the holder portion is disposed on the upper surface of the base; the holder portion is configured to fix a support of the heater assembly; the slide portion includes a front face orthogonal to the upper surface of the base; the slide portion is configured to contact a finger portion of a heater on the support and move the finger portion to a vertical position to compress the wick; An apparatus.

2. The apparatus according to claim 1, further comprising: a wick holding portion; the wick holding portion extends parallel to and adjacent to the wick supply portion so as to hold the wick within the channel; An apparatus.

3. The apparatus according to claim 1, further comprising: a cutter portion; the cutter portion has a blade portion; the blade portion is configured to slide along the upper surface of the slide portion to cut the wick; An apparatus.

4. The apparatus according to claim 1, wherein: the wick supply portion is configured to rotate relative to the base; An apparatus.

5. The apparatus according to claim 1, further comprising: a block portion; the block portion is fixed to the base; the wick supply portion is rotatably attached to and supported by the block portion; An apparatus.

6. The apparatus according to claim 1, wherein: the holder portion is configured to receive the support of the heater assembly therein; the holder portion is configured to fix the support relative to the base for inserting the wick; An apparatus.

7. The apparatus according to claim 6, wherein: the channel of the wick supply portion is configured to guide the wick to be aligned with the heater on the support; An apparatus.

8. The apparatus according to claim 1, wherein: the wick supply portion extends orthogonally to the base; An apparatus.

9. In the apparatus according to claim 1, the holder part includes a locking finger part, the locking finger part is configured to engage with the support of the heater assembly and hold the support within the holder part, apparatus.

10. In the apparatus according to claim 1, the wick supply part includes a plate part and a holding part, the plate part is arranged perpendicular to the base part and defines the channel, the holding part is arranged perpendicular to the base part and adjacent to the plate part, the holding part and the plate part define a slot part for guiding the wick, apparatus.

11. The apparatus according to claim 10, further comprising a block part, the block part is fixed to the base part, the plate part is rotatably attached to and supported by the block part, apparatus.

12. In the apparatus according to claim 11, the holding part is fixed to the plate part, the holding part and the plate part are configured to rotate with respect to the base part and the block part, apparatus.

13. In the apparatus according to claim 1, the holder part is configured to fix the support of the heater assembly and lock the position of the support with respect to the base part, apparatus.

14. In the apparatus according to claim 13, the holder part includes a locking finger part, the locking finger part is configured to engage with the support and hold the support within the holder part, apparatus.

15. The apparatus according to claim 1, further comprising a blade part, the blade part is configured to slide along the upper surface of the slide part, apparatus.

16. A method of assembling a heater assembly of a non - nicotine pod assembly, comprising using a holder part to relatively fix the support of the heater assembly to a base part, using a wick supply part attached to the base part to align the wick within the heater of the support, wherein the wick is structured to draw a non - nicotine pre - vapor formulation by capillary action, using a blade part configured to move along the plane of the upper surface of the base part to cut a part of the wick, using a slide part configured to slide with respect to the base part to clamp a part of the heater around a part of the wick, The holder part includes releasing the support from the base part. The holder part is arranged on the upper surface of the base part. The wick supply part extends toward the base part and defines a channel configured to receive the wick. The slide part includes a front surface orthogonal to the upper surface of the base part. The slide part is configured to contact the finger part of the heater on the support and move the finger part to a vertical position so as to compress the wick. Method.

17. The method according to claim 16, wherein fixing the support to the base part includes locking the support to the holder part. Method.

18. The method according to claim 16, wherein aligning the wick within the heater of the support includes inserting the wick into the channel within the wick supply part. Method.

19. The method according to claim 16, wherein aligning the wick within the heater of the support includes inserting the wick into the channel defined between the wick supply part and the holding plate part fixed to the wick supply part. Method.

Images