Nicotine e-vaping device with integrated heater thermocouple

Abstract

A nicotine cartridge (100) for a nicotine e-vapor device (500) is provided, the nicotine cartridge (100) including a housing defining a reservoir (134) containing a nicotine pre-vapor formulation (180). The nicotine cartridge (100) also includes a wick (240) configured to transport the nicotine pre-vapor formulation (180) by capillary action, and an integrated heater thermocouple (250). The integrated heater thermocouple (250) is configured to heat the nicotine pre-vapor formulation (180) within the wick (240) to generate a nicotine vapor, the integrated heater thermocouple (250) including a first segment (252) made of a first alloy and a second segment (256) made of a second alloy.

Description

[Technical Field]

[0001] The present disclosure relates to temperature measurement and control in nicotine electronic vaping (e-vaping) devices. [Background technology]

[0002] Some nicotine e-vapor devices include a first section connected to a second section. The first section may include a wick and a heater. The wick is configured to transfer 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 achieved manually and / or through puff activation. Summary of the Invention

[0003] At least one embodiment relates to a nicotine cartridge for a nicotine e-vapor device. In an exemplary embodiment, the nicotine cartridge may include a housing, a wick, and an integrated heater thermocouple. The housing defines a reservoir containing a nicotine pre-vapor formulation. The wick is configured to transport the nicotine pre-vapor formulation by capillary action. The integrated heater thermocouple is configured to heat the nicotine pre-vapor formulation to generate a nicotine vapor. The integrated heater thermocouple includes a first segment made of a first alloy and a second segment made of a second alloy.

[0004] At least one embodiment relates to a nicotine e-vapor device. In an exemplary embodiment, the nicotine e-vapor device may include a nicotine cartridge and a device body. The nicotine cartridge includes a nicotine pre-vapor formulation, a wick, and an integrated heater thermocouple. The wick is configured to transport the nicotine pre-vapor formulation by capillary action. The integrated heater thermocouple includes a first segment made of a first alloy and a second segment made of a second alloy. The device body is configured to receive the nicotine cartridge. The device body includes a power source, at least one sensor, and a controller. The power source is configured to supply electrical energy to the integrated heater thermocouple to heat the nicotine pre-vapor formulation to the wick to generate a nicotine vapor. The at least one sensor is configured to measure a voltage difference between the first segment and the second segment of the integrated heater thermocouple as a result of the supply of electrical energy from the power source. The controller is configured to adjust the supply of electrical energy to the integrated heater thermocouple based on the voltage difference measured by the at least one sensor. [Brief explanation of the drawings]

[0005] Various features and advantages of the non-limiting embodiments herein may become more apparent upon consideration of 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 scope of the claims. The accompanying drawings are not intended to be drawn to scale unless expressly noted. Various dimensions of the drawings may be exaggerated for purposes of clarity.

[0006] [Figure 1] FIG. 1 is a front view of a nicotine e-vaping device according to an exemplary embodiment. [Figure 2] FIG. 2 is a side view of the nicotine e-vaping device of FIG. [Figure 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. [Figure 5] FIG. 5 is a distal end view of the nicotine e-vaping device of FIG. [Figure 6] FIG. 6 is a front view of the nicotine e-vaping device of FIG. 1 when the nicotine cartridge and device body are disengaged. [Figure 7] FIG. 7 is an exploded view of the nicotine cartridge of FIG. [Figure 8] FIG. 8 is a first exploded view of the carburetor of FIG. [Figure 9] FIG. 9 is a second exploded view of the carburetor of FIG. [Figure 10] FIG. 10 is an exploded view of the vaporization module of FIG. [Figure 11] FIG. 11 is an exploded view of the vaporization module of FIG. [Figure 12] FIG. 12 is an exploded view of the heater subassembly of FIG. [Figure 13] FIG. 13 is an exploded view of the heater subassembly of FIG. [Figure 14] FIG. 14 is a partial exploded view of the device main body of FIG. [Figure 15] FIG. 15 is a perspective view of the battery section of FIG. [Figure 16] FIG. 16 is a partial exploded view of the battery section of FIG. [Figure 17] FIG. 17 is a partially exploded view of the battery subassembly of FIG. [Figure 18] 18 is a cross-sectional view of the nicotine cartridge and partial cross-sectional view of the device body of FIG. 6 when disengaged. [Figure 19] 19 is a cross-sectional view of the nicotine cartridge and partial cross-sectional view of the device body of FIG. 18 when engaged. [Figure 20] FIG. 20 is an enlarged view of the cross section of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0007] Some 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 set forth herein.

[0008] Accordingly, while exemplary embodiments are susceptible to various modifications and alternative forms, such exemplary embodiments have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed; 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.

[0009] When an element or layer is referred to as "on," "connected to," "coupled to," "attached to," "adjacent to," or "covering" another element or layer, it should be understood that this is directly on, directly connected to, directly coupled to, directly attached to, directly adjacent to, or directly covering the other element or layer, or that intervening elements or layers may be present. In contrast, when an element is referred to as "directly on," "directly connected to," or "directly coupled 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.

[0010] 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 that 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 could also be referred to as a second element, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0011] Spatial relationship terms (e.g., "below," "below," "lower," "above," "above," and the like) may be used herein to help describe the relationship between one element or feature and another element or feature when illustrated in the figures. Of course, the spatial relationship terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "below" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" may encompass both an orientation of above and below. The device may be oriented otherwise (rotated 90 degrees or at another orientation), and the spatial relationship descriptors used herein will be interpreted accordingly.

[0012] The terminology used herein is for the purpose of describing various exemplary embodiments only and is 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 dictates 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.

[0013] When the terms "about" or "substantially" are used herein in conjunction with a numerical value, the associated numerical value is intended to include a manufacturing or operating tolerance (e.g., ±10 percent) around the stated numerical value. Moreover, when the terms "generally" and "substantially" are used in connection with a geometric shape, exactness of the geometric shape is not required, but a tolerance of the shape is intended to be within the scope of the present disclosure. Furthermore, whether a numerical value or shape is modified as "about," "generally," or "substantially," it will be understood that these values and shapes should be interpreted as including a manufacturing or operating tolerance (e.g., ±10 percent) around the stated numerical value or shape.

[0014] 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 example 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 in an idealized or overly formal sense, except as expressly defined herein.

[0015] 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.

[0016] Unless otherwise specified or apparent from the discussion, terms such as "processing" or "calculating" or "computing" or "determining" or "displaying" refer to operations and processes of a computer system or similar electronic computing device that manipulate and convert data represented as physical, electronic quantities in the computer system's registers and memory into other data similarly represented as physical quantities in the computer system's memory or registers or other such information storage, transmission, or display devices.

[0017] In the description that follows, exemplary embodiments may be described with reference to operations and symbolic representations of operations (e.g., in the form of flowcharts, flow diagrams, data flow diagrams, structure diagrams, block diagrams, etc.) that may be implemented as program modules or functional processes, including routines, programs, objects, data structures, etc., that perform particular tasks or implement particular abstract data types. The operations may be implemented using existing hardware in existing e-systems, such as one or more microprocessors, central processing units (CPUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), SoCs, field programmable gate arrays (FPGAs), computers, etc.

[0018] One or more exemplary embodiments may be (or may include) hardware, firmware, hardware running software, or any combination thereof. Such hardware may include one or more microprocessors, CPUs, SoCs, DSPs, ASICs, FPGAs, computers, or the like, configured as dedicated machines to perform the functions described herein as well as any other well-known functions of these elements. At least in some cases, CPUs, SoCs, DSPs, ASICs, and FPGAs may be referred to generically as processing circuits, processors, and / or microprocessors.

[0019] Although a process may be described in terms of sequential operations, many of the operations may be performed in parallel, simultaneously, or concurrently. Additionally, the order of operations may be rearranged. A process may be terminated when its operations are completed, but may have additional steps not included in the figures. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.

[0020] As disclosed herein, the terms "storage medium," "computer-readable storage medium," or "non-transitory computer-readable storage medium" may refer to one or more devices for storing data, including read-only memory (ROM), random-access memory (RAM), magnetic RAM, core memory, magnetic disk storage media, optical storage media, flash memory devices, and / or other tangible, machine-readable media for storing information. The term "computer-readable medium" may include, but is not limited to, portable or non-removable storage devices, optical storage devices, and various other media capable of storing, containing, or retaining instructions and / or data.

[0021] Furthermore, at least some portions of the exemplary embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof. When implemented in software, firmware, middleware, or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine or computer-readable medium, such as a computer-readable storage medium. When implemented in software, a processor, processing circuit, or processing unit may be programmed to perform the necessary tasks, thereby converting it into a special-purpose processor or computer.

[0022] A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and / or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means, such as memory sharing, message passing, token passing, network transmission, etc.

[0023] FIG. 1 is a front view of a nicotine e-vapor device according to an exemplary embodiment. Referring to FIG. 1, the nicotine e-vapor device 500 may include a sleeve section 310 configured to receive a nicotine cartridge 100 (discussed in more detail below with respect to FIG. 6). The sleeve section 310 is connected to a battery section housing 360 via a knurled connector 340. A light pipe 358 may be exposed by the knurled connector 340, such that an exposed surface of the light pipe 358 constitutes the exterior surface of the nicotine e-vapor device 500. The exposed surface of the light pipe 358 may be between the sleeve section 310 and the battery section housing 360. The combination of at least the sleeve section 310 and the battery section housing 360 may be collectively referred to as the device housing of the nicotine e-vapor device 500. When the nicotine e-vapor device 500 is fully assembled / engaged, the mouthpiece 110 is disposed at the proximal end of the sleeve section 310, while the end cap 370 is disposed at the distal end of the battery section housing 360. The mouthpiece 110 (part of the nicotine cartridge 100 ) may have a tapered shape such that the width of its proximal end is smaller than the diameter of the sleeve section 310 .

[0024] The proximal and distal ends of the nicotine e-vaping device 500 (and / or its components) may also be referred to as the downstream and upstream ends, respectively. In particular, as used herein, "proximal" (and conversely, "distal") is relative to the adult e-vaping device user during vaping, and "downstream" (and conversely, "upstream") is relative to the flow of nicotine vapor.

[0025] The sleeve section 310 defines a plurality of air inlets 312. As shown, each of the air inlets 312 may have a hexagonal shape and may be staggered to resemble a honeycomb pattern. However, it should be understood that other shapes and arrangements are possible. For example, instead of (or in addition to) a hexagon, the air inlets 312 may include a triangular, rectangular (e.g., square, diamond), pentagonal, and / or circular shape. Furthermore, instead of an axial arrangement along a portion of the length of the sleeve section 310, the air inlets 312 may be arranged in a circumferential arrangement around the sleeve section 310. In an exemplary embodiment, the nicotine e-vaping device 500 may include at least ten total air inlets 312 (e.g., at least twenty total air inlets 312).

[0026] Figure 2 is a side view of the nicotine e-vaping device of Figure 1. Referring to Figure 2, opposite sides of the sleeve section 310 may define a first array of air inlets 312 and a second array of air inlets 312, such that both arrays are partially visible in side view. In an exemplary embodiment, the first array of air inlets 312 is fully visible based on a front view of the sleeve section 310 as shown in Figure 1, while the second array of air inlets 312 is fully visible based on a rear view of the sleeve section 310 as shown in Figure 3, as discussed below.

[0027] Mouthpiece 110 may have a wedge-shaped or chisel-shaped appearance based on the side view of FIG. 2. However, it should be understood that other shapes and configurations are possible. For example, in one example, mouthpiece 110 may instead have a cylindrical shape. In another example, mouthpiece 110 may have a frusto-conical or truncated conical shape.

[0028] The port 368 may be located near the distal end of the battery section housing 360, adjacent the end cap 370. In the side view of FIG. 2, the port 368 may be visible as a recess in the battery section housing 360. In an exemplary embodiment, the port 368 facilitates charging and / or communication of information to / from the nicotine e-vaping device 500. The port 368 is discussed in more detail in connection with FIG. 3.

[0029] The light pipe 358 is configured to transmit light emitted from at least one internal light source (e.g., an LED) to provide one or more visual indications. In particular, the light transmitted by the light pipe 358 may visually inform an adult e-vapor device user of the status of the nicotine e-vapor device 500. For example, the visual indications provided by the light pipe 358 may include, but are not limited to, whether the nicotine e-vapor device 500 is on, whether nicotine vapor is being generated, whether the battery is low, whether charging is occurring or complete, and / or whether the nicotine pre-vapor formulation is low or depleted.

[0030] As referred to herein, a nicotine pre-vapor formulation is a material or combination of materials that can be transformed into a nicotine vapor. For example, a nicotine pre-vapor formulation can include a liquid, solid, and / or gel formulation. These can include, for example, but are not limited to, water, oil, emulsion, beads, solvent, active ingredient, ethanol, plant extract, nicotine, natural or artificial flavor, vapor formers such as glycerin and propylene glycol, and / or any other ingredients that may be suitable for vaping. During vaping, the nicotine e-vapor 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 and claimed devices, and / or equivalents thereof, which may contain nicotine. In exemplary embodiments, the nicotine e-vapor device 500 can be considered an electronic nicotine delivery system (ENDS).

[0031] 2, the light pipe 358 may be on the opposite side of the nicotine e-vapor device 500 from the port 368. However, it should be understood that exemplary embodiments are not limited to this. For example, in some embodiments, the light pipe 358 may be on the same side of the nicotine e-vapor device 500 as the port 368 (e.g., on the back side of the nicotine e-vapor device 500). Conversely, in other embodiments, the port 368 may be on the same side of the nicotine e-vapor device 500 as the light pipe 358 (e.g., on the front side of the nicotine e-vapor device 500).

[0032] Figure 3 is a rear view of the nicotine e-vapor device of Figure 1. Referring to Figure 3, the second array of air inlets 312 on the rear of the nicotine e-vapor device 500 is as described in relation to the first array of air inlets 312 on the front of the nicotine e-vapor device 500 shown in Figure 1. Therefore, the relevant disclosure of the air inlets 312 already discussed above will not be repeated for the sake of brevity. However, in some embodiments, the second array of air inlets 312 on the rear of the nicotine e-vapor device 500 shown in Figure 3 may be different from the first array of air inlets 312 on the front of the nicotine e-vapor device 500 shown in Figure 1 (or vice versa). For example, instead of three staggered rows of seven, eight, and seven air inlets 312 per array, the number of rows and / or number of air inlets 312 per array can be changed to away from twenty-two air inlets 312 per array (or a total of forty-four air inlets 312 for the nicotine e-vaping device 500).

[0033] The port 368 is configured to receive current from an external power source (e.g., via a USB / mini-USB / USB-C cable) to charge an internal power source within the nicotine e-vaporizing device 500. Additionally, the port 368 may also be configured to transmit and / or receive data (e.g., via a USB / mini-USB / USB-C cable) from another nicotine e-vaporizing device or other electronic device (e.g., a phone, tablet, computer). Additionally, the nicotine e-vaporizing 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-vaporizing device user may control or otherwise interface with the nicotine e-vaporizing device 500 (e.g., locate the nicotine e-vaporizing device, check usage information, change operating parameters) through the app.

[0034] While the port 368 is shown as being located on the rear of the nicotine e-vaporizing device 500 in Figure 3, it should be understood that other locations are possible. For example, in some embodiments, the port 368 may instead be located on the front of the nicotine e-vaporizing device 500 in Figure 1. Additionally, in other embodiments, the port 368 may be located at the distal end of the nicotine e-vaporizing device 500 such that it is accessible through an end cap 370.

[0035] FIG. 4 is a proximal end view of the nicotine e-vapor device of FIG. 1. Referring to FIG. 4, the mouthpiece 110 defines a vapor outlet 112. During vaping, generated nicotine vapor is drawn from the nicotine e-vapor device 500 through the vapor outlet 112. While the vapor outlet 112 is shown as being centered coincident with the central longitudinal axis of the nicotine e-vapor device 500, it should be understood that in some examples, the vapor outlet 112 may be off-center (e.g., offset from the central longitudinal axis). Furthermore, while only one vapor outlet 112 is shown in FIG. 4, it should be understood that exemplary embodiments are not limited in this regard. Notably, in some embodiments, the mouthpiece 110 may define multiple vapor outlets 112. For example, the mouthpiece 110 may define two vapor outlets 112, which may extend parallel (e.g., longitudinally) or in a divergent manner. In another example, the mouthpiece 110 may define three vapor outlets 112. In such an embodiment, the three vapor outlets 112 may be aligned in a linear configuration such that the central vapor outlet 112 extends longitudinally, while the other two vapor outlets 112 extend in a diverging manner. Alternatively, all three vapor outlets 112 may extend in parallel.

[0036] It should also be understood that the positioning, arrangement, and quantity of the one or more vapor outlets 112 may further vary depending on the configuration of the mouthpiece 110. Particularly in exemplary embodiments in which the mouthpiece 110 has a cylindrical or frustoconical shape (instead of a flat shape), additional options may exist for the positioning, arrangement, and quantity of the one or more vapor outlets 112. For example, where space permits, an embodiment with three vapor outlets 112 may have a triangular arrangement for the vapor outlets 112. Similarly, an embodiment with four vapor outlets 112 may have a triangular arrangement with a central vapor outlet 112 or, alternatively, a quadrangular (e.g., square, diamond) arrangement. Similarly, an embodiment with more vapor outlets 112 may have a quadrangular, pentagonal, hexagonal, heptagonal, or octagonal arrangement, which may or may not include a central vapor outlet 112.

[0037] As shown in the drawings, the nicotine e-vaporizing device 500 may have a generally cylindrical and circular cross-section. Alternatively, the nicotine e-vaporizing device 500 may have a generally polyhedral shape with a polygonal cross-section. The selection of the general overall shape of the nicotine e-vaporizing device 500 takes into account various factors, including (but not limited to) aesthetic, functional, and manufacturing considerations. For example, instead of a cylindrical shape, the nicotine e-vaporizing device 500 may have a polyhedral shape to provide a more modern appearance and / or to prevent or reduce the possibility of undesirable rolling (e.g., anti-roll design).

[0038] The polyhedral shape of the nicotine e-vaporizing device 500 may include a triangular prism, a cube, a pentagonal prism, a hexagonal prism, a heptagonal prism, or an octagonal prism. In a shape resembling a triangular prism, the nicotine e-vaporizing device 500 may have a triangular cross-section (e.g., the shape of an equilateral triangle). In a shape resembling a cube, the nicotine e-vaporizing device 500 may have a square cross-section or a rectangular cross-section. In a shape resembling a pentagonal prism, the nicotine e-vaporizing device 500 may have a pentagonal cross-section. In a shape resembling a hexagonal prism, the nicotine e-vaporizing device 500 may have a hexagonal cross-section. In a shape resembling a heptagonal prism, the nicotine e-vaporizing device 500 may have a heptagonal cross-section. In a shape resembling an octagonal prism, the nicotine e-vaporizing device 500 may have an octagonal cross-section.

[0039] FIG. 5 is a distal end view of the nicotine e-vaping device of FIG. 1. Referring to FIG. 5, an end cap 370 and a button 372 are disposed at the distal end of the nicotine e-vaping device 500. The end cap 370 may engage with the battery section housing 360 via an interference fit (which may also be referred to as a press fit or a friction fit). For example, an outer wall of the end cap 370 may engage with a corresponding inner wall of the battery section housing 360. Additionally, the outer wall of the end cap 370 may be knurled to enhance the engagement. In an exemplary embodiment, the end cap 370 also defines an opening configured to accommodate the button 372. In such an example, the end cap 370 is a fixed structure and the button 372 is a movable structure that is movable (e.g., depressible) relative to the end cap 370.

[0040] The button 372 may be a power button for the nicotine e-vapor device 500. In particular, when pressed, the button 372 may activate a power source within the nicotine e-vapor device 500. While the button 372 is shown as being located at the distal end of the nicotine e-vapor device 500, it should be understood that exemplary embodiments are not limited thereto. For example, in some embodiments, the button 372 may instead be located on the front of the nicotine e-vapor device 500 (e.g., on the same side as the light pipe 358).

[0041] FIG. 6 is a front view of the nicotine e-vapor device of FIG. 1 when the nicotine cartridge and device body are not engaged. Referring to FIG. 6, the nicotine e-vapor device 500 includes a nicotine cartridge 100 and a device body 300, where the device body 300 is configured to receive the nicotine cartridge 100. The nicotine cartridge 100 includes a housing configured to hold a nicotine pre-vapor formulation 180. When the nicotine cartridge 100 is engaged with the device body 300, a majority of the nicotine cartridge 100 may be hidden from view by a sleeve section 310, while the mouthpiece 110 remains visible (e.g., as shown in FIG. 1). The nicotine pre-vapor formulation 180 within the nicotine cartridge 100 may also be visible through the device body 300 via the air inlet 312 of the sleeve section 310. During vaping, the nicotine pre-vapor formulation 180 heats to generate a nicotine vapor, which is drawn from the nicotine e-vapor device 500 via the mouthpiece 110.

[0042] The nicotine cartridge 100 may be considered a consumable item that is replaced when the nicotine pre-vapor formulation 180 therein is depleted. The level of nicotine pre-vapor formulation 180 within the nicotine cartridge 100 may be visually confirmed through the air inlet 312 of the sleeve section 310. In some examples, the nicotine e-vapor device 500 may additionally provide notification (e.g., via the light pipe 358) when the nicotine pre-vapor formulation 180 within the nicotine cartridge 100 is deemed depleted. In other examples, the nicotine e-vapor device 500 may also provide an indication (e.g., via the light pipe 358) that another unacceptable condition exists. Examples of other unacceptable conditions include, but are not limited to, a poor electrical connection and / or an unauthorized nicotine cartridge, or an approved nicotine cartridge that is no longer deemed suitable for vaping (if an excessively long period of time has passed, such as one year, since the first vaping event with the nicotine cartridge).

[0043] The shape of the device body 300 may correspond to the shape of the nicotine cartridge 100 (e.g., a generally cylindrical shape for both the device body 300 and the nicotine cartridge 100). However, in other examples, the shape of the device body 300 may differ from the shape of the nicotine cartridge 100. For example, the nicotine cartridge 100 may have a cylindrical shape, while the device body 300 may have one of the different shapes disclosed herein (e.g., a cubic shape), or vice versa. Thus, the nicotine e-vaping device 500 may have an overall shape (influenced primarily by the device body 300) that differs from the shape of the nicotine cartridge 100.

[0044] FIG. 7 is an exploded view of the nicotine cartridge of FIG. 6. Referring to FIG. 7, the nicotine cartridge 100 includes a mouthpiece 110, a first seal 120, a tank 130, a second seal 140, and a vaporizer 150. The tank 130 defines a reservoir 134 configured to hold a nicotine pre-vapor formulation 180 when the nicotine cartridge 100 is assembled. Additionally, the sidewall of the tank 130 may define at least one vapor channel therethrough. As shown, the sidewall of the tank 130 defines vapor channels 132a and 132b (which may also be referred to as a first vapor channel 132a and a second vapor channel 132b). In an exemplary embodiment, the vapor channels 132a and 132b may be defined within opposing sides of the sidewall of the tank 130 (e.g., diametrically opposed) such that the reservoir 134 is between the vapor channels 132a and 132b. Vapor channels 132a and 132b may also be parallel to each other and to the longitudinal axis of reservoir 130. Reservoir 130 may be formed of a transparent material to allow viewing of the contents therein (e.g., nicotine pre-vapor formulation 180).

[0045] The first seal 120 and the second seal 140 are configured to seal or close the reservoir 134. The first seal 120 defines openings 122a and 122b (which may also be referred to as first opening 122a and second opening 122b). As a result, when the first seal 120 engages the reservoir 130 to seal the proximal side of the reservoir 134, the openings 122a and 122b align with the vapor channels 132a and 132b, respectively. This engagement allows nicotine vapor generated by the vaporizer 150 during vaping to travel up the vapor channels 132a and 132b, through the openings 122a and 122b, respectively, to the mouthpiece 110, and out the vapor outlet 112. When the nicotine cartridge 100 is assembled, the first seal 120 may be hidden from view by the mouthpiece 110 (which also engages the reservoir 130). Additionally, the first seal 120 may be formed from or include a resilient structural material (eg, silicone).

[0046] Second seal 140 is configured to engage with tank 130 to seal the distal side of reservoir 134. In particular, second seal 140 is configured to seal the distal side of reservoir 134 by closing opening 136 in tank 130. In an exemplary embodiment, second seal 140 is formed from a resilient material (e.g., silicone) and includes a head portion, a body portion, and a neck portion between the head and body portions. The diameter of the head portion of second seal 140 may be larger than the diameter of opening 136 and smaller than the diameter of the body portion of second seal 140, while the diameter of the neck portion of second seal 140 may correspond to the diameter of opening 136. As a result, when the head portion of the second seal 140 is forced through the opening 136 of the reservoir 130, the neck portion of the second seal 140 can resiliently seat within the opening 136 in a liquid-tight manner, while the head portion of the second seal 140 is within the reservoir 134 and the body portion of the second seal 140 is outside the reservoir 134. In such an example, gripping the opposing surfaces of the reservoir 130 that define the opening 136 can help ensure that the head and body portions of the second seal 140 maintain their proper positioning while ensuring that the second seal 140 provides the desired seal.

[0047] Thus, the first seal 120 and the second seal 140 are configured to engage with the tank 130 such that the reservoir 134 is sealed and isolated from the vapor channels 132a and 132b. The combination of the first seal 120, the tank 130, and the second seal 140 may be collectively referred to as the housing of the nicotine cartridge 100. In exemplary embodiments, the second seal 140 may be configured as a pierceable structure that completely covers (when in an unpierced / non-pierced state) the opening 136 of the tank 130. In such embodiments, the reservoir 134 may remain sealed until a vaporizer 150 is received and engaged by the tank 130 (e.g., during assembly, prior to vaping) such that the tip of the vaporizer 150 penetrates the second seal 140, extends through the opening 136, and into the reservoir 134 to access the nicotine pre-vapor formulation 180 therein (e.g., as shown in FIG. 6 ).

[0048] FIG. 8 is a first exploded view of the vaporizer of FIG. 7. FIG. 9 is a second exploded view of the vaporizer of FIG. 7. Referring to FIGS. 8-9, vaporizer 150 includes a vaporization module 200 that can be at least partially retained within catch ring 160 and bayonet connector 170. Catch ring 160 defines an opening 162 configured to accommodate vaporization module 200. Similarly, bayonet connector 170 defines an opening 172 configured to receive vaporization module 200. When vaporizer 150 is assembled, catch ring 160 engages bayonet connector 170 to surround and retain vaporization module 200. Furthermore, a tip or piercing portion of vaporization module 200 protrudes beyond the edge of catch ring 160, while the remainder of vaporization module 200 is substantially or completely hidden from view within bayonet connector 170, depending on the angle. In the exemplary embodiment, vaporization module 200 may be held by / within catch ring 160 and bayonet connector 170 via an interference fit.

[0049] The bayonet connector 170 (which is part of the vaporizer 150 and, therefore, part of the nicotine cartridge 100) facilitates connection between the nicotine cartridge 100 and the device body 300. As shown in FIGS. 8-9 , the bayonet connector 170 defines a pair of slots 174, each configured to receive a corresponding engaging member. Each of the slots 174 includes a longitudinal portion 174a and a circumferential portion 174b. Additionally, the circumferential portion 174b may include a groove 174c that serves to retain the corresponding engaging member. Establishing a bayonet connection between the nicotine cartridge 100 and the device body 300 is discussed in more detail herein.

[0050] FIG. 10 is an exploded view of the vaporization module of FIG. 8 . FIG. 11 is an exploded view of the vaporization module of FIG. 9 . Referring to FIGS. 10-11 , vaporization module 200 includes a first module cover 210, a module housing 220, and a heater wick subassembly 230. Module housing 220 defines a chamber 222, which may also be referred to as a heating chamber or a vaporization chamber. In an exemplary embodiment, module housing 220 may be formed of a transparent material to allow viewing of the contents within chamber 222. First module cover 210 is configured to engage with a proximal end of module housing 220. Heater wick subassembly 230 is configured to engage with an opposing distal end of module housing 220. In this manner, the open end of module housing 220 may be enclosed (e.g., capped) by first module cover 210 and heater wick subassembly 230.

[0051] The first module cover 210 includes a cap portion 216 and a puncture portion 214 protruding from the cap portion 216. The cap portion 216 of the first module cover 210 defines a plurality of openings 218, which may be evenly spaced from one another and arranged in a circular arrangement around the puncture portion 214. In the exemplary embodiment, the cap portion 216 defines eight openings 218. However, it should be understood that the quantity, shape, and / or arrangement of the openings 218 in the cap portion 216 may be varied as appropriate to achieve the desired passage of aerosol therethrough from the chamber 222. For example, the cap portion 216 may alternatively define only two openings 218, each having an elongated shape and diametrically positioned to align with the vapor channels 132a and 132b of the tank 130 when the vaporizer 150 is engaged with the tank 130. With respect to assembly of vaporization module 200 , cap portion 216 of first module cover 210 has an outer surface configured to engage a corresponding inner surface of module housing 220 .

[0052] The piercing portion 214 defines an orifice 212 that may extend longitudinally through the first module cover 210. For example, the orifice 212 in the piercing portion 214 may be coincident with a central longitudinal axis of the first module cover 210. Furthermore, the piercing portion 214 defines a hole 213 in its sidewall. The hole 213 may be considered to extend laterally through the piercing portion 214 so as to be perpendicular to the orifice 212. While a pair of holes 213 is illustrated in FIG. 10 , it should be understood that the exemplary embodiment is not limited thereto. For example, the piercing portion 214 may instead define a different number of holes 213 (e.g., three, four) in its sidewall. Furthermore, the piercing portion 214 may have a proximal surface that tapers toward a pointed end or tip to facilitate insertion of the piercing portion 214 through the second seal 140, through the opening 136 of the tank 130, and into the reservoir 134. When the vaporizer 150 is in fluid communication with the reservoir 134 , the nicotine pre-vapor formulation 180 enters the vaporization module 200 via the orifice 212 and / or the holes 213 in the piercing portion 214 .

[0053] Heater wick subassembly 230 includes second module cover 260, which may function as a base or support for the other portions of heater wick subassembly 230. As a result, the other portions of heater wick subassembly 230 may be integrally attached to or fixed to second module cover 260. In an exemplary embodiment, second module cover 260 may be formed from an electrically conductive material. For example, the electrically conductive material may include steel (e.g., 304 stainless steel). With respect to assembly of vaporization module 200, second module cover 260 has an outer surface configured to engage a corresponding inner surface of module housing 220.

[0054] The heater wick subassembly 230 further includes a wick 240 configured to draw or transport the nicotine pre-vapor formulation 180 from the reservoir 134 to the vaporization module 200. The wick 240 may be a fibrous structure with pores / interstices designed for capillary action. In an exemplary embodiment, the wick 240 may have a cord-like configuration in which strands of fiber are braided, twisted, and / or woven together. When the vaporization module 200 is assembled, a proximal portion of the wick 240 may extend within the first module cover 210, while a distal portion of the wick 240 may be supported / retained by the second module cover 260.

[0055] For example, the proximal portion of the wick 240 may be disposed within the puncture portion 214 of the first module cover 210 so as to substantially occupy the orifice 212 (e.g., FIG. 8 ), thus helping to regulate the supply of the nicotine pre-vapor formulation 180 from the reservoir 134. As a result, the possibility of excessive flow of the nicotine pre-vapor formulation 180 into the chamber 222 (via the orifice 212 and / or the hole 213) may be reduced or prevented. Instead, the nicotine pre-vapor formulation 180 may be drawn into the chamber 222 substantially as needed. In particular, as the nicotine pre-vapor formulation 180 within the wick 240 heats to generate a nicotine vapor (and thus become depleted) during vaping, the wick 240 draws additional nicotine pre-vapor formulation 180 from the reservoir 134 to replenish the depleted nicotine pre-vapor formulation 180 within the wick 240. The nicotine pre-vapor formulation 180 from the reservoir 134 may enter the first module cover 210 through the orifice 212 and / or the hole 213 before being drawn into the wick 240 via capillary action. Meanwhile, when no vaping is occurring, the drawing of the nicotine pre-vapor formulation 180 from the reservoir 134 by the wick 240 may slow or stop when the wick 240 becomes saturated. Furthermore, penetration of the nicotine pre-vapor formulation 180 into the opening 218 may be reduced or prevented by the engagement of the first module cover 210 and the second seal 140.

[0056] The integrated heater thermocouple 250 is positioned in thermal contact with the wick 240. The nicotine e-vapor device 500 is configured such that the integrated heater thermocouple 250 is activated during vaping to heat the nicotine pre-vapor formulation 180 within the wick 240 to generate a nicotine vapor. The integrated heater thermocouple 250 may be designed to undergo Joule heating (also known as ohmic / resistive heating) as an electric current is applied to it. More specifically, the integrated heater thermocouple 250 may be formed of a conductor (resistive material) and configured to generate heat when an electric current is passed through it. The electric current may be supplied by a power source (e.g., a battery) within the device body 300.

[0057] In an exemplary embodiment, the integrated heater thermocouple 250 is in the form of a helical coil that wraps (e.g., spirals) around the wick 240. For example, the integrated heater thermocouple 250 may be wrapped around the lower portion of the wick 240 (e.g., around a portion of the wick 240 that does not protrude into the puncture portion 214). Furthermore, in such an example, the integrated heater thermocouple 250 may be oriented such that the axis of its helix is at an angle (e.g., not parallel or perpendicular) to the longitudinal axis of the vaporization module 200. The integrated heater thermocouple 250 is discussed in more detail herein.

[0058] As shown in FIG. 11 , first electrical contact 270 may be disposed on the upstream side of second module cover 260. When assembled, the distal end of second module cover 260 extends through an opening defined by first electrical contact 270. In an exemplary embodiment, first electrical contact 270 is structured as a washer having an undulating or wavy form. First electrical contact 270 may be covered with gold plating. For example, first electrical contact 270 may have an interior (base structure) formed of steel (e.g., spring steel) and an exterior formed of gold (e.g., a deposition layer).

[0059] The second electrical contact 290 may be disposed at a distal end of the heater wick subassembly 230, extending through the first electrical contact 270 and the second module cover 260. In an exemplary embodiment, the second electrical contact 290 may be gold-plated. For example, the second electrical contact 290 may have an interior (base structure) formed of brass and an exterior (e.g., as a deposited layer) formed of gold. The second electrical contact 290 also defines a passage 292 that allows air flow into the chamber 222.

[0060] When heater wick subassembly 230 is assembled, a first end of integrated heater thermocouple 250 may be electrically connected to second module cover 260 / first electrical contact 270, while a second end of integrated heater thermocouple 250 may be electrically connected to second electrical contact 290. Insulator 280 electrically insulates second electrical contact 290 from second module cover 260 / first electrical contact 270. In the exemplary embodiment, insulator 280 is structured as a grommet having a sheath-like form that receives second electrical contact 290 and extends through second module cover 260 / first electrical contact 270. Furthermore, in such a case, the first end of integrated heater thermocouple 250 may be secured between second module cover 260 and insulator 280, while a second end of integrated heater thermocouple 250 may be secured between insulator 280 and second electrical contact 290.

[0061] Figure 12 is an exploded view of the heater subassembly of Figure 10. Figure 13 is an exploded view of the heater subassembly of Figure 11. In particular, the heater subassembly is a heater wick subassembly 230 without a wick 240. Referring to Figures 12-13, an integrated heater thermocouple 250 includes a first segment 252 and a second segment 256. The first segment 252 and the second segment 256 are connected at a junction 254 (which may also be referred to as a "hot" junction). Furthermore, the first segment 252 is made of a first alloy, and the second segment 256 is made of a second alloy (different from the first alloy).

[0062] In exemplary embodiments in which integrated heater thermocouple 250 is in the form of a helical structure (wound around core 240), the helical structure includes multiple coils. In such an example, the multiple coils include at least one coil corresponding to first segment 252 and at least one coil corresponding to second segment 256. As a result, at least one coil of first segment 252 is made from a first alloy and at least one coil of second segment 256 is made from a second alloy. Furthermore, at least one coil of the first alloy may be welded to at least one coil of the second alloy at joint 254.

[0063] The multiple coils of the integrated heater thermocouple 250 may be in the form of five to ten total coils (e.g., six to nine total coils). For example, the first segment 252 of the integrated heater thermocouple 250 may include one coil of a first alloy and the second segment 256 may include five coils of a second alloy. Alternatively, the first segment 252 of the integrated heater thermocouple 250 may include two coils of a first alloy and the second segment 256 may include four coils of a second alloy.

[0064] In terms of orientation, vaporization module 200 may be considered to include a housing having a first longitudinal axis, and the helical structure of integrated heater thermocouple 250 may be considered to have a second longitudinal axis that intersects the first longitudinal axis to form an oblique angle. In such an example, at least one coil (made of the first alloy) of first segment 252 is downstream from at least one coil (made of the second alloy) of second segment 256.

[0065] According to an exemplary embodiment, the first alloy is a nickel-aluminum alloy, and the second alloy is a nickel-chromium alloy. For example, the nickel-aluminum alloy may include 95 percent nickel and 2 percent aluminum (e.g., alumel), and the nickel-chromium alloy may include 90 percent nickel and 10 percent chromium (e.g., chromel). Regarding physical properties, the first alloy has a first electrical resistivity and a first thermal conductivity, and the second alloy has a second electrical resistivity and a second thermal conductivity. In an exemplary embodiment, the first electrical resistivity is less than the second electrical resistivity, and the first thermal conductivity is greater than the second thermal conductivity. Furthermore, the integrated heater thermocouple 250 may have a Seebeck coefficient of approximately 35-75 μV / °C (e.g., 41 μV / °C, 50 μV / °C, 68 μV / °C). Furthermore, the integrated heater thermocouple 250 may have a total resistance of approximately 0.5-3.5 Ω (e.g., 1 Ω).

[0066] As described above, the integrated heater thermocouple 250 is configured to undergo Joule heating (also known as ohmic / resistive heating) as an electric current is applied. Furthermore, the integrated heater thermocouple 250 has a first segment 252 of a first alloy connected to a second segment 256 of a second alloy (different from the first alloy) at a junction 254. As a result of the dissimilar alloys and the associated thermoelectric effect, a voltage is generated when the junction 254 experiences a change in temperature (e.g., Joule heating occurs to generate nicotine vapor). This voltage is temperature-dependent and can therefore be used to determine the temperature of the junction 254. For example, the relationship between voltage and temperature can be determined from empirical studies and stored in a look-up table (LUT). In this manner, the integrated heater thermocouple 250 can function as both a heater and a thermocouple.

[0067] The second module cover 260 defines an opening 262 and has a proximal edge 264 and a distal edge 266 around the opening 262. As shown in the drawings, the circumference of the proximal edge 264 may be larger than the circumference of the distal edge 266. The proximal edge 264 of the second module cover 260 may serve to retain a distal portion of the wick 240 and / or contain a small amount of the nicotine pre-vapor formulation 180 that may permeate therethrough. Additionally, the outer edge of the proximal edge 264 may be chamfered to facilitate engagement with the module housing 220.

[0068] First electrical contact 270 defines an opening 272 and has an annular configuration that may be wavy. During assembly, first electrical contact 270 is engaged with second module cover 260 such that distal edge 266 of second module cover 260 extends through opening 272 of first electrical contact 270. As a result, when assembled, first electrical contact 270 can be positioned against the underside of second module cover 260 (e.g., via an interference fit with distal edge 266).

[0069] Insulator 280 includes a sheath portion 284 and a flange portion 286, and also defines an opening 282 therethrough. During assembly, insulator 280 is inserted through second module cover 260 (as well as through first electrical contact 270) such that the outer wall of sheath portion 284 engages the side wall of opening 262 in second module cover 260. Furthermore, when assembled, flange portion 286 of insulator 280 may abut distal edge 266 of second module cover 260.

[0070] The second electrical contact 290 includes a shaft portion 294 and a base 296, and also defines a passageway 292 therethrough. When assembled, the second electrical contact 290 extends through the opening 282 in the insulator 280 (as well as through the first electrical contact 270 and the second module cover 260) such that the passageway 292 in the second electrical contact 290 connects to the chamber 222 of the vaporization module 200. Furthermore, the base 296 of the second electrical contact 290 may abut the flange portion 286 of the insulator 280. As described above, the insulator 280 electrically insulates the second electrical contact 290 from the second module cover 260 / first electrical contact 270. Furthermore, the base 296 also defines a groove 298 that extends perpendicular to the longitudinal axis of the second electrical contact 290. In an exemplary embodiment, as discussed in more detail herein, the groove 298 in the base 296 is configured to provide access for incoming air to enter the passage 292 of the second electrical contact 290 when the nicotine cartridge 100 is engaged with the device body 300.

[0071] In the heater subassembly, a first end corresponding to first segment 252 of integrated heater thermocouple 250 may be electrically connected to second module cover 260 / first electrical contact 270, while a second end corresponding to second segment 256 of integrated heater thermocouple 250 may be electrically connected to second electrical contact 290. In particular, the first end corresponding to first segment 252 of integrated heater thermocouple 250 may be secured between second module cover 260 and insulator 280, while the second end corresponding to second segment 256 of integrated heater thermocouple 250 may be secured between insulator 280 and second electrical contact 290.

[0072] Figure 14 is a partially exploded view of the device body of Figure 6. Referring to Figure 14, device body 300 includes a sleeve section 310 and a battery section 320. The sleeve section 310 is configured to receive the nicotine cartridge 100 when inserted into the device body 300 and engages with the battery section 320. Additionally, as shown, the sleeve section 310 defines an array of inlet openings or air inlets 312. The array of inlet openings or air inlets 312 may be in the form of a honeycomb pattern configured to facilitate the drawing of ambient air that enters the device body 300, travels toward the power source (within the battery section 320), and then travels toward the integrated heater thermocouple 250 of the nicotine cartridge 100.

[0073] The battery section 320 includes a bayonet adapter 330 configured to engage with the bayonet connector 170 of the nicotine cartridge 100. In particular, to engage the nicotine cartridge 100 with the device body 300, the distal end of the nicotine cartridge 100 (the end of the nicotine cartridge 100 having the bayonet connector 170) is inserted into the sleeve section 310 of the device body 300 until the slot 174 of the bayonet connector 170 initially engages with the engaging member of the bayonet adapter 330. Once initial engagement occurs, the nicotine cartridge 100 can then be rotated / twisted / turned relative to the device body 300 to interlock with the device body 300. As a result, a nicotine e-vaping device 500 can be provided in which a bayonet connection is established between the nicotine cartridge 100 and the device body 300. The battery section 320 of the device body 300 also includes the knurled connector 340, light pipe 358, battery section housing 360, and end cap 370 described above in connection with the previous figures. As a result, such descriptions will not be repeated herein for the sake of brevity, although additional details may be provided subsequently herein.

[0074] FIG. 15 is a perspective view of the battery section of FIG. 14. Referring to FIG. 15, the bayonet adapter 330 includes at least one engaging member 334 configured to mate / interlock with the bayonet connector 170 of the nicotine cartridge 100. In an exemplary embodiment, the bayonet adapter 330 includes a pair of engaging members 334 protruding from its outer wall. Further, the engaging members 334 may be diametrically opposed to each other. The bayonet adapter 330 also defines an opening 332 that exposes (e.g., provides access to) a pin 352. The bayonet adapter 330 and the pin 352 of the battery section 320 may be considered electrical contacts of the device body 300. In particular, when the device body 300 is engaged with the nicotine cartridge 100, the bayonet adapter 330 is configured to electrically contact the first electrical contact 270 of the nicotine cartridge 100, and the pin 352 is configured to electrically contact the second electrical contact 290 of the nicotine cartridge 100. The bayonet adapter 330 may be formed from a conductive material such as steel (e.g., 304 stainless steel). The pins 352 may be covered with gold plating. For example, the pins 352 may have an interior (base structure) formed from brass and an exterior (e.g., as a deposited layer) formed from gold.

[0075] The knurled connector 340 defines at least one passage 344 for incoming air (e.g., air flowing inward on its way to the vaporization module 200). The at least one passage 344 of the knurled connector 340 is in fluid communication with the opening 332 of the bayonet adapter 330. In particular, during vaping, air drawn into the nicotine e-vaping device 500 through the air inlet 312 flows (e.g., in a first longitudinal direction) within the annular space between the sleeve section 310 and the nicotine cartridge 100 toward the battery section 320, then flows inward (e.g., radially) through the at least one passage 344 of the knurled connector 340 to the opening 332 in the bayonet adapter 330, and then flows through the opening 332 (e.g., in a second longitudinal direction) to the vaporization module 200. In an exemplary embodiment, the knurled connector 340 may be covered with chrome plating. For example, knurled connector 340 may have an interior (underlying structure) formed of brass and an exterior (eg, as a deposited layer) formed of chrome.

[0076] FIG. 16 is a partially exploded view of the battery section of FIG. 15. Referring to FIG. 16, the dimensions of the engaging members 334 of the bayonet adapter 330 are configured to substantially correspond to the dimensions of the slots 174 of the bayonet connector 170. Furthermore, each of the engaging members 334 may include a ridge 336 that helps maintain an established bayonet connection (e.g., by interlocking with the corresponding slot 174). For example, the ridge 336 of each engaging member 334 is configured to fit within the corresponding groove 174c of each of the slots 174. The ridge 336 may have a linear shape that extends radially from the underside of each engaging member 334 (e.g., from the sidewall of the bayonet adapter 330 to the edge of the engaging member 334). Due to the relatively tight fit between the engagement member 334 of the bayonet adapter 330 and the slot 174 of the bayonet connector 170, tactile and / or auditory feedback (e.g., an audible click) may be generated to notify the adult e-vaping device user that the nicotine cartridge 100 has been properly coupled to the device body 300.

[0077] Knurled connector 340 is configured to connect / couple sleeve section 310 and battery section housing 360 of device body 300. As shown, the indentations on the outer wall of knurled connector 340 may be in the form of two bands separated by an un-knurled section between them, with a proximal (e.g., upper) band for engagement with sleeve section 310 and a distal (e.g., lower) band for engagement with battery section housing 360. In an exemplary embodiment, the indentations are hidden from view by sleeve section 310 and battery section housing 360 when device body 300 is assembled. The exteriors of sleeve section 310 and battery section housing 360 may be flush with the exposed un-knurled section of knurled connector 340 when device body 300 is assembled. The indentations may include linear (e.g., longitudinal) ridges. However, it should be understood that other patterns may be suitable. For example, the indentations may alternatively have a circular pattern, a slanted pattern, or a diamond pattern.

[0078] As shown in FIG. 16 , the knurled connector 340 defines a pair of passageways 344. The pair of passageways 344 may be diametrically disposed within the knurled connector 340. As a result, a line extending through the knurled connector 340 via the passageways 344 may intersect the central longitudinal axis of the knurled connector 340 while coinciding with the diameter of the knurled connector 340. Furthermore, the exterior of the knurled connector 340 may be recessed (e.g., to a greater extent than the notches) from the edge to the area around each passageway 344 to provide an entrance (e.g., a cove-like entry point) to each passageway 344 when the sleeve section 310 engages the knurled connector 340. In such an example, incoming air during vaping can reach the passageways 344 through these recessed entrances.

[0079] The knurled connector 340 also defines an opening 342 and a hole 346 to accommodate a portion of the battery subassembly 350. In particular, when the battery section 320 is assembled, the pin 352 extends through the opening 342 of the knurled connector 340 and into the opening 332 of the bayonet adapter 330. In this assembled state, the proximal end of the pin 352 may be approximately level with the engaging member 334 of the bayonet adapter 330, although exemplary embodiments are not limited thereto. The hole 346 of the knurled connector 340 is configured to expose a light pipe 358. The light pipe 358 may include red, green, and blue (RGB) light-emitting diodes (LEDs), and these primary colors can be combined to produce white light as well as numerous other colors of light. As a result, emitted light can be transmitted by the light pipe 358 in a manner that is visible and useful to adult e-vaping device users.

[0080] The battery subassembly 350 further includes a first printed circuit board (PCB) 354 configured to mechanically support and electrically connect various components of the battery section 320, including a first sensor 356, pins 352, and a light pipe 358. In an exemplary embodiment, the first sensor 356 may be a combination pressure sensor and temperature sensor. Additionally, the pins 352 may be pogo pins or spring-loaded pins. The light pipe 358 may include five light-emitting diodes, although it should be understood that a different number may be implemented. The light pipe 358 may be utilized to communicate various types of information to an adult e-vaping device user.

[0081] For example, with respect to battery level, illumination of all five lights by the light pipe 358 may indicate a full battery level, while illumination of fewer lights, such as three lights, may indicate a medium battery level. Meanwhile, illumination of only one light may indicate a low battery level. One or more of the lights may also change color (e.g., to a warning color, such as red) to enhance awareness of a given indication. Additionally, one or more lights may flash to help indicate the urgency of a particular indication. The desired type of information or function can be accessed by pressing a button 372 ( FIG. 5 ) located on the distal end of the nicotine e-vaping device 500. In an exemplary embodiment, pressing the button 372 once may display the battery level (e.g., for five seconds). In another example, successive presses of the button 372 in a short period of time may result in different functions or displays. Specifically, pressing the button 372 five times in succession may turn the nicotine e-vaping device 500 on and off. Thus, the nicotine e-vaping device 500 may be puff-activated and / or button-activated.

[0082] FIG. 17 is a partially exploded view of the battery subassembly of FIG. 16. Referring to FIG. 17, the battery subassembly 350 also includes a second printed circuit board (PCB) 364 configured to mechanically support and electrically connect at least a second sensor 366. The second sensor 366 may be a temperature sensor (e.g., a second temperature sensor). The battery subassembly 350 further includes a controller 359 that may be mechanically supported by and electrically connected to the first printed circuit board 354 and / or the second printed circuit board 364. A power source 362 is disposed within the battery section housing 360. The power source 362 may be a rechargeable battery configured to provide current to the integrated heater thermocouple 250 of the nicotine cartridge 100 in response to a puff or button activation.

[0083] At least one of the first sensor 356 or the second sensor 366 may be configured to measure a voltage difference between the first segment 252 and the second segment 256 of the integrated heater thermocouple 250 as a result of the supply of electrical energy from the power source 362 (e.g., when the nicotine pre-vapor formulation 180 is heated to generate a nicotine vapor). When both the first sensor 356 and the second sensor 366 are used to measure the voltage, the measurements may be averaged to obtain an average value. The controller 359 may be configured to adjust the supply of electrical energy to the integrated heater thermocouple 250 based on the voltage difference measured by at least one of the first sensor 356 or the second sensor 366. In an exemplary embodiment, the controller 359 is configured to check the temperature of the integrated heater thermocouple 250 based on the voltage difference and to stop the supply of electrical energy if the temperature exceeds an upper threshold.

[0084] Because the voltage measured at the junction 254 of the integrated heater thermocouple 250 is temperature dependent, the relationship between voltage and temperature may be determined from empirical studies and organized / stored in a look-up table (LUT). In such an example, during vaping, the measured voltage may be used by the controller 359 to access the temperature of the junction 254 of the integrated heater thermocouple 250 from a look-up table (which may be stored in the controller 359 or in a separate memory). If the controller 359 determines that the temperature exceeds an upper threshold, the controller 359 may adjust to scale down the duty cycle (e.g., scaling a 50 percent duty cycle down to 25 percent). On the other hand, if the controller 359 determines that the temperature falls below a lower threshold, the controller 359 may adjust to scale up the duty cycle (e.g., a 50 percent duty cycle scaled up to a maximum of 75 percent). Such temperature control may operate in a closed loop. In an alternative embodiment, the relationship between voltage and temperature may be expressed as an equation and calculated instead of being accessed from a LUT.

[0085] Figure 18 is a cross-sectional view of the nicotine cartridge and partial cross-sectional view of the device body of Figure 6 when disengaged. Referring to Figure 18, the nicotine cartridge 100 is configured for insertion into the sleeve section 310 of the device body 300 such that the slots 174 (Figure 8) of the bayonet connector 170 initially mate with the engaging members 334 of the bayonet adapter 330. In particular, the longitudinal portion 174a (Figure 9) of each slot 174 is configured to receive the corresponding engaging member 334 until the engaging member 334 abuts an end surface of the longitudinal portion 174a. Once this initial engagement occurs, the nicotine cartridge 100 can then rotate / twist / turn relative to the device body 300 such that the engagement member 334 slides circumferentially within the corresponding circumferential portion 174b of the slot 174 until the ridge 336 (Figure 16) of the engagement member 334 resiliently seats within the groove 174c (Figure 8) of the slot 174, thereby mechanically interlocking the nicotine cartridge 100 with the device body 300.

[0086] With regard to electrical engagement, a first segment 252 (FIG. 12) of the integrated heater thermocouple 250 of the nicotine cartridge 100 may be electrically connected to a bayonet adapter 330 of the device body 300, while a second segment 256 (FIG. 12) of the integrated heater thermocouple 250 of the nicotine cartridge 100 may be electrically connected to a pin 352 of the device body 300. The bayonet adapter 330 of the device body 300 may then be electrically connected to the negative terminal of a power source 362, while the pin 352 of the device body 300 may be electrically connected to the positive terminal of the power source 362. The electrical path from the terminal of the power source 362 to the integrated heater thermocouple 250 is discussed in more detail herein.

[0087] When engaged (mechanically and electrically) with the device body 300, the nicotine cartridge 100 may be substantially invisible to view, except for the mouthpiece 110. Regarding this substantial invisibility, the reservoir 130, the nicotine pre-vapor formulation 180, and a portion of the vaporizer 150 may be partially visible through the air inlet 312 of the sleeve section 310 of the device body 300. As a result, when adequate ambient light is present, the level of the nicotine pre-vapor formulation 180 in the nicotine cartridge 100 can be visually measured by an adult e-vaping device user. In contrast, when ambient light is absent or insufficient, the adult e-vaping device user can rely on notification from the light pipe 358 that the nicotine pre-vapor formulation 180 in the nicotine cartridge 100 is low and / or depleted.

[0088] Removal of the nicotine cartridge 100 can be achieved by reversing the action associated with engagement, such as, for example, twisting the nicotine cartridge 100 in the opposite direction (e.g., counterclockwise) and pulling the nicotine cartridge 100 away from the device body 300. Because the engagement member 334 of the bayonet adapter 330 is resiliently seated within the groove 174c of the slot 174, the force required to twist and engage the nicotine cartridge 100 may be greater than the force used to twist and engage the nicotine cartridge 100, which can help ensure that disengagement of the nicotine cartridge 100 from the device body 300 is an intentional action rather than an unintentional event. Additionally, for the sake of brevity, it should be understood that not all labeled portions of FIG. 18 have been specifically mentioned in connection with this section because they have already been discussed above and do not merit further repetition or discussion.

[0089] FIG. 19 is a cross-sectional view of the nicotine cartridge and partial cross-sectional view of the device body of FIG. 18 when engaged. Referring to FIG. 19, the flow of air into the integrated heater thermocouple 250 and the resulting vapor flow therefrom are shown by dashed lines. In particular, upon application of negative pressure to the mouthpiece 110 of the nicotine e-vaping device 500, air is drawn into the air inlet 312 (FIG. 1) of the sleeve section 310 and through the annular space between the sleeve section 310 and the nicotine cartridge 100 in a direction toward the knurled connector 340. The air then flows toward and through the passage 344 of the knurled connector 340. The flow of air within the annular space toward the passage 344 of the knurled connector 340 may include circumferential flow (e.g., from the annular space in front of the nicotine cartridge 100 to the side, or from the annular space behind the nicotine cartridge 100 to the side). The air flow through the passage 344 of the knurled connector 340 is in an inward direction (eg, radially toward the central longitudinal axis of the nicotine e-vaping device 500).

[0090] After passing through the passage 344 of the knurled connector 340, the airflow then flows to the second electrical contact 290 and through the second electrical contact 290 via the groove 298 (FIG. 13) in the base 296 of the second electrical contact 290 into the passage 292. As the airflow flows through the passage 292 of the second electrical contact 290, the airflow also converges.

[0091] Air exiting the passageway 292 of the second electrical contact 290 flows through / passes the integrated heater thermocouple 250 (e.g., puff-activated) and the wick 240 to entrain the generated nicotine vapor. The entrained nicotine vapor then passes through the openings 218 ( FIG. 10 ) in the first module cover 210. In an exemplary embodiment, the passage of the nicotine vapor through the first module cover 210 may split the vapor into eight streams as a result of the eight openings 218 ( FIG. 10 ). The split nicotine vapor then converges into two streams that flow through the vapor channels 132 a and 132 b of the reservoir 130 and through the openings 122 a and 122 b of the first seal 120 ( FIG. 7 ). After flowing through the first seal 120, the two streams of nicotine vapor converge into one stream and exit through the vapor outlet 112 of the mouthpiece 110. However, it should be understood that exemplary embodiments are not limited in this respect. For example, as discussed above, the mouthpiece 110 may have different configurations for the vapor outlet 112, thus allowing for other variations in the flow of exiting nicotine vapor.

[0092] FIG. 20 is an enlarged view of the cross section of FIG. 19. Referring to FIG. 20, the electrical path from the terminals of the power supply 362 (FIG. 17) to the integrated heater thermocouple 250 includes multiple electrical junctions (J1-J8). J1 is the electrical junction between the printed circuit board (e.g., copper of the first printed circuit board 354) and the pin 352 (e.g., gold-plated brass). J2 is the electrical junction between the pin 352 (e.g., gold-plated brass) and the second electrical contact 290 (e.g., gold-plated brass). J3 is the electrical junction between the second electrical contact 290 (e.g., gold-plated brass) and the second segment 256 (e.g., nickel-chromium alloy) of the integrated heater thermocouple 250. J4 is the electrical junction between the first segment 252 (e.g., nickel-aluminum alloy) of the integrated heater thermocouple 250 and the second module cover 260 (e.g., stainless steel). J5 is the electrical junction of the second module cover 260 (e.g., stainless steel) and the first electrical contact 270 (gold-plated steel). J6 is the electrical junction of the first electrical contact 270 (e.g., gold-plated steel) and the bayonet adapter 330 (e.g., stainless steel). J7 is the electrical junction of the bayonet adapter 330 (e.g., stainless steel) and the knurled connector 340 (e.g., chrome-plated brass). J8 is the electrical junction of the knurled connector 340 (e.g., chrome-plated brass) and the printed circuit board (e.g., the copper of the first printed circuit board 354).

[0093] Therefore, when the nicotine e-vaping device 500 is activated (e.g., puff activation), current is considered to flow from the positive terminal of the power source 362 to the printed circuit board 354, from the printed circuit board 354 to the pin 352, from the pin 352 to the second electrical contact 290, from the second electrical contact 290 to the second segment 256 of the integrated heater thermocouple 250, from the second segment 256 to the first segment 252 of the integrated heater thermocouple 250, from the first segment 252 of the integrated heater thermocouple 250 to the second module cover 260, from the second module cover 260 to the first electrical contact 270, from the first electrical contact 270 to the bayonet adapter 330, from the bayonet adapter 330 to the knurled connector 340, from the knurled connector 340 to the printed circuit board 354, and from the printed circuit board 354 to the negative terminal of the power source 362. Of course, the necessary circuitry of the nicotine e-vaping device 500 is connected to the power source 362, although such connections are not necessarily shown in the drawings.

[0094] The electrical junctions (J1-J8) described above may be taken into account by the controller 359 when determining the temperature of the junction 254 of the integrated heater thermocouple 250. Based on the known materials of the electrical junctions (J1-J8), empirical studies may be performed to generate a calibration curve that covers the expected operating temperature range of the integrated heater thermocouple 250. As a result, a factor or correction may be applied to the initial temperature determination by the controller 359 to achieve a corrected temperature that takes into account the electrical junctions (J1-J8) connected to the integrated heater thermocouple 250.

[0095] While a number of exemplary embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations should not be considered a departure from the 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. 1. A nicotine cartridge for a nicotine e-vaping device, comprising: a housing defining a reservoir containing a nicotine prevapor formulation; a wick configured to transport the nicotine pre-vapor formulation by capillary action; an integrated heater thermocouple configured to heat the nicotine pre-vapor formulation within the wick to generate a nicotine vapor, the integrated heater thermocouple including a first segment made of a first alloy and a second segment made of a second alloy; Equipped with the integrated heater thermocouple is in the form of a spiral wound around the core, the spiral including a plurality of coils, the plurality of coils including at least one coil of the first alloy and at least one coil of the second alloy, the first alloy having a first electrical resistivity and a first thermal conductivity, the second alloy having a second electrical resistivity and a second thermal conductivity, the first electrical resistivity being less than the second electrical resistivity and the first thermal conductivity being greater than the second thermal conductivity; the at least one coil of the first alloy is downstream from the at least one coil of the second alloy; A nicotine cartridge for a nicotine e-vaping device.

2. 2. The nicotine cartridge of claim 1, wherein the housing includes a sidewall and a first longitudinal axis, the sidewall of the housing defining at least one vapor channel therethrough along the first longitudinal axis of the housing.

3. 3. The nicotine cartridge of claim 2, wherein the at least one vapor channel includes a first vapor channel and a second vapor channel, and the reservoir is between the first vapor channel and the second vapor channel.

4. 4. The nicotine cartridge of claim 1, wherein the integrated heater thermocouple has a Seebeck coefficient of about 35 to 75 μV / °C.

5. 5. The nicotine cartridge of claim 1, wherein the integrated heater thermocouple has a total resistance of about 0.5 to 3.5 ohms.

6. 6. A nicotine cartridge according to any one of claims 1 to 5, wherein the housing has a first longitudinal axis and the helical structure has a second longitudinal axis that intersects with the first longitudinal axis to form an oblique angle.

7. 7. A nicotine cartridge according to any preceding claim, wherein the at least one coil of the first alloy is welded to the at least one coil of the second alloy at a joint.

8. A nicotine cartridge according to any one of claims 1 to 7, wherein the plurality of coils is in the form of five to ten coils.

9. 9. The nicotine cartridge of claim 8, wherein the plurality of coils includes one coil of the first alloy and five coils of the second alloy.

10. 9. The nicotine cartridge of claim 8, wherein the plurality of coils includes two coils of the first alloy and four coils of the second alloy.

11. A nicotine cartridge according to any one of claims 1 to 10, wherein the first alloy is a nickel-aluminum alloy and the second alloy is a nickel-chromium alloy.

12. 12. The nicotine cartridge of claim 11, wherein the nickel-aluminum alloy comprises 95 percent nickel and 2 percent aluminum.

13. 12. The nicotine cartridge of claim 11, wherein the nickel-chromium alloy comprises 90 percent nickel and 10 percent chromium.

14. 1. A nicotine e-vaping device comprising: a nicotine cartridge comprising a nicotine pre-vapor formulation, a wick, and an integrated heater thermocouple, wherein the wick is configured to transport the nicotine pre-vapor formulation by capillary action, the integrated heater thermocouple comprising a first segment made of a first alloy and a second segment made of a second alloy, the integrated heater thermocouple being in the form of a helical structure wound around the wick, the helical structure comprising a plurality of coils, the plurality of coils including at least one coil of the first alloy and at least one coil of the second alloy, the first alloy having a first electrical resistivity and a first thermal conductivity, the second alloy having a second electrical resistivity and a second thermal conductivity, the first electrical resistivity being less than the second electrical resistivity and the first thermal conductivity being greater than the second thermal conductivity, and the at least one coil of the first alloy being downstream from the at least one coil of the second alloy; a device body configured to receive the nicotine cartridge, the device body including a power source, at least one sensor, and a controller, wherein the power source is configured to deliver a supply of electrical energy to the integrated heater thermocouple to heat the nicotine pre-vapor formulation within the wick to generate a nicotine vapor, the at least one sensor is configured to measure a voltage difference between the first segment and the second segment of the integrated heater thermocouple as a result of the supply of the electrical energy from the power source, and the controller is configured to adjust the supply of the electrical energy to the integrated heater thermocouple based on the voltage difference measured by the at least one sensor; 1. A nicotine e-vaping device comprising:

15. 15. The nicotine e-vaping device of claim 14, wherein the controller is configured to calculate a temperature of the integrated heater thermocouple based on the voltage difference, and to terminate the supply of the electrical energy when the temperature exceeds an upper threshold.

16. 16. The nicotine e-vaping device of claim 14 or 15, wherein the device body further comprises a sleeve section configured to receive the nicotine cartridge, the sleeve section defining an array of inlet openings.

17. 17. The nicotine e-vaping device of claim 16, wherein the array of inlet openings is in the form of a honeycomb pattern configured to facilitate the intake of ambient air into the device body, moving towards the power source before moving inward and then towards the integrated heater thermocouple.

Images