Vaporizer heating element assembly and method for manufacturing the same

Abstract

The vaporizer heating element assembly includes a case structure with multiple walls collectively defining a case interior. The upper wall has an access opening, the left side wall has a reservoir window, and the lower wall has a vaporization window. A thin plate heating element formed from a conductive material is positioned within the case structure parallel to the lower wall and adjacent to the vaporization window. The liquid transport structure is configured to transport liquid from the liquid inlet surface to the liquid outlet surface by capillary action and is disposed within the case interior such that the liquid inlet surface is adjacent to the reservoir window and the liquid outlet surface is adjacent to or in contact with the thin plate heating element. The heating element assembly also includes an access closure sized and configured to seal the access opening.

Description

Technical Field

[0001] The present invention generally relates to a micro-vaporizer heater, and more specifically to a modular heating element assembly that can be used in a plurality of vaporizer configurations, and also to a method of manufacturing such a modular assembly.

Background Art

[0002] A liquid vaporization device (referred to herein as a vaporizer or micro-vaporizer) is a device in which a vaporizable liquid is drawn from a storage reservoir into a chamber where it is heated to the vaporization temperature by a heating element. The vaporized liquid is then drawn out of or pushed out of the chamber. In products such as electronic cigarettes (also known as e-cigarettes or personal vaporizers), the vaporized liquid is drawn from the chamber through a mouthpiece and inhaled by the user. In other products, the vaporized liquid is dispersed into the atmosphere.

[0003] Conventional micro-vaporizers use a wick to draw a vaporizable liquid from a reservoir into a vaporization chamber where it is placed in very close proximity to a heating element. The heating element itself typically includes a coiled heating wire that can be positioned near the surface of the wick or, in some cases, wound around a portion of the wick. Coiled wire heaters have several drawbacks with respect to efficiency and cost of manufacture and may require that the wick material and configuration be tailored to the heater. With the growing popularity of low-cost disposable personal vaporization devices, there is a need for a more efficient and lower-cost alternative to the conventional wick / heating element approach.

Prior Art Documents

Patent Documents

[0004] [Patent Document 1] U.S. Patent Application No. 15 / 639,139 [Patent Document 2] U.S. Patent Application No. 17 / 117,373 [Overview of the project] [Means for solving the problem]

[0005] Exemplary aspects of the present invention provide a vaporizer heating element assembly comprising a case structure having a plurality of walls that collectively define the interior of the case. The plurality of walls include an upper wall, a left wall, and a lower wall, the upper wall having an access opening formed through the upper wall, the left wall having a reservoir window formed through the left wall, and the lower wall having a vaporization window formed through the lower wall. The assembly further comprises a thin plate heating element formed from a conductive material. The thin plate heating element is positioned within the case structure parallel to the lower wall and adjacent to the vaporization window. The assembly also comprises a liquid transport structure having a liquid inlet surface and a liquid outlet surface. The liquid transport structure is configured to transport a vaporizable liquid from the liquid inlet surface to the liquid outlet surface by capillary action. The structure is arranged inside the case such that the liquid inlet surface is adjacent to the reservoir window, and the liquid outlet surface is adjacent to or in contact with the surface of the thin-plate heating element. The heating element assembly also includes an access closure, which is disposed within the access opening and attached to the upper wall, and the access closure is sized and configured to seal the access opening.

[0006] Another exemplary aspect of the present invention provides a method for manufacturing a vaporizer heating element assembly. The method includes the steps of providing a sheet heating element formed from a conductive material and positioning the sheet heating element in an injection mold. The injection mold is configured to receive molten plastic material and form the molten plastic material into a case structure, the case structure having a plurality of walls that collectively define the interior of the case. The plurality of walls include an upper wall, a left wall, and a lower wall, the upper wall having an access opening formed through the upper wall, the left wall having a reservoir window formed through the left wall, and the lower wall having a vaporization window formed through the lower wall. The method further includes the step of injecting molten plastic into an injection mold to produce a molded plastic case structure, wherein the sheet heating element is positioned inside the case adjacent to the vaporization window and parallel to the lower wall. A portion of the sheet metal heating element is embedded in one or more of a plurality of wall sections. After injection, the molded plastic case structure and the sheet metal heating element are removed from the injection mold. The method further includes the step of providing a liquid transport structure having a liquid inlet surface and a liquid outlet surface. The liquid transport structure is configured to transport liquid from the liquid inlet surface to the liquid outlet surface by capillary action. The liquid transport structure is then inserted into the case interior through an access opening and positioned such that the liquid inlet surface is adjacent to a reservoir window and the liquid outlet surface is adjacent to or in contact with the surface of the sheet metal heating element. The method also includes the step of sealing the access opening with a closure element sized and configured to partially receive into the access opening.

[0007] Another exemplary aspect of the present invention provides a vaporizer comprising a vaporizer housing having an internal and external housing, and a reservoir disposed within the internal housing. The reservoir has a reservoir exit port and is configured to selectively retain a vaporizable liquid therein. The vaporizer further includes an air inlet passage that is in fluid communication with the outside via an inlet port, a vaporization chamber in the internal housing that is in fluid communication with the air inlet passage, and a vaporization product passage that is in fluid communication with the vaporization chamber and is in fluid communication with the outside via a vaporization product outlet. The vaporizer further includes a power supply, a control processor, and an electrical circuit including a positive heating element contact and a negative heating element contact. The control processor is configured to control the application of power from the power supply to the positive heating element contact and the negative heating element contact. The vaporizer also includes a heating element receiving well formed within the internal housing, and a heating element assembly operably disposed within the receiving well. The heating element assembly includes a case structure defining the interior of the case, a thin plate heating element formed from a conductive material, and a liquid transport structure. The case structure has a reservoir window and a vaporization window formed through it. The case structure and the receiving well are collectively configured such that when the heating element assembly is received into the receiving well, the reservoir window is aligned with the reservoir outlet port, and the vaporization window is adjacent to the vaporization chamber. The thin plate heating element is positioned inside the case such that at least a portion of the heating element is adjacent to the vaporization window. The liquid transport structure is disposed inside the housing such that the liquid inlet surface is adjacent to the reservoir window, and the liquid outlet surface is adjacent to or in contact with the surface of the thin plate heating element.

[0008] The present invention can be more fully understood by reading the following detailed description together with the accompanying drawings. In the accompanying drawings, similar reference numerals are used to specify similar elements. [Brief explanation of the drawing]

[0009] [Figure 1] This is a cross-sectional view of a personal vaporizer from prior technology. [Figure 2A] This is a left side view of a heating element assembly according to an embodiment of the present invention. [Figure 2B] This is a top view of a heating element assembly according to an embodiment of the present invention. [Figure 2C] This is a right-side view of a heating element assembly according to an embodiment of the present invention. [Figure 2D] This is a bottom view of a heating element assembly according to an embodiment of the present invention. [Figure 3] Figure 2 shows the case structure of the heating element assembly and a top view of the thin plate heating element. [Figure 4] Figure 2 shows a front cross-sectional view of the case structure and thin plate heating element of the heating element assembly. [Figure 5] Figure 2 shows a front cross-sectional view of the heating element assembly, including the case structure, the thin plate heating element, and the liquid transport structure. [Figure 6] Figure 2 is a front cross-sectional view of the heating element assembly. [Figure 7] This is a plan view of a thin plate heating element usable in embodiments of the present invention. [Figure 8] This is a plan view of a thin-plate heating element blank. [Figure 9] Figure 7 is an enlarged view of a portion of the thin plate heating element. [Figure 10] This is a plan view of a thin plate heating element usable in embodiments of the present invention. [Figure 11] Figure 10 is a side view of the thin plate heating element. [Figure 12]It is an enlarged view of a part of the thin plate heating element of FIG. 10. [Figure 13] It is a top view of the case structure of the heating element assembly and the thin plate heating element according to an embodiment of the present invention. [Figure 14] It is a front cross-sectional view of the case structure and the thin plate heating element of FIG. 13. [Figure 15] It is a front cross-sectional view of the case structure and the thin plate heating element of FIG. 13 with a fluid transport structure added. [Figure 16] It is a front cross-sectional view of the heating element assembly according to an embodiment of the present invention incorporating the case structure, the thin plate heating element, and the fluid transport structure of FIG. 15. [Figure 17] It is a flow diagram of the operation in a method for manufacturing a heating element assembly according to an embodiment of the present invention. [Figure 18] It is a front cross-sectional view of a partially assembled vaporizer according to an embodiment of the present invention. [Figure 19] It is a front cross-sectional view of the vaporizer of FIG. 18 with the heating element assembly installed. [Figure 20] It is an enlarged view of a part of the vaporizer of FIG. 19.

MODE FOR CARRYING OUT THE INVENTION

[0010] A typical micro-vaporizer has a reservoir from which a vaporizable liquid is drawn (typically through the use of a wick) into a vaporization chamber. Here, the liquid is brought into very close proximity to a heating element. The heating element, and generally a part of the wick, are disposed within the vaporization chamber. When the heating element is activated, the liquid from the wick is vaporized / aerosolized. The resulting vaporized products and unvaporized liquid are mixed with air drawn into the vaporization chamber from outside the device. Then, the mixture is either released from the device or drawn out of the device.

[0011] As shown in Figure 1, a typical prior art personal vaporizer 5 has an outer case 10 with an air intake passage (or multiple passages) 30, the air intake passage 30 supplying air to the vaporization chamber 16. The personal vaporizer 5 has a liquid reservoir 22, in which a vaporizable liquid is disposed. A liquid transport structure 24 (e.g., a wick) is configured and positioned to contact the liquid in the reservoir 22 and to draw the liquid from the reservoir 22 into the vaporization chamber 16 in close proximity to or in contact with the heating element 50. The exemplary personal vaporizer 5 also includes a battery 28 for powering the heating element 50 and a control unit 26. When the heater 50 is activated, the liquid from the liquid transport structure is heated and vaporized and mixed with the air in the vaporization chamber 16. The resulting mixture is drawn into the mouthpiece 40, drawn through the mouthpiece 40, and drawn out through the outlet 42, where it is inhaled by the user.

[0012] The heating element 150 can be configured to heat a vaporizable liquid through any conductive, convective, and / or radiative heat transfer mechanism. In a typical vaporizer, the heating element 150 is or includes a resistive element in the form of a wire coil. As previously mentioned, coiled wire heating elements have significant drawbacks. Plate-type heating elements have been used in vaporizer devices, but they have suffered from many of the same drawbacks as coiled wire heaters. This is at least in part due to the requirements for expensive base materials and / or multiple materials and substrates. These embodiments can make the resulting heater as expensive as or even more expensive than an equivalent coiled wire heater. Also, prior art heaters may be difficult or impossible to use with certain vaporizer housing materials due to heat conduction problems.

[0013] The present invention provides a heating element assembly in the form of a module having a molded plastic case and an internal structure, wherein a conductive sheet heating element is embedded within the internal structure, and a liquid transport structure is disposed within the internal structure adjacent to or in contact with the heating element. This assembly can be structured so that the plastic structure is molded around the heating element to permanently hold the heating element in place without the need for gaskets, seals, or thermal isolation. A variety of liquid transport structures can then be selected and positioned within the structure, which can then be sealed to provide a self-contained module. This module can then be used to provide heating and liquid transport functions to any of a variety of vaporizers configured to accept the heating element module.

[0014] Figures 2 to 6 illustrate a heating element assembly 100 according to an exemplary embodiment of the present invention. The assembly 100 has a case structure 110 which is generally rectangular in shape, in which a thin-walled heating element 150 is partially embedded within a part of the case structure 110. The case structure 110 has an internal space 120, and a liquid transport structure 160 can be disposed within the internal space 120.

[0015] The case structure 110 has upper and lower case walls 111, 112, a left (or reservoir) side case wall 113, a right (or contact) side case wall 114, and front and rear case walls 115, 116, which collectively define the internal case space 120. The lower wall 112 has a vaporization product flow window 118 formed through it. A thin-walled heating element 150 is partially embedded in the lower wall 112 so as to span the flow window 118. As will be discussed in more detail below, the heating element 150 can be configured such that the portion of the heating element 150 bordered by the flow window 118 heats a vaporizable liquid from the liquid transport structure 160, and allows the passage of liquid and vaporization products through the heating element 150 and out of the heating element assembly 100.

[0016] As best seen in Figure 4, the upper case wall 111 has an access opening 117 formed through it. The access opening 117 is sized and configured to allow access to the case interior 120 when the assembly 100 is constructed. As best seen in Figures 2B and 6, the upper wall closure member 130 is received into the access opening 117 and placed on the closure support shelf 122 in the interior 120, thereby enabling the opening 117 to be closed.

[0017] The components of the case structure 110 and the closure member 130 can be formed from a heat-resistant thermoplastic material, including, but not limited to, copolyester such as Eastman Tritan®. The case structure walls 111-116 can be constructed individually and joined together, but they are preferably formed as a single, integrated structure. In certain embodiments, the case structure 110 is formed by injection molding of a suitable plastic material such as Tritan as described above. The size and thickness of the walls can be determined by application. Typical minimum wall thicknesses can range from 0.01 mm to 1.00 mm.

[0018] The reservoir-side case wall 113 has a reservoir communication window 119 formed through it. The reservoir communication window 119 is sized and configured to provide fluid communication between the vaporizer device reservoir (or a flow structure connected to such a reservoir) and the inside of the case 120 when the heating element assembly 100 is installed inside the vaporizer device. The left-side case wall 113 can further define a channel 124 connecting the window 119 into the internal space 120. The channel 124 can be sized to receive a portion of a liquid transport structure 160, so that the intake surface 162 of the liquid transport structure 160 can be positioned in or adjacent to the window 119. Thus, the liquid transport structure 160 can be installed in communication with the liquid in the vaporizer reservoir by positioning the assembly 100 inside the vaporizer such that the reservoir communication window 119 is aligned with the passage into the vaporizer reservoir. In some embodiments, the liquid transport structure 160 can be sized to extend through the window 119 so that when the assembly 100 is installed, the liquid transport structure extends into the vaporizer reservoir or into a passage communicating with it.

[0019] The liquid transport structure 160 is configured to draw vaporizable liquid from the reservoir through the upstream inlet surface 162 into the structure 160, and to transport the liquid to the downstream outlet surface 164, where the liquid can be heated by the heating element 150 until vaporized. The liquid transport structure 160 may be or contain a wick or an assembly of wicking material. Typical personal vaporizer wicks are formed from organic fibrous materials (e.g., cotton, jute, flax, cellulose, or hemp). Some inorganic materials (e.g., silica, carbon, and non-organic polymer fibers, ceramics, and steel mesh) can also be used. Generally, vaporizer wicks can be formed from any material that is thermally stable and provides sufficient wicking action to transport vaporizable liquid from the reservoir to the heating element 150. The liquid transport structure 160 may also contain a composite wick formed from a combination of wicking material and active material. The liquid transport structure may be, in particular, one of the composite cores disclosed in U.S. Patent Application No. 15 / 639,139 ("Application 139"), filed June 30, 2017, the complete disclosure of which is incorporated herein by reference in whole. The composite core material may include woven or nonwoven fibrous wicking material in combination with an embedded, captured, bonded, or alternately layered activating additive material. They are generally configured such that, during transport from a liquid reservoir, a vaporizable liquid must come into contact with the activating additive material. A portion of the activating additive material may be released into the fluid or otherwise influence or impart a desired property to the liquid.

[0020] Although the liquid transport structure 160 in the illustrated embodiment is configured as a rectangular block, it will be understood that other shapes, including cylinders, flat sheets, or curved elongated elements, may also be used. It will also be understood that the internal space 120 can be shaped to accommodate and hold transport structures 160 of various shapes.

[0021] The thin plate heating element 150 can be configured to be installed in contact with or adjacent to the downstream outlet surface 164 of the liquid transport structure 160. While any flat plate heating element may be usable in embodiments of the present invention, in a preferred embodiment, the heating element 150 has a central portion and a peripheral portion, the central portion configured to heat the vaporizable liquid in the liquid transport structure 160 at or adjacent to the outlet surface 164, and the peripheral portion supporting the central heating portion and connecting the central heating portion to a power source. A flat plate heating element having such attributes is disclosed in U.S. Application No. 17 / 117,373, filed December 10, 2020, the complete disclosure of which is incorporated herein by reference. The heating element 160 can be configured such that contact between the heating element 160 and the case structure 110 occurs only through the peripheral portion of the heating element. This isolation of the central heating portion allows the use of case materials that would otherwise be unable to withstand the heat generated by the heating element 160.

[0022] Figure 7 illustrates an exemplary thin-sheet heating element 150 usable in embodiments of the present invention. The heating element 150 is formed from a single planar sheet of a conductive material having a constant sheet thickness. The material and thickness used can be selected to provide a desired combination of electrical and thermal properties, as well as a desired degree of structural integrity and / or rigidity. Exemplary materials that may be used include carbon, graphite, metals, metal alloys, conductive ceramics (e.g., molybdenum disilide), and composite materials made from ceramic and metallic materials. Composite materials can include doped ceramics (e.g., doped silicon carbide). Suitable metals can include titanium, zirconium, tantalum, and metals from the platinum group. Suitable metal alloys may include nichrome, Kanthal, stainless steel, Contantan, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, as well as superalloys based on nickel, iron, cobalt, stainless steel, Timetai®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Typical sheet thicknesses of such materials can range from 0.00005 inches to 0.15000 inches.

[0023] The thin heating element usable in the present invention can be manufactured from a single thin sheet of conductive material. Referring to Figure 8, the heating element 150 can be cut, for example, from a planar sheet 150s of the material according to pattern 150p. The features of the heating element can be formed by cutting out a pattern of channels through the material to provide a flow path for a vaporizable liquid and vaporization products to flow through it. This can be achieved, for example, using any suitable cutting tool (e.g., laser or waterjet), or by punching or chemical etching.

[0024] The resulting thin plate heating element body 150 has a peripheral conductive portion consisting of a positive support arm 151 and a negative support arm 152, and a central heating portion 153 positioned between the support arms 151 and 152. The support arms 151 and 152 have internal edges 158 facing inward toward each other and toward the central heating portion 153, and external lateral edges 159 facing outward. The internal edges 158 are parallel to each other and toward the longitudinal axis 154. The positive support arm 151 includes a positive contact tab 171, and the negative support arm 152 includes a negative contact tab 172, which extends longitudinally away from the central heating portion 153. The positive and negative contact tabs 171 and 172 are configured to make electrical contact with the corresponding elements of a power circuit communicating with a power source.

[0025] In certain embodiments, the heating element 150 may have a plurality of peripheral support tabs 156 extending laterally outward from the outer edges 159 of the support arms 151, 152. These tabs 156 may be sized and configured to engage with a surface or to be engaged by other structures in order to support and / or hold the heating element 150 in a suitable location within the case structure 110.

[0026] Referring to Figures 7 and 9, the central heating section 153 consists of an array of spaced-apart but interconnected heating strips 169. These heating strips 169 are parallel to each other and to the longitudinal axis 154. In certain embodiments, and as illustrated in Figure 7, the heating strips 169 are divided into pairs, with each pair of strips 169 connected to each other at both ends, forming heating element loops 160 surrounding through channels 181 through the material. In the illustrated embodiments, the loop ends 166 are curved, but in other embodiments, the end connections may be straight, thereby forming loops that are "cut to a square." Adjacent heating element loops 160 (e.g., loop 160a and loop 160b) are connected to each other by transverse strips 165. Adjacent strips 169 of adjacent loops 160 combine with adjacent transverse strips 165 to define through channels 182 between adjacent loops 160. Two heating loops 160 adjacent to the internal edges 158 and 159 are connected to the adjacent internal edges 158 by a lateral bridge strip 155. The side strips 169 of these loops, combined with their adjacent internal edges 158 and the lateral bridge strip 155, define a through channel 183 between the loops 160 and the support arm edges 158 and 159.

[0027] In certain embodiments, the central heating portion 153 includes a central support tab 161 extending longitudinally from the end of the heating strip 169. As shown in the illustrated embodiment, the central support tab 161 can extend from the end 166 of the heating element loop 160. Each central support tab 161 can be T-shaped, comprising a stem 167 and a rectangular head 168. To support and / or hold the central heating portion 153 of the heating element 150 in a suitable location within the structure of the micro-vaporizer, the tabs 161 can be sized and configured to engage with a surface or engage with another structure. While the illustrated embodiment has two tabs 161 with respect to each loop 160, it will be understood that in other embodiments, some loops 160 may simply have a tab 161 at one end, or may have no tabs 161 at all.

[0028] Two lateral bridge strips 155 serve to electrically connect the central heating section 153 to the positive and negative support arms 151 and 152. Except for the bridge strips 155, the central heating section 153 is otherwise isolated from the support arms 151 and 152, thereby minimizing heat conduction from the central heating section 153 to the support arms 151 and 152. The array of heating strips 169 of the central heating section 153 can be sized and configured to create a heating profile for heating the spaces on both sides of the heating element 150 and the vaporizable liquid within these spaces, as well as / or for passing through channels 181, 182, and 183. The array of heating strips 169 in combination with the support arms 151 and 152 can also be sized to create specific flow areas for the passage of liquid and vaporized products through the heating element 150. The combination can be further configured to provide the desired overall heating element electrical resistance (i.e., the resistance between the positive contact tab 171 and the negative contact tab 172). A suitable combination can provide an overall heating element resistance in the range of 0.0010 ohms to 5.2000 ohms. In certain embodiments, a suitable combination is structured to provide an overall resistance in the range of 0.0015 ohms to 3.00000 ohms, and in more specific embodiments, in the range of 0.3500 ohms to 0.8000 ohms. It will be understood that the specific configuration of the central heating section 254 and / or the thickness of the heating element 250 can be adjusted to suit the vaporizable liquid (and possibly the power supply). For example, some liquids (e.g., those containing CBD) may need to be vaporized at lower power to prevent scorching or burning. In certain embodiments, the central heating section 254 can be configured to provide a resistance heating temperature in the range of 100 to 600°F at a voltage of 1.0 to 4.2 V.

[0029] Returning to Figures 3 and 4, the thin plate heating element 150 is positioned such that a portion of each support arm is embedded within the case structure 110. As will be discussed later, this can be achieved by molding some or all of the case structure around the heating element 150. In certain embodiments, the heating element 150 can be partially embedded within the case structure 110 on or near the outer surface of the lower case wall 112, with the central heating portion 153 aligned with the vaporization chamber window 118. Thus, the upper surface 152 of the heating element faces inward toward the case interior 120, and the central heating portion of the lower surface 154 of the heating element faces outward through the vaporization chamber window 118. In some embodiments, the positive and negative contact tabs 171, 172 can extend outside the case structure 110. In certain embodiments, similar to assembly 100, the contact tabs 171 and 172 can be bent at a 90-degree angle from the main plane of the heating element 150, and can be positioned so that one surface of each tab engages with or is embedded within the right-side case wall 114. This leaves the opposite surface of each tab exposed and can be made into contact to establish electrical communication.

[0030] As shown in Figures 5 and 6, the upper surface 152 of the thin plate heating element 150 is in close proximity to the outlet surface 164 of the liquid transport structure 160. When the heating element 150 is excited, the vaporizable liquid in the liquid transport structure 160 adjacent to the outlet surface 164 is heated until it vaporizes. When a pressure drop is applied outside the vaporization window 118, the vaporized and unvaporized liquid is drawn out from the outlet surface 164 and through the flow channels 181, 182, and 183 of the heating element 150. This serves to further heat the vaporized products and vaporize the unvaporized liquid. As will be discussed later, these products can be further heated in the vaporization chamber of the vaporizer device outside the heating element assembly 100. The pressure drop can also serve to draw additional vaporizable liquid from the reservoir into and through the transport structure 160.

[0031] Referring to Figures 10 to 16, a heating element assembly 200 according to another exemplary embodiment of the present invention has a generally rectangular parallelepiped case structure 210 in which a thin-walled heating element 250 is partially embedded within a portion of the case structure 210. The case structure 210 has an internal space 220, and a liquid transport structure 260 can be disposed within the internal space 220.

[0032] The case structure 210 has upper and lower case walls 211, 212, a left (or reservoir) side case wall 213, a right (or contact) side case wall 214, and front and rear case walls 215, 216, which collectively define the case interior space 220. The lower wall 212 has a vaporization product flow window 218 formed through it. A thin-walled heating element 250 is partially embedded in the lower wall 212 so as to span the flow window 218. As before, the upper case wall 211 has an access opening 217 formed through it. The access opening 217 is sized and configured to allow access to the case interior 220 during the construction of the assembly 200. An upper wall closure member 230 is received into the access opening 217 and placed on a closure support shelf 222 in the interior 220, thereby enabling the opening 217 to be closed.

[0033] The reservoir-side case wall 213 has a reservoir communication window 219 formed through it. The reservoir communication window 219 is sized and configured to provide fluid communication between the vaporizer device reservoir (or a flow structure connected to such a reservoir) and the case interior 220 when the heating element assembly 200 is installed inside the vaporizer device. The liquid transport structure 260 is positioned inside the case interior 220 in or adjacent to the window 219. Thus, the liquid transport structure 260 can be installed in communication with the liquid in the vaporizer reservoir by positioning the assembly 200 inside the vaporizer such that the reservoir communication window 219 is aligned with the passage into the vaporizer reservoir. The liquid transport structure 260 is configured to draw a vaporizable liquid from a reservoir into the structure 260 through an upstream inlet surface 262, and to transport the liquid to a downstream outlet surface 264, where the liquid can be heated by a heating element 250 until vaporized. As before, it will be understood that the liquid transport structure 260 can have any of the various shapes, and the internal space 220 can be shaped accordingly to receive and hold the transport structure 260.

[0034] The thin plate heating element 250 can be configured to be installed in contact with or adjacent to the downstream outflow surface 264 of the liquid transport structure 260. Similar to the heating element 250 of previous embodiments, the heating element 250 includes a standoff extending from its main body at an angle (or multiple angles). As before, the thin plate heating element 250 has a peripheral conductive portion consisting of a positive support arm 251 and a negative support arm 252, and a central heating portion 253 positioned between the support arms 251 and 252. The support arms 251, 252 have internal edges 258 facing inward toward each other and toward the central heating portion 253, and external lateral edges 259 facing outward. The internal edges 258 are parallel to each other and toward the longitudinal axis 254. The positive support arm 251 includes a positive contact tab 271, and the negative support arm 252 includes a negative contact tab 272, which extends longitudinally away from the central heating portion 253. In some embodiments (for example, in the illustrated embodiment), at least a portion of the contact tabs 271, 272 is angled away from the plane defined by the support arms 251, 252. In certain embodiments, the contact tabs 271, 272 include a portion that is perpendicular to the plane of the support arms 251, 252. The positive and negative contact tabs 271, 272 are configured to make electrical contact with the corresponding elements of the power circuit communicating with the power source.

[0035] The heating element 250 has a plurality of peripheral support tabs 256 extending from the outer edge 259 of each support arm. At least a portion of each tab 256 extends upward from the outer edge at an angle to the surface of the support arm adjacent to the outer edge 259. In certain embodiments where the central heating portion 253 and the support arms 251, 252 are coplanar, the peripheral support tabs 256 extend perpendicularly from the plane of the central heating portion 253 and the support arms 251, 252, respectively. In some embodiments (including the illustrated embodiments), all of the peripheral support tabs 256 extend in the same direction, and in other embodiments, some tabs 256 may extend in one direction and others may extend in the opposite direction. In a typical embodiment where they extend in the same direction, all of the tabs 256 have the same length L pt However, in some embodiments, the tab 256 may have varying lengths to accommodate variable structures within the vaporizer.

[0036] The central heating section 253 consists of an array of spaced-apart but interconnected heating strips 269. These heating strips 269 are parallel to each other and to the longitudinal axis 254. In certain embodiments, the heating strips 269 are divided into pairs, and the strips 269 of each pair are connected to each other at both ends, forming heating element loops 260 surrounding through channels 281 through the material. Adjacent heating element loops 260 (e.g., loop 260a and loop 260b) are connected to each other by transverse strips 265. Adjacent strips 269 of adjacent loops 260 are combined with adjacent transverse strips 265 to define through channels 282 between adjacent loops 260. Two heating loops 260 adjacent to internal edges 258, 259 are connected to adjacent internal edges 258 by transverse bridge strips 255. The side strips 269 of these loops are combined with their adjacent inner edges 258 and lateral bridge strips 255 to define through channels 283 between the loops 260 and the support arm edges 258, 259.

[0037] The central heating section 253 includes central support tabs 261 extending longitudinally from the end of the heating element loop 260. Each central support tab 261 may have a stem 267 and a tab head 268. At least a portion of each tab head 261 extends upward or downward from the heating element loop 260 at an angle to the surface of the loop 260. In certain embodiments where the central heating section 253 and the support arms 251, 252 are coplanar, the central support tabs 261 extend perpendicularly from the plane of the central heating section 253 and the support arms 251, 252, respectively. In some embodiments (including the illustrated embodiments), all of the peripheral support tabs 261 extend in the same direction, while in other embodiments, some tabs 261 may extend in one direction and others may extend in the opposite direction. In a typical embodiment, all tabs 261 extending in the same direction have the same extension length (i.e., the length of the portion of the tab head 268 that extends away from the main plane) L ct However, in some embodiments, the tab head extension can have varying lengths to accommodate variable structures within the vaporizer.

[0038] To support and / or hold the central heating portion 253 of the heating element 250 in a suitable location within the structure of the micro-vaporizer, the peripheral support tabs 256 and central support tabs 261 can be sized and configured to engage with a surface or by another structure. In some embodiments, the peripheral support tabs 256 can all extend in one direction away from the main plane of the heating element 250, while the central support tabs 261 can extend in the opposite direction away from the main plane of the heating element 250. When all of the peripheral support tabs 256 and central support tabs 261 extend in the same direction (as in the illustrated embodiment), their length L is sufficient to provide support against a constant planar surface parallel to the main plane of the heating element 250. pt and L ctThey can be the same. In certain embodiments, the peripheral support tab 256 is configured such that at least a portion of the tab 256 can be embedded in the case structure 110, making it possible to provide support for the heating element 250 of the assembly 200.

[0039] In the heating element assembly 200, the thin plate heating elements 250 are arranged such that a portion of each support arm is embedded within the case structure 210. In some embodiments, one or more portions of the peripheral support tabs 256 can also be embedded within the case structure 210. In certain embodiments, the heating element 250 can be partially embedded within the case structure 210 on or near the outer surface of the lower case wall 212, with the central heating portion 253 aligned with the vaporization chamber window 218. Thus, the upper surface 252 of the heating element faces inward toward the case interior 220, and the central heating portion of the lower surface 254 of the heating element faces outward through the vaporization chamber window 218. In some embodiments, the positive and negative contact tabs 271, 272 can extend outside the case structure 210. In certain embodiments, similar to assembly 200, the contact tabs 271 and 272 can be bent at a 90-degree angle from the main plane of the heating element 250, and can be positioned so that one surface of each tab engages with or is embedded within the right-side case wall 214. This leaves the opposite surface of each tab exposed and can be made into contact to establish electrical communication.

[0040] As shown in Figures 15 and 16, the upper surface 252 of the thin-plate heating element 250 is in close proximity to the outlet surface 264 of the liquid transport structure 260. A gap is maintained between the upper heating element surface 252 and the transport structure outlet surface 264, and the transport structure 260 is supported by peripheral support tabs 256 and central support tabs 261. When the heating element 250 is excited, the vaporizable liquid in the liquid transport structure 260 adjacent to the outlet surface 264 is heated until it vaporizes. When a pressure drop is applied outside the vaporization window 218, the vaporized and unvaporized liquid is drawn out from the outlet surface 264 and through the flow channels 281, 282, and 283 of the heating element 250. This serves to further heat the vaporization products and vaporize the unvaporized liquid.

[0041] Figure 17 illustrates a method M100 for manufacturing a vaporizer heating element assembly according to an embodiment of the present invention. In S110 of method M100, a sheet metal heating element is prepared. This can include, for example, providing a thin sheet of conductive material and cutting a heating element blank from the sheet according to a desired pattern. The pattern can be established according to desired electrical resistance characteristics, heating characteristics, and flow characteristics relating to the heating element. In a particular embodiment, the pattern can be established to produce a heating element similar to any of those described above. The preparation of the sheet metal heating element can further include bending contact tabs and support tabs to a desired angle. In S120, the sheet metal heating element is positioned in an injection mold, which is configured to receive molten plastic material and form it into a desired case structure for the heating element assembly. The injection mold is further configured to support the sheet metal heating element during the injection process, so that a desired portion of the heating element is embedded in the resulting plastic case structure. In S140, the molten plastic is injected into the case structure mold. It will be understood that the case structure can be molded in stages or produced through a series of molding operations. In S150, the molded case structure is cooled and removed from the mold. In some embodiments, excess material can be removed from the molded structure. The resulting case structure includes a reservoir window, a vaporization chamber window, and an access opening, as previously described. The case structure also has a sheet metal heating element, which is partially embedded therein and positioned in or adjacent to the vaporization chamber window. In S160, a liquid transport structure is inserted into the interior of the case structure through the access opening, positioned so that its downstream outlet surface is adjacent to the heating element.In some embodiments, the liquid transport structure is supported solely by the internal case structure. In other embodiments, the liquid transport structure is supported (at least partially) by support tabs extending from the heating element. In S170, a closure is positioned within the access opening, coupled to the case structure, to seal the access opening, and to hold the liquid transport structure in a suitable location within the case. The closure can be coupled in any suitable manner. In certain embodiments, the closure is ultrasonically welded to the case structure. In such embodiments, the final case structure (including the closure) can be formed from only a single plastic material, such that the final heating element assembly consists only of a single material case structure, a sheet heating element, and a liquid transport structure.

[0042] The heating element assemblies of the present invention are structured so that they can be used in a variety of modular vaporizer configurations. These modular vaporizers will have a conventional liquid reservoir, power supply unit, activation system, and air flow passage, and will be configured to operate by separately receiving the heating element assembly and vaporizable liquid. Exemplary examples of such modular vaporizers are shown in Figures 18 to 20. The illustrated vaporizer 1000 has a case or main body 1010, to which an air intake section 1030 and a mouthpiece section 1040 are attached. The main body 1010 can be a single, integrated structure or can be composed of multiple substructures. The air intake section 1030 has an air intake passage 1034 communicating with an air inlet 1032, and air can be drawn in from the atmosphere surrounding the vaporizer 1000 through the air inlet 1032. The mouthpiece section 1040 has a vaporization product exit passage 1044 that communicates with an exit port 1042, and the vaporization product can be drawn in through the exit port 1042 (for example, by inhalation by the user). The main body 1010 of the micro-vaporizer 1000 contains a main path 1014 that communicates with an intake passage 1034 and an exit passage 1044. A portion of the main path 1014 can be configured to provide a vaporization section 1016.

[0043] Furthermore, a reservoir 1022 configured to receive a vaporizable liquid is disposed within the main body 1010. The liquid reservoir 1022 can be configured as a simple tank in which the liquid is disposed. In some embodiments, the reservoir 1022 may include an adsorbent or absorbent material or structure that holds the vaporizable liquid. In any case, the reservoir 1022 has an exit port 1023, and the vaporizable liquid can be drawn out of the reservoir 1022 through the exit port 1023. The vaporizer 1000 also includes an electrical circuit, which includes a power source (e.g., a battery) 1026 that communicates with a control processor 1028. The vaporizer 1000 may also include an activation mechanism (not shown) which allows the user to selectively activate the device, thereby causing power to flow from the power source 1026.

[0044] The interior of the main body 1010 is formed with a receiving well 1050, which is sized and configured to receive a heating element assembly, such as the assembly 100 shown in Figures 2 to 6. The main body 1010, reservoir 1022, and electrical circuit are arranged such that inserting the heating element assembly 100 into the installed configuration shown in Figures 19 and 20 results in (1) the reservoir window 119 of the assembly 100 being aligned with the reservoir exit port 1023, and (2) the contact tabs 171, 172 engaging with complementary contacts 1029 of the electrical circuit. This configuration allows fluid communication between the liquid transport structure 160 and the interior of the reservoir 1022 and establishes selective electrical communication between the power supply 1026 and the heating element 150. Assembly 100 can be held in this position by any of the following means (not shown) (including mechanical fasteners or the addition of locking, coupling, or closure elements to seal the well 1050).

[0045] With the heating element assembly 100 in its installed configuration, the thin plate heating element 150 is positioned so that it is parallel to the direction of airflow into and through the vaporization section 1016, and so that it actually provides part of the boundary surrounding the vaporization section 1016. When vaporizable liquid is added to the reservoir, the vaporizer 1000 becomes ready for use. Upon activation, the heating element 150 begins to heat the outlet surface 164 of the liquid transport structure 160. The vaporizable liquid (typically containing one or more active materials) drawn from the reservoir 1022 to the outlet surface 164 is heated until it vaporizes. When this happens, the user inhales through the mouthpiece passage 1042, drawing air into the intake passage 1034 and the main passage 1014. Simultaneously, the vapor products and / or unvaporized liquids are drawn into the vaporization section 1016 through the heating element 150, where they are further heated and mixed with the air in the main passage 1014. The resulting mixture of air and vaporized products is then drawn through the passage 1014 into the mouthpiece passage 1044 and through the mouthpiece passage 1044, and discharged through the exit port 1042.

[0046] As used herein, the term “active material” refers to any material that controlsly alters or adds to the vapor products of a device. Depending on the application, the active material may include, without limitation, plant materials, minerals, deodorizers, fragrances, insecticides, pharmaceuticals, and disinfectants, as well as any material or structure that contains or incorporates any of the foregoing.

[0047] In certain examples of personal vaporizers, the active material may contain flavoring substances that enhance the flavor of the vaporizable liquid. These may include, without limitation, marijuana, hemp, cannabidiol (CBD), citronella, geraniol, mint, thyme, tobacco, salvia dory, salvia, passionflower, bearberry, lobelia, lemongrass, cedarwood, clove, cinnamon, coumarin, helio, vanilla, menthol, eucalyptus, peppermint, rosemary, lavender, licorice, and cocoa, as well as any material or structure that contains or incorporates any of the aforementioned.

[0048] It will be understood that many other configurations for vaporizer components and air pathways are possible. In some configurations, multiple air inlet ports may be present, and the airflow path from the air inlet port to the vaporization chamber may include one or more intermediate paths and / or chambers. Additionally, additional liquid flow passages and / or wicking structures may be present to provide communication between the reservoir 1022 and the liquid transport structure 160.

[0049] While the above illustrates exemplary embodiments of the present invention, it should be understood that the present invention is not limited to the constructions disclosed herein. The present invention can be embodied in other specific forms without departing from its spirit or essential attributes. [Explanation of Symbols]

[0050] 5. Personal vaporizers with prior technology 10 Outer case 16 Vaporization Chamber 22 Liquid reservoir 24 Liquid transport structure 26 Control Unit 28 batteries 30 Air intake passage 40 mouthpieces 42 Exit section 50 heating elements, heaters 100 Heating Element Assembly 110 Case Structure 111 Upper case wall 112 Lower case wall 113 Left side case wall, reservoir side case wall 114 Right side case wall, contact side case wall 115 Front case wall 116 Rear case wall 117 Access openings 118 Flow Window 119 Reservoir Communication Window 120 interior space 122 Closure support shelf section 124 channels 130 Closure member 150 heating elements, thin-wall heating elements, thin-plate heating elements 150p pattern 150s Flat seat 151 Plus support arm 152 Negative support arm, upper surface 153 Central heating section 154 Longitudinal axis, lower surface 155 Lateral bridge strip 156 Peripheral support tab 158 Inner edge, support arm edge 159 Outer edge, support arm edge 160 Liquid transport structure, heating element loop 160a Loop 160b Loop 161 Central support tab 162 Inlet surface 164 Outflow surface 165 horizontal strips 166 Loop end 167 Stem 168 Rectangular Head 169 Side Strips 171 Plus Contact Tab 172 Negative contact tab 181 Flow Channels 182 flow channels, through channels 183 Flow channels, through channels 200 Heating Element Assembly 211 Upper case wall 212 Lower case wall 213 Left side case wall, reservoir side case wall 214 Right side case wall, contact side case wall 215 Front case wall 216 Rear case wall 217 Access openings 218 Flow Window 219 Reservoir Communication Window 220 Interior space 222 Closure support shelf section 230 Closure component 250 Thin-walled heating element 251 Plus support arm 252 Negative support arm, upper surface 253 Central heating section 254 Longitudinal axis, lower surface 255 Lateral Bridge Strips 256 Peripheral support tab 258 Inner edge, support arm edge 259 Outer edge, support arm edge 260 Liquid transport structure, heating element loop 260a Loop 260b loop 261 Central support tab 262 Inlet surface 264 Outflow surface 265 horizontal strips 266 Loop end 267 Stem 268 tabheads 269 ​​Side Strips 271 Plus Contact Tab 272 Negative contact tab 281 Flow Channels 282 flow channels, through channels 283 flow channels, through channels 1000 Vaporizer 1010 Case, Main Unit 1014 Main Route 1016 Vaporization Section 1022 Liquid Reservoir 1023 Exit Port 1026 Power supply 1028 Control Processor 1029 Contact area 1030 Air intake section 1032 Air inlet section 1034 Air intake passage 1040 Mouthpiece Section 1042 Exit Port 1044 Vaporization product exit passage 1050 Acceptance Well L pt length L ct length

Claims

1. A vaporizer heating element assembly, A case structure having a plurality of wall portions that collectively define the interior of the case, wherein the plurality of wall portions include an upper wall portion, a left wall portion, and a lower wall portion, the upper wall portion having an access opening formed through the upper wall portion, the left wall portion having a reservoir window formed through the left wall portion, and the lower wall portion having a vaporization window formed through the lower wall portion, A thin plate heating element formed from a conductive material, wherein the thin plate heating element is positioned within the case structure parallel to the lower side wall and adjacent to the vaporization window, A liquid transport structure having a liquid inlet surface and a liquid outlet surface, wherein the liquid transport structure is configured to transport a vaporizable liquid from the liquid inlet surface to the liquid outlet surface by capillary action, and is disposed inside the case such that the liquid inlet surface is adjacent to the reservoir window, and the liquid outlet surface is adjacent to or in contact with the surface of the thin plate heating element. An access closure disposed within the access opening and attached to the upper wall, wherein the access closure is sized and configured to seal the access opening. A vaporizer heating element assembly, including the heating element.

2. The vaporizer heating element assembly according to claim 1, wherein the thin plate heating element includes a positive contact tab and a negative contact tab, the positive contact tab and the negative contact tab extending through one of the plurality of wall portions, and the surface portion of each contact tab is exposed to the outside of the case structure.

3. The vaporizer heating element assembly according to claim 1 or 2, wherein at least a portion of the thin plate heating element is embedded in one or more of the plurality of wall portions.

4. The thin plate heating element is The peripheral conductive portion in contact with the aforementioned case structure, It includes a central heating portion that is electrically communicating with the aforementioned peripheral conductive portion, The vaporizer heating element assembly according to any one of claims 1 to 3, wherein the central heating portion is aligned with the vaporization window and is positioned at a distance from the case structure.

5. The vaporizer heating element assembly according to claim 4, wherein the central heating portion includes a plurality of parallel heating strips arranged at intervals, and the spaces between the heating strips define flow channels through the thin plate heating element.

6. The vaporizer heating element assembly according to claim 4 or 5, wherein the central heating portion is configured to provide a resistance heating temperature in the range of 100 to 600°F at a voltage in the range of 1.0 to 4.2V.

7. The vaporizer heating element assembly according to any one of claims 4 to 6, wherein the peripheral conductive portion includes a positive support arm and a negative support arm arranged at a distance from each other, a first bridge strip connecting the positive support arm to the central heating portion, and a second bridge strip connecting the negative support arm to the central heating portion.

8. The vaporizer heating element assembly according to claim 7, wherein the thin plate heating element further comprises a plurality of peripheral support tabs, the plurality of peripheral support tabs extending from the respective outer edges of the positive support arm and the negative support arm, and at least a portion of each support tab is in contact with the case structure.

9. The vaporizer heating element assembly according to claim 8, wherein at least a portion of each support tab is embedded in one of the plurality of wall portions.

10. The vaporizer heating element assembly according to any one of claims 7 to 9, wherein the thin plate heating element further comprises a plurality of central support tabs, the plurality of central support tabs extending at an angle from the central heating portion, and the central support tabs in contact with the liquid outlet surface of the liquid transport structure.

11. The thin plate heating element is A positive contact tab extending from the end of the aforementioned positive support arm, Further including a negative contact tab extending from the end of the negative support arm, The vaporizer heating element assembly according to any one of claims 7 to 10, wherein the positive and negative contact tabs extend through one of the plurality of wall portions, and the surface portion of each contact tab is exposed to the outside of the case structure.

12. The vaporizer heating element assembly according to any one of claims 1 to 11, wherein the liquid transport structure is a core structure or includes a core structure.

13. The vaporizer heating element assembly according to any one of claims 1 to 11, wherein the liquid transport structure is a composite core structure or comprises a composite core structure, the composite core structure comprising a wicking material and an active material selected to impart desired properties to the vaporizable liquid.

14. The vaporizer heating element assembly according to claim 12 or 13, wherein the core structure comprises a plurality of organic or inorganic fibers.

15. The vaporizer heating element assembly according to any one of claims 1 to 14, wherein the plurality of wall portions are formed as a single, integrated structure.

16. The vaporizer heating element assembly according to claim 15, wherein the single, integrated structure is formed from an injection-molded thermoplastic material.

17. A method for manufacturing a vaporizer heating element assembly, wherein the method is: The steps include providing a thin plate heating element formed from a conductive material, A step of positioning the thin plate heating element in an injection molding die, wherein the injection molding die is configured to receive molten plastic material and form the molten plastic material into a case structure, the case structure having a plurality of walls that collectively define the inside of the case, the plurality of walls including an upper wall, a left wall, and a lower wall, the upper wall having an access opening formed through the upper wall, the left wall having a reservoir window formed through the left wall, and the lower wall having a vaporization window formed through the lower wall, A step of injecting molten plastic into the injection mold to create a molded plastic case structure, wherein the thin plate heating element is positioned inside the case adjacent to the vaporization window and parallel to the lower wall, with a portion of the thin plate heating element embedded in one or more of the plurality of walls, The steps include removing the molded plastic case structure and the thin plate heating element from the injection molding die, A step of providing a liquid transport structure, wherein the liquid transport structure has a liquid inlet surface and a liquid outlet surface, and is configured to transport liquid from the liquid inlet surface to the liquid outlet surface by capillary action, The steps include inserting the liquid transport structure into the case through the access opening, positioning the liquid transport structure such that the liquid inlet surface is adjacent to the reservoir window, and the liquid outlet surface is adjacent to or in contact with the surface of the thin plate heating element, The steps include sealing the access opening with a closure element sized and configured to be partially received into the access opening, and Methods that include...

18. The method according to claim 17, wherein the operation of sealing the access opening includes the step of ultrasonically coupling the closure element to the upper wall of the case structure.

19. The thin plate heating element is Peripheral conductive part, It includes a central heating portion that is electrically communicating with the aforementioned peripheral conductive portion, The method according to claim 17 or 18, wherein in the molded plastic case structure, the peripheral conductive portion is in contact with one or more of the plurality of wall portions, and the central heating portion is aligned with the vaporization window and is positioned at a distance from the case structure.

20. It is a vaporizer, A vaporizer housing having an internal and external housing, A reservoir disposed inside the housing, the reservoir having a reservoir outlet port and configured to selectively retain a vaporizable liquid within it, An air inlet passage that is in fluid communication with the outside via an inlet port, The vaporization chamber inside the housing is in fluid communication with the air inlet passage, A vaporization product passage is in fluid communication with the vaporization chamber and is in fluid communication with the outside via a vaporization product outlet, An electrical circuit comprising a power supply, a control processor, and a positive heating element contact and a negative heating element contact, wherein the control processor is configured to control the application of power from the power supply to the positive heating element contact and the negative heating element contact, A heating element receiving well formed inside the housing, A heating element assembly according to any one of claims 1 to 16 and Includes, A vaporizer in which the heating element assembly is operably disposed within the receiving well.

21. The vaporizer according to claim 20, wherein the thin plate heating element further includes a positive contact tab and a negative contact tab, the positive contact tab and the negative contact tab extending through the wall of the case structure, the positive contact tab being in contact with the positive heating element contact, and the negative contact tab being in contact with the negative heating element contact.

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