Heater for vaporizer device

Abstract

A vaporizer atomizer with a heating layer (210) comprising one or more traces. The heating layer (210) includes a first surface and a second surface. A frame layer (220) is disposed on the first surface of the heating layer (210) and comprises an opening that exposes at least a portion of the one or more traces therethrough. A wicking layer (230) is disposed on the second surface of the heating layer (210) and aligned with at least a portion of the one or more traces.

Description

HEATER FOR VAPORIZER DEVICE

[0001] The current application claims priority to U.S. Provisional Patent Application No. 63 / 717,664 filed November 7, 2024, entitled “HEATER FOR VAPORIZER DEVICE” the disclosure of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The subject matter described herein relates generally to a vaporizer device and more particularly, to a heater of a cartridge for a vaporizer device.BACKGROUND

[0003] Vaporizer devices, which can also be referred to as vaporizers, electronic vaporizer devices, or e-vaporizer devices, can be used for delivery of an aerosol (for example, a vapor-phase and / or condensed-phase material suspended in a stationary or moving mass of air or some other gas carrier) containing one or more active ingredients by inhalation of the aerosol by a user of the vaporizing device. For example, electronic nicotine delivery systems (ENDS) include a class of vaporizer devices that are battery powered and that can be used to simulate the experience of smoking, but without burning of tobacco or other substances. Vaporizers are gaining increasing popularity both for prescriptive medical use, in delivering medicaments, and for consumption of tobacco, nicotine, and other plant-based materials. Vaporizer devices can be portable, self-contained, and / or convenient for use.

[0004] In use of a vaporizer device, the user inhales an aerosol, colloquially referred to as “vapor,” which can be generated by a heating element that vaporizes (e.g., causes a liquid or solid to at least partially transition to the gas phase) a vaporizable material, which can be liquid, a solution, a solid, a paste, a wax, and / or any other form compatible for use with a specific vaporizer device. The vaporizable material used with a vaporizer can be provided within a cartridge for example, a separable part of the vaporizer device that contains vaporizable material) that includes an outlet (for example, a mouthpiece) for inhalation of the aerosol by a user.

[0005] To receive the inhalable aerosol generated by a vaporizer device, a user may, in certain examples, activate the vaporizer device by taking a puff, by pressing a button, and / orby some other approach. A puff as used herein can refer to inhalation by the user in a manner that causes a volume of air to be drawn into the vaporizer device such that the inhalable aerosol is generated by a combination of the vaporized vaporizable material with the volume of air.

[0006] An approach by which a vaporizer device generates an inhalable aerosol from a vaporizable material involves heating the vaporizable material in a vaporizer atomizer or vaporization chamber (e.g., a heater chamber) to cause the vaporizable material to be converted to the gas (or vapor) phase. A vaporizer atomizer or vaporization chamber can refer to an area or volume in the vaporizer device within which a heat source (for example, a conductive, convective, and / or radiative heat source) causes heating of a vaporizable material to produce a mixture of air and vaporized material to form a vapor for inhalation of the vaporizable material by a user of the vaporization device.

[0007] Vaporizer atomizers can be used to evaporate liquid into aerosol and may require power and temperature control of a heating element, such as a resistive wire coil, to generate consistent vapor and to prevent liquid degradation from exposure to high temperatures. Typically, two parameters related to heating that may be controlled include electrical power to the heating element and temperature of the heating element.

[0008] In cartridge-based vaporizer systems, a vaporizer cartridge contains an atomizer, which usually includes a wicking element and a heating element. Different heater technologies can include wires, foils, or deposited metal traces. Wick technologies can include cottons, polymer fibers and porous ceramics.

[0009] In many cases, the atomizer represents a substantial part of the cost of the cartridge, hence raising the overall cost of the vaporizer system. The atomizer is also typically made from different materials from the rest of the cartridge, which prevents cartridges from being recycled. Other manufacturing processes for heating elements can also be complex and expensive. Accordingly, there is a need for a more cost effective heating element that maintains the advantages of uniform heating.SUMMARY

[0010] In certain aspects of the current subject matter, challenges associated with powering vaporizer devices may be addressed by inclusion of one or more of the features described herein or comparable / equivalent approaches as would be understood by one ofordinary skill in the art. Aspects of the current subject matter relate to methods and system for powering a heating element of a vaporizer device.

[0011] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. The claims that follow this disclosure are intended to define the scope of the protected subject matter. In some variations, one or more of the following features may optionally be included in any feasible combination.

[0012] In an aspect, a system includes a vaporizer atomizer. The vaporizer atomizer includes a heating layer comprising one or more traces, wherein the heating layer comprises a first surface and a second surface; a frame layer disposed on the first surface of the heating layer and comprising an opening exposing at least a portion of the one or more traces therethrough; and a wicking layer disposed on the second surface of the heating layer and aligned with at least a portion of the one or more traces.

[0013] One or more of the following features can be included in any feasible combination. The heating layer comprises a resistive metal. The resistive metal comprises aluminum. The heating layer has a thickness of about 16 to 24 micrometers. The frame layer comprises a plastic polymer. The plastic polymer comprises polyethylene terephthalate (PET). The PET comprises biaxially-oriented polyethylene terephthalate ( (boPET), such as Mylar®). The frame layer has a width of about 40 to 60 micrometers. The wicking layer comprises a cotton, a fiber, or a porous ceramic. The one or more traces form a serpentine pattern. At least two of the one or more traces have a same length and / or width. The one or more traces have a nonuniform heating profile. At least one of the heating layer, the frame layer, and the wicking layer has a rectangular shape, a circular shape, or a square shape. The heating layer, the frame layer, and the wicking layer together form a circular profile. The wicking layer is adhered to the second surface of the heating layer. The frame layer is adhered to the first surface of the heating layer. The wicking layer is disposed on the first surface of the heating layer. The wicking layer is disposed on the second surface of the heating layer.

[0014] In another aspect, a method of manufacturing a vaporizer atomizer including a heating layer, a frame layer, and a wicking layer, includes (a) forming an opening in the frame layer; (b) disposing the frame layer onto a first surface of the heating layer; (c) forming one ormore traces through the heating layer, wherein the opening of the frame layer exposes at least a portion of the one or more traces therethrough; (d) disposing the wicking layer onto a second surface of the heating layer, wherein the wicking layer is substantially aligned with at least a portion of the one or more traces.

[0015] In another aspect, a method of manufacturing a vaporizer atomizer including a heating layer, a frame layer, and a wicking layer, includes (a) forming one or more traces through the heating layer, (b) forming an opening in the frame layer; (c) disposing the frame layer onto a first surface of the heating layer; wherein the opening of the frame layer exposes at least a portion of the one or more traces therethrough; and (d) disposing the wicking layer onto a second surface of the heating layer, wherein the wicking layer is substantially aligned with at least a portion of the one or more traces.

[0016] One or more of the following features can be included in any feasible combination. The disposing the frame layer onto the first surface of the heating layer comprises adhering the frame layer onto the heating layer. The method further comprises curing the heating layer, the frame layer, and the wicking layer. The disposing the wicking layer onto the heating layer comprises adhering the wicking layer to the heating layer. Steps (a)-(d) are performed using a roll-to-roll process.

[0017] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0018] The accompanying drawings, which are incorporated into and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings:

[0019] FIG. 1 A shows a block diagram of a vaporizer;

[0020] FIG. IB illustrates a top view of an embodiment of the vaporizer of FIG. 1 A, showing a cartridge separated from a vaporizer body;

[0021] FIG. 1C illustrates a top view of an embodiment of the vaporizer of FIG. 1 A, showing the cartridge coupled to the vaporizer body;

[0022] FIGs. 2A and 2B illustrate a layout of a heater, in accordance with some implementations;

[0023] FIGs. 3A-3C illustrate an example manufacturing procedure for a heater, in accordance with some implementations;

[0024] FIG. 4 illustrates a process for manufacturing a heater;

[0025] FIG. 5 schematically illustrates a circular profile implementation 600 of the heater;

[0026] FIG. 6 illustrates an attachment configuration for a heating layer, a frame layer, and a wicking layer, in accordance with some implementations; and

[0027] FIGs. 7A-7B illustrate a vaporizer cartridge, in accordance with some implementations.

[0028] When practical, similar reference numbers denote similar structures, features, or elements. Like reference symbols in the various drawings indicate like elements.DETAILED DESCRIPTION

[0029] Implementations of the current subject matter include methods, apparatuses, articles of manufacture, and systems relating to vaporization of one or more materials for inhalation by a user. Examples of vaporizers consistent with implementations of the current subject matter include electronic vaporizers, electronic cigarettes, e-cigarettes, or the like. The vaporizable material used with a vaporizer device can be provided within a cartridge (for example, a part of the vaporizer that contains the vaporizable material in a reservoir or other container) which can be refillable when empty, or disposable such that a new cartridge containing additional vaporizable material of a same or different type can be used). In some implementations, a vaporizer device can be configured for use with a liquid vaporizable material (for example, a carrier solution in which an active and / or inactive ingredient(s) are suspended or held in solution, or a liquid form of the vaporizable material itself), a paste, a wax, and / or a solid vaporizable material. A liquid vaporizable material can likewise be capable of being completely vaporized or can include some portion of the liquid material that remains after all of the material suitable for inhalation has been vaporized.

[0030] A cartridge of a vaporizer device can include a heating element, or “heater” to vaporize the vaporizable material into an inhalable aerosol. Heating elements can include materials that provide resistive heating to the vaporizable material when a current is applied. Described herein is a heater which can reduce substantial cost in vaporizer cartridge production by reducing the manufacturing cost of a disposable heater.

[0031] FIGs. 1 A- 1C discuss a vaporizer device. Referring to the block diagram of FIG. 1A, a vaporizer 10 typically includes a power source 8 (such as a battery which may be a rechargeable battery), and a controller 19 (e.g., a processor, circuitry, etc. capable of executing logic) for controlling delivery of heat to an atomizer 26 (also referred to herein as an “atomizer assembly”, and exemplified by the heater described herein) to cause a vaporizable material to be converted from a condensed form (e.g., a solid, a liquid, a solution, a suspension, a part of an at least partially unprocessed plant material, etc.) to the gas phase. The controller 19 may be part of one or more printed circuit boards (PCBs) consistent with certain implementations of the current subject matter. After conversion of the vaporizable material to the gas phase, and depending on the type of vaporizer, the physical and chemical properties of the vaporizable material, and / or other factors, at least some of the gas-phase vaporizable material may condense to form particulate matter in at least a partial local equilibrium with the gas phase as part of an aerosol, which can form some or all of an inhalable dose provided by the vaporizer 10 for a given puff or draw on the vaporizer. It will be understood that the interplay between gas and condensed phases in an aerosol generated by a vaporizer can be complex and dynamic, as factors such as ambient temperature, relative humidity, chemistry, flow conditions in airflow paths (both inside the vaporizer and in the airways of a human or other animal), mixing of the gas-phase or aerosolphase vaporizable material with other air streams, etc., may affect one or more physical parameters of an aerosol. In some vaporizers, and particularly for vaporizers for delivery of more volatile vaporizable materials, the inhalable dose may exist predominantly in the gas phase (i.e., formation of condensed phase particles may be very limited). In other examples, the converse may be true.

[0032] Vaporizers for use with liquid vaporizable materials (e.g., neat liquids, suspensions, solutions, mixtures, etc.) typically include an atomizer 26 in which a wicking element (not shown in FIG. 1 A) conveys an amount of a liquid vaporizable material to a part of the atomizer that includes a heating element (also not shown in FIG. 1 A). The atomizer 26 canbe the heater described herein, which can be an assembly of substantially flat layers. Tn the described heater, the wicking element of the heater is a wicking layer and the heating element of the heater is a heating layer.

[0033] A vaporizer consistent with implementations of the current subject matter may be configured to connect (e.g., wirelessly or via a wired connection) to a computing device (or optionally two or more devices) in communication with the vaporizer. To this end, the controller 19 may include communication hardware 49. The controller may also include a memory 43. A computing device can be a component of a vaporizer system that also includes the vaporizer 10, and can include its own communication hardware, which can establish a wireless communication channel with the communication hardware 49 of the vaporizer 10. For example, a computing device used as part of a vaporizer system may include a general-purpose computing device (e g., a smartphone, a tablet, a personal computer, some other portable device such as a smartwatch, or the like) that executes software to produce a user interface for enabling a user of the device to interact with a vaporizer. In other implementations of the current subject matter, such a device used as part of a vaporizer system can be a dedicated piece of hardware such as a remote control or other wireless or wired device having one or more physical or soft (e.g., configurable on a screen or other display device and selectable via user interaction with a touch-sensitive screen or some other input device like a mouse, pointer, trackball, cursor buttons, or the like) interface controls. The vaporizer can also include one or more output 37 features or devices for providing information to the user.

[0034] A computing device that is part of a vaporizer system as defined above can be used for any of one or more functions, such as controlling dosing (e.g., dose monitoring, dose setting, dose limiting, user tracking, etc.), controlling sessioning (e.g., session monitoring, session setting, session limiting, user tracking, etc.), controlling nicotine delivery (e.g., switching between nicotine and non-nicotine vaporizable material, adjusting an amount of nicotine delivered, etc.), obtaining locational information (e.g., location of other users, retailer / commercial venue locations, vaping locations, relative or absolute location of the vaporizer itself, etc.), vaporizer personalization (e.g., naming the vaporizer, locking / password protecting the vaporizer, adjusting one or more parental controls, associating the vaporizer with a user group, registering the vaporizer with a manufacturer or warranty maintenance organization, etc ), engaging in social activities (e.g., games, social media communications, interacting withone or more groups, etc.) with other users, or the like. The terms “sessioning”, “session”, “vaporizer session,” or “vapor session,” are used generically to refer to a period of use of the vaporizer. The period can include a time period, a number of doses, an amount of vaporizable material, and / or the like.

[0035] In the example in which a computing device provides signals related to activation of the heating element, or in other examples of coupling of a computing device with a vaporizer for implementation of various control or other functions, the computing device executes one or more computer instructions sets to provide a user interface and underlying data handling. In one example, detection by the computing device of user interaction with one or more user interface elements can cause the computing device to signal the vaporizer 10 to activate the heating element, either to a full operating temperature for creation of an inhalable dose of vapor / aerosol or to a lower temperature to begin heating the heating element. Other functions of the vaporizer may be controlled by interaction of a user with a user interface on a computing device in communication with the vaporizer.

[0036] The temperature of a heating element of a vaporizer may depend on a number of factors, including a material of the heating element, an amount of electrical power delivered to the resistive heating element and / or a duty cycle at which the electrical power is delivered, conductive heat transfer to other parts of the electronic vaporizer and / or to the environment, latent heat losses due to vaporization of a vaporizable material from the wicking element and / or the atomizer as a whole, and convective heat losses due to airflow (e g., air moving across the heating element or the atomizer as a whole when a user inhales on the electronic vaporizer). As noted above, to reliably activate the heating element or heat the heating element to a desired temperature, a vaporizer may, in some implementations of the current subject matter, make use of signals from a pressure sensor to determine when a user is inhaling. The pressure sensor can be positioned in the airflow path and / or can be connected (e.g., by a passageway or other path) to an airflow path connecting an inlet for air to enter the device and an outlet via which the user inhales the resulting vapor and / or aerosol such that the sensor experiences pressure changes concurrently with air passing through the vaporizer device from the air inlet to the air outlet. In some implementations of the current subject matter, the heating element may be activated in association with a user's puff, for example by automatic detection of the puff, for example by the pressure sensor detecting a pressure change in the airflow path. As noted above, the heatingelement may be entirely and / or selectively plated with one or more other materials to enhance heating performance of the heating element.

[0037] Typically, the pressure sensor (and / or any other sensors 29) can be positioned on or coupled (e.g., electrically or electronically connected, either physically or via a wireless connection) to the controller 19 (e.g., a printed circuit board assembly or other type of circuit board). To take measurements accurately and maintain durability of the vaporizer, it can be beneficial to provide a resilient seal 60 to separate an airflow path from other parts of the vaporizer. The seal 60, which can be a gasket, may be configured to at least partially surround the pressure sensor such that connections of the pressure sensor to internal circuitry of the vaporizer are separated from a part of the pressure sensor exposed to the airflow path.

[0038] In an example of a cartridge-based vaporizer, the seal or gasket 60 may also separate parts of one or more electrical connections between a vaporizer body 50 and a vaporizer cartridge 52. Such arrangements of a gasket or seal 60 in a vaporizer 10 can be helpful in mitigating against potentially disruptive impacts on vaporizer components resulting from interactions with environmental factors such as water in the vapor or liquid phases, other fluids such as the vaporizable material, etc., and / or to reduce escape of air from the designed airflow path in the vaporizer. Unwanted air, liquid or other fluid passing over and / or contacting circuitry of the vaporizer can cause various unwanted effects, such as altered pressure readings, and / or can result in the buildup of unwanted material, such as moisture, the vaporizable material, etc., in parts of the vaporizer where they may result in poor pressure signal, degradation of the pressure sensor or other components, and / or a shorter life of the vaporizer. Leaks in the seal or gasket 60 can also result in a user inhaling air that has passed over parts of the vaporizer device containing or constructed of materials that may not be desirable to be inhaled.

[0039] A general class of vaporizers that have recently gained popularity includes a vaporizer body 50, as shown in FIGs. 1A-1C, that includes a controller 19, a power source 8 (e.g., battery), one or more sensors, charging contacts, a gasket or seal 60, and a cartridge receptacle 69 configured to receive a vaporizer cartridge 52 for coupling with the vaporizer body 50 through one or more of a variety of attachment structures. In some examples, vaporizer cartridge 52 includes a reservoir 55 for containing a liquid vaporizable material and a mouthpiece 21 for delivering an inhalable dose to a user. The vaporizer cartridge can include an atomizer 26 having a wicking element and a heating element, or alternatively, oneor both of the wicking element and the heating element can be part of the vaporizer body 50. In implementations in which any part of the atomizer 26 (e.g., heating element and / or wicking element) is part of the vaporizer body 50, the vaporizer can be configured to supply liquid vaporizable material from a reservoir in the vaporizer cartridge to the atomizer part(s) included in the vaporizer body.

[0040] Cartridge-based configurations for vaporizers that generate an inhalable dose of a non-liquid vaporizable material via heating of a non-liquid vaporizable material are also within the scope of the current subject matter. For example, a vaporizer cartridge may include a mass of a plant material that is processed and formed to have direct contact with parts of one or more resistive heating elements, and such a vaporizer cartridge may be configured to be coupled mechanically and electrically to a vaporizer body that includes a processor, a power source, and electrical contacts for connecting to corresponding cartridge contacts for completing a circuit with the one or more resistive heating elements.

[0041] In vaporizers in which the power source 8 is part of a vaporizer body 50 and a heating element is disposed in a vaporizer cartridge 52 configured to couple with the vaporizer body 50, the vaporizer 10 may include electrical connection features (e.g., means for completing a circuit) for completing a circuit that includes the controller (e.g., a printed circuit board, a microcontroller, or the like), the power source, and the heating element. These features may include at least two, four, or more contacts on a bottom, side, internal, external, or other surface of the vaporizer cartridge 52 (referred to herein as cartridge contacts 65) and at least two, four, or more contacts or contact surfaces disposed in the cartridge receptacle (referred to herein as receptacle contacts 62) of the vaporizer 10 such that the cartridge contacts 65 and the receptacle contacts 62 make electrical connections when the vaporizer cartridge 52 is inserted into and coupled with the cartridge receptacle 69. Other implementations of completing an electrical connection between the device body and the cartridge are contemplated and described herein.

[0042] In some implementations, as shown in FIG. 1 A, when the vaporizer cartridge 52 is inserted into and coupled with the cartridge receptacle 69, the receptacle contacts 65 may be positioned between a portion of the vaporizer cartridge 52 and the cartridge contacts 65. Thus, at least a portion of the vaporizer cartridge 52, may include a female portion that receives at least a portion of the cartridge receptacle 69 that includes the receptaclecontacts 62 such that the cartridge contacts 65 and the receptacle contacts 62 mate within at least a portion of the vaporizer cartridge 52.

[0043] The cartridge contacts 65, as explained below, may form a portion of the heater of the vaporizer cartridge. The circuit completed by these electrical connections between the cartridge contacts 65 and the receptacle contacts 62 can allow delivery of electrical current to the resistive heating element and may further be used for additional functions, such as for example for measuring a resistance of the resistive heating element for use in determining and / or controlling a temperature of the resistive heating element based on a thermal coefficient of resistivity of the resistive heating element, for identifying a cartridge based on one or more electrical characteristics of a resistive heating element or the other circuitry of the vaporizer cartridge, etc.

[0044] In some examples, the cartridge contacts and the receptacle contacts can be configured to electrically connect in varied orientations. One or more circuits necessary for operation of the vaporizer can be completed by insertion of a vaporizer cartridge 52 in the cartridge receptacle 69 in a first rotational orientation (around an axis along which the end of the vaporizer cartridge 52 having the cartridge contacts 65 is inserted into the cartridge receptacle 69 of the vaporizer body 50 and / or at least a portion of the cartridge receptacle 69 having the receptacle contacts 62 is inserted into at least a portion of the vaporizer cartridge 52 having the cartridge contacts 65) such that a first cartridge contact of the cartridge contacts 65 is electrically connected to a first receptacle contact of the receptacle contacts 62, a second cartridge contact opposite the first cartridge contact of the cartridge contacts 65 is electrically connected to a second receptacle contact of the receptacle contacts 62, and so on. Furthermore, the one or more circuits necessary for operation of the vaporizer can be completed by insertion of a vaporizer cartridge 52 in the cartridge receptacle 69 in a second rotational orientation such that the first cartridge contact is electrically connected to the second receptacle contact and the second cartridge contact is electrically connected to the first receptacle contact. This feature of a vaporizer cartridge 52 being reversibly insertable into a cartridge receptacle 69 of the vaporizer body 50 is described further below. For example, the cartridge contacts 65 and the receptacle contacts 62 may mate, such as face-to-face, or as interlocking, with one another. In some implementations, the one or more cartridge and / or receptacle contacts 65, 62 can include angled or shaped surfaces, which are symmetrical, so as to be able tomate with one another in any one of two reversible orientations. Other orientations are contemplated and discussed herein.

[0045] In one example of an attachment structure for coupling a vaporizer cartridge 52 to a vaporizer body, the vaporizer body 50 includes a detent (e.g., a dimple, protrusion, spring, etc.) protruding inwardly from an inner surface the cartridge receptacle 69. One or more exterior surfaces (e.g., surfaces positioned along an exterior of the vaporizer cartridge or an externally accessible surface positioned within the vaporizer cartridge) of the vaporizer cartridge 52 can include corresponding recesses (not shown in FIG. 1A) that can fit, receive, and / or otherwise snap over such detents when an end of the vaporizer cartridge 52 is inserted into the cartridge receptacle 69 on the vaporizer body 50. When the vaporizer cartridge 52 and the vaporizer body 50 are coupled (e.g., by insertion of an end of the vaporizer cartridge 52 into the cartridge receptacle 69 of the vaporizer body 50), the detent in the vaporizer body 50 may fit within and / or otherwise be held within the recesses of the vaporizer cartridge 52 to hold the vaporizer cartridge 52 in place when assembled. Such a detent-recess assembly can provide enough support to hold the vaporizer cartridge 52 in place to ensure good contact between the at least two cartridge contacts 65 and the at least two receptacle contacts 62, while allowing release of the vaporizer cartridge 52 from the vaporizer body 50 when a user pulls with reasonable force on the vaporizer cartridge 52 to disengage the vaporizer cartridge 52 from the cartridge receptacle 69.

[0046] Further to the discussion above about the electrical connections between a vaporizer cartridge and a vaporizer body 50 being reversible such that multiple rotational orientations of the vaporizer cartridge 52 in the cartridge receptacle 69 are possible, in some vaporizers the shape of the vaporizer cartridge 52, or at least a shape of the end of the vaporizer cartridge that is configured for insertion into the cartridge receptacle 69 may have rotational symmetry of at least order two. In other words, the vaporizer cartridge 52 or at least the insertable end of the vaporizer cartridge 52 may be symmetric upon a rotation of 180° around an axis along which the vaporizer cartridge 52 is inserted into the cartridge receptacle 69. In such a configuration, the circuitry of the vaporizer may support identical operation regardless of which symmetrical orientation of the vaporizer cartridge 52 occurs.

[0047] In some examples, the vaporizer cartridge 52, or at least an end of the vaporizer cartridge 52 configured for insertion in the cartridge receptacle 69 may have a non-circular cross-section transverse to the axis along which the vaporizer cartridge 52 is inserted into the cartridge receptacle 69. For example, the non-circular cross-section may be approximately rectangular, approximately elliptical (e.g., have an approximately oval shape), non-rectangular but with two sets of parallel or approximately parallel opposing sides (e.g., having a parallelogram-like shape), or other shapes having rotational symmetry of at least order two. In this context, approximately having a shape indicates that a basic likeness to the described shape is apparent, but that sides of the shape in question need not be completely linear and vertices need not be completely sharp. Rounding of both or either of edges or vertices of the cross-sectional shape is contemplated in the description of any non-circular cross-section referred to herein.

[0048] FIG. IB illustrates an embodiment of the vaporizer body 50 having a cartridge receptacle 69 into which the vaporizer cartridge 52 may be releasably inserted. FIG. IB shows a top view of the vaporization device 10 illustrating the cartridge being positioned for insertion into the vaporizer body 50. When a user puffs on the vaporization device 10, air may pass between an outer surface of the vaporizer cartridge 52 and an inner surface of a cartridge receptacle 69 on the vaporizer body 50. Air can then be drawn into an insertable end 3 of the cartridge, through the vaporization chamber that includes or contains the heating element and wick, and out through an outlet of the mouthpiece 21 for delivery of the inhalable aerosol to a user. The reservoir 55 of the vaporizer cartridge 52 may be formed in whole or in part from translucent material such that a level of vaporizable material 2 is visible along the vaporizer cartridge 52. FIG. 1C shows a top view of an example of the vaporizer device 10 after connecting the vaporizer cartridge 52 to the vaporizer body 50.

[0049] FIGs. 2-7B discuss a heater configured to interoperate with a vaporizer device. The heater can be made from an atomizer assembly of a frame layer, a heating layer, and a wicking layer. The heater can be assembled by stacking the three layers, which may each be substantially flat. The frame layer can be adhered to a first surface of the heating layer, while the wicking layer can be adhered to a second surface of the heating layer. The frame layer can include an opening that exposes one or more traces in the frame layer. Hence, the atomizer assembly can be incorporated into a cartridge such that a side of the wicking layer not in contact with the heating layer is exposed to the vaporizable material (e.g., e-liquid) in a reservoir of the cartridge (e.g., a reservoir formed by inner walls of the cartridge), and a side of the wicking layerin contact with the heating layer is exposed to an air path to allow inhalation of the aerosol. The wicking layer can be thin (e.g., from about 0.1 millimeter (mm) to about 1.0 mm), which allows the wicking element to rapidly saturate. This configuration helps ensure a more consistent vapor production. The heater described herein may be incorporated into a cartridge configuration having an overflow channel layer in fluid communication with the reservoir.

[0050] An additional benefit of the atomizer assembly design described herein is that the mass of the non-plastic material in the atomizer assembly is decreased, as both the heating element and wicking element are themselves thin and small. Additionally, a cartridge made from polyethylene terephthalate (PET), for example, can be considered recyclable, as the proportion by mass of cartridge materials other than the PET is relatively low.

[0051] FIGs. 2A and 2B illustrates a layout of a heater 200, in accordance with some implementations and an expanded view of a heater, in accordance with some implementations. The heater 200 includes heating layer 210, frame layer 220, and wicking layer 230. At least one of the heating layer 210, the frame layer 220, or the wicking layer 230 may be a rectangular, square, otherwise polygonal, or circular shape. At least one of the heating layer 210, the frame layer 220, or the wicking layer 230 may be substantially flat or planar. The heater can be manufactured to have a square, circular, or rectangular profile or outline. In some implementations, the heater 200 may have more or fewer than three layers. In some implementations, the combined mass of the three layers of the heater 200 can be between about 20 milligrams (mg) and about 30 mg.

[0052] The heating layer 210 can use resistive heating to heat a vaporizable material to generate an inhalable aerosol. Heating layer 210 can include a first surface and a second surface. For example, when heating layer 210 is substantially flat, the first surface can be one side of the heating layer and the second surface may be the opposite side of the heating layer. In some implementations, the heating layer is between about 16 and 24 micrometers (pm) in thickness. In some embodiments, the heating layer is between about 10 and 40 pm in thickness. The heating layer 210 can be a sheet of resistive material that is substantially rectangular in shape, but may be another shape (e.g., another polygon or a circle).

[0053] Heating layer 210 can be constructed of or at least include a material (e.g., a metal or alloy, or a non-metallic resistor) configured to dissipate electrical power in the form of heat when electrical current is passed through the heating layer 210. A resistive heating elementcan include a metal. In some implementations, the metal can be chosen to have a low contact resistance such that the metal does not need to be plated to be usable as a heating element. This can be achieved by, for example, using a metal with low resistivity and / or low hardness. In some implementations, the metal is aluminum, which can have a contact resistance of about 20 mQ. If aluminum is used, an electrical contact can pierce, scratch or otherwise embed itself in the aluminum to make good contact, to prevent negative effects caused by an oxide layer building up on the heating element. In other implementations, the resistive metal of the heating element is titanium or steel.

[0054] Heating layer 210 can be activated (e.g., by a controller, which is part of a vaporizer body as discussed above, Heating layer 210 can cause current to pass from the power source through a circuit including the heater, which is part of a vaporizer cartridge as discussed above), in association with a user puffing (e.g., drawing, inhaling, etc.) on a mouthpiece of the vaporizer to cause air to flow from an air inlet, along an airflow path that passes the heater (e.g., one or more wicking elements and one or more heating elements in combination), optionally through one or more condensation areas or chambers, to an air outlet in the mouthpiece. Incoming air passing along the airflow path passes over, around, through, etc., the atomizer, where gas phase vaporizable material is entrained into the air. As noted above, the entrained gasphase vaporizable material may condense as it passes through the remainder of the airflow path such that an inhalable dose of the vaporizable material in an aerosol form can be delivered from the air outlet (e.g., in a mouthpiece for inhalation by a user).

[0055] Heating layer 210 may be implemented using, for example a four- wire circuit. The four-wire circuit can measure current and voltage separately, thus improving measurement of heater resistance by eliminating contact resistance from the measurement. Measuring current and voltage separately can also provide for more accurate temperature control.

[0056] The temperature of heating layer 210 may depend on a number of factors, including a material of the heating layer 210, an amount of electrical power delivered to the heating layer 210 and / or a duty cycle at which the electrical power is delivered, conductive heat transfer to other parts of the electronic vaporizer and / or to the environment, latent heat losses due to vaporization of a vaporizable material from the wicking layer 230 and / or the heater as a whole, and convective heat losses due to airflow (e.g., air moving across the heating layer 210 or the heater as a whole when a user inhales on the electronic vaporizer). To reliably activate theheating layer 210 or heat the heating layer 210 to a desired temperature, a vaporizer may, in some implementations of the current subject matter, make use of signals from a pressure sensor to determine when a user is inhaling. The pressure sensor can be positioned in the airflow path and / or can be connected (e.g., by a passageway or other path) to an airflow path connecting an inlet for air to enter the device and an outlet via which the user inhales the resulting vapor and / or aerosol such that the sensor experiences pressure changes concurrently with air passing through the vaporizer device from the air inlet to the air outlet. In some implementations of the current subject matter, the heating layer 210 may be activated in association with a user's puff, for example by automatic detection of the puff, for example by the pressure sensor detecting a pressure change in the airflow path.

[0057] In use, when a user puffs on the mouthpiece of the vaporizer cartridge when the heater is assembled into the vaporizer cartridge, air flows into the vaporizer cartridge and along an air path. In association with the user puff, the heating layer 210 may be activated, e.g., by automatic detection of the puff via a pressure sensor, by detection of a pushing of a button by the user, by signals generated from a motion sensor, a flow sensor, a capacitive lip sensor, by activation from a remote device, and / or another approach capable of detecting that a user is taking or about to be taking a puff or otherwise inhaling to cause air to enter the vaporizer device and travel at least along the air path. Power can be supplied from the vaporizer device to the heating element at the cartridge contacts when the heating element is activated.

[0058] In some implementations, the heating element may be initially formed of a substrate material. The substrate material can be then cut and / or stamped into the proper shape via various mechanical processes, including but not limited to stamping, laser cutting, photoetching, chemical etching, and / or the like. The substrate material may be made of an electrically conductive metal suitable for resistive heating.

[0059] The heating layer 210 can include one or more traces. A trace can be formed by removing a portion of the heating layer, that is, forming a slit through a portion of the heating layer 210. Such a slit may be a linear slit in the configuration that the heating layer is a planar shape. When the heater is assembled, at least a portion of one or more of the frame layer 220 or wicking layer 230 is exposed through the traces. A trace can be thin (e.g., between about 0.1 mm and about 0.2 mm wide) and can extend nearly up to a width or a length of the heating layer 210. The heating layer 210 can include a plurality of traces. Adjacent traces can have a spacingbetween them of about 0.1 mm and 0.2 mm. Tn some implementations, the traces are all uniform size and / or shape. In some implementations, at least one of the traces can be a different size and / or shape as at least one other trace. The traces can be uniformly spaced or can be non- uniformly spaced. The plurality of traces can be aligned with respect to a vertical or horizontal axis, or can, by varying the lengths of individual traces, have the plurality of traces to be circumscribed by a particular shape (e.g., circle, oval, ellipse, triangle, rectangle, square, another type of polygon, a type of polygon with rounded edges, hourglass, or another shape). The plurality of traces can be arranged in a pattern, or visually repeating sequence. For example, the plurality of traces can be arranged in a serpentine, or snake-like pattern.

[0060] In some implementations, when heat is provided or applied to the heating layer 210, the plurality of traces are heated uniformly. Alternately, when heat is provided to the heating layer 210, the heating profile of the traces varies. That is, a temperature of a first trace of the plurality of traces can differ from a temperature of a second trace (e g., the traces are non- uniformly heated). In other words, a heating profile generated for the plurality of traces can show uniformity or non-uniformity. The heating layer 210 can provide a heating area of between about 4 mm2and about 25 mm2(e.g., having a heating area of about 3 mm in height and 4 mm in width).

[0061] Furthermore, frame layer 220 frames and strengthens the heating layer 210. For example, the frame layer 220 can make the traces of heating layer 210 more robust (e.g., not easily modified or damaged) during manufacture and use. Frame layer 220 can be disposed on the first surface of the heating layer. Frame layer 220 has an opening exposing a portion of the heating layer 210. The opening can align with a region of the heating layer 210 including a portion of the one or more traces. For example, a substantial portion (e.g., 60%, 70%, 80%, 90% or greater) of the traces can be exposed by the alignment of the opening of the frame layer 220. The traces can be formed after the frame layer 220 is attached (e.g., adhered) to the heating layer 210. The frame layer can include a film of a structurally rigid material. For example, the frame layer can be a plastic material that can include a plastic polymer. The plastic polymer can include comprise polyethylene terephthalate (PET). In some implementations, the frame layer includes a film of biaxially-oriented polyethylene terephthalate (BoPET) (e.g., Mylar®), which is a PET film made by stretching. The frame layer 220 can be between 40 and 60 pm thick. The frame layer 220 can be between 30 and 70 pm thick. The frame layer 220 may be between 20 and 80pm thick. The frame layer 220 may be between 10 and 90 pm thick. The frame layer 220 can be adhered to the heating layer. For example, the frame layer 220 can be bonded or attached to the heating layer 210 using lamination. In some implementations, the frame layer 220 can be welded to heating layer 210. In some implementations, frame layer 220 is bonded to heating layer 210 using heat-sealing films or selective melting. However, these techniques are not limiting and the frame layer and heating layer may be connected in any suitable manner to prevent substantial movement of the layers relative to each other.

[0062] The wicking layer 230 is then disposed on the second surface of the heating layer such that it is attached to a surface of the heating layer opposite to which the frame layer is attached. The wicking layer 230 comprises a wicking material that supplies vaporizable material to the heating element from the reservoir. Like heating layer 210 and / or frame layer 220, wicking layer 230 can be substantially flat or planar. In other words, the layers of the heater may each be formed in a substantially similar shape to align upon stacking. Like the adhering of the heating layer 210 and frame layer 220, the wicking layer 230 can be adhered to the heating layer 210. In some implementations, the wicking layer 230 can be adhered to the frame layer 220 through holes in the heating layer 210. In some implementations, the adhering (or bonding) can be performed using an adhesive (e.g., a glue, such as Loctite®).

[0063] The wicking layer 230 can include cotton, a fiber (e.g., a glass fiber, a natural fiber, or a polymer fiber), a porous ceramic, or similar material. A wicking layer 230 can include any component (e g., a fibrous wick, a sintered material, a structure having a narrow gap or channel between surfaces wettable by a liquid vaporizable material) capable of drawing liquid from a reservoir or fluid storage component under capillary pressure), which conveys an amount of a liquid vaporizable material to the heating layer 210. The wicking layer 230 is generally configured to draw liquid vaporizable material from a reservoir of the cartridge such that the liquid vaporizable material is vaporized by heat delivered from the heating layer 210. The wicking layer 230 can also optionally allow air to enter the reservoir to replace the volume of liquid removed. In other words, capillary action pulls liquid vaporizable material into the wicking layer 230 for vaporization by the heating layer 210, and air may, in some implementations of the current subject matter, return to the reservoir through the wicking layer 230 to at least partially equalize pressure in the reservoir.

[0064] The wicking layer 230 can, in some implementations, include a fibrous wick, formed as a substantially flat pad or with other cross-sectional shapes such as circles, ovals, etc. A flat pad can allow for the rate that the vaporizable material is drawn into the wicking layer 230 to be controlled more precisely and / or accurately. A wicking layer 230 forming a flat pad may also provide a greater transfer surface area, which may allow for increased flow of the vaporizable material from the reservoir into the wicking layer 230 for vaporization by the heating element (in other words, larger mass transfer of vaporizable material), and from the wicking layer 230 to air flowing past it. The flat pad may also be more easily shaped and / or cut. Hence, a flat pad may be more easily assembled with the heating layer 210 and frame layer 220 during roll-to-roll processing, as substantially flat components can be easier to re-reel during such a process. In some implementations, the heating layer 210 can be configured to contact the wicking layer 230 on only one side of the wicking layer 230.

[0065] The wicking layer 230 may include one or more rigid or compressible materials, such as cotton, silica, ceramic, and / or the like. Relative to some other materials, a cotton (e.g., Ahlstrom 601 cotton) wicking layer 230 may allow for an increased and / or more controllable flow rate of vaporizable material from the reservoir of the vaporizer cartridge into the wicking layer 230 to be vaporized.

[0066] In some implementations, wicking layer 230 may be disposed between heating layer 210 and frame layer 220, such that wicking layer 230 and frame layer 220 are both on a first surface of heating layer 210.

[0067] FIGs. 3A-3C illustrates an example manufacturing procedure 300 for a heater, in accordance with some implementations. The example manufacturing procedure can be implemented on heater 200 with heating layer 210, frame layer 220, and / or wicking layer 230. Heating layer 210 can include a planar resistive metal layer (e.g., an aluminum layer). Frame layer 220 can include a planar plastic film that is adhered to heating layer 210 (e.g., a PET frame) and includes an opening that is in alignment with a configuration of traces of the heating layer 210, such that a substantial portion of the traces are exposed. Wicking layer 230 can include a planar wicking material (e.g., a cotton wick).

[0068] Before the one or more traces are cut into heating layer 210, the frame layer 220 can be adhered to heating layer 210 (e.g., via lamination). This can prevent damage to heating layer 210 during manufacturing (by providing an increased thickness to the heater thatcan buttress it as the traces are cut) or during operation of the vaporizer device (by providing increased rigidity). In some implementations, the thin film used in the frame layer 220 of the heater allows for the heater to be manufactured using roll-to-roll manufacturing, as the heating layer 210 and wicking layer 230 can be easily attached to a large sheet of thin film material. Roll-to-roll manufacturing can reduce handling of fragile foil heaters and allows high volume throughput manufacturing in a small footprint. A roll-to-roll manufacturing process can be a continuous process of unrolling a flexible substrate onto an assembly line and then depositing, cleaning, patterning, or otherwise modifying materials on that substrate.

[0069] The example manufacturing procedure can include the following steps, which should not be construed to limit this disclosure in FIG. 3A, an opening can be die cut (320) in a sheet of PET fdm (310) to make an array of frame layers (315). In FIG. 3B, heating layers (e.g., strips of aluminum foil) can then be laminated (330) onto the frame layers using a laminating adhesive. In FIG. 3C, the traces (340) can then be formed as slits through a portion of the width or height of the heating layers (e.g., by being laser cut into the heating layers from the laminate.)

[0070] Wicking layers are die cut from a sheet of cotton. A wicking layer can then be bonded onto the heating layer, for example, by using small spots of the same laminating adhesives. The assembled array of heaters can be re-reeled and left to cure.

[0071] To avoid damage to the performance of the adhesive at high temperatures, an adhesive such as Loctite AA3525 can be used to laminate a PET film frame layer to an aluminum foil heating layer, for example. Such an adhesive may show no discoloration, off gassing, or reduced performance when exposed to high temperatures for the duration of the cartridge lifetime. Alternative bonding methods can include using heat-sealing films or selectively melting the PET film to allow deformation around the foil in a process akin to laser welding.

[0072] The foregoing sections described an implementation of the heater and a specific implementation of a process for manufacturing the heater. FIG. 4 provides a diagram for a generalized process 400 for manufacturing a heater. At 410, an opening is formed in a frame layer cut from a sheet of plastic (e.g., PET). At 420, the frame layer is disposed onto a first surface of a heating layer. The heating layer may be a thin metal (e.g., aluminum) foil. The frame layer can be aligned with the heating layer so that the opening of the frame layer exposes at least a portion of the heating layer. The frame layer can be adhered to the first surface of the heatinglayer. The adhesion can be performed using lamination, by welding, or by another method. At 430, once the frame layer and heating layer are bonded, one or more traces are formed through the heating layer. The traces may be formed as slits cut through the heater layer material. The opening of the frame layer is aligned to expose at least a portion of the one or more traces. The traces can form a one-dimensional or two-dimensional pattern on the surface of the heating layer. For example, the traces can form a serpentine pattern. In other implementations, the traces can form a linear, circular, ellipsoid, oblong, triangular, polygonal, zigzag, hourglass, or another type of pattern. At 440, the wicking layer is disposed onto the second surface of the heating layer. The wicking layer can be substantially aligned with at least a portion of the one or more traces.

[0073] In some implementations, the traces may be fully or partially cut into the heating layer before the frame layer is adhered to it. This allows the traces in the heating layer to remain attached to the heating layer to maintain robustness of the assembly during adhesion of the heating layer to the frame layer. After the frame is added, the frame and / or heating layer are then trimmed using horizontal cuts above and below a center line. Once attached, the opening of the frame layer can expose most of each of the traces. In these implementations, the wicking layer can be adhered to the heating layer before or after the frame layer is adhered thereto.

[0074] FIG. 5 schematically illustrates a circular profile implementation 500 of the heater. The circular profile implementation 500 may allow for even (e.g., uniform) thermal distribution and prevent a center of the heater from reaching higher temperatures than the edges of the heater. At least one of the heating layer 510, frame layer 520, or wicking layer 530 of the circular profile implementation 500 may be circular in shape and substantially flat (e.g., a disc). The traces cut into the heater may follow a pattern that can be circumscribed by the circular layer. The pattern can be a serpentine pattern. For example, the serpentine pattern can be configured to “fill in” the circular layer, such that if a circle is drawn outside the serpentine pattern, the radius of the circle drawn outside the pattern would closely approximate that of the circular layer. The pattern can comprise one or more traces. For example, a serpentine pattern can be fashioned as one continuous trace that winds its way back and forth through the metal layer. Or the serpentine pattern can comprise multiple traces arranged in a serpentine shape. In some implementations, one or more portions of one or more traces can extend beyond the heating layer (e.g., resistive metal heating element) into the frame layer 520 (e.g., plastic frame).

[0075] FIG. 6 illustrates an attachment configuration for a heating layer 610, a frame layer 620, and a wicking layer 630, in accordance with some implementations. In some implementations, the wicking layer and frame layer are directly adhered through one or more holes in the heating layer, such that the heating layer is disposed between the wicking layer and the frame layer. In some implementations, the layers are attached by welding. One or more contact points 640 (e.g., weld points) can be placed onto the heating layer. These one or more points represent connection areas to guide the adhesion (e.g., welding together) of the three layers. In some implementations, when the heater is square or rectangular, there are four contact points, with each contact point located in proximity to the corner of the heating layer 610. In other implementations, one or more contact points may be arranged (e.g., symmetrically) with respect to any geometry (e.g., planar geometry) of the heating layer. The contact points can guide adhesion (e.g., welding) to any surface (e.g., the first surface and / or the second surface) of the heating layer.

[0076] The frame layer 620 (e.g., plastic frame) and the wicking layer 630 (e.g., wicking material) are adhered to the heating layer 610. For example, the frame layer 620 may be welded to a first surface of the heating layer 610 and the wicking layer 630 may be welded to the second surface of the heating layer. The heater 600 comprising the heating layer, the frame layer, and the wicking layer, after welding, can be trimmed. Trimming can be performed to decrease the size of the heater so that it can be inserted into a cartridge of the vaporizer device. In some implementations, trimming can be performed to change the shape and size of the heater 600.

[0077] FIG. 7A illustrates a vaporizer cartridge 720, in accordance with some implementations. FIG. 7B illustrates an exploded view of the vaporizer cartridge. The vaporizer cartridge 720 can include the heater 780, a reservoir 740, a collector 760, and an air path 790. The heater can be disposed to allow liquid contact between a collector 760 of the cartridge 720 and the wicking layer (e.g., the wicking layer 230) of the heater. For example, the heater 780 can be disposed between an air path 790 of the cartridge 720 and the collector 760. The heating layer (e.g., a resistive metal heating element) can protrude outside of the air path 790 to allow for an electric connection between a body of the vaporizer device and the cartridge 720.

[0078] The reservoir 740 can contain a liquid vaporizable material and / or a mouthpiece for delivering a dose of an inhalable form of the vaporizable material to a user. Themouthpiece can be formed from a same part or component that forms at least part of one or more walls of the reservoir 740. The liquid vaporizable material within the reservoir 740 can be a carrier solution in which active or inactive ingredients may be suspended, dissolved, or held in solution or a neat liquid form of the vaporizable material itself.

[0079] The air path 790 can provide a channel for transporting the vaporizable material in aerosol form to a user of the vaporizer device. Air passing into the vaporizer device can flow along the air path across a heating element (e.g., in the heating layer) of the heater. This can strip away the vaporized vaporizable material from the heating element. The vaporized vaporizable material can then be condensed due to cooling, pressure changes, etc., such that it exits a mouthpiece of the vaporizer device as an aerosol for inhalation by a user.

[0080] The collector 760 can prevent or limit an undesirable (e.g., excessive) flow of the vaporizable material out of the reservoir. The collector 760 can include a capillary structure configured to retain a volume of the liquid vaporizable material in fluid contact with a storage chamber of the vaporizer cartridge. The collector 760 can include a primary passageway providing a fluid connection between the reservoir 740 and the heater 780 configured to convert the liquid vaporizable material to a gas-phase state, wherein the primary passageway is formed through a structure of the collector 760. In one example implementation, overall resistance of the collector 760 allowing liquid to flow out is smaller than overall wick resistance, for example, to allow the vaporizable material to primarily flow into the collector 760 when a decrease in external pressure occurs.

[0081] The heater described herein can provide a low-cost, disposable heating system in a cartridge-based vaporizer device. The heater uses a thin metal foil as a heating element in contact with a thin wicking layer. The heater can be manufactured at a lower cost using low-cost materials. The heater can be easily mass produced, for example, using a roll-to-roll manufacturing process. And the heater can be manufactured into a variety of shapes to provide versatility with respect to spatial heating.

[0082] The subject matter described herein can be embodied in systems, apparatus, methods, and / or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above,other modifications or additions are possible. Tn particular, further features and / or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and sub combinations of the disclosed features and / or combinations and sub combinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.Terminology

[0083] When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and / or elements can also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements can be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present.

[0084] Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature can have portions that overlap or underlie the adjacent feature.

[0085] Terminology used herein is for the purpose of describing particular embodiments and implementations only and is not intended to be limiting. For example, as used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0086] In the descriptions above and in the claims, phrases such as “at least one of’ or “one or more of’ may occur followed by a conjunctive list of elements or features. The term “and / or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or featuresin combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and / or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and / or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0087] Spatially relative terms, such as “forward”, “rearward”, “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[0088] Although the terms “first” and “second” may be used herein to describe various features / elements (including steps), these features / elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature / element from another feature / element. Thus, a first feature / element discussed below could be termed a second feature / element, and similarly, a second feature / element discussed below could be termed a first feature / element without departing from the teachings provided herein.

[0089] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers can be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and / or position to indicatethat the value and / or position described is within a reasonable expected range of values and / or positions. For example, a numeric value can have a value that is + / - 0.1% of the stated value (or range of values), + / - 1% of the stated value (or range of values), + / - 2% of the stated value (or range of values), + / - 5% of the stated value (or range of values), + / - 10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “X” is disclosed the “less than or equal to X” as well as “greater than or equal to X” (e g., where X is a numerical value) is also disclosed. It is also understood that the throughout the application, data is provided in a number of different formats, and that this data, represents endpoints and starting points, and ranges for any combination of the data points. For example, if a particular data point “10” and a particular data point “15” are disclosed, it is understood that greater than, greater than or equal to, less than, less than or equal to, and equal to 10 and 15 are considered disclosed as well as between 10 and 15. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0090] Although various illustrative embodiments are described above, any of a number of changes can be made to various embodiments without departing from the teachings herein. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments, one or more method steps may be skipped altogether. Optional features of various device and system embodiments may be included in some embodiments and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the claims.

[0091] One or more aspects or features of the subject matter described herein can be realized in digital electronic circuitry, integrated circuitry, specially designed application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) computer hardware, firmware, software, and / or combinations thereof. These various aspects or features can includeimplementation in one or more computer programs that are executable and / or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device. The programmable system or computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

[0092] These computer programs, which can also be referred to programs, software, software applications, applications, components, or code, include machine instructions for a programmable processor, and can be implemented in a high-level procedural language, an object-oriented programming language, a functional programming language, a logical programming language, and / or in assembly / machine language. As used herein, the term “machine-readable medium” refers to any computer program product, apparatus and / or device, such as for example magnetic discs, optical disks, memory, and Programmable Logic Devices (PLDs), used to provide machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor. The machine-readable medium can store such machine instructions non-transitorily, such as for example as would a non-transient solid- state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium can alternatively or additionally store such machine instructions in a transient manner, such as for example, as would a processor cache or other random access memory associated with one or more physical processor cores.

[0093] The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventiveconcept, if more than one is, in fact, disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. Use of the term “based on,” herein and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0094] The subject matter described herein can be embodied in systems, apparatus, methods, and / or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail herein, other modifications or additions are possible. In particular, further features and / or variations can be provided in addition to those set forth herein. For example, the implementations described herein can be directed to various combinations and sub combinations of the disclosed features and / or combinations and sub combinations of several further features disclosed herein. In addition, the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.

Claims

WHAT TS CLAIMED IS:

1. A vaporizer atomizer, comprising: a heating layer comprising one or more traces, wherein the heating layer comprises a first surface; a frame layer disposed on the first surface of the heating layer and comprising an opening exposing at least a portion of the one or more traces therethrough; and a wicking layer disposed on the first surface or on a second surface of the heating layer and aligned with at least a portion of the one or more traces.

2. The vaporizer atomizer of claim 1, wherein the heating layer comprises a resistive metal.

3. The vaporizer atomizer of claim 2, wherein the resistive metal comprises aluminum.

4. The vaporizer atomizer of claim 1, wherein the heating layer has a thickness of about 16 to 24 micrometers.

5. The vaporizer atomizer of claim 1, wherein the frame layer comprises a plastic polymer.

6. The vaporizer atomizer of claim 5, wherein the plastic polymer comprises polyethylene terephthalate (PET).

7. The vaporizer atomizer of claim 6, wherein the PET comprises biaxially-oriented polyethylene terephthalate (boPET).

8. The vaporizer atomizer of claim 1, wherein the frame layer has a width of about 40 to 60 micrometers.

9. The vaporizer atomizer of claim 1, wherein the wicking layer comprises a cotton, a fiber, or a porous ceramic.

10. The vaporizer atomizer of claim 1, wherein the one or more traces form a serpentine pattern.11 . The vaporizer atomizer of claim 1 , wherein at least two of the one or more traces have a same length and / or width.

12. The vaporizer atomizer of claim 1, wherein the one or more traces have a nonuniform heating profile.

13. The vaporizer atomizer of claim 1, wherein at least one of the heating layer, the frame layer, and the wicking layer has a rectangular shape, a circular shape, or a square shape.

14. The vaporizer atomizer of claim 1, wherein the heating layer, the frame layer, and the wicking layer together form a circular profile.

15. The vaporizer atomizer of claim 1, wherein the wicking layer is adhered to the second surface of the heating layer.

16. The vaporizer atomizer of claim 1, wherein the frame layer is adhered to the first surface of the heating layer.

17. The vaporizer atomizer of claim 1, wherein the wicking layer is disposed on the first surface of the heating layer.

18. The vaporizer atomizer of claim 1, wherein the wicking layer is disposed on the second surface of the heating layer.

19. A method of manufacturing a vaporizer atomizer comprising a heating layer, a frame layer, and a wicking layer, comprising:(a) forming an opening in the frame layer;(b) disposing the frame layer onto a first surface of the heating layer;(c) forming one or more traces through the heating layer, wherein the opening of the frame layer exposes at least a portion of the one or more traces therethrough;(d) disposing the wicking layer onto a second surface of the heating layer, wherein the wicking layer is substantially aligned with at least a portion of the one or more traces.

20. The method of claim 19, wherein the disposing the frame layer onto the first surface of the heating layer comprises adhering the frame layer onto the heating layer.

21. The method of claim 19, further comprising (e) curing the heating layer, the frame layer, and the wicking layer.

22. The method of claim 19, wherein the disposing the wicking layer onto the heating layer comprises adhering the wicking layer to the heating layer.

23. The method of claim 19, wherein (a)-(d) are performed using a roll-to-roll process.

24. A method of manufacturing a vaporizer atomizer comprising a heating layer, a frame layer, and a wicking layer, comprising:(a) forming one or more traces through the heating layer;(b) forming an opening in the frame layer;(c) disposing the frame layer onto a first surface of the heating layer, wherein the opening of the frame layer exposes at least a portion of the one or more traces therethrough; and(d) disposing the wicking layer onto a second surface of the heating layer, wherein the wicking layer is substantially aligned with at least a portion of the one or more traces.

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