Thermal extraction device having a thermal break and / or having a convection cap

Abstract

A component for use in a thermal extraction device. The component can comprise a monolithic material comprising a stem, a crucible, and a cold-formed thermal break between the stem and the crucible. The cold-formed thermal break has a substantially minimal cross-sectional area to prevent natural-use deformation for the monolithic material. Also described is a exothermal extraction device comprising a component and a cap. The cap is hand-removably coupled to a crucible of the component. The cap can include a crucible portion and a convection portion. The crucible portion includes an open end accessible to and positionable over the crucible to create an oven chamber. The convection portion includes a heat-exchange material to convection heat the oven chamber.

Description

THERMAL EXTRACTION DEVICE HAVING A THERMAL BREAK AND / OR HAVING A CONVECTION CAP, METHOD OF FORMING THE SAME, AND METHOD OF USING THE SAME RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Application No.63 / 757,193, filed February 11, 2025, entitled “THERMAL BREAK AND METHOD OF FORMING THE SAME”; and also claims priority to and the benefit of U.S. Provisional Application No. 63 / 748,767, filed January 23, 2025, entitled “CONVECTION CAP FOR A THERMAL EXTRATION DEVICE”; the content of each of which is hereby incorporated herein by reference in their entirety.FIELD OF THE DISCLOSURE

[0002] The disclosure relates to the field of thermal extraction devices such as an exothermal vaporizer, and more specifically a modular exothermal vaporizer. The disclosure, in one or more embodiments, relates to the field of convection heating in an exothermal vaporizer. The disclosure, in one or more embodiments, relates to the field of thermal management in a thermal extraction device. The disclosure also discloses methods of forming thermal extraction devices, and methods of using thermal extraction devices.BACKGROUND

[0003] Exothermal vaporizers are known. Example exothermal vaporizers are disclosed in U.S. Patent No. 10,206,425. The patent discloses, more specifically, modular exothermal vaporizers. The vaporizers are heated to the vaporizing temperature via an external heat source. Extraction from the vaporizing material contained within the vaporizers occurs at the vaporizing temperature. The vaporizers do not contain any electronic components. Other example exothermal vaporizers are disclosed in the patent documents identified and incorporated below.

[0004] One challenge with known exothermal vaporizers is that the heat source might not uniformly heat the vaporizing material. An alternative vaporizer to better uniformly heat the vaporizing material and provide a better vaping experience is desired. Another challenge is that a common material used to make known exothermal vaporizers is metal, which is a thermal conductor. Heat may conduct from one end of the vaporizer to the other end of the vaporizer. An alternative vaporizer to limit the transference of thermal energy from one end of the vaporizer to the other is desired.Docket No. 37536-135SUMMARY

[0005] In one or more embodiments, the disclosure provides a component for use in a thermal extraction device. The component comprising a monolithic material comprising a stem, a crucible, and a cold-formed thermal break between the stem and the crucible. The crucible is configured to receive a volatilizable material for heating. The cold-formed thermal break has a substantially minimal cross-sectional area to prevent natural -use deformation for the monolithic material. The monolithic material can be a machine-malleable monolithic material. The cold-formed thermal break allows for an alternative vaporizer to reduce the transference of thermal energy from one end of the vaporizer to the other.

[0006] In one or more embodiments, the crucible includes a first wall partially defining a chamber to receive the volatilizable material, the stem includes a second wall at least partially defining a first channel, and the cold-formed thermal break includes a third wall at least partially defining a second channel fluidly coupling the first channel to the chamber. The first wall has a first thickness, the second wall has a second thickness, and the third wall has a third thickness less than the first thickness and less than the second thickness. The first thickness and the second thickness can be substantially similar.

[0007] In one or more embodiments, the disclosure provides a thermal extraction device having the component with the monolithic material. The thermal extraction device further comprises a cap hand-removably coupled to the crucible, and a mouthpiece disposed adjacent to the stem on an opposite end to the cold-formed thermal break. The cap and the crucible create an oven for volatilizable material. The mouthpiece is in fluid communication with the crucible via the cold-formed thermal break and the stem. The thermal extraction device can be a modular exothermal vaporizer.

[0008] In one or more embodiments, the disclosure provides an exothermal extraction device comprising a component and a cap. The component comprises a mouthpiece, a crucible, and a stem fluidly coupling the crucible and the mouthpiece. The cap is hand-removably coupled to the crucible. The cap includes a crucible portion and a convection portion. The crucible portion includes an open end accessible to and positionable over the crucible to create an oven chamber. The convection portion includes a heat-exchange material to convection heat the oven chamber. The exothermal extraction device provides an alternative vaporizer to better uniformly heat the vaporizing material and provide a better vaping experience.

[0009] In one or more embodiments, the exothermal extraction device is modular. That is, the mouthpiece can hand-removably couple to the stem, and the crucible can hand-removablyDocket No. 37536-135couple to the stem. Further the exothermal extraction device can include other elements, such as a condenser. The condenser can hand-removably couple to the mouthpiece.

[0010] In one or more embodiments, the crucible portion can include a crucible cap portion having a first side wall and a first crown wall. The convection portion can include a convection extension portion fixed to the crucible cap portion. The convection extension portion has a second side wall and a second crown wall.

[0011] In one or more embodiments, the cap can include a side wall, a crown wall, and a heatexchange cartridge readily-removably disposed in the convection portion and adjacent to the crown wall and a first portion of the side wall. A second portion of the side wall and an end of the heat-exchange cartridge opposite the crown wall define the crucible portion.

[0012] In one or more embodiments, the disclosure provides a method of using an exothermal extraction device. The method comprises providing the exothermal extraction device with a convection portion having a thermal indicator thermally associated with the heat-exchange material. The method further comprises applying athermal heat source to the convection portion of the cap until the thermal indicator provides an indication of optimum temperature for convection heating target compounds from the volatilizable material.

[0013] These and other features, advantages, and embodiments of apparatus and methods according to the invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.BRIEF DESCRIPTION OF DRAWINGS

[0014] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

[0015] FIG. 1 is a perspective view of a modular exothermal vaporizer.

[0016] FIG. 2 is a perspective view of the vaporizer of FIG. 1 with a cap removed.

[0017] FIG. 3 is a side view of the vaporizer shown in FIG. 2.

[0018] FIG. 4 is an exploded view of the vaporizer of FIG. 1.

[0019] FIG. 5 is a detail view of a portion of the vaporizer shown in FIG. 3.

[0020] FIG. 6 is a section view of the vaporizer shown in FIG. 3.

[0021] FIG. 7 is a detail view of a portion of the vaporizer shown in FIG. 6.

[0022] FIG. 8 is a perspective view of a convection cap capable of being used with the vaporizer of FIG. 2.Docket No. 37536-135

[0023] FIG. 9 is a side view of the cap of FIG. 8.

[0024] FIG. 10 is a side-exploded view of the cap of FIG. 8.

[0025] FIG. 11 is a perspective-exploded view of the cap shown in FIG. 9.

[0026] FIG. 12 is a side-section view of the cap shown in FIG. 8.

[0027] FIG. 13 is a section view of the cap shown in FIG. 9.

[0028] FIG. 14 is a perspective view of an alternative convection cap capable of being used with the vaporizer of FIG. 2.

[0029] FIG. 15 is a side view of the cap of FIG. 14.

[0030] FIG. 16 is a second perspective view of the cap of FIG. 14.

[0031] FIG. 17 is a third perspective view of the cap of FIG. 14.

[0032] FIG. 18 is a side-exploded view of the cap of FIG. 14.

[0033] FIG. 19 is a perspective view of a canister capable of being used with the cap of FIG.14.

[0034] FIG. 20 is a perspective view of a cover capable of being used with the cap of FIG. 14.

[0035] FIG. 21 is a perspective view of an end cap capable of being used with the cap of FIG.14.

[0036] FIG. 22 is a side-section view of the cap shown in FIG. 15.

[0037] FIG. 23 is a exploded-section view of the cap shown in FIG. 18.

[0038] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, the following description, the claims, and / or the drawings, and in particular the individual features thereof, may be taken independently or in combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally fded claim or fde any new claim accordingly, including the right to amend any originally fded claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.DETAILED DESCRIPTION

[0039] A thermal extraction device is shown in FIG. 1. The thermal extraction device is an exothermal vaporizer, and more specifically a modular exothermal vaporizer 100. As can be readily ascertained in FIGS. 1-7, the modular exothermal vaporizer 100 (referred to below as a vaporizer) is generally divided into five sections: a mouthpiece 102, a body conduit (also referred to as a body or stem) 104, a central conduit (also referred to as a condenser conduit orDocket No. 37536-135condenser) 106, a tip 108, and a cap 110. As best shown in FIG. 4, the vaporizer 100 is modular. That is, portions of the vaporizer 100 can be readily disassembled and assembled without tools or machines. As will be appreciated by the patent documents identified and incorporated below, the modular components of the vaporizer 100 can vary from what is shown in FIG. 4.

[0040] The cap 110 is hand-readily removable from the body 104. The cap 110 can include a temperature indicator and be a temperature-indicating cap. In some constructions, a suitable temperature-indicating cap 110 with a temperature indicator is described in U.S. Patent Publication No. 2014 / 0186015 Al, the content of which is hereby incorporated herein by reference in its entirety. Other alternative caps are described below in FIGS. 8-13 and FIGS.14-23. The temperature-indicating cap 110 of FIGS. 1-7 is calibrated to indicate or provide an alert (e.g., an audible alert, a tactile alert, a visual alert) at a preferred (e.g., substantially ideal) vaporization temperature for the fluid or volatizable material the exothermal vaporizer 100 is enclosing.

[0041] The mouthpiece 102 is coupled to the body 104 and functions as the interface between the vaporizer 100 and the user. The mouthpiece 102 includes a first end 112 having a first opening 114, a second end 116 having a second opening 118, and a channel 120 (may also be referred to as a chamber) fluidly coupling the first opening 114 to the second opening 118. The mouthpiece 102, or a portion thereof, tightly fits within or about a first end (referenced below) of the body 104. The second end 116 of the shown mouthpiece 102 fits within the first end of the body 104. The mouthpiece 102 includes friction fit O-rings 122 / 124 to help with the fit and seal of the mouthpiece 102 to the body 104 and to help with the moving of the mouthpiece 102 with respect to the body 104. The O-rings 122 / 124 allow for toolless assembly and disassembly and can assist with thermal isolation of the mouthpiece 102 from the body 104.

[0042] The body (or stem) 104 provides a conduit or tube with a channel for fluid flow (e.g., air, vapor) and for receiving components (e.g., the central conduit discussed below). The body 104 includes a first end 126 having a first opening 128, a second end 130 having a second opening 132, and a channel 134 (may also be referred to as a chamber) fluidly coupling the first opening 128 to the second opening 132. The shown body 104 further includes an aperture 136 disposed in the body 104. The body aperture 136 is a ventilation hole for receiving ambient air as discussed below. The body 104 may be formed of any suitable material, examples of which include, but are not limited to, plastic, rubberized material, glass, metal, wood, and the like, as well as combinations of the foregoing. For the constructions shown herein, the body 104 is formed of metal, such as titanium or aluminum. Also for some of theDocket No. 37536-135constructions shown herein, the body 104 includes a cold-formed metal. Further discussion regarding the construction and formation of the body 104 will be provided below.

[0043] The central conduit 106 is disposed at least in part in the channel 120 of the mouthpiece 102, the channel 134 of the body 104, and possibly, a channel (referenced below) of a thermal break. The central conduit 106 includes a first end 138 having a first opening 140, a second end 142 having a second opening 144, and a channel 146 (may also be referred to as a chamber) fluidly coupling the first opening 140 to the second opening 144. The shown central conduit 106 includes flexible prongs 148 and grooves 150 to help integrate and secure the first end 138 of the central conduit 106 into the second end 114 and channel 120 of the mouthpiece 102. The flexible prongs 148 and grooves 150 allow for a slidable and repositionable friction fit seal between the central conduit 106 and the mouthpiece 102. That is, flexible prongs 148 and grooves 150 allow for a seal by toolless assembly and disassembly of the central conduit 106 with the mouthpiece 102. The central conduit 106, among other things, acts as a condenser and is adjustable to modulate and / or regulate the flow ratio of dilution air with produced vapor. The central conduit 106 serves to create provides a conduit for vapor extraction, and provides a means of redirecting fluid (e.g., air) back to the reservoir.

[0044] For the construction shown, the central conduit 106 has a smaller exterior surface (e.g., a smaller perimeter diameter) than the interior surface (e.g., inner diameter) of the body 104. The space between the central conduit 106 and the body 104, when the central conduit 106 is inserted into the body 104, provides an air gap between the exterior surface of the central conduit 106 and the interior surface of the body 104.

[0045] The tip 108 is shown in FIGS. 1-7 as being a singular unitary piece with the body 104. However, as is appreciated by somebody skilled in the art reviewing the documents identified below, the tip 108 can be a modular piece separate from the body 104. The tip 108 includes a first end 152 having a first opening 154, a second end 156 having a second opening 158, and a channel 160 fluidly coupling the first opening 154 to the second opening 156. As best seen in FIGS. 6 and 7, the tip 108 includes a filter (e.g. a diffuser disc) 162 retained or integrated with the tip 108. For some of the constructions shown in the referenced documents below, a portion of the tip 108 releasably and tightly fits with the second end 130 of the body 104.

[0046] The tip 108 includes a crucible 165 (may also be referred to as a reservoir), which in portion with the cap 110 creates a chamber 170 (may also be referred to as a chamber oven or oven). The crucible 165 is filled with or contains a vaporizing fluid or material. The specific example discussed herein will be a vaporizing material. The crucible 165 is a vessel used for calcining a substance that requires a high degree of heat.Docket No. 37536-135

[0047] In one or more examples of use of the vaporizer 100, a user first loads or fills the crucible 165 with a substance for vaporization and consumption. The user then places the cap 110 over the tip 108 to create the chamber / oven 170. Next, the user applies a heat source, such as a lighter or an induction heater, to the tip 108 at the chamber 170. The thermo-indicator eventually indicates to the user the substance is ready for consumption and the user removes the heat source. Next, the user applies suction to the mouthpiece 102 to consume the substance. This suction creates a pressure drop in the device 100. Air can be drawn into the aperture 136, along the channel 134 of the body conduit 104 exterior to the central conduit 106, through the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. Air can also be drawn into the cap 110 along the exterior of the tip 108, into the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. The user may then inhale the mixed air and vapor. Vapor production will diminish as the temperature drops in the chamber 170. Shortly after the temperature indicator may indicate it has cooled sufficiently and reset and is now ready for another heating cycle.

[0048] One construction of the vaporizer is shown in the figures. Variations of the vaporizer are shown and described in the following patent documents, each of which is incorporated herein by reference in its entirety; U.S. Patent Publication No. 2014 / 0186015 Al, U.S. Patent Publication No. 2017 / 0013877 Al, and U.S. Patent Publication No. 2022 / 0087327 Al, International Patent Publication No. 2022 / 0178092.

[0049] An improved heat dissipation feature for some constructions of the vaporizer 100 is best shown in FIGS. 6 and 7. The improved heat dissipation feature, in various embodiments, can be in the form of a thermal (e.g., heat) break 200. The thermal break 200 makes the thermal conductive path through the tip 108 and the body 104 smaller by minimizing the cross-sectional area of the thermal break 200. The thermal break 200 also provides an increased exterior surface area for dissipation of errant heat conducted away from the crucible 165 and the tip 108. If the body 104 and the tip 108 are modular, for example as shown in one or more of the incorporated references, above, then the thermal break 200 can be in either the body 104 or the tip 108. However, the thermal break 200 works best in the singular body conduit 104 and tip 108 combination shown in FIGS. 1-7.

[0050] Referring to FIGS. 4 and 6, the body conduit 104, the thermal break 200, and the tip 108 are formed of a monolithic, machine-malleable material, collectively 205. The crucible 165 is formed in the monolithic material 205 on one end of the monolithic material 205, and the thermal break 200 is formed nearer the one end of the monolithic material 205 having theDocket No. 37536-135crucible 165 than the other end of the monolithic material 205 adjacent to the mouthpiece 102. In the embodiment shown, the thermal break 200 is adjacent to the crucible 165 and is between the crucible 165 and the body 104.

[0051] The material of the shown construction is a metal material, such as, but not limited to, aluminum, stainless steel, or titanium. However, those of skill in the art will appreciate that alternative materials having properties suitable for the purposes described herein may be acceptable. The monolithic material 205 is formed or composed of material without discontinuous joints or seams and consists of or constitutes a single unit. With the body 104 and the tip 108 being monolithic, heat can transfer through the material more readily than if the body 104 and the tip 108 are modular. The thermal break 200 reduces that transference of heat from the tip 108 to the body 104.

[0052] A method to form and shape the monolithic material 205 is disclosed. The method minimizes thermal transfer from the crucible 165 with a significant temperature differential (i.e., the thermal break 200) relative to the rest of the component 205 by minimizing the thermal conductive cross section of the thermal break 200. The minimized thermal conductive cross section is done without compromising structural integrity by implementing a coldforming process to toughen and / or work-harden the monolithic material 200. Cold forming also creates an otherwise difficult to machine geometry and facilitates a stronger and more durable intermediary thermal break without the need for an assembly of multiple separable components. The minimized thermal conductive cross section has at least a minimal cross-sectional area to prevent natural-use deformation for the monolithic material.

[0053] Cold forming is a metalworking process in which metal is shaped below its recrystallization temperature, usually at ambient, or near room, temperature. Such processes are contrasted with hot-forming techniques like hot rolling, forging, welding, etc. Unlike hot forming, cold forming causes the crystal grains and inclusions to distort; which typically causes work hardening and anisotropic material properties. Cold forming makes the metal harder, stiffer, and stronger where the lattice changes. However, cold forming is less plastic than hot forming and may cause cracks in the cold-formed piece. The possible uses of cold forming include large flat sheets, complex folded shapes, metal tubes, and more.

[0054] In the illustrated construction, the thermal break 200 is composed of an area of minimized thermal conductive cross section, or minimal cross-sectional area, in a monolithic material 205, forming the crucible 165 on one end and the body 104 on the other end. The thickness 201 is less than the thickness 202 and the thickness 203, which may or may not be equal. The thickness 201 has a relation to the thermal conductive cross section, or crossDocket No. 37536-135sectional area, of the thermal break 200. The thickness 202 has a relation to the thermal conductive cross section, or cross-sectional area, of the body 104. The thickness 203 has a relation to the thermal conductive cross section, or cross-sectional area, of the crucible 165.

[0055] In one method, the monolithic material 205 is first machined to a precise wall thickness. Subsequently using a profiling tool to apply precise pressure, the monolithic material 205 is then formed to the desired geometry while the part is rotating. By machining the material prior to forming, one can establish a very precise wall thickness 202 / 203 and can incorporate variable wall thickness and geometry among walls 202 and 203. The intermediary can then work in concert with the forming process to arrive at the desired combination of wall thicknesses 201-203 (and corresponding conductive path for wall 201), cross-section and length of thermal break 205, and the physical and mechanical properties necessary for proper functioning. The forming process strengthens and work-hardens the material as well as changes its geometry in such a manner as to impart additional physical and / or mechanical properties beyond what would otherwise be exhibited by the part prior to forming.Additionally, the forming operation can stretch the material in such a manner as to further reduce the conductive cross-section without substantially reducing the important physical characteristics of the component.

[0056] The minimal cross-sectional area can be based on various factors such as, but not limited to, type of material (e.g., titanium vs. aluminum vs. stainless steel), diameter of the body 104, cross-sectional area or thickness of the body 104, diameter of the tip 108 or crucible 165, cross-sectional area or thickness of the tip 108 or crucible 165, axial length of the thermal break 200, ratio of the axial length of the thermal break to the diameter of the thermal break for the material used, etc. More particularly, in one implementation, the thickness of the thermal break is based on an aspect ratio, the minimum physical properties necessary for proper functioning of the monolithic material 205, and the desired durability of the monolithic material 205. In more specific examples, a 10mm diameter titanium tube with a 1mm wall thickness or a 10 to 1 aspect ratio can be adjusted to a 6mm diameter titanium tube with a 0.25mm wall or 24 to 1 aspect ratio while maintaining adequate physical properties. The thermal conductivity reduction of this change can be calculated by subtracting the reduced conductive cross section from the initial cross section and multiplying by the conductivity of the material and further accounting for the length of the thermal break. Furthermore, when forming the malleable monolithic material 205 into a compound profile, such as an arch or corrugation, additional strength or resistance to creasing, cracking, and or deformation can be achieved over what a cylindrical profile of the same thickness could provide.Docket No. 37536-135

[0057] Deflection testing can be used to remove the monolithic material 205 that has manufacturing failures. In general, deflection testing can be a means of ensuring that the material was not overwork hardened and cracked during the forming process. The metric for determining if the thermal break had physical limitations or defects is to apply a specific amount of force (e.g., a force less than a force for natural-use deformation) and see if the force bends the monolithic material 205 without rebounding. The metric can be specific to the product. In one example, a mandrel is mounted to the monolithic material and applied approximately 31bs of force is applied to the stem 50mm from the thermal break. If this force induces permanent deformation or reveals a crack, the monolithic material 205 is rejected.

[0058] Referring to FIGS. 8-13, an alternative cap 110b is provided. The cap is a convection cap 110b for use with a thermal extraction device, such as the modular exothermal vaporizer 100. The convection cap 110b comprises a crucible cap portion 210 and a convection extension portion 215. The shown crucible cap portion 210 includes a first side wall 220 and a first crown wall 225. The first side wall 220 substantially surrounds the exterior of the crucible 165, and the first crown wall 225 substantially covers the crucible 165. The shape and number of side walls can vary depending on the design of the crucible 165. The shape and number of crown walls can also vary. The first crown wall 225 includes one or more apertures 230 for a fluid (e.g., air) to travel between the crucible cap portion 210 and the convection extension portion 215. The first side wall 220 includes an indent 235 to fit into the thermal break 200, and to hold the convection cap 110b to the tip 108. The first side wall 220 further includes a rim (or lip) 240 and a neck 245. The rim 240 and neck 245 receive and help secure the convection extension portion 215 to the crucible cap portion 210.

[0059] The shown convection extension portion 215 includes a second side wall 250 and a second crown wall 255. The second side wall 250 includes a first portion 260 that substantially surrounds and couples to the first side wall 210. The coupling can be a mechanical (e.g., press fit), thermal, and / or chemical coupling of the first portion 260 of the second side wall 250 to the neck 245 and / or rim 240. A second portion 265 of the second side wall 250 defines, in part, a chamber 270 for receiving heat-exchange material (referenced below) and a thermal indicator 273. The chamber 270 is also defined in part by the first crown wall 225 of the crucible cap portion 210 and the second crown wall 255 of the convection extension portion 215. The walls surrounding the chamber 270 effectively create a heat-exchange cartridge. The shape and number of second side walls can vary depending on the design of the crucible cap portion 210. The shape and number of second crown walls can also vary. The second side wall 250 includes a rim (or lip) 275 and a neck 280. The rim 275 and neck 280 receive and help secure theDocket No. 37536-135thermal indicator 273, such as a crimped thermal disc. Further discussion regarding the thermal indicator 273 can be obtained from the patent documents incorporated above. The second side wall 250 further includes one or more airflow apertures 285 to allow incoming air into the convection extension portion.

[0060] The chamber 270 of the convection extension portion 215 is filled with a heatexchange material 290 (also referred to as a heat-exchange medium). Heat-exchange material 290 can be composed of a variety of different materials that reciprocally receives heat and gives heat. The heat-exchange material 290 may be a homogeneous media / material, homogeneous medium / material, heterogenous medium / material, or a combination of one or more media / material types. Example shapes of the heat-exchange material 290 include, but are not limited to, balls, spheres, rods, spirals, beads, irregularly shaped material, wound wire, solid or perforated core material, and the like. Effectively, the heat-exchange material 290 is any material that is suitable for receiving heat, substantially holding the received heat, and subsequently releasing the held heat, particularly as incoming air flows through and / or over the material may be an acceptable heat-exchange material 290. Examples include but are not limited to stainless steel, ceramic, glass, ruby, sapphire, etc. The number of heat-exchange material 290 could be much greater than the number of pieces shown in the drawings. The number shown in the drawings is less for simplicity purposes.

[0061] In one or more examples of use of the vaporizer 100, a user first loads or fills the crucible 165 with a substance for vaporization and consumption. The user then places the cap 110b over the tip 108 to create the chamber / oven 170. Next, the user applies heat to the exterior of the convection extension portion 215 adjacent to the location of the heat-exchange material 290. The heat-exchange material 290 can be heated with effectively anything that is hot, such as for example a lighter or torch, or if the media itself is mostly electrically conductive, by induction. The thermo-indicator 273 eventually indicates to the user the heatexchange material 290 is ready for convection heating of the substance. Next, the user applies suction to the mouthpiece 102 to consume the substance. This suction creates a pressure drop in the device 100. Air can be drawn into the aperture 136, along the channel 134 of the body conduit 104 exterior to the central conduit 106, through the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. Additionally, air can also be drawn into the airflow apertures 285 and is heated up to an extraction temperature via the higher temperature heat-exchange material 290, which was subjected to heating. The heated air then flows through the apertures 230 of the crown wall 230 and correspondingly enters the extraction chamber 170 of the tip. The heatedDocket No. 37536-135air heats the substance for vaporization. The resulting vapor proceeds through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. Lastly, air can also be drawn into the cap 110 along the exterior of the tip 108, into the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. The result fluid combination is then inhaled by the user. Vapor production will diminish as the temperature drops in the chamber 270. Shortly after, the temperature indicator may indicate it has cooled sufficiently and reset and is now ready for another heating cycle.

[0062] Referring to FIGS. 14-23, a second alternative cap 110c is provided. The cap is a second convection cap 110c for use with a thermal extraction device, such as the modular exothermal vaporizer device 100. The second convection cap 110c comprises a crucible portion 310 and a convection portion 315. The convection cap 110c includes a side wall 320 and a crown wall 325. The side wall substantially surrounds the exterior of the crucible 165 and a heat material exchange container, which is shown as a heat-exchange cartridge 330. The crown panel 240 covers the heat-exchange cartridge 330 and by extension the crucible 165. The shape and number side walls can vary depending on the design of the crucible 165. The shape and number of crown walls can also vary.

[0063] For the construction shown, the crown wall 325 includes a shelf 335 and a single aperture 340. The shelf 335 acts as a stop for placement of the heat-exchange cartridge 330 in the convection portion 315. The single aperture 340 allows air to flow through the single aperture 340. It is envisioned that a different number of apertures and arrangements are possible for the crown wall 325.

[0064] The side wall 320 includes a indent 345 to snap into the thermal break 210, and to hold the convection cap 110c to the tip 108. The side wall 320 further includes a rim (or lip) 350 and a neck 355. The rim 350 and neck 355 receive and help hold the heat-exchange cartridge 330 in the convection portion 315. The side wall 320 further includes indents 360 to help a user to place and remove the convection cap 110c. Also as shown, the side panel has one or more heat apertures 365 and 370. The number, size, and shape of the heat apertures can vary. The heat apertures 365 and 370 allow the heat source to more directly heat the heat-exchange cartridge 330, and more specifically, the heat-exchange material (referenced below) held by the heat-exchange cartridge 330. As best seen in FIGS. 23 and 24, the crown wall 325 and the portion of the side wall 320 near the convection portions 315 have a thicker cross section 375 than the cross section 380 of the portion of the side wall 320 near the crucible portion 310. The thicker cross section allows for the convection portion 315 to receive and retain a greaterDocket No. 37536-135amount of heat compared to the crucible portion 310. This thickness difference is particularly more relevant depending on the type of material (e.g., titanium) for the second alternative cap 110c.

[0065] The convection portion 315 defines in part a chamber 385 for receiving the convection heat-exchange cartridge 330. The chamber 385 is also defined in part by the crown wall 325 and a portion of the side wall 320. The shown heat-exchange cartridge 330 includes a canister 390 and a cover 395. The canister 390 includes a side wall 400 and an end wall 405. The shape and number of walls of the heat-exchange cartridge 330 can vary from what is shown depending on the shape of the chamber 385, for example. The cover 395 includes a cylindrical side wall 410 to coincide with and friction fit the cylindrical side wall 400 of the canister 390. The cover 395 further includes an end wall 415 to encapsulate the convection heat-exchange cartridge 330. The end wall 415 includes a plurality of apertures 420 to allow air to enter / leave the heat-exchange cartridge 330. Whether the air enters or leaves the heat-exchange cartridge 330 can depend on the orientation of the heat-exchange cartridge 330 in the convection portion 315. If the heat-exchange cartridge 330 is oriented as shown in FIG. 17, then air will generally enter the heat-exchange cartridge 330 via the crown aperture 340. If the heat-exchange cartridge 330 is oriented 180° from what is shown in FIG. 17, then air will generally exit the heat-exchange cartridge 330 towards the oven 170.

[0066] The side wall 400 of the heat-exchange cartridge 330 includes a rim (or lip) 425 and a neck 430. The rim 425 and neck 430 receive and help secure athermal indicator 435, such as be thermal disc crimped into the rim 425 and held by the neck 430. Further discussion regarding the thermal indicator 435 can be obtained from earlier and from the patent documents incorporated above.

[0067] The side wall 400 includes a cylindrical bulge 440. The cylindrical bulge 440 acts as a spring to help toolless assembly and disassembly of the heat-exchange cartridge 330 in the chamber 385 of the second alternative cap 110c. The side wall 400 further includes apertures (or windows) 445 for airflow into or out of the heat-exchange cartridge 330. If the heatexchange cartridge 330 is oriented as shown in FIG. 17, then air will generally exit the heatexchange cartridge 330 through at least some of apertures 445. If the heat-exchange cartridge 330 is oriented 180° from what is shown in FIG. 17, then air will generally enter the heatexchange cartridge 330 through at least some of apertures 445. Further, depending on the placement of the heat-exchange cartridge 330, the user can control access to the heat-exchange material (referenced below) via the heat apertures 365, 370 and the window apertures 420.Docket No. 37536-135That is, as best viewed in FIG. 19, the user can control the placement of the window apertures 420 when placing the heat-exchange cartridge 330 in the convection portion of the cap 110c.

[0068] The interior volume 450 (or chamber) of the heat-exchange cartridge 330 is fdled with a heat-exchange material 455 (also referred to as heat-exchange medium). Heat-exchange material 455 can be composed of a variety of different materials and reciprocally gives and receives heat. The heat-exchange material 455 may be a homogeneous media / material, homogeneous medium / material, heterogenous medium / material, or a combination of one or more media / material types. Example shapes of the material include, but are not limited to, balls, spheres, rods, spirals, beads, irregularly shaped material, wound wire, solid or perforated core material, and the like. Effectively, any material that is suitable for holding heat and subsequently releasing the held heat, particularly as incoming air flows through and / or over the material may be an acceptable exchange material. Examples include but are not limited to stainless steel, ceramic, glass, ruby, sapphire, etc. It should also be noted that the heatexchange cartridge 330 is replaceable, and the heat-exchange material 455 is replaceable. The heat-exchange cartridge 330 may be removable and optionally rotatable for positioning purposes to adjust airflow and or modulate heat exchange to facilitate a different user experience.

[0069] In one or more examples of use of the vaporizer 100, a user loads or fdls the crucible 165 with a substance for vaporization and consumption. Also, the user places the heatexchange cartridge 330 having the heat-exchange material 455 in the convection portion 315 of the cap 110c. The user then places the cap 110b over the tip 108 to create the chamber / oven 170. Next, the user applies heat (e.g., from a torch) to the heat-exchange cartridge 330 via the heat apertures 365 / 370. The heat-exchange material 455 is heated until the thermo-indicator 435 eventually indicates to the user that the heat-exchange material 455 is ready for convection heating of the substance placed in the crucible 165. Next, the user applies suction to the mouthpiece 102 to consume the substance. This suction creates a pressure drop in the device 100. For the arrangement shown, air can be drawn into the aperture 136, along the channel 134 of the body conduit 104 exterior to the central conduit 106, through the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. Additionally, air can also be drawn through the aperture 340 of the crown wall 325, through the apertures 420 of the cover end wall 415, and is heated up to an extraction temperature via the higher temperature heat-exchange material 455, which was subjected to heating. The heated air then flows through the apertures 445 of the canister sidewall 400, along the heat-exchange cartridge 330 into the oven 170. The heated air heats the substance forDocket No. 37536-135vaporization. The resulting vapor proceeds through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. Lastly, air can also be drawn into the cap 110 along the exterior of the tip 108, into the crucible 165 and the substance, through the channel 146 of the central conduit 106, and through the channel 120 of the mouthpiece 102. The result fluid combination is then inhaled by the user. Vapor production will diminish as the temperature drops in the heat-exchange cartridge 330. Shortly after the temperature indicator 435 may indicate it has cooled sufficiently and reset and is now ready for another heating cycle.

[0070] For the convection caps 110b / 110c, the user heats the heat-exchange material 290 / 455 of the caps 110b / l 10c and not the substance placed in the crucible 165. That is, the user does not directly heat the substance as occurred with prior thermal extraction devices. Rather, the caps 110b / l 10c heat the substance through convection. Directly heating the substance can result in hot spots and over calcinating of the substance. Convection heating, on the other hand, provides gentler and more controlled heating of the substance. This provides a smoother, more flavorful, and potentially more potent vaper experience for the user.

[0071] The convection cap 110c also allows for more customization of the vaping experience. The user can change aperture placements of the heat-exchange cartridge 330, allowing for a control of airflow through the cap 110c. Furthermore, the user can interchange multiple heatexchange cartridges 330 and can change the heat-exchange material 455 of the heat-exchange cartridges 330. These user customizations allow for a more controlled experience for the user. For example, better controlled experiences can allow for different types of medical sessions for the user.

[0072] Accordingly, the vaporizer 100 provides a new and useful thermal extraction device having a thermal break. Additionally and / or alternatively, the vaporizer 100 provides a new and useful thermal extraction device having a convection cap. Also, a new and useful method of forming the vaporizer 100 is shown and described. Even further, a new and useful method of using the vaporizer 100 is shown and described.

[0073] It is important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a finite numbers embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations,Docket No. 37536-135etc.) without materially departing from the novel teachings and advantages of the subject matter recited.

[0074] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0075] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

[0076] For the purpose of this disclosure, the term “coupled,” without further limitation, means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

[0077] Elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the various examples of embodiments without departing from the spirit or scope of the invention.

[0078] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvementsDocket No. 37536-135and / or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements, and / or substantial equivalents.

[0079] The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

[0080] The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and / or “having,” as used herein, are defined as comprising (i.e., open language). The phrase “at least one of ... and ....” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase “at least one of A, B, and C” includes A only, B only, C only, or any combination thereof (e.g., AB, AC, BC, or ABC).

[0081] It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0082] Preferences and options for a given aspect, feature or parameter of the disclosure should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features, and parameters of the disclosure.

[0083] Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope hereof.

Claims

Docket No. 37536-135CLAIMSWhat is claimed is:

1. A component for use in a thermal extraction device, the component comprising a monolithic material comprising a stem, a crucible, and a cold-formed thermal break between the stem and the crucible, wherein the crucible is configured to receive a volatilizable material to heat, and wherein the cold-formed thermal break has a substantially minimal cross-sectional area to prevent natural -use deformation for the monolithic material.

2. The component of claim 1, wherein the monolithic material is a machine-malleable monolithic material.

3. The component of claim 2, wherein the machine-malleable monolithic material is selected from the group consisting of aluminum, stainless steel, titanium, and alloys thereof.

4. The component of claim 1, wherein the crucible includes an open end to receive the volatilizable material, and a fdter to retain the volatilizable material, the fdter to allow a fluid to flow through the fdter.

5. The component of claim 4, wherein the fluid includes a vapor resulting from the volatilizable material when properly heated.

6. The component of claim 1, wherein the monolithic material further comprises a mouthpiece disposed adjacent to the stem on an opposite end to the cold-formed thermal break.

7. The component as in any one of claims 1-5, wherein the crucible includes a first wall partially defining a chamber to receive the volatilizable material, wherein the stem includes a second wall at least partially defining a first channel, and wherein the cold-formed thermal break includes a third wall at least partially defining a second channel fluidly coupling the first channel to the chamber.

8. The component of claim 7, wherein the third wall includes a cold-formed deformation distinct from the first wall and the second wall.DocketNo. 37536-1359. The component of claim 8, wherein the cold-formed deformation includes a substantially U-shaped bend circumferentially around the second channel.

10. The component of claim 7, wherein the first wall has a first thickness, wherein the second wall has a second thickness, and wherein the third wall has a third thickness less than the first thickness and less than the second thickness.

11. The component of claim 10, wherein the first thickness has a value A, wherein the third thickness has a value C, and wherein a ratio of C to A (C / A) is less than 1.

12. The component of claim 11, wherein the first thickness and the second thickness are substantially the same.

13. A thermal extraction device comprising :a monolithic material comprising a stem, a crucible, and a cold-formed thermal break between the stem and the crucible, wherein the crucible is configured to receive a volatilizable material that volatilizes upon heating, and wherein the cold-formed thermal break has a substantially minimal cross-sectional area to prevent natural -use deformation for the monolithic material;a cap hand-removably coupled to the crucible, the cap and the crucible to create an oven for volatilizable material; anda mouthpiece disposed adjacent to the stem on an opposite end to the cold-formed thermal break, the mouthpiece in fluid communication with the crucible via the cold-formed thermal break and the stem.

14. The thermal extraction device of claim 13, wherein the thermal extraction device is a modular exothermal vaporizer, and wherein the mouthpiece is hand-removably coupled to the monolithic material.

15. The thermal extraction device of claim 13, wherein the mouthpiece includes a first channel and the stem includes a second channel in fluid communication with the first channel, and wherein the thermal extraction device further comprises a condenser conduit hand-Docket No. 37536-135removably coupled to the mouthpiece and is disposed in the first channel and the second channel.

16. The thermal extraction device of claim 13, wherein the cap includes a thermal indicator, and the cap is a thermal -indicator cap.

17. The thermal extraction device of claim 13, wherein the monolithic material is a machine-malleable monolithic material.

18. The thermal extraction device of claim 13, wherein the crucible includes an open end to receive the volatilizable material, and a filter to retain the volatilizable material, the filter to allow a fluid to flow through the filter.

19. The thermal extraction device of claim 18, wherein the fluid includes a vapor resulting from the volatilizable material when properly heated.

20. The thermal extraction device as in any one of claims 13-19, wherein the crucible includes a first wall partially defining a chamber to receive the volatilizable material, wherein the stem includes a second wall at least partially defining a first channel, and wherein the cold-formed thermal break includes a third wall at least partially defining a second channel fluidly coupling the first channel to the chamber.

21. The thermal extraction device of claim 20, wherein the third wall includes a cold-formed deformation distinct from the first wall and the second wall.

22. The thermal extraction device of claim 21, wherein the cold-formed deformation includes a substantially U-shaped bend circumferentially around the second channel.

23. The thermal extraction device of claim 20, wherein the first wall has a first thickness, wherein the second wall has a second thickness, and wherein the third wall has a third thickness less than the first thickness and less than the second thickness.

24. The thermal extraction device of claim 23, wherein the first thickness has a value A, wherein the third thickness has a value C, and wherein a ratio of C to A (C / A) is less than 1.Docket No. 37536-13525. The thermal extraction device of claim 24, wherein the first thickness and the second thickness are substantially the same.

26. The thermal extraction device as in any one of claims 13-19, wherein the cap includes a crucible portion and a convection portion, wherein the crucible portion is substantially associated with the crucible to create the oven, wherein the convection portion includes a heatexchange material to convection-heat the oven.

27. The thermal extraction device of claim 26, wherein the convection portion of the cap includes a thermal indicator thermally associated with the heat-exchange material, and the cap is a thermal -indicator cap.

28. The thermal extraction device of claim 26, wherein the heat-exchange material includes a homogenous material, a heterogenous material, or a combination of homogenous material and heterogenous material.

29. The thermal extraction device of claim 26, wherein the heat-exchange material includes material comprising a shape, and the shape is selected from the group consisting of balls, spheres, rods, spirals, beads, irregularly shaped material, wound wire, and solid or perforated core material.

30. The thermal extraction device of claim 26, wherein the heat-exchange material includes a material that receives heat, substantially holds the received heat, and subsequently releases the heat to air as air flows past the material.

31. The thermal extraction device of claim 30, wherein the heat-exchange material conventionally heats the oven with the heated air.Docket No. 37536-13532. An exothermal extraction device comprising:a component comprising a mouthpiece, a crucible, and a stem fluidly coupling the crucible and the mouthpiece, wherein the crucible is configured to receive a volatilizable material that volatilizes upon heating; anda cap hand-removably coupled to the crucible, the cap including a crucible portion and a convection portion, wherein the crucible portion includes an open end accessible to and positionable over the crucible to create an oven chamber, wherein the convection portion includes a heat-exchange material to convection heat the oven chamber.

33. The device of claim 32, wherein the crucible and the stem are a single piece of machine malleable monolithic material, and wherein the device further comprises a cold-formed thermal break between the crucible and the stem.

34. The device of claim 32, wherein the crucible includes an open end to receive the volatilizable material, and a filter to retain the volatilizable material, the filter to allow a fluid to flow through the filter.

35. The device of claim 32, wherein the mouthpiece includes a first channel, wherein the stem comprises a second channel, wherein the component further comprises a condenser conduit disposed in the first channel and in the second channel.

36. The device of claim 32, wherein the device is modular, wherein the condenser hand-removably couples to the mouthpiece, wherein the mouthpiece hand-removably couples to the stem, and wherein the crucible hand-removably couples to the stem.

37. The device of claim 32, wherein the heat-exchange material includes a homogenous material, a heterogenous material, or a combination of homogenous material and heterogenous material.

38. The device of claim 32, wherein the heat-exchange material includes material comprising a shape, and the shape is selected from the group consisting of balls, spheres, rods, spirals, beads, irregularly shaped material, wound wire, and solid or perforated core material.Docket No. 37536-13539. The device of claim 32, wherein the heat-exchange material includes a material that receives heat, substantially holds the received heat, and subsequently releases the heat to air as air flows past the material.

40. The device of claim 39, wherein the heat-exchange material conventionally heats the oven chamber with the heated air.

41. The device as in any one of claims 32-40, wherein the crucible portion includes a crucible cap portion having a first side wall and a first crown wall, and wherein the convection portion includes a convection extension portion fixed to the crucible cap portion, the convection extension portion having a second side wall and a second crown wall.

42. The device of claim 41, wherein the first crown wall includes a first plurality of apertures fluidly coupling the crucible cap portion to the convection extension portion.

43. The device of claim 42, wherein the second side wall includes a second plurality of apertures fluidly coupling the convection extension portion to ambient air.

44. The device of claim 41, wherein the first crown wall, the second side wall, and the second crown wall define a chamber, and wherein the heat-exchange material is disposed in the chamber.

45. The device of claim 41 , wherein the convection portion of the cap includes a thermal indicator thermally associated with the heat-exchange material, and the cap is a thermalindicator cap.

46. The device of claim 41, wherein the second side wall of the convection extension portion includes a neck and a rim created by the neck and the second crown wall, and wherein the thermal indicator is disposed and held in the rim.

47. The device as in any one of claims 32-40, wherein the cap includes a side wall and a crown wall, wherein the cap includes a heat-exchange cartridge readily-removably disposed in the convection portion and adjacent to the crown wall and a first portion of the side wall,Docket No. 37536-135wherein a second portion of the side wall and an end of the heat-exchange cartridge opposite the crown wall define the crucible portion.

48. The device of claim 47, wherein the heat-exchange cartridge includes a heat canister having an open end, and a cover coupled to the open end of the heat canister.

49. The device of claim 48, wherein the heat-exchange cartridge includes a first plurality of apertures, and the cover includes a second plurality of apertures.

50. The device of claim 47, wherein the heat- exchange cartridge includes the heatexchange material.

51. The device of claim 47, wherein the first side wall includes a heat window to allow a thermal source to directly heat the heat-exchange cartridge.

52. A method of using an exothermal extraction device, the method comprising:providing the exothermal extraction device of claim 32, wherein the convection portion of the cap includes a thermal indicator thermally associated with the heat-exchange material; andapplying a thermal heat source to the convection portion of the cap until the thermal indicator provides an indication of optimum temperature for convection heating target compounds from the volatilizable material.

53. The method of claim 52, further comprisingapplying suction force to the mouthpiece after the indication of the optimum temperature;the application of the suction force causing ambient air to flow through or past the heatexchange material to heat the ambient air, the heated air proceeding to conventionally heat the target compounds from the volatilizable material to result in a volatized fluid; and drawing the volatized fluid towards the suction force applied to the mouthpiece.

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