VAPORIZER APPARATUS WITH AIR VENTS PROVIDED ON LONGITUDINAL FEMALE COUPLING

Abstract

Systems and techniques are provided for an atomizer assembly comprising a mouthpiece portion, a fluid reservoir portion, and an atomizer. The mouthpiece portion includes a vapor outlet channel and one or more radial vent channels in communication with the vapor outlet channel. The fluid reservoir portion includes a longitudinal vapor channel and a reservoir volume. The longitudinal vapor channel is disposed along a central longitudinal axis of the fluid reservoir portion. The reservoir volume is operable to receive a fluid. The atomizer is configured to receive the fluid stored in the reservoir volume of the fluid reservoir portion. The atomizer includes at least one heating element for vaporizing the fluid received from the reservoir volume.

Description

CROSS-REFERENCE

This application claims priority to U.S. Provisional Patent Application No. 63/410,090 filed Sep. 26, 2022, which is herein incorporated by reference in its entirety.

FIELD

The present disclosure relates generally to systems and techniques for vaporizing fluid, and more specifically pertains to an atomizer assembly with radial vent channels thereof.

BACKGROUND

Electronic cigarettes and vaporizers can be used to produce inhalable vapor from various fluids, oils, and liquids. For example, vapor can be produced from fluids that contain nicotine and/or flavoring agents. Users can inhale such vapors produced by an electronic cigarette or vaporizer device as an alternative to smoking burned or combusted matter, which is often organic and can contain various combustion byproducts that may be associated with undesirable health effects.

As electronic cigarettes and vaporizer devices have grown in popularity, so too has the range of different vaporization fluids, flavors, etc., grown in response. In some cases, vaporization fluid can be provided separately from an electronic cigarette or vaporization device, e.g., in a ‘pod’ or cartridge form that can be detachably coupled to a user's electronic cigarette or vaporization device. In this manner, a single electronic cigarette or vaporization device can be utilized with multiple different vaporization fluids or flavors, based on a user's selection of a pod or cartridge to install on their electronic cigarette or vaporization device. Accordingly, there is a need for a vaporizer or atomizer cartridge that can easily be coupled to a user's electronic cigarette or vaporization device but contains a reduced number of separate parts and/or occupies a reduced spatial volume.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understand that these drawings depict only exemplary embodiments of the disclosure and are not, therefore, to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1A illustrates a side view of an example atomizer assembly;

FIG. 1B illustrates a cross-sectional view of the atomizer assembly;

FIG. 1C illustrates a perspective view of the atomizer assembly;

FIG. 2A illustrates a side exploded view of the atomizer assembly;

FIG. 2B illustrates an exploded cross-sectional view of the atomizer assembly;

FIG. 2C illustrates a perspective exploded view of the atomizer assembly;

FIG. 3A illustrates a perspective view of a mouthpiece portion;

FIG. 3B illustrates a side view of the mouthpiece portion;

FIG. 3C illustrates a front view of the mouthpiece portion;

FIG. 3D illustrates a cross-sectional view of the mouthpiece portion;

FIG. 3E illustrates a top view of the mouthpiece portion;

FIG. 4A illustrates a cross-sectional view of the fluid reservoir portion;

FIG. 4B illustrates a side view of the fluid reservoir portion;

FIG. 4C illustrates a perspective, partially transparent view of the fluid reservoir portion; and

FIG. 4D illustrates a top view of the fluid reservoir portion.

DETAILED DESCRIPTION

It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure.

Several definitions that apply throughout this disclosure will now be presented. The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The term “substantially” is defined to be essentially conforming to the particular dimension, shape or other word that substantially modifies, such that the component need not be exact. For example, substantially cylindrical means that the object resembles a cylinder, but can have one or more deviations from a true cylinder. The term “about” means reasonably close to the particular value. For example, about does not require the exact measurement specified and can be reasonably close. As used herein, the word “about” can include the exact number. The term “near” as used herein is within a short distance from the particular mentioned object. The term “near” can include abutting as well as relatively small distance beyond abutting. The terms “comprising,” “including” and “having” are used interchangeably in this disclosure. The terms “comprising,” “including” and “having” mean to include, but not necessarily be limited to the things so described.

FIGS. 1A-1C illustrate perspective views of an example atomizer assembly 100, according to one or more aspects of the present disclosure. In some examples, the atomizer assembly 100 can be attached to a vaporizer housing (e.g., an electronic cigarette body) and used to vaporize fluid stored in an internal reservoir of the atomizer assembly 100. In addition to the internal reservoir for storing fluid, the atomizer assembly 100 can further include a heating element and one or more mechanisms for delivering the fluid from the internal reservoir to the heating element. The heating element receives electrical power from an internal or external power supply (or a combination of the two) and generates heat to vaporize the fluid delivered to the heating element. When the atomizer assembly 100 is attached to an electronic cigarette or other vaporizer body, the electronic cigarette can comprise the external supply of electrical power to the heating element of the atomizer assembly 100. In some examples, the heating element can be an atomizer heating element. Vaporized fluid produced by the heating element of atomizer cartridge 100 can then be inhaled or otherwise delivered to a user of the atomizer assembly 100.

As illustrated, the atomizer assembly 100 includes a mouthpiece portion 110, a fluid reservoir portion 120, and an atomizer 140, which are described in turn below. It is noted that the mouthpiece portion 110 and the reservoir portion 120 can be detachably connected. For example, in some examples, the mouthpiece portion 110 and the fluid reservoir portion 120 can be attached via a friction fit or a press fit. In some examples, the mouthpiece portion can be integrally formed to comprise a mouthpiece housing 112 and a vapor outlet channel 116. The vapor outlet channel 116 can have an outlet port 117 formed at a first distal end of the mouthpiece portion 110 and an inlet port 118 formed at a second distal end of the mouthpiece portion 110 opposite the first distal end. In at least one example, the mouthpiece portion 110 can be provided as a single piece of injection-molded plastic.

In some examples, one or more components of the atomizer assembly 100 (e.g., in addition to the mouthpiece portion 110) can be provided as injection-molded plastic and/or formed from other plastic material(s). For example, one or more components or portions of the fluid reservoir portion 120 can be provided as injection-molded plastic or otherwise formed from plastic material(s). In some examples, the mouthpiece portion 110 and/or the fluid reservoir portion 120 can include one or more components formed from plastic material(s) such that any oils or fluids stored in reservoir volume 122 (and later consumed using the atomizer assembly 100) do not come in to contact with any metal materials prior to consumption/vaporization by the atomizer assembly 100. For instance, fluid or oil stored in reservoir volume 122 (e.g., fluid used or consumed via atomizer assembly 100) may be acidic, basic, or otherwise have chemical properties that may cause undesirable reactions (e.g., corrosion, degradation, etc.) with materials the fluid or oil contacts. In some examples, one or more components of atomizer assembly 110 can be provided as plastic material(s) that are non-reactive with one or more types of oils and/or fluids that may be stored in reservoir volume 122 and consumed using atomizer assembly 100. In some examples, any oils or fluids stored in reservoir volume 122 do not make contact with any non-plastic materials before being provided to atomizer 140 for vaporization (e.g., oils or fluids stored in reservoir volume 122 do not contact any non-plastic materials prior to being absorbed by one or more wicking materials or absorbent pads disposed about the outer surface of an atomizer located in the atomizer 140).

In some examples, the atomizer assembly 100 with the mouthpiece portion 110 can be used in a modular fashion with different vaporizer housings, bases, electronic cigarettes, etc. For example, the atomizer 140 can include a base connector 162 to provide a detachable coupling between the atomizer assembly 100 and one or more different vaporizer housings. As illustrated in FIGS. 1A-1C, base connector 162 can be a threaded connector located at a distal end of the atomizer 140. However, it is appreciated that various other connection mechanisms can also be utilized for base connector 162 and/or that base connector 162 can be provided at locations other than the distal end of the atomizer assembly 100.

In some examples, base connector 162 can include one or more power distribution elements (e.g., positive and negative battery leads) that receive electrical power and couple the electrical power to an internal heating element disposed within the atomizer 140. Base connector 162 can receive electrical power from a source that is external to the atomizer assembly 100, such as an electronic cigarette or other vaporizer housing that is attached to atomizer assembly 100 via base connector 162 (e.g., an electronic cigarette or vaporizer housing can have an internal battery that is an external power source to atomizer assembly 100). Additionally or alternatively, base connector 162 can receive electrical power from a source that is internal to or otherwise associated with the atomizer assembly 100. For example, although not depicted in FIGS. 1A-1C, in some cases atomizer assembly 100 can be configured with one or more batteries that provide electrical power to the internal heating element of lower assembly 160.

The disclosure turns now to FIGS. 2A-2C, which depict various exploded views of example the atomizer assembly 100 according to aspects of the present disclosure. FIG. 2A illustrates a side exploded view of the atomizer assembly 100. FIG. 2B illustrates an exploded cross-sectional view of the atomizer assembly 100. FIG. 2C illustrates a perspective exploded view of the atomizer assembly 100.

As shown in FIGS. 2A-3E, the mouthpiece portion 110 is substantially cylindrical. In some examples, the mouthpiece portion 110 as including the mouthpiece housing 112 can have a domed outer wall that tapers radially inwards as it extends away from the approximately cylindrical distal end portion of the mouthpiece portion 110 (e.g., tapers radially inwards as it extends towards the proximal end portion of the mouthpiece portion 110). In some examples, the outer wall of mouthpiece housing 112 can be used to provide a mouthpiece of atomizer assembly 100, e.g., wherein the outer wall of mouthpiece housing 112 is placed in a user's mouth or brought into contact with the user's lips to allow the user to inhale the vapor produced by the atomizer assembly 100.

As contemplated herein, the second distal end portion of the mouthpiece portion 110 can be the bottom portion of the mouthpiece portion 110 when the mouthpiece portion 110 is oriented as shown in the examples of FIGS. 2A-3E. In other words, the second distal end portion of the mouthpiece portion 110 can be the portion of mouthpiece portion 110 that is nearest to the fluid reservoir portion 120 when the atomizer assembly 100 is in an assembled state. The first distal end of the mouthpiece portion 110 can be opposite from the second distal end (e.g., the first distal end can be the top portion of the mouthpiece portion 110 when in the orientation shown in the examples of FIGS. 2A-3E). As illustrated, the outlet port 117 can be located at the first distal end of the mouthpiece portion 110, and inlet port 118 can be located at the second distal end of the mouthpiece portion 110.

In some examples, a binding ring 150 can be provided in a compressive engagement about an outer surface of the approximately cylindrical second distal end of the mouthpiece portion 110. For example, binding ring 150 can apply a radially compressive force to the outer surface of the approximately cylindrical second distal end of the mouthpiece portion 110 when the mouthpiece portion 110 has been press-fit or otherwise installed onto the fluid reservoir portion 120. Binding ring 150 can comprise a different material than the material utilized by one or more of the mouthpiece portion 110 and the fluid reservoir portion 120. In some examples, the mouthpiece portion 110 and/or the fluid reservoir portion 120 can be injection molded and/or can be formed from one or more plastics, polymers, etc., and binding ring 150 can be formed from one or more metals. In some examples, binding ring 150 can be thinner (e.g., having a smaller cross-sectional width) than the outer wall of the mouthpiece portion 110 about which binding ring 150 is installed. In some examples, and as illustrated in FIGS. 2A-2C, the mouthpiece portion 110, and binding ring 150 can be sized such that the outer surface of binding ring 150 is flush with the outer surface of the mouthpiece portion 110 when installed onto the assembled atomizer assembly 100. Binding ring 150 can additionally, or alternatively, be sized such that the outer surface of binding ring 150 is flush with the outer surface of the fluid reservoir portion 120 when installed onto the assembled atomizer assembly 100.

In some examples, the radially compressive force applied by binding ring 150 can be a sealing force that augments or otherwise works in cooperation with a press-fit or another type of attachment between the mouthpiece portion 110 and the fluid reservoir portion 120. For example, as mentioned above, the mouthpiece portion 110 and/or the fluid reservoir portion 120 can be formed from one or more plastics, polymers, etc., in which case a press-fit between the two assemblies can cause plastic (e.g., permanent) deformation at or about the location of the press-fit interface. This plastic deformation can enhance the binding strength of the press-fit, such that in some examples, the mouthpiece portion 110 cannot be manually separated from the fluid reservoir portion 120. However, the plastic deformation resulting from the press-fit between the mouthpiece portion 110 and the fluid reservoir portion 120 can also result in cracking or other damage, which can be cosmetic and/or structural. In some cases, cracking can result from the plastic-on-plastic press-fit interface that results when the mouthpiece portion 110 and the fluid reservoir portion 120 are formed from the same or like materials. For example, the press-fit can cause cracks to appear on the outer surface of the approximately cylindrical lower distal end of the mouthpiece portion 110. As such, binding ring 150 can be provided to contain and/or reinforce any cracks or other deformations that appear on the mouthpiece portion 110 when it is press-fit to the fluid reservoir portion 120. In some examples, one or more sealing gaskets can be included to provide a sealing force between the mouthpiece portion 110 and the fluid reservoir portion 120. For example, the sealing gaskets can include but are not limited to, O-rings formed from a rubber, plastic, polymer, etc., material, wherein a press-fit attachment between the mouthpiece portion 110 and the fluid reservoir portion 120 compresses the sealing gaskets into a corresponding receiving groove or channel on the outer surface of the fluid reservoir portion 120.

The fluid reservoir portion 120 is operable to form a reservoir volume 122 for storing and providing a fluid, oil, or other liquid (collectively referred to herein as a “fluid”) to one or more heating elements located within the atomizer 140 of the atomizer assembly 100. For example, as illustrated in FIGS. 1B, 2B, 2C, and 4A-4D, a reservoir volume 122 can be provided as the empty volume between the outer surface of the longitudinal vapor channel 124 and an inner surface of the housing 121 of the fluid reservoir portion 120. In some examples, the fluid reservoir 314 can comprise the empty volume given by the radial extent between the outer surface of longitudinal vapor channel 124 and the inner surface of the housing 121 of the fluid reservoir portion 120.

In some examples, the reservoir volume 122 can be at least partially open at its lower end, e.g., to permit filling of the reservoir volume 122 and/or to convey fluid from the reservoir volume 122 to a heating element (e.g., such as the heating element 240 of atomizer 140 shown in FIGS. 2A-2C). In use, the reservoir volume 122 can be isolated or otherwise sealed to prevent leaking or undesired discharge of any fluids it may contain. Accordingly, the fluid stored within the reservoir volume 122 can surround the longitudinal vapor channel 124 while being prevented from entering the longitudinal vapor channel 124 directly. For example, as will be explained in greater depth below, fluid can flow downward (e.g., out of the reservoir volume 122 of the fluid reservoir portion 120) to an atomizer 140 located opposite the mouthpiece 110 in relation to the fluid reservoir portion 120 (e.g., via the one or more fluid transfer openings 128 shown in FIGS. 1B, 2B, 4A, 4C, and 4D), where the fluid can then be vaporized and drawn back upward into the central longitudinal vapor channel 124.

For instance, the fluid flow from the reservoir volume 122 to atomizer 140 can be driven by gravity when the atomizer assembly 100 is in a substantially upright orientation (e.g., such as that depicted in FIGS. 1A-1C). In some example, gravitational forces can cause fluid to be fed from the reservoir volume 122 to one or more absorbent pads 130 disposed between the reservoir volume 122 and the atomizer 140. Upon the fluid interacting with or otherwise being absorbed by the one or more absorbent pads 130, capillary and/or wicking forces can convey the absorbed fluid from the one or more absorbent pads 130 to atomizer 140, as will be described in greater depth below. In some examples, although not depicted in the figures, one or more absorbent pads can additionally be provided between the atomizer 140 and the base portion 162. The one or more additional absorbent pads can be the same as or similar to the absorbent pads 130. For example, the additional absorbent pads can comprise a plurality of absorbent pads (e.g., such as the absorbent pads 130) arranged in a stack or layer that at least partially occupies the volume between the atomizer 140 and the base portion 162. In some cases, the additional absorbent pads can be of a same or similar thickness to that of the absorbent pads 130, with a smaller length and/or width than that of the absorbent pads 130. For example, the additional absorbent pads can be sized to fit within the volume between atomizer 140 and base portion 162.

Accordingly, in some examples, the longitudinal vapor channel 124 can be operable to receive vaporized fluid from atomizer 140. The vapor outlet channel 116 can be in communication with the longitudinal vapor channel 124 such that the vaporized fluid flows from the atomizer 140 into the longitudinal vapor channel 124 and then into the vapor outlet channel 116 of the mouthpiece 110 via the inlet port 118. The user can then access the vaporized fluid from the vapor outlet channel 116 via the outlet port 117.

In operation, fluid from the reservoir volume 122 can be vaporized by atomizer 140 (e.g., using a heating element such as the heating element 240 of FIGS. 2A-2C). Vapor produced by atomizer 140 can be conveyed to the longitudinal vapor channel 124 and the vapor outlet channel 116 via the coupling between the atomizer 140 and the fluid reservoir portion 120. From this coupling point, vapor enters and flows along the longitudinal length of longitudinal vapor channel 124 before ultimately exiting both the vapor outlet channel 116 and the atomizer assembly 100. As illustrated, in order for vaporized fluid to exit the vapor outlet channel 116, the mouthpiece portion 110 of atomizer assembly 100 can include at least one outlet port 117 for communicating vapor to a user of the atomizer assembly 100.

For example, FIGS. 3A-3E depict an outlet port 117 integrally formed with an outer wall of mouthpiece housing 112 of the mouthpiece portion 110. In some examples, outlet port 117 can comprise an aperture or other opening that extends through the otherwise closed surface of the outer wall of mouthpiece housing 112 of mouthpiece portion 110. As illustrated, outlet port 117 can be circular in shape and symmetrically aligned with respect to the central longitudinal axis of mouthpiece portion 110 and/or atomizer assembly 100, although other shapes, geometries, and/or alignments can also be utilized without departing from the scope of the present disclosure. For example, the outlet port 117 can have a size and shape that are chosen to match the size and shape of the vapor channel located within the mouthpiece portion 110 (e.g., the outlet port 117 can have a circular shape corresponding to the cylindrical shape of the vapor outlet channel 116). In some examples, the outlet port 117 can comprise an open upper end of the vapor outlet channel 116.

For example, the vapor outlet port 116 as seen in the cross-sectional view of FIG. 3D can include an open upper end of a longitudinally oriented vapor outlet channel 116, such that vapor outlet port 117 and vapor outlet channel 116 have the same (or a substantially similar) size and shape. As illustrated, vapor outlet channel 116 can connect the vapor outlet port 117 (e.g., located at the first distal end of the vapor outlet channel 116) to a vapor inlet port 118. Vapor inlet port 118 can be provided as an aperture or opening located at a second distal end of vapor outlet channel 116. In operation, vaporized fluid can enter vapor outlet channel 116 via the vapor inlet port 118, flow through the vapor outlet channel 116, and exit through the vapor outlet port 117.

Although not shown, in some examples the open distal end of reservoir volume 122 can be ring-shaped, e.g., provided as the open annular space surrounding the circular vapor inlet port 118 and/or the central longitudinal vapor channel 124.

For example, with reference to FIGS. 2A-2C, when the fluid reservoir portion 120 is attached to the atomizer 140, the annular open distal end of the reservoir volume 122 can be brought into contact with and sealed by the annular upper surface of the atomizer 140 upon which the plurality of fluid transfer openings 128 are disposed. In other words, the open annular distal end of the reservoir volume 122 can have a maximum radial width or diameter that is less than a maximum radial width or diameter of the annular upper surface of the atomizer 140 (e.g., the surface upon which the open distal end of the reservoir volume 122 is seated). In this manner, the open annular distal end of the reservoir volume 122 can be sealed to prevent any fluid leakage or fluid movement out of the reservoir volume 122, other than through the plurality of fluid transfer openings 128 defined on the bottom end of the fluid reservoir portion 120.

As illustrated, the plurality of fluid transfer openings 128 can include seven circular openings arranged on the lower surface of the fluid reservoir portion 120, although a greater or lesser number of fluid transfer openings 128 may also be utilized without departing from the scope of the present disclosure. For example, in some examples the plurality of fluid transfer openings 128 can comprise six circular openings. In some examples, the plurality of fluid transfer openings 128 can include five or less circular openings. In some cases, the fluid transfer openings 128 can be provided as two or more slots or rectangular openings, etc. It is further noted that the plurality of fluid transfer openings 128 can be arranged symmetrically or asymmetrically on the lower surface of the fluid reservoir portion 120. Similarly, one or more different shapes, sizes, and/or geometries, etc., can be utilized by one or more of the plurality of fluid transfer openings 128 without departing from the scope of the present disclosure. In some examples, each of the plurality of fluid transfer openings 128 can have a same diameter. In some cases, the size or diameter of the plurality of fluid transfer openings 128 can be based on characteristics of the fluid or oil that may be used (e.g., viscosity, etc.) and/or desired fluid handling and delivery with respect to the atomizer. For example, a larger diameter can be used for one or more of the fluid transfer openings 128 when a relatively high viscosity fluid will be used and/or when a relatively high fluid flow rate through the fluid transfer openings 128 is desired. Similarly, a smaller diameter can be used for one or more of the fluid transfer openings 128 when a relatively low viscosity fluid will be used and/or when a relatively low fluid flow rate through the fluid transfer openings 128 is desired.

In some examples, a total open surface area can be distributed across the plurality of fluid transfer openings 128, either symmetrically or asymmetrically. For example, the plurality of fluid transfer openings 128 can each have a size or surface area (e.g., based on each opening diameter) and be provided in sufficient quantity to provide a total surface contact area of a given value. For example, a total surface contact area of 12.6 mm² can be achieved by using four fluid transfer openings 128 that are each circles having a diameter of 2 mm. The same total surface contact area of 12.6 mm² can also be achieved by using six fluid transfer openings 128 that are each circles having a diameter of approximately 1.6 mm.

In some examples, the total surface contact area can be between 1 mm² and 15 mm². For example, in some examples a total surface contact area of 1 mm² can be provided by using two fluid transfer openings 128 that are each circles having a diameter of 1 mm. As mentioned previously, the total surface contact area provided by the plurality of fluid transfer openings 128 and/or the quantity of the plurality of fluid transfer openings 128 can be based at least in part on a viscosity of a fluid that will be used in the atomizer assembly 100 or stored in the reservoir volume 122. For example, for a high viscosity (and/or high purity) fluid or oil, the plurality of fluid transfer openings 128 may comprise a total of four fluid transfer openings that are each circles having a diameter of 2 mm. In some examples, for a lower viscosity (and/or lower purity) fluid or oil, the plurality of fluid transfer openings 128 may comprise a total of two fluid transfer openings that are each circles having a diameter of 1 mm. In some examples, the plurality of fluid transfer openings 128 can comprise a total of six fluid transfer openings that provide a total surface contact area of approximately 15 mm².

In some examples, the plurality of fluid transfer openings 128 can be configured based on viscosity and/or other material properties of a fluid that will be stored in the reservoir volume 122. In some cases, the plurality of fluid transfer openings 128 can be configured based on a type of fluid that may be stored in the reservoir volume 122. For example, as illustrated in FIGS. 4C and 4D, the plurality of fluid transfer openings 128 can include a chamfered or beveled edge on their upper surface (e.g., the upper surface where fluid first passes from the reservoir volume 122 and into the fluid transfer openings 128). In some examples, a chamfered edge can be provided on the plurality of fluid transfer openings 128 based at least in part on an expectation that a high-viscosity fluid will be stored in the reservoir volume 122, and therefore that the high-viscosity fluid will be conveyed through the fluid transfer openings 128. In some examples, the inclusion of chamfered and/or beveled edges on the plurality of fluid transfer openings 128 can improve the flow characteristics of fluids that are conveyed from the reservoir volume 122 and through the plurality of fluid transfer openings 128. For example, high viscosity fluids such as oils may exhibit poor flow characteristics when the fluid transfer openings 128 are provided with a 90-degree edge (e.g., in the absence of a chamfered or beveled edge).

Fluid can be conveyed from the reservoir volume 122 to an atomizer 140 via one or more of the plurality of fluid transfer openings 128. As illustrated, atomizer 140 can be coupled with and positioned below the fluid reservoir portion 120 along the central longitudinal axis of the fluid reservoir portion 120 (e.g., opposite the mouthpiece 110 in relation to the fluid reservoir portion 120). When assembled, the mouthpiece portion 110 can be disposed above the reservoir volume 122 and the atomizer assembly 140, along the central longitudinal axis of the fluid reservoir portion 120. Accordingly, the atomizer 140 can include an underfeeder design, as the atomizer 140 pulls the fluid from the bottom of the reservoir volume 122 through the fluid transfer openings 128. For example, with an underfeeder design, the fluid is conveyed from the reservoir volume 122 disposed longitudinally above the underfeeder atomizer 140 to an upper surface of the underfeeder atomizer 140. In some examples, the atomizer 140 extracts the fluid via the absorbent pads 130 and is not in direct contact with the reservoir volume 122. One or more fluid absorbent pads 130 can be included, for example provided between an upper surface of atomizer 140 and a lower surface of the plurality of fluid transfer openings 128. In some examples, at least two fluid absorbent pads 130 can be provided to absorb fluid from the reservoir volume 122 and transfer the absorbed fluid to atomizer 140.

The absorbent pads 130 can sit on or otherwise make contact with an upper surface of the atomizer 140, such that the absorbent pads 130 can convey fluid to atomizer 140 based at least in part on this contact area. In some examples, the absorbent pads 130 can store (e.g., absorb) a volume of fluid that depends at least in part on factors such as the total surface area provided by the absorbent pads 13, the total thickness of the absorbent pads 130, etc. As illustrated, the absorbent pads 130 can be circular or ring-shaped, with a central hole that is aligned with one or more of the central longitudinal vapor channel 124 of the fluid reservoir portion 120 and/or a central longitudinal channel of the atomizer 140.

In some examples, atomizer 140 can comprise a ceramic material. In some examples, the ceramic material can itself absorb and/or store fluid, such as the fluid(s) that may be contained in the reservoir volume 122. Although the ceramic material of atomizer 140 can absorb fluid directly, in some examples absorbent pads 130 can be provided between atomizer 140 and the reservoir volume 122 to increase or otherwise enhance the efficacy of fluid absorption/conveyance into the ceramic material of atomizer 140. For example, the ceramic material of atomizer 140 can have a smaller total surface area for fluid absorption in comparison to that of the absorbent pads 130, in which case the use of absorbent pads 130 allows a greater volume of fluid to be conveyed into the ceramic material of atomizer 140. In some cases, the ceramic material of atomizer 140 may dry out too quickly in the absence of the absorbent pads 130, either from an evaporative drying and/or as fluid is consumed from the ceramic material of atomizer 140 and vaporized. As such, the fibrous material of the absorbent pads 130 can provide a consistent and reliable conduit for fluid to travel from the reservoir volume 122 to the atomizer 140, whereupon the fluid can become embedded in the ceramic material of atomizer 140 until the embedded fluid is subsequently vaporized.

In some examples, heating element 240 can include a ceramic material with a porosity between 60-70%, although other porosity values and/or ceramic materials can also be utilized without departing from the scope of the present disclosure. In some examples, the heating element 240 can comprise a ceramic material with a higher porosity (e.g., 70-80%). A higher porosity ceramic material can be associated with an improved taste or flavor of vapor produced by atomizer 500; however, a higher porosity ceramic material can also be associated with increased fragility and/or decreased manufacturing and assembly yield(s). In some examples, the heating element 240 can comprise a ceramic material having a porosity between 45-65%, with such porosity values providing a balance between manufacturability and vapor taste, although it is again noted that other porosity values and/or ceramic materials can be utilized without departing from the scope of the present disclosure.

In some examples, the ceramic material of the heating element 240 can itself act as a fluid reservoir, e.g., in addition to or separate from the dedicated reservoir volume 122. In some examples, the ceramic material of the heating element 240 can store a volume of fluid sufficient to ‘feed’ or otherwise maintain a steady fluid supply to the heating element 240 for one or more vaporization cycles. In other words, the ceramic material of the heating element 240 can be sized to store/absorb a volume of fluid that is sufficient for heating element 240 to produce vapor for at least one full inhalation by a user of the presently disclosed atomizer assembly. Accordingly, in some examples it is contemplated that the heating element 240 can be provided in various geometric shapes and configurations other than the multi-diameter stepped cylindrical shape(s) illustrated herein, without departing from the scope of the present disclosure. In some examples, the heating element 240 can be provided with a flanged or plug-like cylindrical shape, without departing from the scope of the present disclosure.

In some examples, the heating element 240 can be provided with a different geometric shape, configuration, etc., having a substantially same or similar total volume (e.g., fluid absorption capacity) as the multi-diameter stepped cylindrical atomizer(s) 140. For example, one or more of the atomizers 140 or heating elements 240 can be provided with a constant cylindrical diameter, a continuously changing or tapering diameter, a conical shape, etc. In some examples, an internal diameter of atomizer vapor channel (e.g., the channel running along the central longitudinal axis of the heating element 240) can be variable along its longitudinal length. For instance, the internal diameter of atomizer vapor channel can vary with an outer diameter of the heating element 240, although it is also possible for the internal diameter of atomizer vapor channel to vary independently from the outer diameter (or any other dimension) of the heating element 240.

As illustrated, heating element 240 of the atomizer 140 includes an upper surface, which can be brought into contact with one or more absorbent pads, such as the absorbent pads 130. As described previously, the absorbent pads can be used to convey fluid from the reservoir volume 122 to the atomizer 140. In some examples, fluid can be initially absorbed into the upper surface of the heating element 240 and subsequently distributed throughout the interior of the ceramic material of the heating element 240 (e.g., the absorbent pads 130 can be placed in contact with only the upper surface of the heating element 240). In examples in which the ceramic material of the heating element 240 stores enough fluid to produce vapor for multiple full inhalations by a user, the absorbent pads 130 can be provided with a relatively small size and/or total absorptive volume—e.g., the absorbent pads can be sized to maintain a constant fluid supply to ‘recharge’ or ‘feed’ the ceramic core of the heating element 240, even if the absorbent pads themselves do not store enough fluid to produce vapor for a full inhalation. In some examples one or more additional absorbent pads can be provided about the outer surface of the heating element 240. For example, one or more additional absorbent pads can be provided between the two electrical leads 245 extending from the distal end of the heating element 240, such that at least a portion of the absorbent pad material makes contact with the distal end of the heating element 240 (e.g., the distal end of the heating element 240 to which the electrical leads 245 are coupled).

The heating element 240 can include or more resistive heating elements, e.g., which generate heat in response to the application of electrical power. In some examples, the heating element 240 can include electrical leads 245 for coupling electrical power to the heating element 240. The electrical leads 245 can receive electrical power from one or more internal power sources and/or external power sources. For example, an internal power source can be provided by one or more batteries included in the atomizer assembly described herein (e.g., an internal battery included in atomizer assembly 100). In some examples, the electrical leads 245 can receive electrical power from an external power source, such as a battery included in an electronic cigarette body, vaporizer body, or other body components to which the cartridge assembly described herein (such as atomizer assembly 100) can be attached to for use.

In some examples, the atomizer support structure 246 can be received within a threaded base 162. For example, atomizer support structure 246 can be attached to threaded base 162 via a press-fit, an internally threaded engagement, etc. The threaded base 162 can include an externally threaded portion, shown here as being provided at a distal lower end of the threaded base 162. As described previously, a threaded base portion such as threaded base 162 can be used to removably couple the atomizer assembly described herein to an electronic cigarette or other vaporizer body. Accordingly, in some examples threaded base 162 can include one or more battery leads (not depicted) for electrically coupling the electrical leads 645 of atomizer 140 to a battery or other power source provided by an electronic cigarette or other vaporizer body to which the threaded base 162 is attached. For instance, an interior of threaded base 162 can include one or more battery leads to electrically couple electrical leads 245 of atomizer 140 to a battery located within an electronic cigarette or vaporizer body.

By providing heating element 240 at or near the center of mass of the ceramic core of atomizer 140, fluid embedded within the ceramic material can be drawn more evenly towards the inner surface of atomizer vapor channel (e.g., because heating element 240 vaporizes fluid near the inner surface of atomizer vapor channel). In some examples, by providing heating element 240 at or near the center of mass of the ceramic core of atomizer 140, embedded or absorbed fluid within the ceramic core of atomizer 140 can be consumed (e.g., vaporized) by heating element 240 in an approximately radially symmetric fashion. The radially symmetric consumption of fluid from the ceramic core of atomizer 140 by heating element 240 can help avoid or otherwise minimize the presence of ‘dead spots.’ For example, dead spots can occur where fluid stagnates within the ceramic material of atomizer 140 rather than flowing to the inner surface of atomizer vapor channel where the fluid can be consumed and vaporized by heating element 240 (e.g., the consumption of fluid from the ceramic material of atomizer 140 causes fresh fluid to be drawn into the ceramic material, whereupon the cycle of fluid consumption/vaporization by heating element 240 can repeat). In some examples, the ceramic core of atomizer 140, the atomizer vapor channel, and/or the heating element 240 can be designed to avoid stagnation spots by causing heating element 240 to consume and vaporize fluid in an approximately first-in-first-out fashion, wherein fluid is vaporized by heating element 240 in approximately the order in which the fluid was absorbed into the ceramic core of atomizer 140.

FIGS. 2A-2C also illustrate an air inlet plug 247 and an air inlet regulator 274 (e.g., pressure regulator), which can be installed in an open distal end of threaded base 162 (e.g., in the orientation shown in FIGS. 2A-2C, the open bottom end of threaded base 162). Air inlet regulator 274 can include one or more air inlet holes or openings, which in some examples can be brought into alignment with one or more corresponding holes or openings disposed on an outer surface of threaded base 162. For example, air inlet regulator 274 (and therefore, threaded base 162) can include four symmetrically arranged air inlet holes or openings, although different quantities, sizes, and/or shapes of the air inlet holes or openings can be utilized without departing from the scope of the present disclosure.

Air inlet plug 247 can have a maximum outer diameter that is greater than a maximum outer diameter of air inlet regulator 274. In some examples, the outer diameter of air inlet plug 247 can be selected to adapt the outer diameter of air inlet regulator 274 to the relatively larger internal diameter of threaded base 162, e.g., such that air inlet regulator 274 when installed into air inlet plug 247 forms a seal against the inner surface of threaded base 162. In some examples, the seal formed between the inner surface of threaded base 162 and air inlet plug 247 can form a fluid trap within threaded base 162, which can catch any excess fluid that may drip from or otherwise be exuded by the ceramic material of the atomizer 140. For example, when air inlet plug 247 and air inlet regulator 274 are installed into the threaded base 162, a fluid trap volume can be defined along the longitudinal distance running from a lower-most extent given by the flanged base of air inlet plug 247 to an upper-most extent given by the air inlet holes or openings of air inlet regulator 274.

In operation, air inlet regulator 274 can include air inlet holes or openings that permit atmospheric or environmental air (e.g., from the ambient environment surrounding atomizer assembly 100) to enter the atomizer assembly 100 and carry away vapor produced by atomizer 140. For example, when a user inhales from the atomizer assembly 100, a volume of ambient air approximately equal to the volume of the user's inhalation can enter atomizer assembly via the air inlet holes or opening of air inlet regulator 274. In some examples, the quantity, size and/or diameter of the air inlet holes/or openings provided on air inlet regulator 274 can be restricted such that, when a user inhales from atomizer assembly 100, a pressure differential can be created or otherwise maintained between the ambient atmosphere and the internal volume of atomizer assembly 100.

In some examples, a volumetric flow rate of ambient air through the air inlet regulator 274 during use of the atomizer assembly 100 can be chosen to improve the taste or flavor of the vaporized fluid produced by atomizer assembly 100. For instance, a greater volumetric flow rate of ambient air can lower one or more of a temperature at which fluid is vaporized by atomizer 140 and/or a temperature of the vapor conveyed to a user of atomizer assembly 100. Accordingly, air inlet regulator 274 can be designed to provide a desired volumetric flow rate known to correspond to a desired vaporization temperature or vaporization temperature range. In some examples, the volumetric flow rate of ambient air through air inlet regulator 274 can be chosen to achieve a desired flavor intensity, e.g., the same amount of vaporized fluid carried in a greater volume of ambient air can result in a flavor that is milder or smoother than the same amount of vaporized fluid when carried in a smaller volume of ambient air.

As shown in FIGS. 2C, 3A, 3B, and 3E, the mouthpiece portion 110 can include one or more radial vent channels 1100. In some examples, the radial vent channels 1100 can be disposed towards the inlet port 118 at the second distal end of the mouthpiece 110. The radial vent channels 1100 can include press-regulating radial vent channels which are configured to provide pressure relief to the reservoir volume 122 while in a first position (e.g., when the fluid reservoir portion 120 is first engaging with the mouthpiece 110 and does not block the radial vent channels 1100) and configured to provide pressurization of the reservoir volume 122 while in a second position (e.g., when the fluid reservoir portion 120 blocks the radial vent channels 1100 to prevent air from flowing into and through the radial vent channels 1100) longitudinally different than the first position.

The radial vent channels 1100 enable the mouthpiece 110 to engage with and couple with the fluid reservoir portion 120 and prevent fluid in the reservoir volume 122 to undesirably be pressurized and pushed into the atomizer 140. When the mouthpiece 110 is initially engaged with the fluid reservoir portion 120 to couple the mouthpiece 110 with the reservoir portion 120, the air above the fluid in the reservoir portion 122 is pushed down towards the fluid. If not vented, that air can compress the fluid and push the fluid out of the reservoir portion 122 into the atomizer 140, undesirably. The radial vent channels 1100 provide an outlet for the air to vent so that the fluid is not compressed and remains in the reservoir volume 122 until the atomizer assembly 100 is in operation. The mouthpiece 110 can then be fit onto the fluid reservoir portion 120.

In some examples, to couple the mouthpiece 110 with the fluid reservoir portion 120, the inlet port 118 at the second distal end of the mouthpiece portion 110 can be configured to couple to the longitudinal vapor channel 124 of the fluid reservoir portion 120. For example, as illustrated in FIGS. 1B, 2A-2C, 3D, and 4A-4C, the inlet port 118 at the second distal end of the mouthpiece portion 110 can include a female receptacle 119 that is configured to receive a corresponding male coupler 125 of the longitudinal vapor channel 124 of the fluid reservoir portion 120. In at least one example, the female receptacle 119 can be in communication with the inlet port 118 of the mouthpiece portion 110. In some examples, the male coupler 125 can include a wall that spans between the reservoir volume 122 and the longitudinal vapor channel 124, and forms the longitudinal vapor channel 124. In some examples, the male coupler 125 can extend past the housing 121 of the fluid reservoir portion 120. For example, the female receptacle 119 and the corresponding male coupler 125 can be associated with a coupling length in the longitudinal direction. The coupling length can include the longitudinal length of the female receptacle 119 on the mouthpiece portion 110 that couples around the male coupler 125 forming the longitudinal vapor channel 124 of the fluid reservoir portion 120.

The radial vent channels 1100 are configured to connect the vapor outlet channel 116 with external the mouthpiece portion 110. Accordingly, when the mouthpiece portion 110 is engaging with the fluid reservoir portion 120, the radial vent channels 1100 can connect the reservoir volume 122 external to the mouthpiece portion 110 with the vapor outlet channel 116. Air can then vent from the reservoir volume 122 into the vapor outlet channel 116 and out the outlet port 117.

In some examples, as illustrated herein, the radial vent channels 1100 can be disposed along the longitudinal coupling length of the female receptacle 119 of the mouthpiece portion 110. In some examples, the radial vent channels 1100 can be disposed on opposing sides of the mouthpiece portion 110. When the male coupler 125 of the fluid reservoir portion 120 is initially inserted into the female receptacle 119 of the mouthpiece portion 110, the radial vent channels 1100 can be operable to enable air to vent from the reservoir volume and into the vapor outlet channel 116 of the mouthpiece portion 110. Upon further engagement, when the male coupler 125 of the fluid reservoir portion 120 is subsequently inserted beyond the radial vent channels 1100 in communication with the female receptacle 119, air is prevented from venting from the reservoir volume 122 and into the vapor outlet channel 116. For example, the male coupler 125, when fully engaged with the female receptacle 119, is operable to block the radial vent channels 1100 such that air and/or fluid from the reservoir volume 122 does not pass into the radial vent channels 1100 into the vapor outlet channel 116. This can prevent leakage of the fluid during operation of the atomizer assembly 100. When the male coupler 125 prevents fluid communication of the reservoir volume 122 with the radial vent channels 1100, the fluid provided in the reservoir volume 122 is pressurized by further inserting the male coupler 125 while the radial vent channels 1100 are blocked. The pressurization of the fluid in the reservoir volume 122 allows the fluid to be drawn out of the reservoir volume 122 towards the atomizer 140 to be vaporized.

The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the appended claims.

Claims

1. An atomizer assembly comprising:

a mouthpiece portion including a vapor outlet channel and one or more radial vent channels in communication with the vapor outlet channel;

a fluid reservoir portion including a longitudinal vapor channel and a reservoir volume, wherein: the longitudinal vapor channel is disposed along a central longitudinal axis of the fluid reservoir portion; and the reservoir volume operable to receive a fluid; and

an atomizer configured to receive the fluid stored in the reservoir volume of the fluid reservoir portion, wherein the atomizer includes at least one heating element for vaporizing the fluid received from the reservoir volume.

2. The atomizer assembly of claim 1, wherein an inlet port at a second distal end of the mouthpiece portion is configured to couple to the longitudinal vapor channel of the fluid reservoir portion.

3. The atomizer assembly of claim 2, wherein the inlet port of the mouthpiece portion is in communication with a female receptacle configured to receive a corresponding male coupler of the fluid reservoir portion.

4. The atomizer assembly of claim 3, wherein the coupling comprises a press-fit based on longitudinally inserting the male coupler into the female receptacle.

5. The atomizer assembly of claim 3, wherein the female receptacle and the corresponding male coupler are associated with a longitudinal coupling length.

6. The atomizer assembly of claim 5, wherein the one or more radial vent channels connect the vapor outlet channel with external the mouthpiece portion.

7. The atomizer assembly of claim 6, wherein the one or more radial vent channels are disposed along the longitudinal coupling length of the female receptacle of the mouthpiece portion, such that:

when the male coupler of the fluid reservoir portion is initially inserted into the female receptacle of the mouthpiece portion, the one or more radial vent channels allow air to vent from the reservoir volume and into the vapor outlet channel of the mouthpiece portion; and

when the male coupler of the fluid reservoir portion is subsequently inserted beyond the radial vent channels in communication with the female receptacle, air is prevented from venting from the reservoir volume and into the vapor outlet channel.

8. The atomizer assembly of claim 7, wherein the fluid provided in the reservoir volume is pressurized by further inserting the male coupler while the one or more radial vent channels are blocked.

9. The atomizer assembly of claim 1, wherein the one or more radial vent channels included on the mouthpiece portion include pressure-regulating radial vent channels, configured to provide pressure relief to the reservoir volume while in a first position and configured to provide pressurization of the reservoir volume while in a second position longitudinally different than the first position.

10. The atomizer assembly of claim 1, wherein:

the mouthpiece portion is coupled to a first distal end of the fluid reservoir portion; and

the atomizer is coupled to a second distal end of the fluid reservoir portion, the second distal end opposite from the first distal end.

11. The atomizer assembly of claim 1, wherein the atomizer is disposed beneath the reservoir volume, along the central longitudinal axis of the fluid reservoir portion.

12. The atomizer assembly of claim 11, wherein the mouthpiece portion is disposed above the reservoir volume and the atomizer assembly, along the central longitudinal axis of the fluid reservoir portion.

13. The atomizer assembly of claim 1, wherein the atomizer comprises an underfeeder design.

14. The atomizer assembly of claim 13, wherein the fluid is conveyed from the reservoir volume disposed longitudinally above the underfeeder atomizer to an upper surface of the underfeeder atomizer.

15. A mouthpiece for an atomizer assembly, the mouthpiece comprising:

a mouthpiece housing;

a vapor outlet channel formed through the mouthpiece housing between an outlet port and an inlet port, the inlet port operable to receive vaporized fluid from a longitudinal vapor channel of a fluid reservoir portion of the atomizer assembly;

one or more radial vent channels in communication with the vapor outlet channel; and

a female receptacle in communication with the one or more radial vent channels, the female receptacle operable to receive a male coupler of the fluid reservoir portion.

16. The mouthpiece of claim 15, further comprising the outlet port at a first distal end of the mouthpiece portion and the inlet port in communication with the female receptacle, the inlet port is configured to couple to a longitudinal vapor channel of the fluid reservoir portion.

17. The mouthpiece of claim 16, wherein the inlet port of the mouthpiece portion is in communication with the female receptacle configured to receive the corresponding male coupler of the fluid reservoir portion.

18. The mouthpiece of claim 15, wherein the one or more radial vent channels connect the vapor outlet channel with external the mouthpiece portion.

19. The mouthpiece of claim 15, wherein the one or more radial vent channels are disposed along a longitudinal coupling length of the female receptacle of the mouthpiece portion, such that:

when the male coupler of the fluid reservoir portion is initially inserted into the female receptacle of the mouthpiece portion, the one or more radial vent channels allow air to vent from a reservoir volume and into the vapor outlet channel of the mouthpiece portion; and

when the male coupler of the fluid reservoir portion is subsequently inserted beyond the radial vent channels in communication with the female receptacle, air is prevented from venting from the reservoir volume and into the vapor outlet channel.

20. The mouthpiece of claim 15, wherein the one or more radial vent channels included on the mouthpiece portion include pressure-regulating radial vent channels, configured to provide pressure relief to a reservoir volume while in a first position and configured to provide pressurization of the reservoir volume while in a second position longitudinally different than the first position.