JP7662485B2 - Cartridges for Vaporizer Devices - Google Patents

Description

RELATED APPLICATIONS This application is related to U.S. Provisional Application No. 62/915,005, filed October 14, 2019, entitled "CARTRIDGE FOR A VAPORIZER DEVICE," U.S. Provisional Application No. 62/812,161, filed February 28, 2019, entitled "CARTRIDGE FOR A VAPORIZER DEVICE," U.S. Provisional Application No. 62/747,099, filed October 17, 2018, entitled "WICK SUPPLY AND HEATING ELEMENT FOR VAPORIZER DEVICE," U.S. Provisional Application No. 62/812,148, filed February 28, 2019, entitled "OVERFLOW CONTROL FOR RESERVOIRS WITH CONSTRAINED POINTS," U.S. Provisional Application No. This application claims priority to U.S. Provisional Application No. 62/747,055, entitled "Reservoir Overflow Control," filed on October 17, 2018, U.S. Provisional Application No. 62/747,130, entitled "Evaporator Concentrate Recovery and Recycling," filed on October 17, 2018, U.S. Provisional Application No. 62/913,135, entitled "Heating Elements," filed on October 9, 2019, and U.S. Provisional Application No. 16/653,455, entitled "Heating Elements," filed on October 15, 2019, each of which is incorporated by reference in its entirety herein to the extent permitted by law.

TECHNICAL FIELD The disclosed inventions relate generally to mechanisms for cartridges for vaporization devices and, in some instances, to managing leakage of liquid vaporizable material, controlling airflow within and near the cartridge, forming an aerosol by heating the vaporizable material, and/or other assembly mechanisms between the cartridge and a device to which the cartridge is detachably connected.

Vaporizer devices, generally referred to herein as vaporizers, include devices that heat a vaporizable material (e.g., liquids, plant materials, other solids, waxes, etc.) to a temperature sufficient to release one or more compounds from the vaporizable material in a form (e.g., gas, aerosol, etc.) that can be inhaled by a user of the vaporizer. Some vaporizers, such as those in which at least one of the compounds released from the vaporizable material is nicotine, are useful as an alternative to smoking combustible tobacco.

SUMMARY OF THE DISCLOSURE For purposes of summary, certain aspects, advantages, and novel features have been described herein. It is to be understood that not all such advantages are achieved by one particular embodiment. Thus, the disclosed invention may be embodied or performed in a manner that achieves or optimizes one advantage or group of advantages without achieving all advantages that may be taught or suggested herein. The various features and items described herein may be combined together or separated, except where not feasible based on the present disclosure and what one skilled in the art would understand therefrom.

In one aspect, the vaporizer includes a reservoir configured to contain a liquid vaporizable material. The reservoir is at least partially defined by at least one wall, the reservoir including a storage chamber and an overflow volume. The vaporizer further includes a collector disposed within the overflow volume. The collector includes a capillary structure configured to hold a volume of the liquid vaporizable material in fluid contact with the storage chamber. The capillary structure includes a microfluidic mechanism configured to prevent air and liquid from bypassing each other during filling and draining of the collector.

In a related aspect that may be included in the vaporizer of the aforementioned aspect, a microfluidic gate for controlling the flow of liquid vaporizable material between a reservoir and an adjacent overflow volume in the vaporizer includes a plurality of openings connecting the reservoir and a collector and a pinch-off point between the plurality of openings. The plurality of openings includes a first channel and a second channel. The first channel has a higher capillary driving force than the second channel. Optionally, the microfluidic gate may include an edge of the opening between the reservoir and the collector, where a first side facing the reservoir is flatter than a second, more rounded side facing the collector.

In another interrelated aspect that can be incorporated into other aspects, a collector configured for insertion into a vaporizer cartridge includes a capillary structure configured to hold a volume of liquid vaporizable material in fluid contact with a reservoir of the vaporizer cartridge. The capillary structure includes microfluidic features configured to prevent air and liquid from bypassing each other during filling and draining of the collector.

In optional variations, one or more of the following features may also be included in the workable combination. For example, a primary passageway may be included to provide a fluid connection between the storage chamber and an atomizer configured to convert the liquid vaporizable material to a gaseous state. The primary passageway may be formed through the structure of the collector.

The primary passageway may include a first channel configured to allow the liquid vaporizable material to flow from the reservoir toward the wicking element of the atomizer. The first channel may have a cross-sectional shape with at least one irregularity configured to allow liquid in the first channel to bypass an air bubble blocking the remainder of the first channel. The cross-sectional shape may resemble a cross. The capillary structure may include a secondary passageway including a microfluidic feature, which may be configured to allow the liquid vaporizable material to move along the length of the secondary passageway with only a meniscus completely covering the cross-sectional area of the secondary passageway. The cross-sectional area may be small enough that for the material from which the walls of the secondary passageway are formed and the composition of the liquid vaporizable material, the liquid vaporizable material preferentially wets the secondary passageway around the entire circumference of the secondary passageway.

The storage chamber and collector may be configured to maintain a continuous column of liquid vaporizable material in the collector in contact with the liquid vaporizable material in the storage chamber such that a reduction in pressure in the storage chamber relative to ambient pressure causes the continuous column of liquid vaporizable material in the collector to be drawn at least partially back into the storage chamber. The secondary passage may include a plurality of spaced apart constriction points having a smaller cross-sectional area than the portion of the secondary passage between the constriction points. The constriction points may have flatter surfaces oriented along the secondary passage toward the storage compartment and rounder surfaces oriented along the secondary passage away from the storage compartment.

A microfluidic gate can be disposed between the collector and the storage compartment. The microfluidic gate can include an edge of an opening between the storage compartment and the collector, with a first side facing the storage compartment being flatter than a second, more rounded side facing the collector. The microfluidic gate can include a plurality of openings connecting the storage compartment and the collector, and a pinch-off point between the plurality of openings. The plurality of openings can include a first channel and a second channel, the first channel having a higher capillary drive than the second channel. A meniscus of the gas-liquid vaporizable material reaching the pinch-off point can be directed to the second channel by the higher capillary drive of the first channel such that a gas bubble is formed and escapes to the liquid vaporizable material in the storage compartment.

The liquid vaporizable material may include one or more of propylene glycol and vegetable glycerin.

The collector may include a primary passageway providing a fluid connection between the reservoir and an atomizer configured to convert the liquid vaporizable material to a gaseous state, the primary passageway being formed through a structure of the collector. In an optional variation, the capillary structure may include a secondary passageway including a microfluidic mechanism configured to allow the liquid vaporizable material to move along the length of the secondary passageway with only a meniscus completely covering the cross-sectional area of the secondary passageway. The cross-sectional area may be sufficiently small for the material from which the walls of the secondary passageway are formed and the composition of the liquid vaporizable material such that the liquid vaporizable material preferentially wets the secondary passageway around the entire circumference of the secondary passageway. The reservoir and collector may be configured to maintain a continuous column of liquid vaporizable material in the collector in contact with the liquid vaporizable material in the reservoir such that a reduction in pressure in the reservoir chamber relative to the surrounding pressure causes the continuous column of liquid vaporizable material in the collector to be at least partially drawn back into the reservoir chamber. The secondary passageway may include a plurality of spaced constriction points having a smaller cross-sectional area than the portion of the secondary passageway between the constriction points. The constriction point may have a flatter surface directed along the secondary passage towards the storage compartment and a rounder surface directed along the secondary passage away from the storage compartment.

In yet another related aspect, a vaporizer cartridge includes a cartridge housing, a reservoir disposed within the cartridge housing and configured to contain a liquid vaporizable material, an inlet configured to allow air to enter an internal airflow path within the cartridge housing, an atomizer configured to convert at least a portion of the liquid vaporizable material to an inhalable state, and a collector as described in the previous aspect.

In an optional variation, such a vaporizer cartridge may include one or more features described herein, such as, for example, a wicking element disposed within the internal airflow path and in fluid communication with the reservoir. The wicking element may be configured to draw the liquid vaporizable material from the reservoir under capillary action. The heating element may be arranged to cause heating of the wicking element to convert at least a portion of the liquid vaporizable material drawn from the reservoir to a gaseous state. The inhalable state may include an aerosol formed by condensing at least a portion of the liquid vaporizable material from the gaseous state. The cartridge housing may include a monolithic hollow structure having a first open end and a second end opposite the first end. The collector may be insertably received within the first end of the monolithic hollow structure.

In yet another interrelated aspect, a reservoir for a cartridge usable in a vaporizer device is provided. In one embodiment, the reservoir includes a storage chamber (e.g., a reservoir) for storing a vaporizable material, and an overflow volume separable from the storage chamber and in communication with the storage chamber via a vent opening to a passageway in the overflow volume.

The passageway of the overflow volume may lead to a port connected to the ambient air. The storage chamber or reservoir may include a first wick supply and optionally a second wick supply, implemented in the form of a first cavity and a second cavity, respectively, through a collector disposed in the cartridge. The collector may include one or more support structures forming a passageway in the overflow volume. The first and second cavities may control the flow of vaporizable material toward a wick housing configured to receive a wicking element.

The wicking element disposed in the wick housing or wicking element housing may be configured to absorb vaporizable material passing through the first and second wick supplies such that upon thermal interaction with the atomizer, the vaporizable material absorbed in the wicking element is converted to at least one of a vapor or an aerosol and flows through an outlet tunnel structure formed through the collector and the storage chamber to an opening in the mouthpiece. The mouthpiece may be formed in close proximity to the storage chamber.

The collector may have a first end and a second end. The first end may be coupled to an opening in the mouthpiece, and the second end opposite the first end may be configured to accommodate a wick or wicking element. A wick housing according to certain embodiments may include a set of prongs projecting outwardly from the second end for at least partially receiving the wicking element, and one or more compression ribs disposed near the first or second wick supply and extending from the second end of the collector for compressing the wicking element.

In yet another interrelated aspect, a vent may be provided to maintain an equilibrium pressure condition in the reservoir of the cartridge and prevent the pressure in the reservoir from increasing to a point where the vaporizable material would overflow the wick housing. The equilibrium pressure condition may be maintained by establishing a liquid seal at the opening of the vent located at the point where the reservoir communicates with a passage in the overflow volume of the cartridge. A liquid seal is established and maintained at the vent by maintaining sufficient capillary pressure to cause a meniscus of vaporizable material to form in the portion of the vent that opens into the passage in the overflow volume.

The capillary pressure of the meniscus of the vaporizable material is controlled, for example, by a vent structure forming a primary or secondary channel that effectively creates a fluid valve to control at least the pinch-off point of one of the primary or secondary channels. Depending on the embodiment, the primary and secondary channels are tapered such that as the meniscus continues to recede, the capillary drive of the primary channel decreases more than the capillary drive of the secondary channel. The gradual reduction in capillary drive of the primary and secondary channels reduces the partial headspace vacuum maintained in the reservoir chamber.

In yet another interrelated aspect, the capillary drive of the primary and secondary channels gradually reduces one another, resulting in the primary channel's drain pressure falling below the secondary channel's drain pressure. The primary channel's meniscus continues to drain as the primary channel's drain pressure changes, while the secondary channel's meniscus remains stationary. The drainage pressure associated with the primary channel's receding contact angle is lower than the flooding pressure associated with the secondary channel's advancing contact angle, which can result in the primary and secondary channels filling with vaporizable material.

Thus, in response to an increase in pressure conditions within the reservoir, vaporizable material flows through the vent into the collector passage (i.e., the overflow volume), and the vent is configured to maintain a liquid seal at the pinch-off point, desirably at all times. In certain embodiments, the vent is constructed to promote a liquid seal at the opening from which vaporizable material flows between the reservoir reservoir and the collector passage in the overflow volume.

In yet another interrelated aspect, one or more wick supply channels can be implemented to control the direct flow of vaporizable material toward the wick. The first wick supply channel can be formed through a collector disposed in the overflow volume and can be independent of the primary and secondary channels of the control valve described above. The collector can include a support structure that forms the first channel or an additional wick supply channel. The wick can be disposed within the wick housing such that the wick is configured to absorb vaporizable material traveling through the first channel. Depending on the embodiment, the first channel can have a cross-shaped cross section or have a partial partition. The shape of the first channel can provide one or more non-primary subchannels and one or more primary subchannels that are larger in diameter compared to the non-primary subchannels.

Depending on the embodiment, if a primary or non-primary subchannel becomes restricted or blocked (e.g., due to the formation of a gas bubble), the vaporizable material may pass through an alternate subchannel or the primary channel. In a cross-shaped wick feed, the primary subchannel may extend through the center of the cross-shaped wick feed. When the primary subchannel becomes restricted due to the formation of a gas bubble in a portion of the primary subchannel, the vaporizable material flows through at least one of the non-primary subchannels.

In some embodiments, the collector has a first end facing the storage chamber and a second end facing away from the storage chamber and configured to contain the wick housing. The second wick supply may be implemented in the form of a second channel that allows vaporizable material stored in the storage chamber to flow toward the wick while vaporizable material flows through the first wick supply. The second wick supply may have a cross-shaped cross section.

According to one or more aspects, a reservoir for a cartridge usable with a vaporizer device may include a storage chamber configured to contain a vaporizable material. The reservoir may be in operative relationship with an atomizer configured to convert the vaporizable material from a liquid phase to a vapor or aerosol phase for inhalation by a user of the vaporizer device. The cartridge may also include an overflow volume for retaining at least a portion of the vaporizable material, for example, when one or more factors cause the vaporizable material in the reservoir chamber to move into an overflow volume in the cartridge.

The one or more factors may include the cartridge being exposed to a pressure state different from the previous ambient pressure state (e.g., by transitioning from a first pressure state to a second pressure state). In some aspects, the overflow volume may include an opening to the exterior of the cartridge (i.e., ambient air) or a passageway connecting to an air control port. The passageway in the overflow volume may be in communication with the reservoir chamber so as to function as a vent to allow equalization of pressure within the reservoir chamber. In response to a negative pressure event in the cartridge ambient environment, the volume of vaporizable material remaining in the reservoir chamber is reduced as vaporizable material is drawn from the reservoir chamber into the atomizer and converted to a gas or aerosol phase.

The reservoir chamber is connected to the overflow volume, for example, by one or more openings between the reservoir chamber and the overflow volume, such that the one or more openings lead to one or more passages through the overflow volume. The flow of vaporizable material through the openings to the passages may be controllable by capillary properties of fluid vents leading to the one or more passages or by capillary properties of the passages themselves. Furthermore, the flow of vaporizable material into the one or more passages may be reversible, allowing the vaporizable material to be returned from the overflow volume to the reservoir chamber.

In at least one embodiment, the flow of vaporizable material can be reversed in response to a change in pressure condition (e.g., when a second pressure condition within the cartridge returns to the first pressure condition). The second pressure condition can be associated with a negative pressure event. A negative pressure event can be the result of a reduction in the ambient pressure relative to the ambient pressure of one or more volumes of air held within the reservoir or other portion of the cartridge. Alternatively, a negative pressure event can result from compression of an internal volume of the cartridge due to mechanical pressure on one or more exterior surfaces of the cartridge.

The heating element may include a heating portion and at least two legs. The heating portion may include at least two tines spaced apart from one another. The heating portion may be preformed to define an interior volume configured to receive the wicking element such that the heating portion secures at least a portion of the wicking element to the heating element. The heating portion may be configured to contact at least two distinct surfaces of the wicking element. The at least two legs may be coupled to the at least two tines and spaced apart from the heating portion. The at least two legs may be configured to be in electrical communication with a power source. Power is configured to be provided from the power source to the heating portion to generate heat, thereby vaporizing a vaporizable material stored within the wicking element.

In some embodiments, the at least two legs include four legs. In some embodiments, the heating portion is configured to contact at least three separate surfaces of the wicking element.

In some embodiments, the at least two teeth include a first side tooth portion, a second side tooth portion opposite the first side tooth portion, and a platform tooth portion connecting the first side tooth portion and the second side tooth portion. The platform tooth portion may be disposed substantially perpendicular to a portion of the first side tooth portion and the second side tooth portion. The first side tooth portion, the second side tooth portion, and the platform tooth portion define an interior volume in which the wicking element is disposed. In some embodiments, the at least two legs are spaced apart from the heating portion by a bridge.

In some embodiments, each of the at least two legs includes a cartridge contact disposed at an end of each of the at least two legs. The cartridge contacts can be in electrical communication with a power source. The cartridge contacts can be angled and extend away from the heating portion.

In some embodiments, the at least two tines include a first pair of tines and a second pair of tines. In some embodiments, the tines of the first pair of tines are equally spaced apart from one another. In some embodiments, the tines of the first pair of tines are spaced apart by a width. In some embodiments, the width of an inner region of the heating element adjacent the platform tine portion is greater than the width of an outer region of the heating element adjacent an outer edge of the first side tine portion opposite the inner region.

In some embodiments, the vaporizer device is configured to measure the resistance of the heating element at each of the four legs to control the temperature of the heating element. In some embodiments, the heating element includes a heat shield configured to insulate the heating portion from the body of the vaporizer device.

In some embodiments, the vaporizer device further includes a heat shield configured to surround at least a portion of the heating element and to insulate the heating portion from the wicking element and a body of the wick housing configured to surround at least a portion of the heating element.

In some embodiments, the heating section is folded between the heating section and the at least two legs to insulate the heating section from the at least two legs. In some embodiments, the heating section further includes at least one tab extending from a side of the at least two tines to facilitate access of the wicking element to the interior volume of the heating section. In some embodiments, the at least one tab extends at an angle away from the interior volume.

In some embodiments, the at least two legs include a capillary feature. The capillary feature can cause a rapid change in capillary pressure, thereby preventing the vaporizable material from flowing past the capillary feature. In some embodiments, the capillary feature includes one or more bends in the at least two legs. In some embodiments, the at least two legs extend at an angle toward the interior volume of the heating section, and the angled at least two legs define the capillary feature.

In some embodiments, the vaporizer device includes a reservoir containing a vaporizable material, a wicking element in fluid communication with the reservoir, and a heating element. The heating element includes a heating portion and at least two legs. The heating portion may include at least two tines spaced apart from one another. The heating portion may be preformed to define an interior volume configured to receive the wicking element such that the heating portion secures at least a portion of the wicking element to the heating element. The heating portion may be configured to contact at least two distinct surfaces of the wicking element. The at least two legs may be coupled to the at least two tines and spaced apart from the heating portion. The at least two legs may be configured to be in electrical communication with a power source. Power is configured to be provided from the power source to the heating portion to generate heat, thereby vaporizing the vaporizable material stored within the wicking element.

A method of forming an atomizer assembly for a vaporizer device may include securing a wicking element to an interior volume of a heating element. The heating element may include a heating portion including at least two tines spaced apart from one another and at least two legs spaced apart from the heating portion. The legs may be configured to be in electrical communication with a power source of the vaporizer device. The heating portion is configured to contact at least two surfaces of the wicking element. The method may also include coupling the heating element to a wick housing configured to enclose at least a portion of the wicking element and the heating element. The securing may also include sliding the wicking element into the interior volume of the heating element.

In some embodiments, the vaporizer device includes a heating portion including one or more heater traces integrally formed and spaced apart from one another, the one or more heater traces configured to contact at least a portion of a wicking element of the vaporizer device, and the vaporizer device includes a connection portion configured to receive power from a power source and conduct the power to the heating portion, and a plating layer having a plating material different from a material of the heating portion. The plating layer may be configured to reduce contact resistance between the heating element and the power source, thereby localizing heating of the heating element to the heating portion.

In certain aspects of the present invention, problems associated with condensation collecting along one or more internal channels and outlets (e.g., along the mouthpiece) of some vaporizer devices may be solved by one or more mechanisms described herein or equivalent/equivalent approaches as understood by those of skill in the art. Aspects of the present invention relate to systems and methods for capturing vaporizable material condensate within a vaporizer device.

In some variations, one or more of the following features may optionally be included in the viable combination:

Aspects of the invention relate to a cartridge for a vaporizer device. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to contain a vaporizable material within the reservoir chamber. The cartridge may include a vaporizer chamber in communication with the reservoir and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporizer chamber for vaporization by a heating element. The cartridge may include an airflow passage extending through the vaporizer chamber. The cartridge may include at least one capillary channel adjacent to the airflow passage. Each capillary channel of the at least one capillary channel may be configured to receive a fluid and direct the fluid from a first location to a second location via capillary action.

In one aspect consistent with the present disclosure, each capillary channel of the at least one capillary channel may be tapered in size. The tapered size may increase capillary drive through each capillary channel of the at least one capillary channel. Each capillary channel of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wick. The first location may be adjacent an end of the airflow passage and the mouthpiece. The at least one capillary channel may collect fluid condensate.

In a related aspect, the vaporizer device may include a vaporizer body including a heating element configured to heat a vaporizable material. The vaporizer device may include a cartridge configured to be releasably coupled to the vaporizer body. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to contain a vaporizable material within the reservoir chamber. The cartridge may include a vaporizer chamber in communication with the reservoir and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporizer chamber for vaporization by the heating element. The cartridge may include an airflow passage extending through the vaporizer chamber. The cartridge may include at least one capillary channel adjacent to the airflow passage. Each capillary channel of the at least one capillary channel may be configured to receive a fluid and direct the fluid from a first location to a second location via capillary action.

Each capillary channel of the at least one capillary channel may be tapered in size. The tapered size may increase capillary drive through each capillary channel of the at least one capillary channel. Each capillary channel of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wick. The first location may be adjacent an end of the airflow passage and the mouthpiece. The at least one capillary channel may collect fluid condensate.

In a related aspect, a method of a cartridge of a vaporizer may include collecting condensate in a first capillary channel of at least one capillary channel of the cartridge. Each of the at least one capillary channel may be configured to receive a fluid and direct the fluid from a first location to a second location via capillary action. The cartridge may include a reservoir including a reservoir chamber defined by a reservoir barrier. The reservoir may be configured to contain a vaporizable material in the reservoir chamber. The cartridge may include a vaporization chamber in communication with the reservoir and may include a wicking element configured to draw the vaporizable material from the reservoir chamber to the vaporization chamber for vaporization by a heating element. The cartridge may include an airflow passage that may extend through the vaporization chamber. The at least one capillary channel may be adjacent to the airflow passage. The method may include directing the collected condensate along the first capillary channel toward the vaporization chamber.

The method may include vaporizing the collected condensate in an evaporation chamber. The first capillary channel may be tapered in size. Each capillary channel of the at least one capillary channel may be formed by a groove defined between a pair of walls. The at least one capillary channel may be in fluid communication with the wick. The first location may be adjacent an end of the airflow passage and the mouthpiece.

The details of one or more variations of the invention described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the invention described herein will be apparent from the description and drawings, and from the claims. However, the disclosed invention is not limited to the particular embodiments disclosed.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the invention disclosed herein and, together with the description, serve to explain some of the principles associated with the disclosed embodiments provided below.

FIG. 1 illustrates a block diagram of an exemplary vaporizer device according to one or more embodiments. 1 illustrates a top view of an exemplary vaporizer body and an insertable vaporizer cartridge according to one or more embodiments. 2B illustrates a perspective view of the vaporizer device of FIG. 2A according to one or more embodiments. FIG. 2B illustrates a perspective view of the cartridge of FIG. 2A in accordance with one or more embodiments. FIG. 2D illustrates another perspective view of the cartridge of FIG. 2C in accordance with one or more embodiments. 1 illustrates a diagram of a reservoir system configured for a vaporizer cartridge and/or vaporizer device to improve airflow within the vaporizer device, according to one or more embodiments. 1 shows a diagram of a reservoir system configured for a vaporizer cartridge or vaporizer device to improve airflow within the vaporizer device, according to another embodiment. 1 illustrates an exemplary cross-sectional plan view of a cartridge having a reservoir and an overflow volume according to one or more embodiments. 1 illustrates an exemplary cross-sectional plan view of a cartridge having a reservoir and an overflow volume according to one or more embodiments. FIG. 3C illustrates an exploded perspective view of an exemplary embodiment of the cartridge of FIGS. 3A and 3B, according to one or more embodiments. 1 illustrates a top cross-sectional side view of selected partitions of a cartridge according to one or more embodiments. 1 illustrates a cross-sectional top view of an exemplary cartridge structure according to one or more embodiments. FIG. 6B illustrates a perspective side view of the exemplary cartridge of FIG. 6A in accordance with one or more embodiments. 1 illustrates an exemplary embodiment of a cartridge connection port having a male or female configuration, according to one or more embodiments. 1 illustrates an exemplary embodiment of a cartridge connection port having a male or female configuration, according to one or more embodiments. 1 illustrates an exemplary embodiment of a cartridge connection port having a male or female configuration, according to one or more embodiments. 1 illustrates an exemplary embodiment of a cartridge connection port having a male or female configuration, according to one or more embodiments. FIG. 1 illustrates a planar top view of a cartridge with an exemplary motif or logo, according to one or more embodiments. 1 illustrates a perspective view of an exemplary cartridge split according to one or more embodiments. 1 illustrates a top cross-sectional view of an exemplary cartridge according to one or more embodiments. 1 illustrates a closed, exploded perspective view of an exemplary cartridge embodiment with a separable structure for housing a collector mechanism, according to one or more embodiments. 1 illustrates a closed, exploded perspective view of an exemplary cartridge embodiment with a separable structure for housing a collector mechanism, according to one or more embodiments. FIG. 1 illustrates a perspective front view of an exemplary cartridge structural component with a flow management collector having one or more flow channels, according to one or more embodiments. 1 illustrates a side view of an exemplary cartridge structural component with a flow management collector having one or more flow channels, according to one or more embodiments. 1A-1C show perspective views of exemplary cartridge structural components with a flow management collector having one or more flow channels, according to one or more embodiments. FIG. 1 illustrates a side plan view of an exemplary single vent, single channel collector structure according to one or more embodiments. FIG. 11B illustrates a side view of an exemplary cartridge having a translucent housing structure including an exemplary collector as shown in FIG. 11A in accordance with one or more embodiments. 1A-1D show perspective and plan side views of an exemplary collector structure incorporating a flow management constriction within a flow channel, according to one or more embodiments. 1A-1D show perspective and plan side views of an exemplary collector structure incorporating a flow management constriction within a flow channel, according to one or more embodiments. 1A-1D show perspective and plan side views of an exemplary collector structure incorporating a flow management constriction within a flow channel, according to one or more embodiments. 1 illustrates a front view of an exemplary collector structure with a flow management constriction incorporated into the collector flow channel, according to one or more embodiments. 1 illustrates a side view of an exemplary collector structure with a flow management constriction incorporated into the collector flow channel, according to one or more embodiments. FIG. 13 is a close-up perspective view of an exemplary collector structure with one or more vents that can control the flow of liquid between a reservoir and an overflow volume in a cartridge, according to one or more embodiments. FIG. 1 illustrates a perspective view of an exemplary collector structure with flow management control according to one or more embodiments. FIG. 1 illustrates a perspective view of an exemplary collector structure with flow management control according to one or more embodiments. FIG. 1 illustrates a perspective view of an exemplary collector structure with flow management control according to one or more embodiments. 1 illustrates a close-up view of an exemplary flow management feature within a collector structure, according to one embodiment. 1 illustrates a front plan view of an exemplary flow management feature within a collector structure, according to one embodiment. 1 illustrates a close-up view of an exemplary flow management feature within a collector structure, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 11A-11N show snapshots of the flow of vaporizable material collected in the exemplary collector of FIGS. 11L-11N as it is managed to accommodate proper venting as the meniscus of vaporizable material stored in the overflow volume continues to recede, according to one embodiment. 1 illustrates an example of a single vent multi-channel collector structure according to one or more embodiments. 1 illustrates an example of a single vent multi-channel collector structure according to one or more embodiments. 1 illustrates an example of a double vent multi-channel collector structure according to one or more embodiments. FIG. 13 is a perspective view of an exemplary collector configuration for a cartridge with a dual wick supply according to one or more embodiments. FIG. 13 is a cross-sectional plan side view of an exemplary collector structure for a cartridge with a dual wick supply, according to one or more embodiments. 14A-14C are additional perspective views of exemplary collector structures for dual wick feed structures according to one or more embodiments. 14A-14C are additional perspective views of exemplary collector structures for dual wick feed structures according to one or more embodiments. FIG. 13 is a cross-sectional plan side view of an exemplary collector structure for a dual wick feed structure according to one or more embodiments. 1 illustrates a cross-sectional plan side view of an exemplary cartridge according to one or more embodiments. FIG. 1 illustrates a top side view of an exemplary wicking element housed in a collector structure according to one or more embodiments. 1 illustrates a perspective view of an exemplary cartridge having a collector structure according to one or more embodiments. FIG. 2 is a perspective view of a first side of a cartridge according to one or more embodiments. 13 illustrates a cross-sectional view of a second side of a cartridge having a wicking element protruding into a reservoir according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates an example of a heating element and airflow passages within a vaporizer cartridge according to one or more embodiments. 1 illustrates a side view of an exemplary collector structure including one or more ribs or sealing bead profiles to support a particular manufacturing technique for securing the collector to a reservoir within a cartridge. 1 illustrates a side view of an exemplary collector structure including one or more ribs or sealing bead profiles to support a particular manufacturing technique for securing the collector to a reservoir within a cartridge. 1 illustrates an example of a heating element according to one or more embodiments. 1 illustrates an example of a heating element according to one or more embodiments. 1 illustrates an example of a portion of a wick housing according to one or more embodiments. 1 illustrates an example of an identification chip according to one or more embodiments. 1A-1D are perspective, front, side and exploded views of an exemplary embodiment of a cartridge. 1A-1D show perspective, front, side, bottom and top views of an exemplary embodiment of a collector with a V-shaped vent. 1A-1C show perspective and cross-sectional views of an exemplary collector structure from different viewing angles, focusing on structural details to ensure alignment of the wicking element and wick housing relative to the atomizer toward one end of the cartridge, in accordance with one or more embodiments. 1A-1C show perspective and cross-sectional views of an exemplary collector structure from different viewing angles, focusing on structural details to ensure alignment of the wicking element and wick housing relative to the atomizer toward one end of the cartridge, in accordance with one or more embodiments. 1 illustrates a top view of an exemplary wick supply mechanism formed or structured through a collector, according to one or more embodiments. 1 illustrates a top view of an exemplary wick supply mechanism formed or structured through a collector, according to one or more embodiments. 1 illustrates a top view of an exemplary wick supply mechanism formed or structured through a collector, according to one or more embodiments. 1 illustrates a front view of an exemplary flow management feature in a collector structure according to one or more embodiments. 1 illustrates a front view of an exemplary flow management feature in a collector structure according to one or more embodiments. 1 illustrates a front view of an exemplary cartridge including an exemplary collector structure. 1 illustrates a perspective view of an exemplary embodiment of a cartridge. 1 illustrates a front view of an exemplary embodiment of a cartridge. 1 illustrates a side view of an exemplary embodiment of a cartridge. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. 1A-1D show perspective views of an exemplary cartridge at different fill levels according to one or more embodiments. FIG. 1 illustrates a front view of an exemplary cartridge filled and assembled, according to one embodiment. FIG. 1 illustrates a front view of an exemplary cartridge filled and assembled, according to one embodiment. FIG. 1 illustrates a front view of an exemplary cartridge filled and assembled, according to one embodiment. 1 illustrates a front view of an exemplary cartridge air path. 1 illustrates a top view of an exemplary cartridge air path. 1 illustrates a bottom view of an exemplary cartridge air path. FIG. 1 shows a front view of an exemplary cartridge with air flow paths, liquid supply channels, and a condensate collection system. FIG. 1 illustrates a top view of an exemplary cartridge with airflow paths, liquid supply channels, and a condensate collection system. FIG. 1 illustrates a front view of an exemplary cartridge body with an external airflow path. FIG. 1 illustrates a side view of an exemplary cartridge body with an external airflow path. 1 illustrates a perspective view of a portion of an exemplary cartridge with a collector structure having a void in a bottom rib of the collector structure. 1 illustrates a perspective view of a portion of an exemplary cartridge with a collector structure having a void in a bottom rib of the collector structure. 13A-13C show top views of various exemplary wick supply configurations of the cartridge. 13A-13C show top views of various exemplary wick supply configurations of the cartridge. 13A-13C show top views of various exemplary wick supply configurations of the cartridge. 1 is an exemplary embodiment of a collector with a double wick supply embodiment. 1 is an exemplary embodiment of a collector with a double wick supply embodiment. 1 shows an enlarged view of an end of a wick supply positioned proximate to the wick and configured to at least partially receive the wick. FIG. 1 shows a perspective view of an exemplary collector structure having a square design wick supply combined with a gap at one end of the overflow passage. 1 shows a rear view of a collector structure with, for example, four separate discharge sites. FIG. 13 is a side view of the collector structure, particularly showing the clamp-shaped end of the wick supply, which can hold the wick firmly within the channel of the wick supply. A top view of a collector structure having a wick supply channel for receiving vaporizable material from a storage chamber of a cartridge and directing the vaporizable material toward a wick held at the end position of the wick supply channel by the protruding end of the wick supply channel is shown. 1 shows a front plan view of a collector structure. As shown, a void cavity can be formed in the lower part of the collector structure at the end of the lower rib of the collector structure, where the overflow passage of the collector leads to an air control vent that communicates with the ambient air. FIG. 13 shows a bottom view of a collector structure with a wick supply channel terminating in clamp-shaped protrusions configured to hold the wick in place at each end. A planar top view of a collector structure with two clamp-shaped ends of two corresponding wick supplies is shown. FIG. 13 shows a side view of a collector structure with two clamp-shaped ends of two corresponding wick supplies. 1A-1D show various perspective, top and side views of an exemplary collector having different structural embodiments. 1A-1D show various perspective, top and side views of an exemplary collector having different structural embodiments. 1A-1D illustrate various perspective, top, and side views of an exemplary wick housing, according to one or more embodiments. 13 illustrates the collector and wick housing components of an exemplary cartridge configured with a structure on the wick housing such that the protruding tabs are insertably received in corresponding bottom receiving notches or cavities in the collector. 1 illustrates an exploded perspective view of an embodiment of a cartridge, consistent with an embodiment of the present invention. 1 illustrates a top perspective view of an embodiment of a cartridge consistent with embodiments of the present invention. 1 illustrates a bottom perspective view of an embodiment of a cartridge consistent with embodiments of the present invention. 1 shows a schematic diagram of a heating element for use in a vaporizer device consistent with embodiments of the present invention. 1 shows a schematic diagram of a heating element for use in a vaporizer device consistent with embodiments of the present invention. 1 shows a schematic diagram of a heating element for use in a vaporizer device consistent with embodiments of the present invention. 1 shows a schematic diagram of a heating element disposed in a vaporizer cartridge for use in a vaporizer device consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element disposed within a vaporizer cartridge consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element disposed within a vaporizer cartridge consistent with an embodiment of the present invention. 1 illustrates a heating element disposed within a vaporizer cartridge consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a heating element coupled with a portion of a vaporizer cartridge consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element disposed within a vaporizer cartridge consistent with an embodiment of the present invention. 1 illustrates a heating element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element and a wicking element in a partially bent state consistent with an embodiment of the present invention. 1 illustrates a heating element in an unbent state and having plating consistent with an embodiment of the present invention. 1 illustrates a heating element in a bent state and having plating consistent with an embodiment of the present invention. 1 illustrates a heating element having plated portions disposed within a vaporizer cartridge consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a side view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a front view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element and a wicking element in a bent state consistent with an embodiment of the present invention. 1 illustrates a heating element disposed within a vaporizer cartridge consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a side view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a front view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in an unbent state consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in an unbent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a side view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a front view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in an unbent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in an unbent state consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in an unbent state consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a top perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates a bottom perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates an exploded perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates a perspective view of a heat shield consistent with an embodiment of the present invention. 1 illustrates a side cross-sectional view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates another cross-sectional side view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates a schematic of a heating element consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a side view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a perspective view of a heating element in a bent state consistent with an embodiment of the present invention. FIG. 2 illustrates a side view of a heating element in a bent state consistent with an embodiment of the present invention. 1 illustrates a top view of a substrate material with a heating element consistent with an embodiment of the present invention. FIG. 1 illustrates a top view of a heating element in an unbent state consistent with an embodiment of the present invention. 1 illustrates a top perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates an enlarged view of a portion of a wick housing of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates a bottom perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates an exploded perspective view of an atomizer assembly consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 illustrates a process for assembling an atomizer consistent with an embodiment of the present invention. 1 shows a process flow diagram illustrating aspects of a method for forming and implementing a heating element consistent with embodiments of the present invention. 1 illustrates an embodiment of a vaporizer cartridge. 1 illustrates an embodiment of a vaporizer cartridge and/or a mouthpiece of a vaporizer device. FIG. 1 shows a side cross-sectional view of the vaporizer cartridge condensate recycler system. A first perspective view of the condensate recycler system of Figure 119A is shown. A second perspective view of the condensate recycler system of Figure 119A is shown.

Unless otherwise noted, the same or similar reference numbers may indicate the same, similar, or equivalent structure, function, aspect, or element in one or more embodiments.

Vaporizers configured to convert liquid vaporizable material to a gas phase and/or an aerosol phase (e.g., a suspension of gas-phase and particulate-phase material in air in relative local equilibrium between the phases) typically include a reservoir or storage vessel (also referred to herein as a reservoir, storage compartment, or storage volume) that contains a quantity of liquid vaporizable material, an atomizer (also referred to as an atomizer assembly), a heating element (e.g., an electrical resistance element that passes an electric current and converts the electric current into thermal energy) that heats the liquid vaporizable material and converts at least a portion of the liquid vaporizable material to the gas phase, and a wicking element (sometimes simply referred to as a wick, but generally referring to an element or combination of elements that exerts capillary forces to draw the liquid vaporizable material from the reservoir to a location that is heated by the action of the heating element). The resulting liquid vaporizable material in the gas phase may then (and selectively almost immediately) begin to at least partially condense, in some cases (depending on a variety of factors), forming an aerosol in the air passing through, over, near, around, etc., the atomizer.

As the liquid vaporizable material in the wicking element is heated and converted to the gas phase (and then, optionally, converted to aerosol), the volume of the liquid vaporizable material in the reservoir decreases. Because there is no mechanism for introducing air or other material into the void (e.g., the portion of the reservoir volume not occupied by liquid vaporizable material) created in the reservoir when the volume of the liquid vaporizable material is reduced by conversion to the gas/aerosol phase, a reduced pressure condition (e.g., at least a partial vacuum) is created in the reservoir. Because the partial vacuum pressure acts against the capillary pressure created in the wicking element, this reduced pressure condition can adversely affect the efficacy of the wicking element to draw the vaporizable material from the storage compartment or reservoir into the vicinity of the heating element for vaporization into the gas phase.

More specifically, reduced pressure in the reservoir can result in insufficient saturation of the wick and ultimately insufficient vaporizable material delivered to the atomizer for reliable operation of the vaporizer. To counter the reduced pressure, ambient air can be admitted to the reservoir to equalize the pressure between the interior of the reservoir and the ambient pressure. This occurs in some vaporizers by flowing air through a wicking element into the reservoir, backfilling the void in the reservoir created by the vaporized liquid vaporizable material. However, this process may generally require that the wicking element be at least partially dry. Because a dry wicking element may not be easily achieved and/or may not be desirable for reliable operation of the vaporizer, another typical approach is to provide a vent that allows equalization of pressure between ambient conditions and within the reservoir.

The presence of air in the reservoir cavity, whether through a wick or other vent or structure, can cause one or more other problems. For example, if the air pressure in the reservoir cavity equalizes (or at least approaches equalization) with the ambient pressure, especially as the volume of the air-filled cavity increases relative to the total volume of the reservoir, a negative pressure differential (e.g., the air in the cavity is at a higher pressure than the ambient) can occur, causing the liquid vaporizable material to leak from the reservoir, for example, through a wick, an provided vent, etc. A negative pressure difference between the air in the reservoir and the current ambient pressure can be created by one or more of several factors, such as heating of the air in the cavity (e.g., by holding the reservoir in one's hand or moving the vaporizer from a cold place to a warm place), mechanical forces that can distort the shape of the reservoir and thereby reduce its internal volume (e.g., by squeezing a portion of the vaporizer causing a distortion of the reservoir volume), or a sudden drop in ambient pressure (such as occurs in an airplane cabin during air travel, when a car or train enters or exits a tunnel, when a window is opened or closed while the vehicle is traveling at high speed, etc.).

Leaking of liquid vaporizable material from the vaporizer reservoir as described above is generally undesirable because the leaked liquid vaporizable material may cause an undesirable mess (e.g., by staining clothing or other items near the vaporizer), may enter the inhalation pathway of the vaporizer and thereby be ingested by the user, may interfere with the function of the vaporizer (e.g., by fouling pressure sensors, affecting the operability of electrical circuits and/or switches, fouling charging ports and/or connections between the cartridge and the vaporizer body, etc.). Thus, leakage of liquid vaporizable material may interfere with the function and cleanliness of the vaporizer.

Examples of vaporizers include, but are not limited to, electronic vaporizers, electronic nicotine delivery systems (ENDS), or devices and systems with the same, similar, or equivalent structural or functional features or capabilities. FIG. 1 shows an exemplary block diagram of an exemplary vaporizer 100. The vaporizer 100 may include a vaporizer body 110 and a vaporizer cartridge 120 (also referred to simply as vaporizer cartridge 120). The vaporizer body 110 may include a power source 112 (e.g., a rechargeable battery), and a controller 104 (e.g., a programmable logic device, processor, or circuitry capable of executing logic code) for controlling the delivery of heat to an atomizer 141 to convert a vaporizable material (not shown) from a condensed form (e.g., a solid, liquid, solution, suspension, at least partially unprocessed plant material, etc.) to a gas phase, or more generally, to convert a vaporizable material to an inhalable form or a precursor to an inhalable form. In this context, the inhalable form may be a gas or an aerosol, or some other airborne form. The inhalable form of the precursor may include a vapor phase of a vaporizable material that at some point after the vapor phase is formed (optionally immediately or nearly immediately, or after some delay or cooling) condenses at least partially to form an aerosol. The controller 104 may be part of one or more printed circuit boards (PCBs) consistent with certain embodiments and may be utilized to control certain functions of the vaporizer body 110 in conjunction with one or more sensors 113.

As shown, the vaporizer body 110, in some embodiments of the present invention, may include another sensor 113, a vaporizer body contact 125, a seal 115, and optionally a cartridge receptacle 118 configured to receive at least a portion of a vaporizer cartridge 120 for coupling with the vaporizer body 110 through one or more of various attachment structures. As described below with reference to Figures 7A-7D, the vaporizer cartridge 120 may be coupled to the vaporizer body 110 using male or female receptacle structures or some combination thereof. For example, in some embodiments of the present invention, an inner portion of a first end of the cartridge is received in the cartridge receptacle 118 of the vaporizer body 110 and an outer portion of the first end of the cartridge at least partially covers a portion of an outer surface of the structure on the vaporizer body 110 that forms the cartridge receptacle 118. Such a configuration for coupling the vaporizer cartridge 120 to the vaporizer body 110 may allow for a convenient and easy to use joining method that also provides sufficient mechanical bond strength to avoid undesired separation of the vaporizer cartridge 120 and the vaporizer body 110. Such a configuration may also provide desirable resistance to flexing of the vaporizer formed by coupling the vaporizer cartridge 120 to the vaporizer body 110. With regard to the vaporizer body contacts 125, it should be understood that these may also be referred to as “receptacle contacts 125” in embodiments where the corresponding cartridge contacts 124 (discussed below) are on a portion of the vaporizer cartridge 120 that is inserted into a receptacle or receptacle-like structure of the vaporizer body 110. However, the terms "vaporizer body contacts 125" and/or "receptacle contacts 125" are used herein as well, as aspects of the present invention are not limited to (and may be used to provide various other system benefits) electrical coupling between the vaporizer cartridge 120 and the vaporizer body 110 that occurs between contacts in the cartridge receptacle 118 of the vaporizer body 110 and a portion of the vaporizer cartridge 120 that is inserted into the cartridge receptacle 118.

In some examples, the vaporizer cartridge 120 may include a reservoir 140 for containing a liquid vaporizable material and a mouthpiece 130 for delivering a dose of an inhalable form of the vaporizable material. The mouthpiece may optionally be a separate component from the structure forming the reservoir 140, or may be formed from the same part or component that forms at least a portion of one or more walls of the reservoir 140. The liquid vaporizable material in the reservoir 140 may be a carrier solution in which active or inactive ingredients may be suspended, dissolved, or held in solution or in the neat liquid form of the vaporizable material itself.

According to one embodiment, the vaporizer cartridge 120 may include an atomizer 141 that may include a wick or wicking element as well as a heater (e.g., a heating element). As described above, the wicking element may include any material capable of causing fluid absorption by capillary pressure through the wick to transport a quantity of liquid vaporizable material to a portion of the atomizer 141 that includes the heating element. The wick and heating element are not shown in FIG. 1, but are disclosed and discussed in further detail herein with reference to at least FIGS. 3A, 3B, and 4. Briefly, the wicking element is configured to draw liquid vaporizable material from a reservoir 140 configured to contain the liquid vaporizable material, and the liquid vaporizable material is vaporized (i.e., converted to a gas-phase state) by heat provided to the wicking element from the heating element, and the liquid vaporizable material is drawn into the wicking element. In some implementations, in response to liquid vaporizable material being removed from the reservoir 140 during vapor and/or aerosol formation, air may enter the reservoir 140 through a wicking element or other opening, at least partially equalizing the pressure within the reservoir 140.

As shown in FIG. 1, the pressure sensor (and other sensors) 113 may be disposed on or coupled to the controller 104 (e.g., via electrical, electronic, physical, or wireless connections). The controller 104 may be a printed circuit board assembly or other type of circuit board. To ensure accurate measurements and to maintain the durability of the vaporizer 100, it may be beneficial to provide a resilient seal 115 to isolate the airflow path from other portions of the vaporizer 100. The seal 115, which may be a gasket, may be configured to at least partially surround the pressure sensor 113 such that the connection of the pressure sensor 113 to the internal circuitry of the vaporizer may be isolated from the portion of the pressure sensor exposed to the airflow path.

The liquid vaporizable material used in the vaporizer 100 may be provided in a vaporizer cartridge 120 that can be refilled when empty or disposed of by selecting a new cartridge containing additional vaporizable material of the same or different type. The vaporizer may be a vaporizer that uses a cartridge or a multi-purpose vaporizer that can be used with or without a cartridge. For example, a multi-purpose vaporizer may include a heating chamber (e.g., an oven) configured to receive the vaporizable material directly into the heating chamber and also to receive a cartridge or other replaceable device having a reservoir, volume, or other functional or structural equivalent that at least partially contains a usable amount of vaporizable material.

In the example of a vaporizer that uses a cartridge, the seal 115 may separate portions of one or more electrical connections between the vaporizer body 110 and the vaporizer cartridge 120. Such placement of the seal 115 within the vaporizer 100 helps to mitigate potentially destructive effects on the vaporizer components resulting from interaction with one or more environmental factors, such as condensed water, vaporizable material leaking from the reservoir and/or condensing after vaporization, and to reduce air leakage from the designed airflow path of the vaporizer, etc.

Unwanted air, liquid, or other fluid passing through or contacting the circuitry of the vaporizer 100 can cause various undesirable effects, such as altered pressure measurements, or undesirable matter (e.g., moisture, vaporizable materials, and/or the like) can accumulate on parts of the vaporizer 100 that can cause a degradation of the pressure signal, degradation of pressure sensors or other electrical or electronic components, and/or a shortened vaporizer life. A leak in the seal 115 can also result in a user inhaling air that has passed through parts of the vaporizer 100 that contain or are composed of material that is not suitable for inhalation.

Vaporizers configured to generate at least a portion of an inhalable dose of a non-liquid vaporizable material via heating of the non-liquid vaporizable material may also be within the scope of the disclosed invention. For example, instead of or in addition to a liquid vaporizable material, the vaporizer cartridge 120 may include a mass of plant material or other non-liquid material (e.g., a solid form of the vaporizable material itself, such as "wax") that is processed and formed to be in direct contact with at least a portion of one or more resistive heating elements (or radiatively and/or convectively heated by the heating elements), which may be selectively included in the vaporizer cartridge 120 or part of the vaporizer body 110. Solid vaporizable materials (e.g., those that include plant material) may release only a portion of the plant material as vaporizable material (e.g., such that after the vaporizable material is released for inhalation, a portion of the plant material remains as waste), or may be capable of ultimately vaporizing all of the solid material for inhalation. Similarly, liquid vaporizable materials may be fully vaporized, or may include a portion of the liquid material that remains after all of the material suitable for inhalation is consumed.

When configured with a vaporizable material and a heating element within the vaporizer cartridge 120, the vaporizer cartridge 120 may be mechanically and electrically coupled to the vaporizer body 110. The vaporizer body 110 may include a processor, a power source 112, and one or more vaporizer body contacts 125 that connect to corresponding cartridge contacts 124 to complete a circuit with a resistive heating element included in the vaporizer cartridge 120. Various vaporizer configurations may be implemented with one or more of the features described herein.

In some embodiments, the vaporizer 100 can include a power source 112 as part of the vaporizer body 110, and the heating element can be disposed within a vaporizer cartridge 120 configured to mate with the vaporizer body 110. A vaporizer 100 so configured can include electrical connections to complete a circuit including the controller 104, the power source 112, and the heating element included in the vaporizer cartridge 120.

In some embodiments of the invention, the connection mechanism may include at least two cartridge contacts 124 on the bottom surface of the vaporizer cartridge 120 and at least two contacts 125 located near the base of the cartridge receptacle of the vaporizer 100, the cartridge contacts 124 and the receptacle contacts 125 electrically connecting when the vaporizer cartridge 120 is inserted into and mated with the cartridge receptacle 118. In some embodiments of the invention, the vaporizer body contacts 125 may be compressible pins (e.g., pogo pins) that retract under the pressure of the corresponding cartridge contacts 124 when the vaporizer cartridge is inserted into and secured in the cartridge receptacle 118. Other configurations are also contemplated. For example, brush contacts may be used that electrically connect with corresponding contacts in the mating portion of the vaporizer cartridge. Such contacts need not be electrically connected to cartridge contacts at the bottom end of the vaporizer cartridge 120, but may instead be biased outwardly from one or more side walls of the cartridge receptacle 118 to mate with cartridge contacts 124 on a portion of a side of the vaporizer cartridge 120 that is within the receptacle when the vaporizer cartridge 120 is properly inserted into the cartridge receptacle 118.

The circuit completed by the electrical connections allows for current to be sent to the resistive heating element and may further be used for additional functions, such as measuring the resistance of the resistive heating element for use in determining and/or controlling the temperature of the resistive heating element based on the thermal coefficient of resistivity of the resistive heating element, identifying the vaporizer cartridge 120 based on one or more electrical characteristics of the resistive heating element or other circuitry of the vaporizer cartridge 120, etc.

In some examples, at least two cartridge contacts 124 and at least two vaporizer body contacts 125 (e.g., receptacle contacts for embodiments in which a portion of the vaporizer cartridge 120 is inserted into the cartridge receptacle 118) may be configured to electrically connect in either of at least two orientations. In other words, one or more circuits configured for operation of the vaporizer 100 can be completed by inserting (or otherwise mating) at least a portion of the vaporizer cartridge 120 into the cartridge receptacle 118 in a first rotational direction (e.g., about an axis along which the end of the vaporizer cartridge having the vaporizer cartridge 120 is inserted into the cartridge receptacle 118 of the vaporizer body 110), such that a first cartridge contact of the at least two cartridge contacts 124 is electrically connected to a first receptacle contact of the at least two receptacle contacts 125, and a second cartridge contact of the at least two cartridge contacts 124 is electrically connected to a second receptacle contact of the at least two receptacle contacts 125.

Furthermore, one or more circuits configured for operation of the vaporizer 100 can be completed by inserting (or otherwise mating) the vaporizer cartridge 120 into the cartridge receptacle 118 in a second rotational orientation such that a first cartridge contact of the at least two cartridge contacts 124 is electrically connected to a second receptacle contact of the at least two receptacle contacts 125, and a second cartridge contact of the at least two cartridge contacts 124 is electrically connected to a first receptacle contact of the at least two receptacle contacts 125. The vaporizer cartridge 120 may be reversibly insertable into the cartridge receptacle 118 of the vaporizer body 110, as provided in further detail herein.

In one example of an attachment structure for coupling the vaporizer cartridge 120 to the vaporizer body 110, the vaporizer body 110 may include detents (e.g., indentations, protrusions, etc.) that project inwardly from an inner surface of the cartridge receptacle 118. One or more outer surfaces of the vaporizer cartridge 120 may include corresponding recesses (not shown in FIG. 1) that fit or snap into such detents when an end of the vaporizer cartridge 120 is inserted into the cartridge receptacle 118 of the vaporizer body 110.

The vaporizer cartridge 120 and vaporizer body 110 may be coupled, for example, by inserting an end of the vaporizer cartridge 120 into the cartridge receptacle 118 of the vaporizer body 110. A detent of the vaporizer body 110 may fit and/or be retained within a recess of the vaporizer cartridge 120 to hold the vaporizer cartridge 120 in place when assembled. Such a detent recess assembly may provide sufficient support to hold the vaporizer cartridge 120 in place and ensure sufficient contact between the at least two cartridge contacts 124 and the at least two receptacle contacts 125, while allowing the user to pull the vaporizer cartridge 120 with a reasonable force to disengage the vaporizer cartridge 120 from the cartridge receptacle 118, thus allowing release of the vaporizer cartridge 120 from the vaporizer body 110.

In addition to the above discussion of the electrical connection between the vaporizer cartridge 120 and the vaporizer body 110 being reversible such that at least two rotational orientations of the vaporizer cartridge 120 in the cartridge receptacle 118 may be possible, in some embodiments of the vaporizer 100, the shape of the vaporizer cartridge 120, or at least the shape of the end of the vaporizer cartridge 120 configured for insertion into the cartridge receptacle 118, may have at least two-fold rotational symmetry. In other words, the mechanical mating features and electrical contacts on the vaporizer cartridge 120 or at least the insertable end of the vaporizer cartridge 120 may have 180° rotational symmetry along the axis along which the vaporizer cartridge 120 is inserted into the cartridge receptacle 118. In such a configuration, the circuitry of the vaporizer 100 may support the same operation regardless of which symmetrical orientation of the vaporizer cartridge 120 occurs. It will be understood that the entire insertable end of the cartridge need not be symmetrical in all embodiments of the invention. For example, a vaporizer cartridge 120 that is shaped and sized to fit within the cartridge receptacle 118 of the vaporizer body 110, has rotationally symmetric mechanical features for cooperatively engaging corresponding features inside or outside the cartridge receptacle 118, and similarly has cartridge electrical contacts 124 with rotational symmetry and internal circuitry (optionally in either or both of the vaporizer cartridge 120 and vaporizer body 110) that is compatible with reversal of the electrical contacts is consistent with the present disclosure, even if the overall shape and appearance of the insertable end of the vaporizer cartridge 120 is not rotationally symmetric.

As mentioned above, in some exemplary embodiments, the vaporizer cartridge 120, or at least an end of the vaporizer cartridge 120, configured for insertion into the cartridge receptacle 118 may have a non-circular cross-section transverse to an axis along which the vaporizer cartridge 120 is inserted into the cartridge receptacle 118. For example, the non-circular cross-section may be generally rectangular, generally elliptical (e.g., generally oval), non-rectangular but with two sets of parallel or nearly parallel opposing sides (e.g., having a parallelogram shape), or other shape with at least two-fold rotational symmetry. In this context, having an approximately (nearly, approximately) shape indicates that a basic similarity to the described shape is evident, but that the sides of the shape in question need not be perfectly straight and the apex need not be perfectly sharp. The description of non-circular cross-sections referred to herein contemplates some degree of rounding of both or either the edges or apex of the cross-sectional shape.

The at least two cartridge contacts 124 and the at least two receptacle contacts 125 can take a variety of forms. For example, one or both sets of contacts may include conductive pins, tabs, posts, receiving holes for the pins or posts, etc. Some types of contacts may include springs or other biasing mechanisms that improve physical and electrical contact between the vaporizer cartridge and vaporizer body contacts. The electrical contacts may be gold plated and/or include other materials.

A vaporizer 100 consistent with embodiments of the disclosed invention may be configured to connect (e.g., via a wireless or wired connection) to one or more computing devices that communicate with the vaporizer 100. To this end, the controller 104 may include communications hardware 105. The controller 104 may also include memory 108. The computing device may be a component of a vaporizer system that also includes the vaporizer 100, or may include separate communications hardware capable of establishing a wireless communications channel with the communications hardware 105 of the vaporizer 100.

Computing devices used as part of the vaporizer system include general-purpose computing devices (such as smartphones, tablets, personal computers, other portable devices such as smart watches, etc.) that execute software to create a user interface that allows a user of the device to interact with the vaporizer 100. In other embodiments, a device used as part of the vaporizer system may be a dedicated hardware component, such as a remote control or other wireless or wired device having one or more physical or soft interface controls (e.g., configurable with a screen or other display device and selectable via user interaction with a touch-sensitive screen or other input device such as a mouse, pointer, trackball, cursor buttons, etc.). The vaporizer 100 may also include one or more outputs 117 or devices for providing information to a user.

A computing device that is part of a vaporizer system as defined above may be used for one or more of the following optional functions: dose control (e.g., dose monitoring, dose setting, dose limiting, user tracking, etc.), session control (e.g., session monitoring, session setting, session limiting, user tracking, etc.), nicotine delivery control (e.g., switching between nicotine and non-nicotine vaporizable materials, adjusting the amount of nicotine delivered, etc.), location information acquisition (e.g., location of other users, location of retail/commercial establishment, location of inhalation, relative or absolute location of the vaporizer itself, etc.), vaporizer personalization (e.g., naming the vaporizer, locking/password protecting the vaporizer, adjusting one or more parental controls, associating the vaporizer with a user group, registering the vaporizer with a vaporizer manufacturer or warranty maintenance provider, etc.), and participating in social activities with other users (e.g., social media communication, interacting with one or more groups, etc.). The terms "sessionization," "session," "vaporizer session," or "vapor session" may be used to refer to a period of time spent using a vaporizer. The period may include a time period, number of doses, amount of vaporizable material, etc.

In examples where a computing device provides signals related to activation of resistive heating elements, or other examples where a computing device couples with vaporizer 100 for implementation of various control or other functions, the computing device executes one or more sets of computer instructions to provide a user interface and basic data processing. In one example, detection of a user's interaction with one or more user interface elements by the computing device may cause the computing device to send a signal to vaporizer 100 to activate the heating elements to either a full operating temperature for generating an inhalable dose of vapor/aerosol. Other functions of vaporizer 100 may be controlled by user interaction with a user interface on a computing device in communication with vaporizer 100.

In some embodiments, the vaporizer cartridge 120 usable with the vaporizer body 110 may include an atomizer 141 having a wicking element and a heating element. Alternatively, one or both of the wicking element and the heating element may be part of the vaporizer body 110. In embodiments where any portion of the atomizer 141 (e.g., the heating element or the wicking element) is part of the vaporizer body 110, the vaporizer 100 may be configured to deliver liquid vaporizable material from a reservoir 140 in the vaporizer cartridge to the wick and other atomizer components, such as the wicking element, the heating element, etc. Those skilled in the art will appreciate that the capillary structure including the wicking element is just one potential embodiment usable with other features described herein.

Activation of the heating element may be triggered by automatic detection of a puff based on one or more signals generated by one or more sensors 113, such as, for example, a pressure sensor positioned to detect pressure along the airflow path relative to ambient pressure (or which may measure changes in absolute pressure), one or more motion sensors in the vaporizer 100, one or more flow sensors in the vaporizer 100, a capacitive lip sensor in the vaporizer 100, in response to detection of a user's interaction with one or more input devices 116 (e.g., a button or other tactile control device in the vaporizer 100), receiving a signal from a computing device in communication with the vaporizer 100, or via other approaches to determine that a puff has occurred or is imminent.

The heating element may be or include one or more of a conductive heater, a radiative heater, and a convective heater. One type of heating element is a resistive heating element, which may be constructed of or at least include a material (e.g., a metal or alloy, such as a nickel-chromium alloy, or a non-metallic resistor) configured to dissipate power in the form of heat when an electric current is passed through one or more resistive segments of the heating element.

In some embodiments, the atomizer 141 can include a heating element, including a resistive coil or other heating element, wrapped, internally disposed, embedded in a bulk shape, pressed in thermal contact, positioned in close proximity, configured to heat air to cause convective heating, or otherwise arranged to deliver heat to the wicking element, which draws liquid vaporizable material from the reservoir 140 and vaporizes it for subsequent inhalation of the gas and/or condensed (e.g., aerosol particle or droplet) phase by the user. Other wicking element, heating element, or atomizer assembly configurations are possible, as described further below.

After converting the vaporizable material to the gas phase, depending on the type of vaporizer, the physical and chemical properties of the vaporizable material, or other factors, at least a portion of the gas-phase vaporizable material may condense to form particulate matter that is at least partially in local equilibrium with the gas phase as part of an aerosol, which may form part or all of the inhalable dose provided by the vaporizer 100 for a given puff or inhalation at the vaporizer.

The interaction of the gas and condensed phases of the aerosol generated by a vaporizer can be complex and dynamic, as factors such as ambient temperature, relative humidity, chemistry (e.g., acid-base interactions, protonation, or lack of compounds released from the vaporizable material upon heating), flow conditions in the airflow path (both within the vaporizer and in the airways of humans or other animals), mixing of the vaporizable material in the gas or aerosol phase with other airflows, etc., can affect one or more physical and/or chemical parameters of the aerosol. In some vaporizers, particularly those that deliver more volatile vaporizable materials, the inhalable dose may be primarily present in the gas phase (i.e., formation of condensed phase particles may be very limited).

As noted elsewhere herein, certain vaporizers may also (or alternatively) be configured to generate an inhaled dose of gas-phase and/or aerosol-phase vaporizable material, at least in part, through heating of a non-liquid vaporizable material, such as, for example, a solid-phase vaporizable material (e.g., wax) or a plant material containing a vaporizable material (e.g., tobacco leaves or portions of tobacco leaves). In such vaporizers, a resistive heating element is part of, or otherwise incorporated into, or in thermal contact with, a wall of an oven or other heating chamber in which the non-liquid vaporizable material is placed.

Alternatively, a resistive heating element may be used to heat air passing or through the non-liquid vaporizable material, causing convective heating of the non-liquid vaporizable material. In yet another example, a resistive heating element may be positioned in intimate contact with the plant material such that direct conductive heating of the plant material occurs from within the mass of plant material (e.g., as opposed to inward conduction from the oven walls).

The heating element may be activated by a controller 104, which may be part of the vaporizer body 110. The controller 104 may pass current from a power source 112 through a circuit that includes a resistive heating element, which may be part of the vaporizer cartridge 120. The controller 104 may be activated in association with a user's puff (e.g., inhalation, etc.) at the mouthpiece 130 of the vaporizer 100, which causes air to flow from the air inlet along an airflow path through the atomizer 141. The atomizer 141 may include a wick, for example, in combination with the heating element.

The airflow caused by the user's puff may pass through one or more condensation regions or chambers within and/or downstream of the atomizer 141 and then flow toward the air outlet of the mouthpiece. Thus, incoming air flowing along the airflow path may pass over, through, and around the atomizer 141 such that gas-phase vaporizable material (or other inhalable form of vaporizable material) is entrained in the air by the atomizer 141, which converts some of the vaporizable material to the gas phase. As described above, the entrained gas-phase vaporizable material may condense as it passes through the remainder of the airflow path such that an inhalable dose of the vaporizable material in aerosol form is delivered from the air outlet (e.g., via the mouthpiece 130 for inhalation by the user).

The temperature of the resistive heating element of the vaporizer 100 may depend on one or more of a number of factors, including the amount of power supplied to the resistive heating element, or the duty cycle at which power is supplied, conductive or radiative heat transfer to other parts of the vaporizer 100 or the environment, specific heat transfer to the air and/or liquid or gas phase vaporizable material (e.g., raising the temperature of the vaporizable material to its vaporization point or raising the temperature of a gas such as air or air mixed with the vaporized vaporizable material), latent heat loss due to vaporization of the vaporizable material from the wick and/or across the atomizer 141, convective heat loss due to airflow (e.g., air moving across the heating element or atomizer 141 when a user inhales on the vaporizer 100), etc.

As noted above, to reliably activate or heat the heating element to a desired temperature, the vaporizer 100, in some embodiments, utilizes a signal from a pressure sensor to determine when the user is inhaling. The pressure sensor can be located in the airflow path or can be connected (e.g., by a passageway or other path) to an airflow path connecting an inlet for air entering the device and an outlet where the user inhales the resulting vapor and/or aerosol, and the pressure sensor can experience pressure changes simultaneously with air passing through the vaporizer 100 from the air inlet to the air outlet. In some embodiments, the heating element may be activated in conjunction with a user's puff, e.g., by automatic detection of the puff, such as by a pressure sensor detecting a pressure change in the airflow path.

1, 2A and 2B, the vaporizer cartridge 120 can be removably inserted into the vaporizer body 110 via the cartridge receptacle 118. As shown in FIG. 2A, which shows a top view of the vaporizer body 110 next to the vaporizer cartridge 120, the reservoir 140 of the vaporizer cartridge 120 may be formed in whole or in part from a translucent material so that the level of the liquid vaporizable material 102 in the vaporizer cartridge 120 is visible. The vaporizer cartridge 120 may be configured such that the level of the vaporizable material 102 in the reservoir 140 of the vaporizer cartridge 120 remains visible through a window in the vaporizer body 110 when the vaporizer cartridge 120 is received in the cartridge receptacle 118. Alternatively or additionally, the level of the liquid vaporizable material 102 in the reservoir 140 can be seen through a transparent or translucent outer wall or window formed in the outer wall of the vaporizer cartridge 120.

Air Flow Path Embodiments
2C and 2D, an exemplary vaporizer cartridge 120 is shown in which an airflow path 134 is formed during a user's puff on the vaporizer 100. The airflow path 134 can direct air to a vaporizer chamber 150 (see, e.g., FIG. 2D) contained in a wick housing where the air combines with an inhalable aerosol delivered to the user via a mouthpiece 130, which may be part of the vaporizer cartridge 120. The vaporizer chamber 150 can include and/or at least partially surround an atomizer 141 consistent with the remainder of the disclosure. For example, when a user puffs on the vaporizer 100, the airflow path 134 can pass between an exterior surface (e.g., window 132) of the vaporizer cartridge 120 and an interior surface of the cartridge receptacle 118 of the vaporizer body 110. Air can then be drawn into the insertable end 122 of the cartridge, through a vaporizer chamber 150 that includes or houses a heating element and a wicking element, and out the outlet 136 of the mouthpiece 130 to deliver an inhalable aerosol to the user. Other airflow path configurations are within the scope of this disclosure, including, but not limited to, those discussed in more detail below.

2D illustrates additional features that may be included in a vaporizer cartridge 120 consistent with the present invention. For example, the vaporizer cartridge 120 may include a plurality of cartridge contacts (such as cartridge contacts 124) disposed at an insertable end 122 configured to be inserted into a cartridge receptacle 118 of the vaporizer body 110. Each of the cartridge contacts 124 may be part of a single metal piece that selectively forms a conductive structure (such as conductive structure 126) that is connected to one of two ends of a resistive heating element. The conductive structure may selectively form both sides of the heating chamber and may selectively function as a heat shield and/or heat sink to reduce the transfer of heat to the exterior walls of the vaporizer cartridge 120. More details about this aspect are provided below.

2D also illustrates a cannula 128 (an example of a more general concept also referred to herein as an airflow passage) within the vaporizer cartridge 120 that defines a portion of an airflow path 134 passing between a heating chamber (sometimes referred to herein as an atomizer chamber, vaporizer chamber, etc.) that may be formed at least in part by the conductive structure 126 and the mouthpiece 130. Such a configuration allows air to flow down around the insertable end 122 of the vaporizer cartridge 120 into the cartridge receptacle 118 and back in the opposite direction after passing around the insertable end 122 of the vaporizer cartridge 120 (e.g., the end opposite the end including the mouthpiece 130) as it enters the cartridge body toward the vaporizer chamber 150. The airflow path 134 then travels through the interior of the vaporizer cartridge 120, e.g., via one or more tubes or internal channels (e.g., cannula 128) and through one or more outlets (e.g., outlets 136) formed in the mouthpiece 130.

(Pressure equalization vent)
As discussed above, removal of vaporizable material 102 from reservoir 140 (e.g., by capillary suction by the wicking element) can create at least a partial vacuum (e.g., a reduced pressure created in a portion of the reservoir emptied by consumption of liquid vaporizable material) relative to the ambient air pressure within reservoir 140, which can interfere with the capillary action provided by the wicking element. This reduced pressure can, in some instances, be large enough to reduce the effectiveness of the wicking element to draw liquid vaporizable material 102 into vaporization chamber 150, thereby reducing the effectiveness of vaporization device 100 to vaporize a desired amount of vaporizable material 102, such as when a user puffs on vaporization device 100. In extreme cases, the vacuum created within reservoir 140 can prevent all of vaporizable material 102 from being drawn into vaporization chamber 150, thereby leading to incomplete use of vaporizable material 102. To alleviate this problem, one or more venting mechanisms may be included in association with the vaporizer reservoir 140 (regardless of the placement of the reservoir 140 in the vaporizer cartridge 120 or elsewhere in the vaporizer) to allow for at least partial equalization (and optionally complete equalization) of the pressure within the reservoir 140 to the surrounding pressure (e.g., the pressure of the ambient air outside the reservoir 140).

In some cases, pressure equalization within the reservoir 140 improves the efficiency of delivery of liquid vaporizable material to the atomizer 141, but by allowing an otherwise empty void volume within the reservoir 140 (e.g., space vacated by use of the liquid vaporizable material) to fill with air. As described in more detail below, this air-filled void volume may then be subject to pressure changes relative to the ambient air, which may, under certain conditions, cause leakage of liquid vaporizable material from the reservoir 140 and ultimately to the outside of the vaporizer cartridge 120 and/or other portions of the vaporizer, including the reservoir 140. Embodiments of the present invention may provide advantages and benefits with respect to this issue as well.

Various features and devices that improve or overcome these problems are described below. For example, various features for controlling airflow and flow of vaporizable material are described herein that provide advantages and improvements over existing approaches and also introduce additional advantages as described herein. The vaporizer devices and/or cartridges described herein include one or more features that control and improve airflow within the vaporizer device and/or cartridge, thereby improving the efficiency and effectiveness of vaporization of liquid vaporizable material by the vaporizer device without introducing additional features that may lead to leakage of the liquid vaporizable material.

2E and 2F show diagrams of first and second embodiments of reservoir systems 200A, 200B, respectively, configured for use with a vaporizer cartridge (such as vaporizer cartridge 120) and/or vaporizer device (such as vaporizer 100) to improve pressure equalization and airflow within the vaporizer. More specifically, the reservoir systems 200A, 200B shown in FIGS. 2E and 2F improve regulation of pressure within the reservoir 240, such that the vacuum created within the reservoir 240 is released after a user puffs the vaporizer, reducing or even eliminating the occurrence of leakage of liquid vaporizable material through the vent structure. This allows the vaporizable material 202 to continue to be effectively drawn from the reservoir 240 into the vaporization chamber 242 after each puff due to capillary action of the porous material (e.g., wicking element) associated with the reservoir 240 and vaporization chamber 242.

As shown in FIGS. 2E and 2F, the reservoir system 200A, 200B includes a reservoir 240 configured to contain a liquid vaporizable material 202. The reservoir 240 is sealed on all sides by reservoir walls 232, except for the entire wick housing area extending between the reservoir 240 and the vaporization chamber 242. A heating element or heater may be included within the vaporization chamber 242 and coupled to a wicking element. The wicking element is configured to provide capillary action to draw the vaporizable material 202 from the reservoir 240 into the vaporization chamber 242, where it is vaporized by the heater into an aerosol. The aerosol is then combined with an airflow 234 traveling along an airflow passageway 238 of the vaporizer for inhalation by the user.

The reservoir systems 200A, 200B also include an airflow restrictor 244 that restricts the passage of the airflow 234 along the airflow passage 238 of the vaporizer, such as when a user puffs on the vaporizer. The restriction of the airflow 234 caused by the airflow restrictor 244 can create a vacuum along a portion of the airflow passage 238 downstream of the airflow restrictor 244. The vacuum created along the airflow passage 238 can help pull the aerosol formed in the vaporizer chamber 242 (e.g., the chamber that includes at least a portion of the atomizer 141) along the airflow passage 238 for inhalation by the user. At least one airflow restrictor 244 can be included in each reservoir system 200A, 200B, and the airflow restrictor 244 can include any number of mechanisms for restricting the airflow 234 along the airflow passage 238.

As shown in FIGS. 2E and 2F, each of the reservoir systems 200A, 200B may also include a vent 246 configured to selectively allow the passage of air into the reservoir 240 to increase pressure therein, such as to relieve the reservoir 240 from a negative pressure (vacuum) relative to the surrounding pressure caused by the vaporizable material 202 being drawn from the reservoir 240. At least one vent 246 may be associated with the reservoir 240. The vent 246 may be an active or passive valve, and the vent 246 may include any number of mechanisms for allowing air to flow into the reservoir 240 to relieve negative pressure created within the reservoir 240.

For example, an embodiment of the vent 246 may include a vent passageway extending between the reservoir 240 and the airflow passageway 238, with a diameter (or more generally, a cross-sectional area) sized such that when pressure is equalized across the vent 246 (e.g., the pressure in the reservoir 240 is approximately the same as the pressure in the airflow passageway 238), the fluid tension (also referred to as surface tension) of the vaporizable material 202 prevents the vaporizable material 202 from passing through the passageway. However, the diameter (or more generally, a cross-sectional area) of the vent 246 and/or the vent passageway may be sized such that the vacuum pressure created within the reservoir 240 can overcome the surface tension of the vaporizable material 202 within the vent 246 or the vent passageway such that air bubbles are released into the reservoir 240 through the vent in response to a sufficiently low pressure within the reservoir 240 relative to the ambient pressure.

Thus, a volume of air can pass from the air flow passage 238 to the reservoir 240, relieving the vacuum pressure. As the volume of air is added to the reservoir 240, the pressure again becomes more uniform across the vent 246, whereby the surface tension of the vaporizable material 202 prevents air from entering the reservoir 240 and prevents the vaporizable material from escaping the reservoir 240 through the vent passage.

In an exemplary embodiment, the diameter of the vent 246 or vent passage may range from about 0.3 mm to 0.6 mm, and may include diameters ranging from about 0.1 mm to 2 mm. In some examples, the vent 246 and/or vent passage may be non-circular, as characterized by a non-circular cross-section along the direction of fluid flow in the vent passage. In such examples, the cross-section is defined by the cross-sectional area, rather than the diameter. Generally speaking, regardless of whether the cross-sectional shape of the vent 246 and/or vent passage is circular or non-circular, in certain embodiments of the invention, it may be advantageous for the cross-sectional area of the vent 246 to vary along the path between exposure to ambient air pressure and the interior of the reservoir 240. For example, the portion of the vent 246 closer to the external ambient pressure may advantageously have a smaller cross-sectional area (e.g., a smaller diameter in examples where the vent 246 has a circular cross-section) relative to the portion of the vent 246 closer to the interior of the reservoir 240. A smaller cross-sectional area closer to the exterior of the system may provide greater resistance to the escape of liquid vaporizable material, while a larger cross-sectional area closer to the interior of the reservoir 240 may provide relatively less resistance to the escape of air bubbles from the vent 246 into the reservoir 240. In some embodiments of the invention, the transition between the smaller and larger cross-sectional areas is advantageously not continuous, but instead involves a discontinuity along the length of the vent 246 and/or vent passage. Such a structure may be useful for providing greater overall resistance to leakage of liquid material than balancing reservoir pressure due to the release of air bubbles from the vent 246, since the larger cross-sectional area near the reservoir may have a lower capillary driving force than the smaller cross-sectional area exposed to the surrounding air.

The material of the vent 246 and/or vent passage can also aid in the control of the vent 246 and/or vent passage by affecting the contact angle between the walls of the vent 246 and/or vent passage and the vaporizable material 202. The contact angle can affect the surface tension generated by the vaporizable material 202 and therefore the threshold pressure difference that occurs across the vent 246 and/or vent passage before a volume of fluid passes through the vent 246, as described above. The vent 246 can include a variety of shapes/sizes and configurations that are within the scope of the present disclosure. In addition, various embodiments of the cartridge and cartridge parts that include one or more of the various venting mechanisms are described in more detail below.

The placement of the vent 246 (e.g., a passive vent) and airflow restrictor 244 relative to the vaporization chamber 242 aids in the effective functioning of the reservoir system 200A, 200B. For example, improper placement of either the vent 246 or the airflow restrictor 244 may result in undesirable leakage of the vaporizable material 202 from the reservoir 240. The present disclosure addresses effective placement of the vent 246 and airflow restrictor 244 relative to the vaporization chamber 242 (including the wick). For example, a low or no pressure differential between the passive vent and the wick results in an effective reservoir system that releases vacuum pressure in the reservoir, providing effective capillary action of the wick while preventing leakage. The configuration of the reservoir system with effective placement of the vent 246 and airflow restrictor 244 relative to the vaporization chamber 242 is described in more detail below.

As shown in FIG. 2E, the airflow restrictor 244 can be positioned along the airflow passageway 238 upstream of the vaporization chamber 242, and the vent 246 is positioned along the reservoir 240, thereby fluidly connecting the reservoir 240 to a portion of the airflow passageway 238 downstream of the vaporization chamber 242. Thus, when a user puffs on the vaporizer, a negative pressure is created downstream of the airflow restrictor 244 such that the vaporization chamber 242 is subjected to a negative pressure. Similarly, the side of the vent 246 that communicates with the airflow passageway 238 is also subjected to a negative pressure.

Therefore, during a puff (e.g., when a user draws or inhales air from the vaporizer), there is little to no pressure difference between the vent 246 and the vaporization chamber 242. However, after a puff, the capillary action of the wick draws vaporizable material 202 from the reservoir 240 into the vaporization chamber 242, replenishing the vaporizable material 202 that was vaporized and inhaled as a result of the previous puff. As a result, a vacuum or negative pressure is created in the reservoir 240. A pressure difference is then created between the reservoir 240 and the airflow passage 238. As described above, the vent 246 can be configured to allow a pressure difference (e.g., a threshold pressure difference) between the reservoir 240 and the airflow passage 238 to allow a volume of air to pass from the airflow passage 238 to the reservoir 240, thereby releasing the vacuum in the reservoir 240 and returning to a uniform pressure across the vent 246 and a stable reservoir system 200A.

In another embodiment, as shown in FIG. 2F, the airflow restrictor 244 can be positioned along the airflow passage 238 downstream of the vaporization chamber 242, and the vent 246 can be positioned along the reservoir 240, thereby providing fluid communication between the reservoir 240 and a portion of the airflow passage 238 upstream of the vaporization chamber 242. Thus, when a user puffs on the vaporization device, there is little or no suction or negative pressure on the vaporization chamber 242 and the vent 246 as a result of the puff, and therefore little or no pressure difference between the vaporization chamber 242 and the vent 246. As in FIG. 2E, the pressure difference at the vent 246 is the result of the capillary action of the wick drawing the vaporizable material 202 into the vaporization chamber 242 after the puff. As a result, a vacuum or negative pressure is created in the reservoir 240. A pressure difference is then created across the vent 246.

As mentioned above, the vent 246 may be configured such that a pressure difference (e.g., a threshold pressure difference) between the reservoir 240 and the airflow passage 238 or atmosphere will cause a volume of air to flow into the reservoir 240, thereby relieving the vacuum within the reservoir 240. This will equalize pressure across the vent 246 and stabilize the reservoir system 200B. The vent 246 may include a variety of configurations and mechanisms and may be positioned at a variety of locations along the vaporizer cartridge 120 to achieve a variety of results. For example, one or more vents 246 may be adjacent to or form part of the vaporizer chamber 242 or a portion of the wick housing. In such a configuration, the one or more vents 246 may provide fluid (e.g., air) communication between the reservoir 240 and the vaporizer chamber 242 (through which airflow passes when a user puffs on the vaporizer and thus is part of the airflow path).

Similarly, as noted above, the vent 246 adjacent to or forming part of the vaporization chamber 242 or wick housing allows air from within the vaporization chamber 242 to move through the vent 246 into the reservoir 240, increasing the pressure within the reservoir 240, thereby effectively relieving the vacuum pressure that resulted from the vaporizable material 202 being drawn into the vaporization chamber 242. The release of the vacuum pressure thus allows for continued efficient and effective capillary action of the vaporizable material 202 through the wick into the vaporization chamber 242 to generate inhalable vapor during a subsequent puff by the user on the vaporizer. The following provides various exemplary embodiments of a venting vaporizer element (e.g., an atomizer assembly) including a wick housing 1315, 178 (containing the vaporizer) and at least one vent 596 coupled to or forming part of the wick housing 1315, 178 to achieve the above-described effective venting of the reservoir 140.

Open Face Cartridge Assembly Embodiments
3A and 3B, an exemplary cross-sectional plan view of an alternative cartridge embodiment 1320 is shown, where the cartridge 1320 includes a mouthpiece or mouthpiece region 1330, a reservoir 1340, and an atomizer (not shown separately). The atomizer can include a heating element 1350 and a wicking element 1362, together or separately, depending on the embodiment, where the wicking element 1362 is thermally or thermodynamically coupled to the heating element 1350 for the purpose of vaporizing vaporizable material 1302 drawn from or stored in the wicking element 1362.

In one embodiment, a plate 1326 may be included to provide an electrical connection between the heating element 1350 and the power source 112 (see FIG. 1). An airflow passage 1338 defined through or on the side of the reservoir 1340 may connect an area within the cartridge 1320 that contains the wicking element 1362 (e.g., a wick housing, not shown separately) to an opening leading to the mouthpiece or mouthpiece area 1330, providing a path for the vaporized vaporizable material 1302 to travel from the heating element 1350 area to the mouthpiece area 1330.

As provided above, the wicking element 1362 may be coupled to an atomizer or heating element 1350 (e.g., a resistive heating element or coil) that is connected to one or more electrical contacts (e.g., plate 1326). The heating element 1350 (and other heating elements described herein according to one or more embodiments) may have various shapes and/or configurations and include one or more heating elements 1350, 500, or mechanisms thereof, as provided in more detail below with respect to FIGS. 44A-116.

According to one or more exemplary embodiments, the heating element 1350 of the cartridge 1320 is made (e.g., punched) from a sheet of material and is crimped or bent around at least a portion of the wicking element 1362 to provide a preformed element configured to receive the wicking element 1362 (e.g., the wicking element 1362 is pressed into the heating element 1350 and/or the heating element 1350 is held in tension and pulled over the wicking element 1362).

The heating element 1350 may be bent such that the heating element 1350 secures the wicking element 1362 between at least two or three portions of the heating element 1350. The heating element 1350 may be bent to conform to the shape of at least a portion of the wicking element 1362. The configuration of the heating element 1350 allows for more consistent, high quality manufacturing of the heating element 1350. Consistency in the manufacturing quality of the heating element 1350 is particularly important during scaled and/or automated manufacturing processes. For example, the heating element 1350 according to one or more embodiments helps reduce tolerance issues that may arise during the manufacturing process when assembling a heating element 1350 having multiple components.

The heating element 1350 may also improve the accuracy of measurements (e.g., resistance, current, temperature, etc.) taken from the heating element 1350 due at least in part to improved consistency in manufacturability of the heating element 1350 with reduced tolerance issues. The heating element 1350 being made (e.g., punched) from a sheet of material and crimped or bent around at least a portion of the wicking element 1362 to provide a preformed element desirably helps minimize heat loss and ensures that the heating element 1350 operates predictably to heat to the appropriate temperature.

Additionally, as described further below with respect to embodiments including heating elements formed of crimped metal, the heating element 1350 may be fully and/or selectively plated with one or more materials to enhance the heating performance of the heating element 1350. Plating all or a portion of the heating element 1350 can minimize heat loss. The plating also helps to concentrate heat in a portion of the heating element 1350, thereby providing a heating element 1350 that heats more efficiently and further reduces heat loss. Selective plating helps direct the current supplied to the heating element 1350 to the appropriate location. Selective plating also helps to reduce the amount of plating material and/or costs associated with manufacturing the heating element 1350.

In addition to or in combination with the exemplary heating elements described and/or illustrated below, the heating elements may include a flat heating element 1850 disposed within a vaporizer cartridge 1800 including two airflow passages 1838 (see FIGS. 18A-18D), a folded heating element 1950 disposed within a vaporizer cartridge 1900 including two airflow passages 1938 (see FIGS. 19A-19C, 22A-22B, and 44A-116), and a folded heating element 2050 disposed within a vaporizer cartridge 2000 including a single airflow passage 2038 (see FIGS. 20A-20C).

As mentioned above, in one embodiment, the heating element 1350 can include a wicking element 1362. For example, the wicking element 1362 can extend near or adjacent to the plate 1326 and through a resistive heating element in contact with the plate 1326. A wick housing can surround at least a portion of the heating element 1350 and directly or indirectly connect the heating element 1350 to the airflow passage 1338. The vaporizable material 1302 can be drawn by the wicking element 1362 through one or more passages connected to the reservoir 1340. In one embodiment, one or both of the primary passages 1382 or secondary passages 1384 can be utilized to help direct the vaporizable material 1302 to one or both ends of the wicking element 1362 or radially along the length of the wicking element 1362.

Overflow Collector Embodiments
As provided in further detail below, with particular reference to Figures 3A and 3B, the exchange of air and liquid vaporizable material in and out of the cartridge reservoir 1340 is advantageously controlled, and the volumetric efficiency of the vaporizer cartridge (defined as the volume of liquid vaporizable material ultimately converted into inhalable aerosol relative to the total volume of the cartridge itself) may also be improved, optionally, by incorporating a structure called a collector 1313.

According to some embodiments, the cartridge 1320 may include a reservoir 1340 at least partially defined by at least one wall (which may optionally be a wall shared with the outer shell of the cartridge) configured to contain the liquid vaporizable material 1302. The reservoir 1340 may include a storage chamber 1342 and an overflow volume 1344, which may contain or contain the collector 1313. The storage chamber 1342 may contain the vaporizable material 1302, and the overflow volume 1344 may be configured to collect or hold at least a portion of the vaporizable material 1302 when the vaporizable material 1302 in the reservoir storage chamber 1342 moves to the overflow volume 1344 due to one or more factors. In some embodiments of the present invention, the liquid vaporizable material may be initially filled into the cartridge to pre-fill the void in the collector with the liquid vaporizable material.

In an exemplary embodiment, when the volume of the contents within the storage chamber 1342 expands due to the maximum anticipated pressure change that the reservoir may experience relative to the ambient pressure, the volume size of the overflow volume 1344 can be configured to be equal to, approximately equal to, or greater than the increase in volume of the contents (e.g., vaporizable material 1302 and air) contained within the storage chamber 1342.

In response to changes in ambient pressure or temperature or other factors, the cartridge 1320 may experience a change from a first pressure state to a second pressure state (e.g., a first relative pressure difference between the reservoir interior and the ambient pressure and a second relative pressure difference between the reservoir interior and the ambient pressure). In some aspects, the overflow volume 1344 may have an opening to the exterior of the cartridge 1320 and may be in communication with the reservoir storage chamber 1342, so that the overflow volume 1344 may equalize pressure within the cartridge 1320 and/or function as a vent channel to collect, at least temporarily hold, and selectively reversibly return liquid vaporizable material that moves from the storage chamber in response to fluctuations in the pressure difference between the storage chamber and the ambient air. As described herein, pressure difference refers to the absolute pressure difference between the interior of the reservoir and the ambient air. Vaporizable material 1302 may be drawn from the reservoir 1342 into the atomizer and converted to a vapor or aerosol phase, reducing the volume of vaporizable material remaining in the reservoir 1342, and potentially resulting in at least a partial vacuum as previously described herein, due to the absence of any mechanism for returning air to the reservoir and equalizing the pressure therein with the ambient pressure.

3A and 3B, the reservoir 1340 may be implemented to include first and second separable regions such that the volume of the reservoir 1340 is divided into a reservoir storage chamber 1342 and a reservoir overflow volume 1344. The storage chamber 1342 may be configured to store the vaporizable material 1302 and may be further coupled to the wicking element 1362 via one or more primary passages 1382. In some examples, the primary passages 1362 may be very short in length (e.g., a through hole from a space containing the wicking element or other parts of the atomizer). In other examples, the primary passages may be part of a longer containment fluid path between the storage chamber and the wicking element. The overflow volume 1344 may be configured to store and contain a portion of the vaporizable material 1302 that may overflow the storage chamber 1342 in a second pressure state in which the pressure in the storage chamber 1342 is higher than the ambient pressure, as provided in further detail below.

In a first pressure state, the vaporizable material 1302 may be stored in the storage chamber 1342 of the reservoir 1340. The first pressure state may exist, for example, when the ambient pressure is approximately equal to or greater than the pressure inside the cartridge 1320. In this first pressure state, the structural and functional characteristics of the primary passageway 1382 and the secondary passageway 1384 are such that the vaporizable material 1302 can flow from the storage chamber 1342 through the primary passageway 1382 toward the wicking element 1362, for example, under the capillary action of the wicking element, which draws the liquid near the heating element, which acts to convert the liquid vaporizable material to a gas phase.

In one embodiment, in a first pressure state, the vaporizable material 1302 does not flow or flows only in a limited amount into the secondary passageway 1384. In a second pressure state, the vaporizable material 1302 may flow from the storage chamber 1342 to, for example, an overflow volume 1344 of the reservoir 1340, which includes a collector 1313 that prevents or limits undesired (e.g., excessive) flow of the vaporizable material 1302 from the reservoir. The second pressure state may exist or be caused, for example, when a gas bubble expands in the storage chamber 1342 (e.g., by the ambient pressure becoming less than the pressure in the cartridge 1320).

Advantageously, the flow of vaporizable material 1302 may be controlled by sending the vaporizable material 1302 drawn from the reservoir 1342 by the pressure increase to the overflow volume 1344. The collector 1313 in the overflow volume may include one or more capillary structures that contain at least some (and advantageously all) of the excess liquid vaporizable material pushed out of the reservoir 1342 without allowing the liquid vaporizable material to reach the outlet of the collector 1313. The collector 1313 may also advantageously include a capillary structure that may reversibly draw back into the reservoir 1342 the liquid vaporizable material forced into the collector 1313 by the excess pressure in the reservoir 1342 relative to the ambient pressure when the pressure of the reservoir 1342 relative to the ambient pressure equalizes or otherwise decreases. In other words, the secondary passage 1384 of the collector 1313 may have a microfluidic feature or characteristic that prevents air and liquid from bypassing each other during filling and draining of the collector 1313. That is, microfluidic mechanisms can be used to manage the flow of vaporizable material 1302 to and from collector 1313 (i.e., provide a flow reversal mechanism) to prevent or reduce leakage of vaporizable material 1302 or trapping of bubbles in reservoir 1342 or overflow volume 1344.

Depending on the embodiment, the above microfluidic features or characteristics may relate to the size, shape, surface coating, structural features and capillary properties of the wicking element 1362, the primary passageway 1382 and the secondary passageway 1384. For example, the secondary passageway 1384 of the collector 1313 may selectively have different capillary properties than the primary passageway 1382 leading to the wicking element 1362 to allow a quantity of the vaporizable material 1302 to move from the reservoir 1342 to the overflow volume 1344 during the second pressure condition.

In one exemplary embodiment, the overall resistance of the collector 1313 to allow liquid to flow out is greater than the overall wick resistance, for example, allowing the vaporizable material 1302 to flow primarily through the primary passageway 1382 toward the wicking element 1362 during the first pressure condition.

The wicking element 1362 may provide a capillary path through or into the wicking element 1362 for the vaporizable material 1302 stored in the reservoir 1340. The capillary path (e.g., primary passageway 1382) may be large enough for wicking or capillary action to displace the vaporized vaporizable material 1302 in the wicking element 1362, and small enough to prevent the vaporizable material 1302 from leaking out of the cartridge 1320 during a negative pressure event. The wick housing or wicking element 1362 may be treated to prevent leakage. For example, the cartridge 1320 may be coated after filling to prevent leakage or vaporization through the wicking element 1362. Any suitable coating may be used, including, for example, a thermal vaporizable coating (e.g., wax or other material).

For example, when a user inhales through the mouthpiece area 1330, air enters the cartridge 1320 through an inlet or opening in operative relationship with the wicking element 1362. The heating element 1350 may be activated in response to a signal generated by one or more sensors 113 (see FIG. 1). The one or more sensors 113 may include at least one of a pressure sensor, a motion sensor, a flow sensor, or other mechanism capable of detecting a change in the airflow passage 1338. When the heating element 1350 is activated, the heating element 1350 may increase in temperature due to an electrical current passing through the plate 1326 or through other electrically resistive portions of the heating element that act to convert electrical energy to thermal energy.

In one embodiment, the generated heat is transferred to at least a portion of the vaporizable material 1302 within the wicking element 1362 via conductive, convective, or radiative heat transfer, thereby vaporizing at least a portion of the vaporizable material 1302 drawn into the wicking element 1362. Depending on the embodiment, air entering the cartridge 1320 flows over (or around, near, etc.) the wicking element 1362 and the heated elements within the heating element 1350, drawing the vaporized vaporizable material 1302 away into the airflow passage 1338, where the vapor may be selectively condensed and delivered through an opening in the mouthpiece region 1330, e.g., in the form of an aerosol.

Referring to FIG. 3B, the reservoir 1342 may be connected to the airflow passageway 1338 (i.e., via a secondary passageway 1384 of the overflow volume 1344) so that liquid vaporizable material drawn from the reservoir 1342 due to an increase in pressure in the reservoir 1342 relative to the environment can be retained without leaking from the vaporizer cartridge. While the embodiments described herein relate to a vaporizer cartridge including a reservoir 1340, it should be understood that the described approach is also compatible with and contemplated for use in vaporizers that do not have a separable cartridge.

Returning to the example, the air contained within the reservoir 1342 may expand due to a pressure differential with the surrounding air. This expansion of air within the reservoir 1342 void may cause the liquid vaporizable material to move through at least a portion of the secondary passage 1384 within the collector 1313. Due to the microfluidic characteristics of the secondary passage 1384, the liquid vaporizable material may move along the length of the secondary passage 1384 within the collector 1313 with only a meniscus completely covering the cross-sectional area of the secondary passage 1384 transverse to the direction of flow along the length.

In some embodiments of the invention, the microfluidic mechanism may include a cross-sectional area that is sufficiently small for the material from which the walls of the secondary passages are formed and the composition of the liquid vaporizable material that the liquid vaporizable material preferentially wets the secondary passages 1384 around the entire circumference of the secondary passages 1384. In an example where the liquid vaporizable material includes one or more of propylene glycol and vegetable glycerin, the wetting properties of such liquids are advantageously considered in combination with the shape of the secondary passages 1384 and the material from which the walls of the secondary passages are made. In this manner, as the sign (e.g., positive, negative, or equal) and magnitude of the pressure difference between the reservoir 1340 and the ambient pressure changes, a meniscus between the liquid in the secondary passages and the air entering from the ambient atmosphere is maintained, and the liquid and air cannot pass each other. If the pressure in the reservoir 1342 drops sufficiently relative to the surroundings and there is sufficient void volume in the reservoir 1342 to allow it, the liquid in the secondary passage 1384 of the collector 1313 will be drawn into the reservoir 1342 enough for a primary liquid-air meniscus to reach the gate or port between the secondary passage 1384 of the collector 1313 and the reservoir 1342. At such a time, if the pressure difference in the reservoir 1342 relative to the surroundings is negative enough to overcome the surface tension forces maintaining the meniscus at the gate or port, the meniscus will break free from the gate or port wall and form one or more air bubbles that are released into the reservoir 1342 in a volume sufficient to equalize the pressure of the reservoir relative to the surroundings.

When the air that has been admitted (or that has become present) in the storage chamber 1340 as described above becomes under high pressure relative to the surroundings (e.g., a drop in the surroundings pressure, which may occur when a window of a moving vehicle is opened in an airplane cabin or other high altitude, when a train or vehicle leaves a tunnel, etc., or an increase in the interior pressure of the storage chamber 1340, which may occur due to local heating, mechanical pressures that distort the shape and thereby reduce the volume of the storage chamber 1340, etc.), the above process may be reversed. The liquid enters the secondary passage 1384 of the collector 1313 through a gate or port, and a meniscus forms at the leading edge of the column of liquid entering the secondary passage 1384, preventing air from flowing in a bypass against the progress of the liquid. If the high pressure in the storage chamber 1340 is later reduced, the column of liquid is selectively drawn back into the storage chamber until the meniscus reaches the gate or port, by maintaining this meniscus due to the presence of the microfluidic properties described above. If the pressure difference is sufficiently favorable to the surroundings pressure compared to the pressure in the storage chamber, the above-mentioned bubble formation process occurs until the pressures are equalized. In this manner, the collector functions as a reversible overflow volume to receive liquid vaporizable material expelled from the storage chamber under temporary conditions of higher than ambient pressure in the storage chamber, and allows at least a portion (and preferably all or most) of this overflow volume to be returned to the storage compartment for subsequent delivery to the atomizer for conversion to an inhalable form.

Depending on the embodiment, the reservoir 1342 may or may not be connected to the wicking element 1362 via the secondary passageway 1384. In embodiments in which the second end of the secondary passageway 1384 leads to the wicking element 1362, any vaporizable material 1302 that may exit the secondary passageway 1384 at the second end (opposite the first end that defines the contact point to the reservoir 1342) may further saturate the wicking element 1362.

The reservoir 1342 may be selectively located closer to the end of the reservoir 1340 near the mouthpiece area 1330. The overflow volume 1344 may be located, for example, between the reservoir 1342 and the heating element 1350, closer to the end of the reservoir 1340 closer to the heating element 1350. The exemplary embodiment shown in the figures should not be construed as limiting the scope of the claimed invention with respect to the location of the various components disclosed herein. For example, the overflow volume 1344 may be located at the top, middle, or bottom of the cartridge 1320. The location and location of the reservoir 1342 may be adjusted relative to the location of the overflow volume 1344 by one or more modifications, such that the reservoir 1342 may be located at the top, middle, or bottom of the cartridge 1320.

In one embodiment, when the vaporizer cartridge 1320 is filled to capacity, the volume of liquid vaporizable material may be equal to the internal volume of the storage chamber 1342 plus the overflow volume 1344 (which in some examples may be the volume of the secondary passageway 1384 between the gate or port connecting the secondary passageway 1384 to the storage chamber 1340 and the outlet of the secondary passageway 1384). In other words, a vaporizer cartridge consistent with an embodiment of the present invention may be initially filled with liquid vaporizable material such that all or at least a portion of the internal volume of the collector is filled with liquid vaporizable material. In such an example, the liquid vaporizable material is pumped to the atomizer when needed for delivery to the user. The pumped liquid vaporizable material is drawn from the storage chamber 1340, which may draw the liquid in the secondary passageway 1384 of the collector 1313 back into the storage chamber 1340. This is because air cannot enter through the secondary passage 1384 due to the meniscus maintained by the microfluidic properties of the secondary passage 1384, which prevents air from flowing past the liquid vaporizable material in the secondary passage 1384. After enough liquid vaporizable material has been sent from the storage chamber 1340 to the atomizer (e.g., for vaporization and user inhalation) to draw the original volume of the collector 1313 into the storage chamber 1340, the above action occurs, i.e., as more liquid vaporizable material is used, air bubbles may be released from a gate or port between the secondary passage 1384 and the storage chamber to equalize the pressure in the storage compartment. If the air thus entering the storage compartment becomes high pressure relative to the surroundings, the liquid vaporizable material will move out of the storage chamber 1340 through the gate or port into the secondary passage until the high pressure condition no longer exists in the storage compartment, at which point the liquid vaporizable material in the secondary passage 1384 may be drawn back into the storage chamber 1340.

In certain embodiments, the overflow volume 1344 is large enough to selectively contain up to about 100% of the percentage of vaporizable material 1302 stored in the storage chamber 1342. In one embodiment, the collector 1313 is configured to contain at least 6% to 25% of the volume of vaporizable material 1302 storable in the storage chamber 1342. Other ranges are possible.

The structure of the collector 1313 may be configured, constructed, shaped, fabricated or arranged in the overflow volume 1344 to have different shapes and different properties to allow the overflow portion of the vaporizable material 1302 to be received, contained or stored in the overflow volume 1314 in a controlled manner (e.g., by capillary pressure) to prevent the vaporizable material 1302 from leaking from the cartridge 1320 or from oversaturating the wicking element 1362. It will be understood that the above description referring to a secondary passage is not intended to be limited to a single such secondary passage 1384. One or alternatively two or more secondary passages may be connected to the storage chamber 1340 through one or more gates or ports. In some embodiments of the invention, a single gate or port may connect to multiple secondary passages or a single secondary passage may split into multiple secondary passages to provide additional overflow volume or other benefits.

In some implementations of the invention, the air vent 1318 can connect the overflow volume 1344 to an air flow passageway 1338 that ultimately leads to the ambient air environment outside the cartridge 1320. This air vent 1318 can allow a path for air or bubbles formed or trapped within the collector 1313 to escape through the air vent 1318, for example, during a second pressure condition when the secondary passageway 1384 fills with an overflow of vaporizable material 1302.

According to some aspects, the air vent 1318 can act as a reverse vent during the return from the second pressure state to the first pressure state to equalize the pressure within the cartridge 1320 when the overflow of the vaporizable material 1302 returns from the overflow volume 1344 back to the storage chamber 1342. In this embodiment, as the ambient pressure becomes greater than the internal pressure of the cartridge 1320, ambient air can flow through the air vent 1318 into the secondary passageway 1384 and help effectively push the vaporizable material 1302 temporarily stored in the overflow volume 1344 back in the reverse direction back to the storage chamber 1342.

In one or more embodiments, the secondary passageway 1384 in the first pressure state can include air. In the second pressure state, the vaporizable material 1302 can enter the secondary passageway 1384, for example, through an opening (i.e., a vent) at the interface between the reservoir 1342 and the overflow volume 1344. As a result, air in the secondary passageway 1384 can move and exit through the air vent 1318. In some embodiments, the air vent 1318 can act as or include a control valve (e.g., a selectively permeable membrane, a microfluidic gate, etc.) that allows air to exit the overflow volume 1344 but blocks the vaporizable material 1302 from exiting the secondary passageway 1384 to the airflow passageway 1338. As previously mentioned, the air vent 1318 may function as an air exchange port to allow air to enter or exit the collector 1313, for example, when the collector 1313 fills during a negative pressure event and empties after the negative pressure event (i.e., during the transition between the first and second pressure states described above).

Thus, the vaporizable material 1302 may be stored in the collector 1313 until the pressure in the cartridge 1320 stabilizes (e.g., the pressure returns to ambient or reaches a specified equilibrium) or until the vaporizable material 1302 is removed from the overflow volume 1344 (e.g., by vaporization in an atomizer). Thus, the level of vaporizable material 1302 in the overflow volume 1344 can be controlled by managing the flow of vaporizable material 1302 into and out of the collector 1313 as the ambient pressure changes. In one or more embodiments, the overflow of vaporizable material 1302 from the storage chamber 1342 to the overflow volume 1344 may be reversible or reversible in response to changes detected in the environment (e.g., the pressure event causing the overflow of vaporizable material 1302 subsides or ends).

As described above, in some embodiments of the present invention, in a state where the internal pressure of the cartridge 1320 becomes relatively lower than the ambient pressure (e.g., when returning from the second pressure state described above to the first pressure state), the flow of the vaporizable material 1302 can be reversed to cause the vaporizable material 1302 to flow back from the overflow volume 1344 to the storage chamber 1342 of the reservoir 1340. Thus, depending on the embodiment, the overflow volume 1344 may be configured to temporarily accommodate the overflow portion of the vaporizable material 1302 during the second pressure state. Depending on the embodiment, during or after the reversal to the first pressure state, at least a portion of the overflow of the vaporizable material 1302 held in the collector 1313 is returned to the storage chamber 1342.

To control the flow of vaporizable material 1302 in cartridge 1320, in other embodiments of the present invention, collector 1313 can optionally include absorbent or semi-absorbent material (e.g., material having sponge-like properties) to permanently or semi-permanently collect or contain overflow of vaporizable material 1302 passing through secondary passage 1384. In exemplary embodiments in which collector 1313 includes absorbent material, backflow of vaporizable material 1302 from overflow volume 1344 to reservoir 1342 may not be practical or possible compared to embodiments implemented without (or with) much absorbent material in collector 1313. Thus, the reversibility or rate of reversibility of vaporizable material 1302 to reservoir 1342 can be controlled by including more or less density or volume of absorbent material in collector 1313 or by controlling the texture of the absorbent material, such properties resulting in higher or lower absorption rates immediately or over a longer period of time.

4 is an exploded perspective view of an exemplary embodiment of the cartridge 1320. As shown, the body of the cartridge 1320 may be made of two connectable (or separable) parts, such as a first part 1422 (e.g., upper housing) and a second part 1424 (e.g., lower housing), which are assembled together by a top-down architecture implementation model or assembly process. This separable architecture simplifies the assembly and manufacturing process and eliminates the need to assemble or configure multiple smaller parts to build a larger part. Instead, as in the exemplary embodiment shown in FIG. 4, larger parts (e.g., first part 1422 and second part 1424) may be connected to form, for example, an external cartridge feature (e.g., siding) and smaller internal cartridge components (e.g., opposing rib-shaped elements that form one or more of the collector 1313, reservoir 1340, storage chamber 1342, overflow volume 1344, etc.).

Referring to FIG. 4, the heating element 1450 may be disposed in a cavity or housing mounted between the first portion 1422 and the second portion 1424 of the body of the cartridge 1420. In one example, a sponge or other absorbent material 1460 may also be disposed in the mouthpiece area 1430 for the purpose of collecting excess liquid vaporizable material (e.g., vaporizable material and/or water vapor that may form due to condensation, forming larger droplets that may cause an unpleasant sensation when ingested during inhalation) passing through the airflow passage 1438. Thus, assembly or disassembly of additional components (e.g., the heating element 1450 or the sponge 1460) may be performed in a simple and efficient manner, which may not require a large number of machines or assembly automation parts to build the cartridge 1320 from a small set of components into an integrated separable two-piece housing in the exemplary implementations disclosed herein.

The separable two-piece construction described herein may provide one or more of the following exemplary advantages or improvements over alternative embodiments: reduced part count, reduced assembly or manufacturing costs (e.g., the embodiment shown in FIG. 4 requires four parts to manufacture and assemble), no or reduced tooling requirements, no or limited deep, fragile, low draft tooling cores, and relatively shallow rib construction. Depending on the embodiment, ultrasonic or laser welding techniques may be utilized to create a solid-state weld between the first portion 1422 and the second portion 1424 of the cartridge 1420.

Ultrasonic welding is a process commonly used for plastics in which high frequency ultrasonic vibrations are applied locally to workpieces (e.g., first portion 1422 and second portion 1424) that are held together under pressure to form a solid-state weld. Laser welding is a welding process used to join metal or thermoplastic parts using a laser beam that provides a focused heat source (such as a laser beam) allowing for narrow and deep welds at high welding speeds.

With reference to FIG. 5, a planar cross-sectional side view of selected portions of the cartridge 1320 is shown. With reference to both FIGS. 4 and 5, the first portion 1422 (not shown in FIG. 5) and second portion 1424 of the cartridge 1420 may be molded from a plastic part by injection molding (e.g., top-down mounting model). In an exemplary embodiment, a line-drawing tool technique is used to allow separation of the mold halves (e.g., first portion 1422 and second portion 1424 shown in FIG. 4) to allow the portions to be ejected unobstructed from the developing undercuts, and to allow significant hollowing out of the mold, thereby shortening the tooling cycle and making the manufacturing time and process more efficient.

6A and 6B, a cross-sectional top view and a perspective side view of the cartridge 1320 are shown, respectively. As shown, a fill port 610 can be implemented in one or more embodiments of the cartridge 1320 to fill the reservoir chamber 1342, for example, via a fill needle 622. As shown, the fill needle 622 can be easily and conveniently insertable into the fill port 610, for example, via a fill passage 630 leading to the reservoir chamber 1342 (or overflow volume 1344), depending on the embodiment. Thus, the vaporizable material 1302 can be injected into the reservoir 1340, for example, via the fill passage 630 using the fill needle 622. In some embodiments, the fill passage 630 can be constructed or located on a side of the cartridge 1320, for example, opposite the side where the airflow passage 1338 is located.

7A-7D show alternative designs of the cartridge connection port. FIGS. 7A and 7B are perspective views and FIGS. 7C and 7D are plan cross-sectional side views of alternative connection port embodiments, which may include male or female engagement portions, for example. With reference to FIGS. 1, 2 and 7A-7D, the cartridge 1320 may be implemented with different configurations at the end where the cartridge 1320 engages with the vaporizer body 110. In one embodiment, as shown in FIGS. 1 and 2, the vaporizer body 110 may include a cartridge receptacle 118 that removably receives the cartridge 1320 with a male configuration port 710 (see FIGS. 7A and 7C), such that in an attached state, the contacts 124 disposed at the male port of the cartridge 1320 are received by corresponding receptacle contacts 125 in the cartridge receptacle 118, for example, in a snap-lock manner. The mating configuration may be directed to a cartridge 1320 having a female configuration port 712 (see FIGS. 7B and 7D) for receiving the end of the vaporizer body 110 that includes the receptacle contacts 125.

8, a planar top view of the cartridge 1320 is shown. In one example, the cartridge 1320 may be implemented using a separable two-piece construction, and a relief (e.g., proprietary trademark, serial number, patent number, etc.) or optional decorative or ornamental features may be imprinted on the exterior wall of the cartridge 1320 by a molding process. The molding process allows flexibility in designing the exterior shape or an externally displayable logo or decorative design without affecting the placement or formation of the internal functional components (e.g., reservoir 1340, storage chamber 1342, or overflow volume 1344).

In particular, the JUUL® mark shown in FIG. 8 is a registered trademark of JUUL LABS, Inc., a Delaware corporation headquartered in San Francisco, California. All rights are reserved to the mark owner or assignee. Use of the exemplary mark in FIG. 8 should not be construed as limiting the scope of the disclosed invention to include such exclusive designs or markings. Certain embodiments may be devoid of marks or include no decorative or external design features at all. Thus, FIG. 8 provides a non-limiting illustration of a molded relief that may appear as a mark or design on one or more sides of the cartridge 1320.

9A and 9B, a perspective view and a top cross-sectional view of an exemplary cartridge 1320 are shown, with a first portion 1422 of the cartridge 1320 separated from a second portion 1424 (see also FIG. 4). In one or more embodiments, the cartridge 1320 may be designed and manufactured in a split-part manner, i.e., multiple split sections of a part are connected to generate an entire part, as shown in the example of FIG. 4, depending on the embodiment.

Referring to FIG. 9A, part separation may allow for a molded fit for electrical contacts and heating element retention within the wick housing region 910 of the cartridge 1320. As shown in more detail in FIG. 9B, one or more vents 920 may be drilled or placed by injection molding or other suitable method into the body of the cartridge 1320 in an area proximate the wick housing region 910 to allow pinpoint evacuation of vapor or airflow to the wick, for example, to control condensation within the cartridge 1320 or to affect capillary forces therein.

10A and 10B, assembled and exploded perspective views, respectively, of an alternative exemplary embodiment of the cartridge 1320 are shown. As previously described, a top-down mounting model can be used to build an open-face cartridge structure with two attachable (or removable) housings, including, for example, a first portion 1422 and a second portion 1424. As shown, the first portion 1422 (e.g., upper housing) and the second portion 1424 (e.g., lower housing) can provide a two-piece structure having one or more internal cavities that can be utilized to accommodate at least one of the heating element 1350, the wicking element 1362, or the plate 1326. It should be understood that alternative assembly methods can be used to result in a structure having some or all of the features described herein.

In particular, in the exemplary embodiment shown in Figures 10A and 10B, instead of or in addition to using molded cavities and walls to form the internal structure of the cartridge (e.g., reservoir 1340 in Figure 3A), some features, such as secondary passage 1384 (see Figure 3A), may be constructed independently as separate parts and embodied in a removable or attachable collector 1313 that may then either be placed between first portion 1422 and second portion 1424 (see, e.g., Figures 10A and 10B) or inserted into an optional monolithic hollow cartridge body adapted to receive the collector 1313 from an open end (see Figures 10C, 10D, 11B, 13, 16C, 17A, 22F).

With reference to Figures 10A through 43B, various embodiments are disclosed that may utilize a collector 1313 that is configured, designed, manufactured, fabricated or constructed completely or partially independent of the cartridge 1320 housing. It is worth noting that the disclosed embodiments are provided as examples. In alternative embodiments or embodiments, the collector 1313 may be formed with a structure that is at least structurally semi-dependent or completely independent of the structure of the other components of the cartridge 1320, as shown in Figures 10A through 14B.

In certain interchangeable embodiments, various embodiments or types of collector 1313, such as those shown in FIGS. 10A-14B, may be inserted or placed into a standardized cartridge 1320 housing, for example. As provided in further detail herein, some of the primary functions for controlling the flow of vaporizable material 1302 within the cartridge 1320 can be accomplished by manipulating the collector 1313 structure or its material properties, so that cost savings and other efficiencies and advantages are derived from having a structure that allows for interchangeable collector 1313 models that can be fitted to different cartridge housings, for example.

10C and 10D, for example, in some embodiments, instead of the separable two-piece structure shown in FIGS. 10A and 10B, the cartridge 1320 may have a cartridge housing formed of a monolithic hollow structure having a first end and a second end. The first end (i.e., the first end, also referred to as the receiving end of the cartridge housing) may be configured to insertably receive at least the collector 1313. In one embodiment, the second end of the cartridge housing may function as a mouthpiece with an orifice or opening. The orifice or opening may be located opposite the receiving end of the cartridge housing where the collector 1313 may be insertably received. In some embodiments, the opening may be connected to the receiving end by an airflow passage 1338, which may extend, for example, through the body of the cartridge 1320 and the collector 1313. As with other cartridge embodiments consistent with the present disclosure, the atomizer, for example those including wicking and heating elements described elsewhere herein, may be disposed adjacent to or at least partially within the airflow passage 1338 such that an inhalable form of liquid vaporizable material, or a precursor in a selectively inhalable form, may be released from the atomizer into air flowing through the airflow passage 1338 toward an orifice or opening.

(Air Exchange Port Embodiments)
11A and 11B, exemplary planar side views of a single-gate, single-channel collector 1313 are shown. In these exemplary embodiments, a gate 1102 may be provided at an opening facing a first portion (e.g., top) of the collector 1313 where the collector 1313 contacts or communicates with a reservoir chamber 1342 (see also FIGS. 3A and 3B above). The gate 1102 may dynamically connect the reservoir chamber 1342 to an overflow volume 1344 formed by a second portion (e.g., middle portion) of the collector 1313.

In one embodiment, the second portion of the collector 1313 may have a ribbed or multi-fin shaped structure that forms an overflow channel 1104 that is spiraled, tapered or sloped in a direction away from the gate 1102 and toward the air exchange port 1106, as shown in FIG. 11A, to move the vaporizable material 1302 toward the air exchange port 1106 after the vaporizable material 1302 passes through the gate 1102 and enters the overflow volume 1344. The air exchange port 1106 may be connected to the ambient air through an air path or air flow passage connected to the mouthpiece. This air path or air flow passage is not explicitly shown in FIG. 11A.

In some embodiments, the collector 1313 is configured to have a central opening or tunnel through which an airflow channel leading to the mouthpiece is implemented, as provided in further detail below (see, for example, the opening designated 1100 in FIG. 11D). The airflow channel may be connected to the air exchange port 1106 such that the volume in the overflow passage of the collector 1313 is connected to the ambient air via the air exchange port 1106 and to the volume of the reservoir 1342 via the gate 1102. Thus, according to one or more embodiments, the gate 1102 may be utilized as a control fluid valve to primarily control the flow of liquid and air between the overflow volume 1344 and the reservoir 1342. The air exchange port 1106 may be utilized to primarily control the flow of air (and possibly liquid) between, for example, the overflow volume 1344 and the air path leading to the mouthpiece. The overflow channel 1104 may be oblique, vertical, or horizontal to the elongated body of the cartridge 1320.

The vaporizable material 1302 may have at least an initial interface with the collector 1313 through the gate 1102 at the time the cartridge 1320 is filled. This is because the initial interface between the vaporizable material 1302 and the gate 1102 may prevent, for example, air trapped in the overflow channel 1104 from entering the area of the cartridge where the vaporizable material 1302 is stored (e.g., the storage chamber 1342). Furthermore, such an interface may initiate a first capillary interaction between the vaporizable material 1302 and the wall of the overflow channel 1104 at equilibrium to allow a limited amount of the vaporizable material 1302 to flow into the overflow channel 1104 to achieve or maintain the equilibrium state.

An equilibrium state refers to a state in which vaporizable material 1302 does not flow into or out of overflow volume 1344, or such forward or reverse flow is negligible. In at least some embodiments, when the internal pressure of reservoir 1342 is approximately equal to the ambient pressure, the capillary action (or interaction) between the walls of overflow channel 1104 and vaporizable material 1302 is such that an equilibrium state is maintained when cartridge 1320 is in the first pressure state.

Establishment of equilibrium and further capillary interaction between the vaporizable material 1302 and the walls of the overflow channel 1104 can be established or configured by adapting or adjusting the volumetric size of the overflow channel 1104 along the length of the channel. As provided in further detail herein, the diameter of the overflow channel 1104 (used herein to generally refer to a measure of the size of the cross-sectional area of the overflow channel 1104, including embodiments of the invention in which the overflow channel does not have a circular cross-section) can be constricted at predetermined intervals or points, or over the entire length of the channel, in response to pressure changes to allow sufficiently strong capillary interactions to allow forward or reverse flow of the vaporizable material 1302 into or out of the collector 1313, and further increase the total volume of the overflow channel while maintaining the gate point of meniscus formation to prevent air from passing through the liquid in the overflow channel 1104.

As provided in further detail herein, the diameter of the overflow channel 1104 may be small or narrow enough that a combination of surface tension forces caused by cohesion in the vaporizable material 1302 and wetting forces between the vaporizable material 1302 and the walls of the overflow channel 1104 may act to cause the formation of a meniscus that separates the liquid from the air in a dimension transverse to the axis of flow in the overflow channel 1104 such that the air and liquid cannot pass each other. It will be understood that the meniscus has an inherent curvature, so reference to a dimension transverse to the direction of flow does not imply that the gas-liquid interface is planar in this or any other dimension.

The wicking element 1362 may be in thermal or thermodynamic communication with the heating element 1350 (see, e.g., FIGS. 3B and 11B) to induce the generation of vapor from heating of the vaporizable material 1302, as described in detail above with reference to FIGS. 3A and 3B. Alternatively, the air exchange port 1106 may be constructed to provide an escape route for gas but prevent the flow of the vaporizable material 1302 from the overflow channel 1104.

11A and 11B, the forward or reverse flow of the vaporizable material 1302 in the collector 1313 can be controlled (e.g., enhanced or reduced) by implementing appropriate structures (e.g., microchannel configurations) that introduce or utilize capillary properties that may exist between the vaporizable material 1302 and the retaining walls of the overflow channel 1104. For example, factors related to the length, diameter, interior surface texture (e.g., roughness vs. smoothness), protrusions, directional taper of the channel structure, constrictions, or materials used to construct or coat the surfaces of the gate 1102, overflow channel 1104, or air exchange port 1106 can positively or negatively affect the rate at which liquid is drawn into or moves through the overflow channel 1104 by capillary action or other forces acting on the cartridge 1320.

Depending on the embodiment, one or more of the factors described above can be used to control the displacement of the vaporizable material 1302 in the overflow channel 1104 as it is collected in the channel structure of the collector 1313, to introduce a desired degree of reversibility. Thus, in some embodiments, the flow of the vaporizable material 1302 to the collector 1313 can be fully reversible or semi-reversible in response to changes in pressure conditions inside or outside the cartridge 1320, selectively controlling the various factors described above.

As shown in Figures 3A, 3B, 11A, and 11B, in one or more embodiments, the collector 1313 may be formed, constructed, or configured to have a single channel single vent structure. In such embodiments, the overflow channel 1104 may be a continuous passage, tube, channel, or other structure to selectively connect the gate 1102 to an air exchange port 1106 located near the wicking element 1362 (see also, for example, Figures 3A and 3B, which show a single elongated overflow channel 1104 in the overflow volume 1344). Thus, in such embodiments, the vaporizable material 1302 may enter or exit the collector 1313 from the gate 1102 through a single constructed channel, where the vaporizable material 1302 flows in a first direction when the collector 1313 is being filled and in a second direction when the collector 1313 is being drained.

To help maintain equilibrium or, depending on the embodiment, to control the flow of vaporizable material 1302 in overflow channel 1104, the shape and structural configuration of overflow channel 1104, gate 1102, or air exchange port 1106 may be adapted or modified to balance the flow rate of vaporizable material 1302 in overflow channel 1104 at different pressure conditions. In one example, overflow channel 1104 may be tapered such that the tapered end (i.e., the end with the smaller opening or diameter) leads into gate 1102.

In one embodiment, the non-tapered end (i.e., the end of the overflow channel 1104 with a larger opening or diameter) can lead to the air exchange port 1106, which can be connected to the ambient environment outside the cartridge 1320, or to an airflow path from which the vaporized vaporizable material 1302 is delivered to the mouthpiece (see, for example, air port 1318 connected to airflow passage 1338 in FIG. 3A). In one embodiment, the non-tapered end can also lead to an area near the wick housing, so that the vaporizable material 1302 can be used to saturate the wicking element 1362 as it exits the overflow channel 1104.

Depending on the embodiment, the tapered channel structure may reduce or increase the restriction of flow to the collector 1313. For example, in an embodiment where the overflow channel 1104 is tapered toward the gate 1102, a favorable capillary pressure toward reverse flow is induced in the overflow channel 1104, such that when the pressure conditions change (e.g., when the negative pressure event clears or subsides), the direction of flow of the vaporizable material 1302 is out of the collector 1313 and into the reservoir 1342. In particular, implementing the overflow channel 1104 with a smaller opening may impede the free flow of the vaporizable material 1302 into the collector 1313. The non-tapered configuration of the overflow channel 1104 in the direction toward the air exchange port 1106 provides efficient storage of the vaporizable material 1302 in the collector 1313 during the second pressure condition (e.g., negative pressure condition) as the vaporizable material 1302 flows from a narrower portion of the overflow channel 1104 to a larger volume portion of the overflow channel 1104 to the collector 1313.

Thus, the diameter and shape of the collector structure 1313 can be implemented such that the flow of vaporizable material 1302 through the gate 1102 and into the overflow channel 1104 is controlled at a desired rate during the second pressure condition (e.g., a negative pressure event) in such a way that the vaporizable material 1302 does not flow too freely (e.g., above a certain flow rate or threshold) into the collector 1313, and also helps backflow into the reservoir 1342 in the first pressure condition (e.g., when the negative pressure event is relieved). It is noteworthy that in one embodiment, the combination of interactions between the vent 1002, the overflow channel 1104 in the collector 1313 that constitutes the overflow volume 1344, and the air exchange port 1106 provide suitable venting of air bubbles that may be introduced into the cartridge due to various environmental factors, as well as the controlled flow of vaporizable material 1302 into and out of the overflow channel 1104.

(Embodiments of the mouthpiece)
11B (see also FIGS. 10C, 10D), in some embodiments, the portion of the cartridge 1320 that includes the reservoir 1342 may also be configured to include a mouthpiece that can be utilized by a user to inhale the vaporized vaporizable material 1302. An airflow passage 1338 may extend through the reservoir 1342, thereby connecting the vaporization chambers. Depending on the embodiment, the airflow passage 1338 may be, for example, a straw-shaped structure or a hollow cylinder that forms a channel inside the reservoir 1342 to allow the vaporized vaporizable material 1302 to pass through. The airflow passage may have a circular or at least approximately circular cross-sectional shape, although it will be understood that other cross-sectional shapes of the airflow passage are within the scope of the present disclosure.

A first end of the airflow passage 1338 may connect to an opening in the first "mouthpiece" end of the reservoir 1342 through which the user may inhale the vaporized vaporizable material 1302. As provided in further detail herein, a second end of the airflow passage 1338 (opposite the first end) may be received in an opening in the first end of the collector 1313. Depending on the embodiment, the second end of the airflow passage 1338 may extend completely or partially through the collector 1313 and through a receiving cavity that connects to a wick housing in which the wicking element 1362 may be housed.

In some configurations, the airflow passage 1338 may be an integral part of a monolithically molded mouthpiece that includes the reservoir 1342 through which the airflow passage 1338 extends. In other configurations, the airflow passage 1338 may be a separate structure that may be separately inserted into the reservoir 1342. In some configurations, the airflow passage 1338 may be a structural extension of the collector 1313 or the body of the cartridge 1320, for example, extending inwardly from an opening in the mouthpiece portion.

Without limitation, a variety of different structural configurations may be possible for connecting the mouthpiece (and the airflow passage 1338 within the mouthpiece) to the air exchange port 1106 of the collector 1313. As provided herein, the collector 1313 may be inserted into the body of the cartridge 1320, which may also function as the reservoir 1342. In some embodiments, the airflow passage 1338 may be constructed as an internal sleeve that is an integral part of the monolithic cartridge body, such that an opening at the first end of the collector 1313 may receive the first end of the sleeve structure that forms the airflow passage 1338.

With reference to Figures 18A-18D, certain embodiments may include a vaporizer cartridge 1800 that includes a dual-barrel mouthpiece 1830 connected to two airflow passages 1838. In such embodiments, a larger dose of vaporized vaporizable material 1302 may be delivered as compared to a single-barrel mouthpiece. Depending on the embodiment, the dual-barrel mouthpiece 1830 may also advantageously provide a smoother and more satisfying inhalation experience.

Fluid Gate Embodiments
10A-11H, depending on the embodiment, various factors can be considered to help monitor and control the forward and reverse flow of vaporizable material 1302 into and out of collector 1313. Some of these factors can include configuring the capillary drive of the fluid vent, referred to herein as gate 1102. The capillary drive of gate 1102 may be less than the capillary drive of wicking element 1362, for example. Additionally, the flow resistance of collector 1313 may be greater than that of wicking element 1362. Overflow channel 1104 may have a smooth or wavy inner surface to control the flow rate of vaporizable material 1302 through collector 1313. The overflow channel 1104 may be formed with a tapered curve to provide suitable capillary interactions and forces that restrict flow through the gate 1102 into the overflow volume 1344 to facilitate backflow through the gate 1102 during a first pressure condition, and restrict flow out of the overflow volume 1344 during a second pressure condition.

Additional modifications to the shape and structure of the collector 1313 components may help to further tune or fine-tune the flow of vaporizable material 1302 into and out of the collector 1313. For example, a smoothly curved helical channel configuration (i.e., as opposed to a channel with sharp bends or edges) as shown in FIGS. 11A-11H may allow for additional features, such as one or more vents, channels, openings, or constriction structures, to be included in the collector 1313 at predetermined intervals along the overflow channel 1104. As provided in further detail herein, such additional features, structures, or configurations may help to provide a high level of flow control of vaporizable material 1302, for example, along the overflow channel 1104 or through the gate 1102.

Regardless of the various structural elements and embodiments discussed throughout this disclosure, it is worth noting that certain features and functionality (e.g., capillary interactions between various components) may be implemented in the collector 1313 structure to assist in controlling the flow of vaporizable material 1302 through, for example, (1) a single vent, single channel structure, (2) a single vent, multi-channel structure, or (3) a multi-vent, multi-channel structure, etc.

10E, 11A, 11C, 11D, and 11E, exemplary structural configurations of the collector 1313 according to certain variations are presented. As shown, fully or partially inclined helical surfaces can be implemented to define one or more sides of the interior volume of the overflow channel 1104 of the collector 1313, such that the vaporizable material 1302 is free to flow through the overflow channel 1104 by capillary pressure (or gravity) upon entering the overflow channel 1104. One or more, optionally central, channels or tunnels, such as the central tunnel 1100, may be configured through the longitudinal height of the collector 1313 having two opposing ends.

At a first end, the central shaft or central tunnel 1100 through the collector structure 1313 may interact or connect with a housing area where the wicking element 1362 or atomizer may be located. At a second end, the central tunnel 1100 may interact, connect, or receive one end of a duct or tube that forms an airflow passage 1338 in the mouthpiece portion of the cartridge 1320. The first end of the airflow passage 1338 may be connected (e.g., by insertion) to the second end of the central tunnel 1100. The second end of the airflow passage 1338 may include an opening or orifice formed in the mouthpiece area.

According to one or more embodiments, the vaporized vaporizable material 1302 generated by the atomizer may enter a first end of the central tunnel 1100 in the collector 1313, pass through the central tunnel 1100, and exit from a second end of the central tunnel 1100 to a first end of an airflow passage 1338. The vaporized vaporizable material 1302 may then travel through the airflow passage 1338 and exit through a mouthpiece opening formed at the second end of the airflow passage 1338.

The collector 1313 may be configured as a separate component with a structure that can be inserted into the body of the cartridge 1320 (see, for example, FIGS. 10C, 11B, 11C-11E). Upon insertion, an airtight seal may be formed between the inner wall of the shell body of the cartridge 1320 and the outer edge of the ribbed structure of the collector 1313 that forms a helical slope. In other words, the three walls of the overflow channel 1104 bounded by the surface of the inner wall of the shell body of the cartridge 1320 form the overflow channel 1104 when the collector 1313 is inserted into the body of the cartridge 1320.

The overflow channel 1104 may thus be formed by the inner wall of the body of the cartridge 1320 surrounding the inner wall of the rib-like structure. As shown, the gate 1102 may be located at one end of the overflow channel 1104 facing the reservoir 1342 to control and provide for the passage of vaporizable material 1302 in and out of the overflow channel 1104 of the collector 1313. The air exchange port 1106 may be located facing another end of the overflow channel 1104, preferably opposite the end where the gate 1102 is located.

The gate 1102 can control the flow of vaporizable material 1302 into and out of the overflow channel 1104 in the collector 1313. The air exchange port 1106 can control the flow of air into and out of the overflow channel 1104 via a connection path to ambient air to regulate the air pressure in the collector 1313 and in the reservoir 1342 of the cartridge 1320, as provided in further detail herein. In certain embodiments, the air exchange port 1106 can be configured to prevent vaporizable material 1302 that may have filled the overflow channel 1104 of the collector 1313 (e.g., as a result of a negative pressure event) from exiting the overflow channel 1104.

In certain embodiments, the air exchange port 1106 may be configured to direct the vaporizable material 1302 toward a path leading to an area in which the wicking element 1362 is housed. This embodiment may help to avoid leakage of the vaporizable material 1302 into the airflow passageway (e.g., central tunnel 1100) leading to the mouthpiece, for example, during a negative pressure event. In some embodiments, the air exchange port 1106 may have a membrane that allows gaseous material (e.g., air bubbles) to enter and exit, but prevents the vaporizable material 1302 from entering or exiting the collector 1313 through the air exchange port 1106.

11C-11H, the flow rate of vaporizable material 1302 into and out of collector 1313 through gate 1102 may be directly related to the volumetric pressure in overflow channel 1104. Thus, the flow rate into and out of collector 1313 through gate 1102 may be controlled by manipulating the hydraulic diameter of overflow channel 1104, and the pressure in overflow channel 1104 may be increased by decreasing the total volume of overflow channel 1104 (e.g., either uniformly or by introducing multiple constriction points) to adjust the flow rate into collector 1313. Thus, in at least one embodiment, the hydraulic diameter of overflow channel 1104 may be decreased (e.g., narrowed, pinched, constricted or restricted) either uniformly or by introducing one or more constriction points 1111a along the length of the helical path of overflow channel 1104.

As an example, Figs. 11C-11E show two partial length and three full length levels constructed on one or more sides of the collector 1313, with each full length level having, for example, three constriction points 1111a on the side shown in the figures. It is worth noting that in different embodiments, more or fewer levels or constriction points 1111a can be implemented, defined, constructed or introduced to adjust the volumetric pressure within the collector 1313. The constriction points 1111a are prominently shown by circles at the mid-level of the collector 1313 for illustrative purposes.

The constriction points 1111a may be formed or introduced along the length of the overflow channel 1104 in a variety of ways and shapes. Below, exemplary embodiments with different constriction points or shapes are disclosed to better illustrate certain features. However, it should be noted that these exemplary embodiments should not be construed as limiting the scope of the claimed invention to any particular configuration or shape.

11C, in one exemplary embodiment, the constriction point 1111a may be formed by a ridge, raised edge, protrusion, or projection (hereinafter referred to as a "protrusion") extending from the ceiling, floor, or sidewall (or any or all such) surfaces of the overflow channel 1104 (i.e., the blades of the collector 1313). The shape of the protrusion may be defined as a ridge, finger, prong, fin, edge, or other shape that restricts the cross-sectional area transverse to the flow direction in the overflow channel. In the illustration of FIG. 11C, the cross-sectional side view of the protrusion is shown as resembling, for example, a shark fin shape, with the distal end of the protrusion tapering toward the edge.

As shown in FIG. 11C, the pointed or cantilevered edge of the shark fin shape may be rounded. However, in other embodiments, the cantilevered edge may taper to a sharp end. The sharpness, size, relative position, and placement frequency of the protrusions in the overflow channel 1104 can be manipulated to further fine-tune the tendency for a meniscus to form in the overflow channel 1104, separating the liquid and air.

For example, as shown in FIG. 11C, the protrusions can have a rounded side on one side and a flat side on the other side. The rounded side of the protrusions can face (i.e., point toward) the outward flow of vaporizable material 1302 (i.e., out of collector 1313 and into reservoir 1342), while the flat side of the protrusions can face the inward flow of vaporizable material 1302 through gate 1102 (i.e., into collector 1313 and out of reservoir 1342).

As discussed above, in different embodiments, the formation of protrusions along the overflow channel 1104 can be manipulated in number, size, shape, location, and frequency to fine-tune the hydraulic flow rate of vaporizable material 1302 into and out of the collector 1313. For example, if it is instead desirable to maintain the inflow flow of the overflow channel 1104 at a higher velocity than the outflow flow, the protrusions may be shaped to have flat surfaces facing the outflow flow and rounded surfaces facing the inflow flow to facilitate the formation and retention of a meniscus that resists the outward flow of liquid (e.g., away from the reservoir 1340) and to facilitate the meniscus breaking off from the side of the protrusion that faces back toward the reservoir 1340. In this way, a series of such protrusions may function as a kind of "hydraulic ratchet" system in which the backflow of liquid into the reservoir is microfluidically promoted relative to the outward flow from the reservoir. This effect may be achieved, at least in part, by the relative tendency of the meniscus to break from the reservoir side of the protrusion than from the opposite side.

11C, in one exemplary embodiment, in addition to (or instead of) the protrusions extending from the floor or ceiling of the overflow channel 1104, several protrusions may extend from the inner wall of the overflow channel 1104. As shown more clearly in FIG. 11F, the protrusions may extend from the inner wall of the overflow channel 1104 at the same constriction point 1111a, with two additional protrusions extending from the floor and ceiling of the overflow channel 1104 to form a C-shaped constriction point 1111a. Because the hydraulic diameter of the overflow channel 1104 is more constricted (i.e., narrower) at the constriction point 1111a shown in FIGS. 11D and 11F, the exemplary embodiment shown in FIGS. 11D and 11F can more effectively tune the microfluidic properties of the overflow channel 1104 to promote the liquid flow back toward the reservoir 1340 relative to the embodiment of FIG. 11C.

The protrusions formed along the overflow channel 1104 need not be uniform in shape, size, frequency, or symmetry. That is, depending on the embodiment, different constriction points 1111a or 1111b may be implemented with different sizes, designs, shapes, positions, or frequencies along the overflow channel 1104. In one example, the shape of the constriction point 1111a or 1111b may resemble the shape of the letter C with a rounded inner diameter. In some embodiments, instead of forming the inner diameter as a rounded C shape, the inner wall of the constriction point may have an angle (e.g., an acute angle) as shown in Figures 11F and 11G.

In some examples, the overflow channel 1104 may have protrusions at a first level extending from the ceiling of the overflow channel 1104, while at a second level the protrusions may extend from the floor of the overflow channel 1104. At a third level, for example, the protrusions may extend from the inner wall. Alternatives to the above embodiments are possible by adjusting or varying the number of protrusions and the shape of the protrusions or the location of the protrusions at different sequences or levels to help control the microfluidic effects on the bidirectional flow in the overflow channel 1104. In one example, the constriction point 1111a may be implemented, for example, at one or more (or all) levels, sides, or widths of the collector 1313.

11E and 11G, in addition to defining the constriction point 1111a along the longer length of the overflow channel 1104 or the wider side of the collector 1313, one or more additional constriction points 1111b can be defined along the narrower side of the collector 1313. Thus, the exemplary embodiment shown in FIG. 11E and 11G can improve tuning of resistance to or promotion of meniscus separation in a desired direction in the overflow channel 1104 compared to the embodiment of FIG. 11D, since the overall hydraulic diameter (or flow volume) of the overflow channel 1104 is more constrained by the addition of the additional constriction points 1111b.

11F and 11G, for greater clarity, each full level in the illustrated example may include, for example, three constriction points 1111a on each side in addition to two more constriction points 1111b. Thus, the collector 1313 in FIG. 11D may include a total of 18 constriction points, while the collector 1313 in FIG. 11E may include a total of 26 constriction points. In this example, the embodiment shown in FIG. 11E provides improved (e.g., outward) microfluidic flow control due to enhanced capillary pressure at the multiple constriction points 1111a and 1111b.

11H, in some embodiments, the gate 1102 may be constructed to include an opening or aperture configuration having a tapered edge, rim, or flange that is flatter in one direction, similar to the constriction points 1111a or 1111b. For example, the rim of the opening of the gate 1102 may be shaped to be flat on one side (e.g., the side facing the reservoir 1342) and rounded on the other side (e.g., the side facing away from the reservoir 1342). In such a configuration, the microfluidic forces promoting backflow into the reservoir 1340 relative to flow away from the reservoir 1340 may be enhanced due to easier meniscus separation on the less rounded side compared to the more rounded side.

Thus, depending on the implementation and modification of the structure of the constriction point and the gate 1102, the resistance to the flow of the vaporizable material 1302 from the collector 1313 may be higher than the resistance to the flow of the vaporizable material 1302 into the collector 1313 and toward the storage chamber 1340. In certain embodiments, the gate 1102 is configured to maintain a liquid seal such that a layer of the vaporizable material 1302 is present in the medium in which the storage chamber 1342 communicates with the overflow channel 1104 in the overflow volume 1344. The presence of the liquid seal can help maintain a pressure equilibrium between the storage chamber 1342 and the overflow volume 1344 to promote a sufficient level of vacuum (e.g., partial vacuum) in the storage chamber 1342, thereby preventing the vaporizable material 1302 from being completely discharged into the overflow volume 1344 and from depriving the wicking element 1362 of proper saturation.

In one or more exemplary embodiments, a single passage or channel in the collector 1313 may be connected to the reservoir 1342 through two vents such that the two vents maintain a liquid seal regardless of the position of the cartridge 1320. The formation of a liquid seal at the gate 1102 may help prevent air in the collector 1313 from entering the reservoir 1342 even when the cartridge 1320 is held at an angle to the horizontal or positioned with the mouthpiece facing down. This is because when air bubbles from the collector 1313 enter the reservoir, the pressure in the reservoir 1342 equals that of the ambient pressure. That is, when ambient air flows into the reservoir 1342, any partial vacuum in the reservoir 1342 (e.g., resulting from the exhaust of vaporizable material 1302 from the wick supply 1368) is offset.

With reference to Figures 11I-11K, perspective views of alternative gate 1102 configurations for the collector 1313 structure are provided. These alternative configurations may provide advantages with respect to managing and controlling the flow of air and/or liquid vaporizable material 1302. In some scenarios, when the empty space in the reservoir 1342 (i.e., the headspace above the vaporizable material 1302) contacts the gate 1102, the headspace vacuum may not be maintained. As a result, the liquid seal established with the gate 1102 may be broken, as previously described. This effect is due to the gate 1102 being unable to maintain a fluid film when the collector 1313 is evacuated and the headspace contacts the gate 1102, which may lead to a loss of partial headspace vacuum.

In certain embodiments, the headspace of the reservoir 1342 may have ambient pressure, and if a hydrostatic offset exists between the gate 1102 and the atomizer of the cartridge 1320, the contents of the reservoir 1342 will be expelled into the atomizer, resulting in wick box flooding and leakage. To avoid leakage, one or more embodiments can be implemented to remove the hydrostatic offset between the gate 1102 and the atomizer when the reservoir 1342 is nearly empty, and maintain the functionality of the gate 1102.

As shown in the exemplary embodiment of Figures 11I and 11J, a small dividing wall or maze-shaped structure 1190 can be constructed around the gate 1102 to establish a high drive connection between the gate 1102 and the overflow channel 1104 of the collector 1313 to maintain a liquid seal at the gate 1102. In the example of Figure 11J, a moat-shaped structure 1190 is shown as a means to further improve the maintenance of a liquid seal at the gate 1102, according to one or more embodiments.

Controlled Fluid Gate Embodiments
11L-11N show plan and close-up views of a controlled fluid gate 1102 in a collector 1313 structure according to one or more embodiments. As shown, a passageway or overflow channel 1104 in the collector 1313 may be connected to a reservoir 1342 via, for example, a V-shaped or horn-shaped controlled fluid gate 1102, which includes at least two (and preferably three) openings connected to the reservoir 1342. As provided in further detail herein, a liquid seal at the gate 1102 can be maintained regardless of whether the cartridge 1320 is oriented vertically or horizontally.

As shown in FIG. 11L, on a first side of the vent, a vent path is maintained between the overflow channel 1104 and the gate 1102 through which air bubbles can escape from the collector overflow channel 1104 to the reservoir. On a second side, one or more high drive channels connected to the reservoir can be implemented to facilitate pinch-off at pinch-off point 1122 to prematurely expel air bubbles from the overflow channel 1104 to the reservoir, as well as to maintain a liquid seal to prevent undesired ingress of air or vaporizable material 1302 from the reservoir into the overflow channel 1104.

Depending on the embodiment, the high drive channel, shown by way of example on the right side of FIG. 11L, is preferably maintained in a sealed state due to the capillary pressure exerted by the liquid vaporizable material 1302 in the cartridge reservoir. The low drive channel formed on the opposite side (i.e., shown on the left side of FIG. 11L) may be configured to have a relatively low capillary drive compared to the high drive channel, but still have sufficient capillary drive such that a liquid seal is maintained in both the high drive channel and the low drive channel at the first pressure state.

Thus, in a first pressure state (e.g., when the pressure in the reservoir is approximately equal to or greater than the ambient air pressure), a liquid seal is maintained in both the low and high drive channels, preventing air bubbles from entering the reservoir. Conversely, in a second pressure state (e.g., when the pressure in the reservoir is less than the ambient air pressure), air bubbles forming in the overflow channel 1104 (e.g., entering through the air exchange port 1106), or more generally, the leading edge of the meniscus at the interface between the liquid vaporizable material and the air, may rise toward the controlled fluid gate 1102. When the meniscus reaches the pinch-off point 1122 located between the low and high drive channels of the vent 1104, air is preferentially directed through the low drive channel(s) due to the presence of higher capillary resistance in the high drive channel.

When the air bubble passes through the low drive channel portion of the gate 1102, the air bubble enters the reservoir and equalizes the pressure in the reservoir to that of the ambient air. Thus, the air exchange port 1106, in combination with the control fluid gate 1102, allows ambient air to enter and pass through the overflow channel 1104 to the reservoir until an equilibrium pressure condition is established between the reservoir and the ambient air. As previously mentioned, this process may be referred to as reservoir venting. Once an equilibrium pressure condition is established (e.g., transitioning from the second pressure condition to the first pressure condition), a liquid seal is re-established at the pinch-off point 1122 by the presence of liquid in the high and low drive channels supplied by the liquid vaporizable material 1302 stored in the reservoir.

Figures 11O-11X show snapshots of the airflow collected by the exemplary collector 1313 of Figures 11L-11N being managed to accommodate proper ventilation as the meniscus of the vaporizable material 1302 continues to recede.

Figure 11O shows the receding meniscus where the strength of the partial headspace vacuum increases as vaporizable material 1302 is removed from the reservoir to the wick. This is sufficient to overcome the receding capillary drive of the meniscus and move it through the collector toward the constriction point where the meniscus experiences the maximum pressure difference dictated by the geometry.

Figure 11P shows how the meniscus crosses the first junction of the gate 1102 as it approaches the gate 1102. At this first junction, the partial vacuum in the headspace is at a maximum since it corresponds to the minimum feature of the gate 1102 structure, and the partial vacuum in the reservoir continues to grow up to this point.

Figure 11Q shows how the menisci retract as the headspace reaches its maximum partial vacuum. The menisci are at their tightest curvature across the major plane, and at these locations the exhaust pressures in the three channels are equal and the three menisci retract simultaneously as opposed to from only one channel. As the curvature increases as these menisci retract, the pressure differential maintained across them decreases and the partial vacuum in the headspace begins to decrease.

Figure 11R shows how the secondary meniscus begins to fill the capillary channel. The taper of these channel geometries is such that as the meniscus continues to recede, the capillary drive in the primary channel decreases at a greater rate than the capillary drive in the secondary channel. This gradual decrease in capillary drive reduces the partial headspace vacuum that is maintained. When the drainage pressure of the primary meniscus falls below the drainage pressure of the secondary channel, this meniscus continues to drain while the other meniscus remains stationary. The drainage pressure with the receding contact angle of the primary channel can be lower than the flooding pressure with the advancing contact angle of the secondary channel, refilling them as shown in the figure.

Figure 11S shows how the secondary meniscus from one of the two menisci in each secondary channel reaches a contact point where the two menisci merge into one. The curvature of this compound meniscus increases and the capillary drive decreases. The higher drive of the primary meniscus can cause the system to react instantaneously by making the primary meniscus an advancing meniscus. Subsequent retreat of the primary meniscus can occur with the secondary meniscus held in this location.

Figure 11T shows how the secondary meniscus moves towards the collector. In a scenario where the reservoir is filled with liquid, the primary meniscus continues to recede, further reducing the partial vacuum in the headspace as the curvature increases. When the partial vacuum falls below the advancing capillary pressure of the secondary meniscus, the secondary meniscus begins to advance again, closing the gap. In a scenario where the reservoir is empty or near empty, the liquid seal at gate 1102 remains stable until a gas bubble bursts, connecting the headspace to the surroundings.

Figure 11U shows how the secondary meniscus closes the junction at the gate 1102. As the secondary meniscus advances until it reaches the apex of the corner of the primary channel, the secondary meniscus is designed in a shape that splits to fill both the gate 1102 and the collector 1313 channel. These two newly formed menisci may act to isolate the headspace from the surrounding air, thereby re-establishing a partial vacuum in the headspace and ensuring that leakage from the liquid supply channel is mitigated. Because the newly formed meniscus has a smaller curvature than before it split, the increased capillary drive allows the newly formed meniscus to continue into the channel.

11V-11X show the release of the air bubble into the reservoir 1342. The pressure in the cartridge 1320 at this point reaches a steady state as the air bubble trapped in the primary meniscus channel is expelled by the imbalance created by the advancing and receding meniscus. Vaporizable material 1302 is then introduced, displacing the air bubble through the upper right channel. Thus, while a high drive channel structure can be provided via a closed moat near the gate 1102, a shorter moat can be utilized instead, reducing the risk of air bubble trapping.

In some embodiments, tapered channels can be designed to enhance the driving force to the controlled vent. Considering the pinch-off of the two advancing menisci, the reservoir tank walls and channel bottom can be configured to continue to provide the driving force, while the side walls provide the pinch-off location for the meniscus. In one configuration, the net driving force of the advancing meniscus does not exceed the net driving force of the receding meniscus, thus keeping the system statically stable.

Multi-Gate Multi-Channel Collector Embodiments
12A and 12B, an exemplary perspective side view and an exemplary planar side view of an embodiment of a single vent, multi-channel collector 1200 structure are shown. As shown in FIG. 12A, the collector 1200 is formed with a single gate 1202 and multiple channels 1204(a)-1204(j). As shown in FIG. 12A, according to one or more embodiments, the gate 1202 is located, for example, at the center or midpoint of the longitudinal width of the collector 1313, to allow vaporizable material 1302 to enter at least a first channel 1204(a) of the collector 1313 and gradually spread into and through additional channels 1204(b)-1204(j).

The location of the gate 1202 can vary to the center, side, corner, or other location along the length or width of the collector 1313 depending on the embodiment. The single-vent, multi-channel collector 1200 structure can have the added advantage that the vaporizable material 1302 can enter through a single gate 1202 at a first flow rate and spread through multiple channels 1204(a)-1204(j) of the collector 1200 at a second flow rate (e.g., a rate faster than the first flow rate).

Advantageously, the single-gate, multi-channel collector 1200 structure allows for a controlled (e.g., restricted) flow of vaporizable material 1302 from the reservoir 1342 to the overflow volume 1344 (see FIG. 3A) and allows for less controlled (e.g., less restricted) flow once the vaporizable material 1302 enters the overflow volume 1344. In certain embodiments, as shown in FIG. 12B, for example, a multi-layer multi-channel structure may be implemented in which the flow of vaporizable material 1302 in a first set of channels 1204(a)-1204(f) is at a second rate and the flow of vaporizable material 1302 in a second set of channels 1204(g)-1204(k) is at a third rate. The third rate may be faster or slower than the second rate.

12B, the vaporizable material 1302 flows through the gate 1202 at a first velocity, through the channels 1204(a)-1204(f) at a second velocity, and through the channels 1204(g)-1204(k) at a third velocity. In one or more embodiments, for example, the second velocity may be faster than both the first velocity and the third velocity, such that the vaporizable material 1302 may have a restricted flow through the gate 1202, a slightly restricted flow through the first set of channels (e.g., layer 1), and a relatively more restricted flow through the second set of channels (e.g., layer 2). This multi-layer configuration may help improve the flow rate through the collector 1200, while maintaining a controllable restriction to the rapid flow of the vaporizable material 1302 toward the wicking element 1362 once the vaporizable material 1302 enters the collector 1200.

In the bilayer embodiment shown in FIG. 12B, the first set of channels 1204(a)-1204(f) (e.g., layer 1) may have a reversible configuration such that vaporizable material 1302 collected in the first set of channels flows back to the reservoir 1340. Conversely, the second set of channels 1204(g)-1204(k) (e.g., layer 2) may not have a reversible configuration. In such an embodiment, due to the proximity of the second set of channels to the wicking element 1362, the vaporizable material 1302 is drawn primarily from the second set of channels and then from the first set of channels (e.g., layer 1, which acts as a reserve). As mentioned above, having reversible and non-reversible structures can help provide additional improvements over other embodiments described herein.

In some multi-layered embodiments, by configuring the second set of channels 1204(g)-1204(k) as irreversible, there may be additional assurance that the wicking element 1362 will not be depleted since vaporizable material 1302 will be available in the vicinity of the wicking element 1362 if stored in the second set of channels 1204(g)-1204(k) during an overflow event. Additionally, because the second set of channels 1204(g)-1204(k) may be configured to have a more restricted flow compared to the first set of channels 1204(a)-1204(f) as described above, the multi-layered implementation may prevent the possibility of strong flow of vaporizable material 1302 into the wick housing during a negative pressure event. Additionally, due to the reversibility, the first set of channels 1204(a)-1204(f) may not contain a relatively large amount of vaporizable material 1302. In some embodiments, an absorbent material (e.g., a sponge) may be introduced into one or both of the channel regions to increase or limit the reversibility or flow of vaporizable material 1302 in the first set of channels 1204(a)-1204(f) or the second set of channels 1204(g)-1204(k).

With reference to FIG. 13, an exemplary perspective side view of a multi-vent, multi-channel collector 1300 structure is shown, according to one or more embodiments. As shown, the collector 1300 may be positioned within a cartridge such that the collector 1300 has a dual vent 1301. This embodiment may allow vaporizable material 1302 to flow into the channel 1204 at a relatively fast rate, especially compared to the single vent collector 1200 shown in FIGS. 21A and 12B.

(Embodiments of the Wick Supply Unit)
10C, 10D, and 11B, in certain variations, the collector 1313 may be configured to be insertably received by the receiving end of the reservoir 1342. The end of the collector 1313 opposite the end received by the reservoir 1342 may be configured to receive the wicking element 1362. For example, fork-shaped prongs may be formed to securely receive the wicking element 1362. A wick housing 1315 may be used to further secure the wicking element 1362 in a fixed position between the prongs. This configuration may also help prevent the wicking element 1362 from expanding substantially and becoming weak due to oversaturation.

11C, 11D, and 11E, depending on the embodiment, one or more additional ducts, channels, tubes, or cavities passing through the collector 1313 may be constructed or configured as paths to supply the wicking element 1362 with the vaporizable material 1302 stored in the reservoir 1342. In certain configurations, such as those described in more detail herein, the wick supply duct, tube, or cavity (i.e., wick supply 1368) may run generally parallel to the central tunnel 1100. In at least one configuration, there may be multiple wick supplies running diagonally along the length of the collector 1313, for example, independently or in conjunction with a wick replacement that includes one or more other wick supplies.

In certain embodiments, multiple wick supplies can be interactively connected in a multi-link configuration such that the junction of supply paths that may cross one another leads to the wick housing region. This configuration can help prevent complete blockage of the wick supply mechanism, for example, if one or more of the supply paths at the wick supply junction are blocked by air bubbles or other types of clogging. Advantageously, even if some or certain paths at the wick supply junction are fully or partially clogged or blocked, the instrumentation of the multiple supply paths allows the vaporizable material 1302 to safely travel one or more paths (or crossovers to different but open paths) toward the wick housing region.

Depending on the embodiment, the wick supply passage may be shaped to be, for example, tubular, having a circular or multi-sided cross-shaped diameter shape. For example, the hollow cross-section of the wick supply may be triangular, rectangular, pentagonal, or other suitable geometric shape. In one or more embodiments, the cross-sectional perimeter of the wick supply may be in the shape of a hollow cross, for example, such that the arms of the cross have a narrower width relative to the diameter of the central intersection of the cross from which the arms extend. More generally, the wick supply channel (also referred to herein as the first channel) may have a cross-sectional shape with at least one irregularity (e.g., protrusion, side channel, etc.) that provides an alternative path for the liquid vaporizable material to flow even if an air bubble blocks the remainder of the cross-sectional area of the wick supply. The cross-shaped cross-section in this example is an example of such a structure, but one of skill in the art will understand that other shapes are also contemplated and workable consistent with the present disclosure.

Embodiments of a cruciform duct or tube formed through a wick supply path can overcome the problem of clogging because the cruciform duct is essentially considered to include five separate paths (e.g., a central path formed in the hollow center of the cross and four additional paths formed in the hollow arms of the cross). In such embodiments, a blockage of the supply tube, e.g., by an air bubble, is likely to form in the center of the cruciform tube, while the sub-pathways (i.e., paths through the arms of the cruciform tube) remain open.

According to one or more aspects, the wick supply path may be wide enough to allow the vaporizable material 1302 to move freely through the supply path toward the wick. In some embodiments, the flow through the wick supply is enhanced or adjusted by engineering the relative diameter of certain portions of the wick supply that exert a capillary pulling force or pressure on the vaporizable material 1302 moving through the wick supply path. In other words, depending on the shape and other structural or material factors, some wick supply paths can rely on gravity or capillary forces to induce the movement of the vaporizable material 1302 into the wick housing portion.

In a cross-tube embodiment, for example, the feed path through the arms of the cross-tube may be configured to feed the wick by capillary pressure instead of relying on gravity. In such an embodiment, the flow of vaporizable material 1302 in the arms of the cross-tube may be supported by capillary pressure, while the central portion of the cross-tube feeds the wick by, for example, gravity. It should be noted that the cross-tube disclosed herein is for purposes of providing an exemplary embodiment. The concepts and functionality implemented in this exemplary embodiment may be extended to wick feed paths of different cross-sectional shapes (e.g., a tube having a hollow star-shaped cross section with two or more arms extending from a central tunnel running along the wick feed path).

Referring to FIG. 11C, an exemplary collector 1313 configuration is shown in which two wick supplies 1368 are positioned on opposite sides of the central tunnel 1100, allowing vaporizable material 1302 to enter the supplies and flow directly toward a cavity region at the other end of the collector 1313 where the wick housing is formed.

The wick supply mechanism may be formed through the collector 1313 such that at least one wick supply passage within the collector 1313 may be shaped as a multi-sided cross-diameter hollow tube. For example, the hollow cross-section of the wick supply may be in the shape of a plus sign (e.g., a hollow cross-shaped wick supply when viewed from a top cross-sectional view) such that the arms of the cross have a narrower width in relation to the diameter of the central intersection of the cross from which the arms extend.

A duct or tube having a cross-shaped diameter formed through the wick supply path can overcome the problem of clogging because the tube having a cross-shaped diameter is considered to include five separate paths (e.g., a central path formed in the hollow center of the cross and four additional paths formed in the hollow arms of the cross). In such an embodiment, blockage of the supply tube by air bubbles (e.g., air bubbles) is more likely to form in the central portion of the cross-shaped tube.

Such central placement of the bubble ultimately leaves a sub-pathway (i.e., a path through the arms of the cross-shaped tube) that remains open to the flow of vaporizable material 1302 even if the central path is blocked by a bubble. Other embodiments of the wick supply passage structure are possible that can achieve the same or similar objectives as those disclosed above with respect to trapping bubbles or preventing trapped bubbles from completely clogging the wick supply passageway.

Adding more vents to the collector 1300 structure allows for faster flow rates depending on the embodiment, due to the relatively large collective volume of vaporizable material 1302 moving when additional vents are available. Thus, even if not explicitly shown, embodiments with more than two vents (e.g., triple vent embodiments, quadruple vent embodiments, etc.) are within the scope of the disclosed invention.

With reference to Figures 14A and 14B, certain embodiments can include a collector 1400 structure with dual feeds for the wick. In such embodiments, the wick can have higher saturation levels and less chance of depletion compared to embodiments where a single feed is provided.

15A, 15B, and 15C, perspective and cross-sectional plan side views of an exemplary collector configuration for a dual-feed wick 1562 are provided. As shown, the wick or wicks 1562 are disposed or housed in a cartridge 1500 such that at least two separate wick supplies 1566 and 1568 are provided to allow the vaporizable material 1302 to move toward the area of the cartridge 1500 in which the wick 1562 is housed.

As previously mentioned, a dual wick supply may have the advantage of, for example, providing twice the flow rate of vaporizable material 1302 to the wick 1562 compared to a single wick supply alternative. Advantageously, the dual wick supply embodiment provides an adequate supply to the wick 1562, helping to prevent the wick 1562 from drying out if, for example, one of the wick supplies becomes blocked. As shown, a lower portion of the wick 1562 may extend down into a region of the cartridge 1500 that forms the heating chamber or atomizer.

With reference to FIG. 16A, a cross-sectional plan view of an exemplary cartridge is provided in which a dual horn or dual feed wick 1562 is disposed within a collector structure. FIG. 16B is a cross-sectional plan view of an exemplary collector structure in which the wick 1562 can be housed. FIG. 16C provides an exemplary perspective view of a cartridge, according to one or more embodiments. As shown, a first end of the wick 1562 may have two or more feeds, horns, or flanged ends for at least partially engaging two or more wick openings in the partition 1513, such that, for example, at least one of the flanged ends tangentially engages the volume of the reservoir 1542 or extends, for example, at least partially within the volume of the reservoir 1542.

According to one or more embodiments, the cartridge 1500 may include a reservoir with a storage chamber 1542 for storing the vaporizable material 1302. A secondary volume 1510 separable from the storage chamber 1542 may also be formed inside the cartridge 1500. The secondary volume 1510 may be in communication with the storage chamber 1542 via one or more wick supplies 1590. The secondary volume 1510 may be configured to accommodate at least a wick 1562. The wick 1562 may be configured to absorb the vaporizable material 1302 traveling through the wick supply 1590 such that upon thermal interaction with the atomizer, the vaporizable material 1302 is absorbed into the wick 1562 and converted to at least one of a vapor or an aerosol.

The wick 1562 may be at least partially enclosed by one or more heating elements of an atomizer disposed within the secondary volume 1510. A partition 1513 may be provided to at least partially separate the reservoir 1542 from the secondary volume 1510 to allow for controlled flow of vaporizable material 1302 through the wick supply 1590. At least a first portion of the wick supply 1590 may be formed by at least one or more openings in the partition 1513.

At least a second portion of the wick supply 1590 may include a vaporizable material passageway connecting one or more openings in the partition 1513 to the secondary volume 1510. An airflow passageway 1538 may be provided connecting the secondary volume 1510 to the mouthpiece such that the vaporizable material 1302 converted to vapor travels from the secondary volume 1510 toward the mouthpiece through the airflow passageway 1538.

16A, 16B, 16C, 17A, and 17B, a perspective view of a first side of the cartridge and a cross-sectional view of a second side of the cartridge having a wick 1562 protruding into the reservoir 1542 are provided. The wick 1562 can include at least a first end 1592 and a second end 1594, where the first end 1592 is proximate to the partition 1513 and the second end extends distally in a direction opposite the first end 1592.

The first end 1592 of the wick 1562 can protrude at least partially through the wick opening of the partition 1530 and extend at least partially into the volume of the storage chamber 1542. In one aspect, the first end 1592 of the wick 1562 can protrude at least partially through the wick opening of the partition 1530 and engage at least tangentially with the volume of the storage chamber 1542.

26A shows perspective, front, side, bottom and top views of an exemplary embodiment of a collector 1313 with a V-shaped gate 1102. As shown in FIGS. 25 and 26, the collector 1313 may be attached inside the hollow cavity of the cartridge 1320 with additional components (e.g., wicking element 1362, heating element 1350, and wick housing 1315). The wicking element 1362 may be placed between the second end of the collector 1313 with the heating element 1350 wrapped around the wicking element 1362. During assembly, the collector 1313, wicking element 1362, and heating element 1350 may be combined with each other and covered by the wick housing 1315 before being inserted into the internal cavity of the cartridge 1320.

The wick housing 1315 may be inserted into the end of the cartridge 1320 opposite the mouthpiece along with the other described components to hold the internal components in a pressure sealed or press fit fashion. The seal or fit of the wick housing 1315 and collector 1313 inside the inner wall of the receiving sleeve of the cartridge 1320 is desirably tight enough to prevent leakage of the vaporizable material 1302 held in the reservoir of the cartridge 1320. In some embodiments, the pressure seal between the wick housing 1315 and collector 1313 and the inner wall of the receiving sleeve of the cartridge 1320 is also tight enough to prevent a user from manually disassembling the components with bare hands.

10C, 10D, 11B, 26B, and 26C, in certain variations, the collector 1313 may be configured to be insertably received by the receiving end of the reservoir 1342. As shown in FIGS. 26B and 26C, the end of the collector 1313 opposite the end received by the reservoir 1342 may be configured to receive the wicking element 1362. For example, fork-shaped protrusions 1108 may be formed to securely receive the wicking element 1362. The wick housing 1315 may be used to further secure the wicking element 1362 in a fixed position between the fork-shaped protrusions 1108, as shown in the cross-sectional views near the bottom of FIGS. 26B and 26C. This configuration may also help prevent the wicking element 1362 from expanding substantially and becoming weak due to oversaturation.

26B, in one embodiment, the wicking element 1362 can be restrained or compressed at certain locations along its length (e.g., toward the distal longitudinal end of the wicking element 1362 located directly below the wick supply 1368) by compression ribs 1110, which can help prevent leakage, for example, by maintaining a greater saturated area of vaporizable material 1302 toward the ends of the wicking element 1362, which allows the central portion of the wicking element 1362 to remain drier and leak less. Additionally, the compression ribs 1110 can be used to force the wicking element 1362 further into the atomizer housing to prevent leakage into the atomizer.

26D-26F, top views of an exemplary wick supply mechanism formed or structured through a collector 1313 are shown, according to one or more embodiments. As shown in FIG. 26D, at least one wick supply 1368 pathway within the collector 1313 may be shaped as a multi-sided intersecting diameter hollow tube. For example, the hollow cross section of the wick supply 1368 pathway may be in the shape of a plus sign (e.g., a hollow cross-shaped wick supply when viewed from a top cross-sectional view) such that the arms of the cross have a narrower width in relation to the diameter of the central intersection of the cross from which the arms extend.

Referring to FIG. 26E, a duct or tube with a cross-shaped diameter formed through the wick supply 1368 path can overcome the problem of clogging because the tube with a cross-shaped diameter is considered to include five separate paths (e.g., a central path formed in the hollow center of the cross and four additional paths formed in the hollow arms of the cross). In such an embodiment, as shown in FIG. 26E, blockage of the supply tube by an air bubble (e.g., an air bubble) is more likely to form in the central portion of the cross-shaped tube. Such central placement of the air bubble ultimately leaves a sub-pathway (i.e., a path through the arms of the cross-shaped tube) that remains open to the flow of vaporizable material 1302 even if the central path is blocked by an air bubble.

26F, other embodiments of the wick supply 1368 pathway structure are possible that can achieve the same or similar objectives as disclosed above with respect to trapping air bubbles or preventing trapped air bubbles from completely clogging the wick supply 1368 pathway. As shown in the exemplary diagram of FIG. 26F, to aid in passing the vaporizable material 1302 through the wick supply 1368 pathway when air bubbles are trapped in the central region of the wick supply 1368 pathway, one or more droplet-shaped protrusions 1368a/1368b (e.g., similar in shape to one or more separation nipples with the wick supply 1368 pathway therebetween) can be formed at the ends of the wick supply 1368 pathway through which the vaporizable material 1302 flows from the reservoir 1342 to the collector 1313. In this way, a reasonably controllable and consistent flow of vaporizable material 1302 can be directed toward the wick while preventing the scenario of the wick becoming inappropriately saturated with vaporizable material 1302.

Heating Element Embodiments
18A-18D, as described above, the vaporizer cartridge 1800 can also include a heating element 1850 (e.g., a flat heating element). The heating element 1850 includes a first portion 1850A disposed generally parallel to the airflow passage 1838 and a second portion 1850B disposed generally perpendicular to the airflow passage 1838. As shown, the first portion 1850A of the heating element 1850 can be disposed between opposing portions of the collector 1813. When the heating element 1850 is activated, for example, an electrical current flows through the heating element 1850, causing it to heat up and thus increase in temperature.

Heat may be transferred to a quantity of the vaporizable material 1302 via heat transfer by conduction, convection, and/or radiation such that at least a portion of the vaporizable material 1302 vaporizes. Heat transfer may occur to the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 drawn from the collector 1813, and/or to the vaporizable material 1302 drawn into the wick held by the heating element 1850. Air entering the vaporizer device flows along an air path across the heating element 1850, removing the vaporized vaporizable material 1302 from the heating element 1850 and/or the wick. The vaporized vaporizable material 1302 condenses due to cooling, pressure changes, etc., thereby exiting the mouthpiece 1830 through at least one of the airflow passages 1838 as an aerosol for inhalation by the user.

Referring to FIGS. 19A-19C, the vaporizer cartridge 1900 can include a folded heating element 1950 and two airflow passages 1938. As described above, the heating element 1950 can be crimped around the wick 1962 or can be preformed to receive the wick 1962. The heating element 1950 can include one or more tines 1950A. The tines 1950A can be positioned on the heating portion of the heating element 1950 and are designed such that the resistance of the tines 1950A matches the appropriate amount of resistance to affect localized heating within the heating element 1950 to more efficiently and effectively heat the vaporizable material 1302 from the wick 1962.

The tines 1950A form thin path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular shape of the tines 1950A may be desirably selected to generate a particular local resistance for heating the heating element 1950. For example, the tines 1950A may include one or more of the various tine configurations and features described and discussed in more detail below.

When the heating element 1950 is activated, an electric current flows through the heating element 1950, causing it to generate heat and thus increase in temperature. The heat is transferred to a quantity of the vaporizable material 1302 via heat transfer by conduction, convection, and/or radiation such that at least a portion of the vaporizable material 1302 vaporizes. Heat transfer can occur to the vaporizable material 1302 in the reservoir, to the vaporizable material 1302 drawn from the collector 1913, and/or to the vaporizable material 1302 drawn into the wick 1962 held by the heating element 1950. In some embodiments, the vaporizable material 1302 can vaporize along one or more edges of the tines 1950A.

Air entering the vaporizer device flows along an air path across the heating element 1950, removing vaporized vaporizable material 1302 from the heating element 1950 and/or wick 1962. The vaporized vaporizable material 1302 condenses due to cooling, pressure changes, etc., thereby exiting the mouthpiece through at least one of the airflow passages 1938 as an aerosol for inhalation by the user.

20A-20C, the vaporizer cartridge 2000 may include a folded heating element 2050 and a single (e.g., central) airflow passage 2038. As described above, the heating element 2050 may be crimped around the wick 2062 or may be preformed to receive the wick 2062. The heating element 2050 may include one or more tines 2050A. The tines 2050A may be positioned on the heating portion of the heating element 2050 and are designed such that the resistance of the tines 2050A matches the appropriate amount of resistance to affect localized heating within the heating element 2050 to more efficiently and effectively heat the vaporizable material from the wick 2062.

The tines 2050A form thin path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular shape of the tines 2050A may be desirably selected to generate a particular local resistance for heating the heating element 2050. For example, the tines 2050A may include one or more of a variety of tine configurations described in more detail below.

When the heating element 2050 is activated, an electric current flows through the heating element 2050, causing it to generate heat and thus increase in temperature. The heat is transferred to a quantity of the vaporizable material 1302 via heat transfer by conduction, convection, and/or radiation such that at least a portion of the vaporizable material 1302 vaporizes. Heat transfer can occur to vaporizable material 1302 in the reservoir, to vaporizable material 1302 drawn from the collector 2013, and/or to vaporizable material 1302 drawn into the wick 2062 held by the heating element 2050.

In some embodiments, the vaporizable material 1302 may vaporize along one or more edges of the tines 2050A. Air entering the vaporizer device flows along an air path across the heating element 2050, removing the vaporized vaporizable material 1302 from the heating element 2050 and/or the wick 2062. The vaporized vaporizable material 1302 condenses due to cooling, pressure changes, etc., thereby exiting the mouthpiece through at least one of the airflow passages as an aerosol for inhalation by the user.

Referring to Figures 10C, 11B, and 21A, in some embodiments, the collector 1313 is configured to include a flat rib 2102 extending from the lower periphery of the collector 1313 to create a suitable surface for welding the collector 1313 to the inner wall of the storage chamber 1342 after the collector 1313 is inserted into a receiving cavity or receptacle of the storage chamber 1342.

Depending on the embodiment, a full perimeter weld or tack weld option may be used to securely fasten the collector 1313 within the receiving cavity or receptacle of the reservoir 1342. In some embodiments, a friction-tight, leak-free bond may be established without the use of welding techniques. In certain embodiments, adhesive materials may be utilized in place of or in addition to the above bonding techniques.

11B and 21B, in accordance with one or more aspects, a sealing bead profile 2104 is formed around the helical rib of the collector 1313 that defines the overflow channel 1104, so that the sealing bead profile 2104 can support a rapid rotational injection molding process. The geometry of the sealing bead profile 2104 can be devised in various ways so that the collector 1313 is inserted into the receiving cavity or receptacle of the storage chamber 1342 in a friction-tight manner and the vaporizable material 1302 flows through the overflow channel 1104 along the sealing bead profile 2104 without leakage.

22A, 22B, and 82-86, the vaporizer cartridge 2200 can include a folded heating element, such as a heating element 500 and two airflow passages 2238. As described above, the heating element 500 can be crimped around the wick 2262 or can be preformed to receive the wick 2262. The heating element 500 can include one or more tines 502. The tines 502 can be positioned on the heating portion of the heating element 500 and are designed to match the resistance of the tines 502 with an appropriate amount of resistance to affect localized heating within the heating element 500 to more efficiently and effectively heat the vaporizable material 1302 from the wick 2262.

The tines 502 form thin path heating segments or traces in series and/or parallel to provide a desired amount of resistance. The particular shape of the tines 502 may be desirably selected to generate a particular local resistance for heating the heating element 500. For example, the tines 502, and thus the heating element 500, may include one or more of a variety of tine configurations and features described in more detail below.

In some embodiments, the tines 502 include a platform tine portion 524 and a side tine portion 526. The platform tine portion 524 is configured to contact one end of the wick 2262 and the side tine portion 526 is configured to contact an opposing side of the wick 2262. The platform tine portion 524 and the side tine portion 526 form a pocket shaped to receive the wick 2262 and/or conform to the shape of at least a portion of the wick 2262. The pocket allows the wick 2262 to be secured and held by the heating element 500 within the pocket.

In some embodiments, the side teeth portion 526 and the platform teeth portion 524 hold the wick 2262 by compression. The platform teeth portion 524 and the side teeth portion 526 contact the wick 2262 to provide multi-dimensional contact between the heating element 500 and the wick 2262. The multi-dimensional contact between the heating element 500 and the wick 2262 provides more efficient and/or faster transfer of the vaporizable material 1302 to be vaporized from the reservoir of the vaporizer cartridge to the heating portion (via the wick 2262).

The heating element 500 can include one or more legs 506 extending from the tines 502, and cartridge contacts 124 formed at and/or as part of at least one of the ends of the one or more legs 506. The heating element 500 shown in FIGS. 22A-22B and 82-86 includes four legs 506 as an example. At least one of the legs 506 can include and/or define one of the cartridge contacts 124 configured to contact a corresponding one of the receptacle contacts 125 of the vaporizer. In some embodiments, a pair of the legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125.

The legs 506 may be spring loaded to allow the legs 506 to maintain contact with the receptacle contacts 125. The legs 506 may include curved portions to help maintain contact with the receptacle contacts 125. The spring loaded legs 506 and/or the curvature of the legs 506 may help increase and/or maintain a consistent pressure between the legs 506 and the receptacle contacts 125. In some embodiments, the legs 506 are coupled with supports 176 to help increase and/or maintain a consistent pressure between the legs 506 and the receptacle contacts 125. The supports 176 may include plastic, rubber, or other materials to help maintain contact between the legs 506 and the receptacle contacts 125. In some embodiments, the supports 176 are formed as part of the legs 506.

The legs 506 may contact one or more wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or the power source 112. For example, the wiping contacts may include at least two parallel but offset protrusions that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

In some embodiments, the legs 506 include a retaining portion 180 configured to be bent around at least a portion of the wick housing 178 surrounding at least a portion of the wick 2262. The retaining portion 180 forms an end of the legs 506. The retaining portion 180 helps secure the heating element 500 and the wick 2262 to the wick housing 178 (and the vaporizer cartridge).

When the heating element 500 is activated, an electric current flows through the heating element 500, causing it to generate heat and thus increase in temperature. The heat is transferred to a quantity of the vaporizable material 1302 via heat transfer by conduction, convection, and/or radiation such that at least a portion of the vaporizable material 1302 vaporizes. Heat transfer can occur to vaporizable material 1302 in the reservoir, to vaporizable material 1302 drawn from the collector 2213, and/or to vaporizable material 1302 drawn into the wick 2262 held by the heating element 500.

In some embodiments, the vaporizable material 1302 may vaporize along one or more edges of the tines 502. Air entering the vaporizer device flows along an air path across the heating element 500, removing the vaporized vaporizable material 1302 from the heating element 500 and/or the wick 2262. The vaporized vaporizable material 1302 condenses due to cooling, pressure changes, etc., thereby exiting the mouthpiece through at least one of the airflow passages 2238 as an aerosol for inhalation by the user.

Figure 23 shows a cross-sectional view of the wick housing 178 consistent with an embodiment of the present invention. The wick housing 178 may include wick support ribs 2296 that extend from the outer shell of the wick housing 178 toward the wick 2262 when assembled. The wick support ribs 2296 help prevent deformation of the wick 2262 during assembly.

FIG. 24 illustrates an example of a wick housing 178 that includes an identification chip 2295. The identification chip 2295 may be at least partially carried by the wick housing 178. The identification chip 2295 may be configured to communicate with a corresponding chip reader disposed on the vaporizer.

25 shows perspective, front, side, and exploded views of an exemplary embodiment of a cartridge 1320 with a press-fit component. As shown, the cartridge 1320 can include a combination mouthpiece reservoir shaped in the shape of a sleeve with an airflow passage 1338 defined through the sleeve. The cartridge 1320 region houses a collector 1313, a wicking element 1362, a heating element 1350, and a wick housing 1315. An opening at a first end of the collector 1313 leads to an airflow passage 1338 in the mouthpiece, providing a path for the vaporized vaporizable material 1302 to travel from the heating element 1350 region to the mouthpiece where the user inhales.

Additional and/or Alternative Fluid Vent Embodiments
27A-B, a front plan view of an exemplary flow management feature in a collector 1313 structure is shown. Similar to the flow management features described with reference to Figs. 11M and 11N, the flow management vent feature 2701 or 2702 may be implemented in various shapes in different embodiments. In the example of Fig. 27A, the passageway or overflow channel 1104 in the collector 1313 may be connected to a reservoir via, for example, a fluid vent 2701, such that the vent 2701 includes at least two openings that are connected to the reservoir of the cartridge.

As previously mentioned, a liquid seal may be maintained at the vent 2701 regardless of the position of the cartridge. In one aspect, a vent path may be maintained between the overflow channel and the vent 2701. In another aspect, a high drive channel may be implemented to facilitate pinch-off and maintain the liquid seal.

Figure 27B shows an alternative vent 2702 configuration with three openings connected to the cartridge reservoir by pinch-off paths that prevent the liquid seal between the vent 2701 and the reservoir from being broken.

28 shows a snapshot of the flow of vaporizable material collected in the exemplary collector of FIG. 27A or FIG. 27B as it is managed to accommodate proper venting of the cartridge reservoir, according to one embodiment. As shown, the vent 2701 structure of FIG. 27A is distinguishable from the vent 2702 structure of FIG. 27B, which provides an open area on one side instead of the wall structure shown in FIG. 27A. This more open embodiment provides enhanced microfluidic interaction between the vaporizable material 1302 and the open side of the vent 2702.

With reference to Figures 29A-29C, perspective, front, and side views of an exemplary embodiment of a cartridge are shown. The illustrated cartridge may be assembled from multiple components including a collector, a heating element, and a wick housing that holds the cartridge components in place when inserted into the body of the cartridge. In one embodiment, a laser weld may be performed at a circumferential joint located at the approximate point where one end of the collector structure meets the wick housing. The laser weld prevents the flow of liquid vaporizable material 1302 from the collector into the heating chamber in which the atomizer is located.

30A-30F, perspective views of an exemplary cartridge at different fill volumes are shown. As previously mentioned, the volume size of the overflow volume may be configured to be equal to, approximately equal to, or greater than the increase in the volume of the contents contained in the reservoir. When the volume of the contents of the reservoir expands as a result of one or more environmental factors, if the volume of the contents contained in the reservoir is X, then when the pressure in the reservoir increases to Y, an amount Z of vaporizable material 1302 may be displaced from the reservoir into the overflow volume. Thus, in one or more embodiments, the overflow volume is configured to be large enough to accommodate at least an amount Z of vaporizable material 1302.

30A shows a perspective view of an exemplary cartridge body having a reservoir that contains a storage volume of vaporizable material 1302 of, for example, about 1.20 mL when filled. FIG. 30B shows a perspective view of an exemplary cartridge fully assembled, with the reservoir and collector overflow passage containing a combined volume of vaporizable material 1302 of, for example, about 1.20 mL when both are filled. FIG. 30C shows a perspective view of an exemplary cartridge fully assembled, for example, when the collector overflow passage is filled to a volume of about 0.173 mL. FIG. 30D shows a perspective view of an exemplary cartridge fully assembled, for example, when the reservoir is filled to a volume of about 0.934 mL. FIG. 30E shows a perspective view of an exemplary cartridge fully assembled, with the wick supply channel and airflow passage in the mouthpiece shown in cross section, with the wick supply channel having a volume of, for example, about 0.094 mL. FIG. 30F shows a perspective view of an exemplary fully assembled cartridge in which the overflow air channel is integrated into a portion of the collector toward the bottom rib and the airflow air channel has a volume of, for example, about 0.043 mL.

FIGS. 31A-31C are front views of an exemplary cartridge according to one embodiment, in which a dual needle filling application is implemented to fill the cartridge reservoir (FIG. 31A) before the collector and encapsulation plug are inserted into the cartridge body (FIG. 31B) to form the fully assembled cartridge (FIG. 31C).

34A and 34B show front views of an exemplary cartridge body with an external airflow path. In some embodiments, the vaporizer body 110 can be provided with one or more gates, also referred to as air inlet holes. The inlet holes can be located inside an air inlet channel of a width, height, and depth sized such that a user does not unintentionally block individual air inlet holes while holding the vaporizer 100. In one aspect, the structure of the air inlet channel can be long enough so as not to significantly block or restrict airflow through the air inlet channel if, for example, a user's finger blocks an area of the air inlet channel.

In some configurations, the geometry of the air inlet channel may provide, for example, at least one of a minimum length, a minimum depth, or a maximum width to prevent a user from completely covering or blocking the air inlet hole in the air inlet channel with a hand or other body part. For example, the length of the air inlet channel may be greater than the width of an average human finger, and the width and depth of the air inlet channel may be such that a fold of skin formed when a user's finger presses over the channel does not interface with the air inlet hole in the air inlet channel.

The air inlet channel may be constructed or formed with rounded edges or shaped to wrap around one or more corners or areas of the vaporizer body 110 so that it cannot be easily covered by a user's fingers or body parts. In certain embodiments, an optional cover may be provided to protect the air inlet channel and prevent a user's fingers from blocking or completely restricting the flow of air to the air inlet channel. In one exemplary embodiment, the air inlet channel may be formed at the interface between the vaporizer cartridge 120 and the vaporizer body 110 (e.g., in the receptacle area, see FIG. 1). In such an embodiment, the air inlet channel may be protected from obstruction because it is formed inside the receptacle area. This embodiment may also be configured to not show the air inlet channel.

Figures 32A-32C show front, top, and bottom views, respectively, of an exemplary cartridge body with a condensate collector 3201 integrated inside the air path.

Referring to FIG. 33A, air or vapor may flow into an airflow path within the cartridge. The airflow path may extend longitudinally from an opening or aperture in the mouthpiece along the interior of the cartridge body such that vaporizable material 1302 inhaled from the mouthpiece passes through a condensate collector 3201. As shown in FIG. 33B, in addition to the condensate collector 3201, a condensate recycler channel 3204 (e.g., a microfluidic channel) may be formed to travel, for example, from the mouthpiece opening to the wick.

The condensate collector 3201 acts on the vaporized vaporizable material 1302, which cools and turns into droplets in the mouthpiece, to collect the condensed droplets and send them to the condensate recycler channel 3204. The condensate recycler channel 3204 collects the condensate and larger vapor droplets and returns them to the wick, preventing the liquid vaporizable material formed on the mouthpiece from building up in the mouth when puffing or inhaling through the mouthpiece. The condensate recycler channel 3204 may be implemented as a microfluidic channel to capture the condensation of the droplets, thereby eliminating direct inhalation of the vaporizable material in liquid form and avoiding undesirable sensations and tastes in the user's mouth. Additional and/or alternative embodiments of the condensate recycler channel and/or one or more other mechanisms for controlling, collecting, and/or recycling the condensate in the vaporizer device are described and illustrated with respect to FIGS. 117-119C. The condensate recycler channel (and/or one or more other features described and illustrated with respect to FIGS. 117-119C) may assist in controlling, collecting, and/or recycling the condensate of the vaporizer device, either alone or in combination with one or more features of the vaporizer cartridge.

35 and 36, a perspective view of a portion of an exemplary cartridge is shown in which the collector structure 1313 includes a void 3501 in the bottom rib of the collector structure. The location of the void 3501 may coincide with where the air exchange port is located in the collector structure 1313. As previously described, the collector structure 1313 may be configured to have a central opening in which an air flow channel leading to the mouthpiece is implemented. The air flow channel may be connected to the air exchange port such that the volume in the overflow passage of the collector 1313 is connected to the ambient air through the air exchange port and to the volume of the reservoir through the vent.

According to one or more embodiments, the vent may be utilized as a control valve to primarily control liquid flow between the overflow passage and the storage chamber. The air exchange port may be utilized to primarily control air flow between the overflow passage and the air path leading to the mouthpiece, for example. The combination of interactions between the vent, the collector channel of the overflow passage, and the air exchange port provides adequate wick saturation and adequate venting of air bubbles that may be introduced into the cartridge due to various environmental factors, as well as the controlled flow of vaporizable material 1302 into and out of the collector channel. The presence of the void 3501 in the air exchange port allows for a more robust venting process to prevent liquid vaporizable material 1302 stored in the collector from permeating into the wick housing area.

37A-37C show top views of various exemplary wick supply shapes and configurations of a cartridge according to one or more embodiments. As shown, FIG. 37A shows a cross-shaped wick supply cross section according to an exemplary embodiment. FIG. 37B shows a wick supply having a generally rectangular cross section. FIG. 37C shows a wick supply having a generally square cross section. As previously mentioned, depending on the embodiment, one or more wick supplies 3701 can be configured as ducts, channels, tubes, or cavities passing through the collector structure 1313 as a path to supply the vaporizable material 1302 stored in the reservoir to the wick. In certain configurations, the wick supplies 3701 may run generally parallel to the central channel 3700 of the collector 1313.

Depending on the embodiment, the wick supply path may be shaped to be tubular, for example, having a substantially rectangular or square cross-sectional shape, as shown in FIGS. 37B and 37C. A duct or tube of variable width cross-sectional shape formed in the wick supply path can overcome clogging issues if such a shape provides a multi-pass configuration that allows vaporizable material 1302 to pass through the wick supply even if bubbles form in certain areas of the wick supply. In such an embodiment, a blockage of the wick supply tube is more likely to form in a portion of the wick supply tube, but a sub-path (e.g., an alternate path) remains open.

According to one or more aspects, the wick supply path may be wide enough to allow the vaporizable material 1302 to move freely through the supply path toward the wick. In some embodiments, the flow through the wick supply is enhanced or adjusted by engineering the relative diameter of certain portions of the wick supply that exert a capillary pulling force or pressure on the vaporizable material 1302 moving through the wick supply path. In other words, depending on the shape and other structural or material factors, some wick supply paths can rely on gravity or capillary forces to induce the movement of the vaporizable material 1302 into the wick housing portion.

37D and 37E show an exemplary embodiment of a collector 1313 with a double wick supply 3701 embodiment. At least one of the wick supplies 3701 may be formed to include a partial de-missing wall. The partial de-missing wall may be configured to divide the interior volume of the wick supply 3701 into two separate volumes (i.e., chambers), as shown in the cross-sectional perspective views of FIGS. 37D and 37E. The partial wall embodiment allows the liquid vaporizable material 1302 to easily flow from the reservoir toward the wick housing region to saturate the wick.

In certain embodiments, the partial walls of the single wick supply essentially form two chambers of the single wick supply. The chambers of the wick supply may be separated by partial walls and utilized separately to allow the vaporizable material 1302 to flow toward the wick housing. In such an embodiment, when a bubble is removed from one of the chambers of the wick supply, the other chamber may remain open. The chambers may be volumetrically large to provide sufficient flow of the vaporizable material 1302 toward the wick for proper saturation.

Thus, in an embodiment where two wick supplies 3701 are utilized, there may effectively be four chambers available to convey the flow of vaporizable material 1302 toward the wick. Thereby, even if bubbles form in one, two, or three of the chambers, at least the fourth chamber is available to direct the flow of vaporizable material 1302 toward the wick, reducing the chance of dehydration of the wick.

Referring to FIG. 38, an enlarged view of the end of a wick supply positioned proximate to the wick (e.g., at an end configured to at least partially receive the wick), optionally with at least a portion of the wick sandwiched between two or more protrusions extending from the end of the wick supply.

Figure 39 shows a perspective view of an exemplary collector structure with a square design wick supply combined with an air gap at one end of the overflow passage.

Referring to Figures 40A-40E, rear, side, top, front, and bottom views of an exemplary collector structure are shown, respectively. Figure 40A shows a rear view of a collector structure with, for example, four separate discharge sites. Figure 40B shows a side view of the collector structure, particularly showing the clamp-shaped end 4002 of the wick supply, which can hold the wick securely within the wick supply passage, for example. As shown in Figure 40C, the portion of the cartridge body extending from the mouthpiece into the interior of the cartridge body can be received through a central channel 3700 of the collector structure, which forms an airway passageway through which the vaporized vaporizable material 1302 escapes from the atomizer to the mouthpiece.

Figure 40C shows a top view of a collector structure having a wick supply channel 4001 for receiving vaporizable material from a cartridge reservoir and directing the vaporizable material towards a wick that is held in position at the end of the wick supply channel 4001 by a protruding end of the wick supply channel 4001 forming a clamp-shaped end 4002.

Figure 40D shows a front plan view of the collector structure. As shown, a void cavity can be formed in the lower part of the collector structure at the end of the lower rib of the collector structure, where the overflow passage of the collector leads to an air control vent 3902 that communicates with the ambient air. The portion of the cartridge body extending from the mouthpiece can be received through a central channel 3700 of the collector structure that forms an airway passage through which the vaporized vaporizable material 1302 escapes from the atomizer to the mouthpiece.

Figure 40E shows a bottom view of the collector 1313 structure in which two wick supply channels terminate in two clamp-shaped ends 4002 configured to hold the wick in place at the bottom end of the collector 1313. Optionally, a segmented ridge, flange, or lip 4003 may be formed on the surface of the bottom end of the collector 1313 as shown, which connects to the top of the plug 760 during assembly. The lip 4003 provides a pressure engagement between the top of the plug 760 and the bottom of the collector 1313, functioning in a manner similar to a flexible O-ring, so that a proper seal can be established during assembly. In one embodiment, the bottom end of the collector 1313 may be laser welded to the top of the plug 760.

41A and 41B show plan and side views of an alternative embodiment of a collector structure having two clamp-shaped ends 4002 and two corresponding wick supplies. As shown, this alternative embodiment has a reduced height compared to the embodiment shown in FIG. 40A. This reduced height provides improved functionality by structurally modifying the shape of the collector 1313 and the length of the passages in the collector 1313 through which the vaporizable material 1302 flows. Thus, depending on the embodiment, in certain embodiments, the length of the passage of the vaporizable material 1302 into the collector 1313 can be shortened to provide a more effective capillary pressure and better manage the flow of the vaporizable material 1302 into the passages of the collector 1313.

Figures 42A and 42B show various perspective, top, bottom and side views of an exemplary collector 1313 having different structural embodiments. For example, the embodiment shown in Figure 42A includes a constriction point that includes a vertically disposed C-shaped wall. In contrast, in the embodiment shown in Figure 42B, the C-shaped wall is disposed at an angle to promote a more controlled flow of vaporizable material 1302 along the collector 1313 passageway. As shown in the exemplary embodiment of Figure 42B, the C-shaped wall is disposed at an angle relative to the bottom blade of the collector and perpendicular to the portion of the blade within the collector that slopes downward.

As previously discussed, the flow rate into and out of the collector 1313 is controlled by manipulating the hydraulic diameter of the overflow channel 1104 in the collector 1313 through the introduction of one or more constriction points, which effectively reduces the overall volume of the overflow channel 1104. As shown, the introduction of multiple constriction points in the overflow channel 1104 divides the overflow channel into multiple segments within which the vaporizable material 1302 can flow in a first or second direction, e.g., toward or away from the air control vent 3902, respectively.

The introduction of the constriction point helps establish or control the capillary pressure condition in the overflow channel 1104, which minimizes the hydraulic flow of the vaporizable material 1302 toward the air control vent 3902 when the pressure condition in the cartridge reservoir is equal to or less than the ambient air. In a pressure condition where the pressure in the reservoir is less than the ambient pressure (e.g., above a first threshold), the constriction point is configured to control the capillary pressure or hydraulic flow of the vaporizable material 1302 in the overflow channel 1104, which allows the ambient air to enter the overflow channel 1104 through the air control vent 3904 and rise toward the controlled fluid gate 1102 into the reservoir, venting the cartridge (i.e., establishing an equilibrium pressure condition).

In certain embodiments or scenarios, the venting process described above may not include or require the ingress of ambient air via the air control vent 3904. For example, as provided in further detail herein with reference to FIG. 11M and FIG. 11N, in some exemplary scenarios, instead of or in addition to air entering through the air control vent 3904, air bubbles or gas trapped within the overflow channel 1104 may rise toward the controlled fluid gate 1102 and assist in establishing an equilibrium pressure condition within the cartridge by venting the reservoir as the air bubbles are introduced into the reservoir from the overflow channel 1104 via the controlled fluid gate 1102. As shown in FIG. 42A and FIG. 42B, the constriction point formed in the path of the overflow channel 1104 and the C-shaped wall design promote a more controlled flow of the vaporizable material 1302 through the overflow channel 1104 due to better management of the capillary pressure throughout the path of the overflow control channel 1104.

FIG. 43A shows various perspective, top, bottom and side views of an exemplary wick housing 1315 according to one or more embodiments. As shown, one or more perforations or holes can be formed in the bottom of the wick housing 1315 to accommodate airflow through a wick disposed within the wick housing 760 of the wick housing 1315. A sufficient number of holes facilitate adequate airflow through the wick housing 760 to provide for proper and timely vaporization of the vaporizable material 1302 absorbed by the wick in response to heat generated by a heating element disposed near or around the wick.

43B illustrates the collector 1313 and wick housing 760 components of an exemplary cartridge 1320, according to one or more embodiments. As shown, the wick housing 1315 (including the wick housing portion of the cartridge) may be implemented to include a protruding member or tab 4390. The tab 4390 may be configured to extend from a top end of the wick housing 1315, which mates with a receiving end of the collector 1313 during assembly. The tab 4390 may include, for example, one or more facets that correspond to or match one or more facets of a receiving notch or receiving cavity 1390 at the bottom of the collector 1313. The receiving cavity 1390 may be configured to removably receive the tab 4390, for example, for a snap-fit engagement. The snap-fit arrangement can help hold the collector 1313 and wick housing 1315 together during or after assembly.

In certain embodiments, the tabs 4390 can be utilized to indicate the orientation of the wick housing 1315 during assembly. For example, in one embodiment, one or more vibration mechanisms (e.g., vibrating bowls) can be utilized to temporarily store or stage various components of the cartridge 1320. According to some embodiments, the tabs 4390 can help orient the top of the wick housing 1315 for a mechanical gripper for easy engagement and correct automated assembly.

Additional and/or Alternative Heating Element Embodiments
As mentioned above, vaporizer cartridges consistent with embodiments of the present invention may include one or more heating elements. Figures 44A-116 illustrate embodiments of heating elements consistent with embodiments of the present invention. The features described and illustrated with respect to Figures 44A-116 may be included in the various embodiments of the vaporizer cartridges described above and/or may include one or more features of the various embodiments of the vaporizer cartridges described above, and the heating element features described and illustrated with respect to Figures 44A-116 may additionally and/or alternatively be included in one or more other exemplary embodiments of the vaporizer cartridges, such as those described below.

Heating elements consistent with embodiments of the present invention may desirably be shaped to receive the wicking element and/or at least partially crimped or pressed around the wicking element. The heating element may be bent such that the heating element is configured to secure the wicking element between at least two or three portions of the heating element. The heating element may be bent to conform to the shape of at least a portion of the wicking element. The heating element may be more easily manufacturable than a typical heating element. Heating elements consistent with embodiments of the present invention may be made of a conductive metal suitable for resistive heating, and in some embodiments, the heating element may include selective plating of another material to allow for more efficient heating of the heating element (and thus the vaporizable material).

Figure 44A shows an exploded view of one embodiment of the vaporizer cartridge 120, Figure 44B shows a perspective view of one embodiment of the vaporizer cartridge 120, and Figure 44C shows a bottom perspective view of one embodiment of the vaporizer cartridge 120. As shown in Figures 44A-44C, the vaporizer cartridge 120 includes a housing 160 and an atomizer assembly (or atomizer) 141.

The atomizer assembly 141 (see Figs. 99-101) may include a wicking element 162, a heating element 500, and a wick housing 178. As described in more detail below, at least a portion of the heating element 500 is disposed between the housing 160 and the wick housing 178 and is exposed to couple with a portion of the vaporizer body 110 (e.g., electrically couple with the receptacle contacts 125). The wick housing 178 may include four sides. For example, the wick housing 178 may include two opposing short sides and two opposing long sides. Each of the two opposing long sides may include at least one (two or more) recess 166 (see Figs. 99, 111A). The recess 166 may be disposed along the long sides of the wick housing 178 adjacent to respective intersections between the long and short sides of the wick housing 178. The recess 166 can be configured to releasably mate with a corresponding feature (e.g., a spring) on the vaporizer body 110 to secure the vaporizer cartridge 120 to the vaporizer body 110 within the cartridge receptacle 118. The recess 166 provides a mechanically stable fastening means for coupling the vaporizer cartridge 120 to the vaporizer body 110.

In some embodiments, the wick housing 178 also includes an identification chip 174, which may be configured to communicate with a corresponding chip reader disposed on the vaporizer. The identification chip 174 may be glued and/or otherwise attached to the wick housing 178, such as on a short side of the wick housing 178. The wick housing 178 may additionally or alternatively include a chip recess 164 (see FIG. 100) configured to receive the identification chip 174. The chip recess 164 may be surrounded by two, four, or more walls. The chip recess 164 may be shaped to secure the identification chip 174 to the wick housing 178.

As described above, the vaporizer cartridge 120 may generally include a reservoir, an air path, and an atomizer 141. In some configurations, the heating element and/or atomizer described by embodiments of the present invention may be mounted directly to the vaporizer body and/or may not be removable from the vaporizer body. In some embodiments, the vaporizer body may not include a removable cartridge.

Various advantages and benefits of the present invention may relate to improvements regarding the configuration, manufacturing method, etc. of the present vaporizer. For example, a heating element of a vaporizer device consistent with embodiments of the present invention is desirably made (e.g., punched) from a sheet of material and crimped or bent around at least a portion of a wicking element to provide a preformed element configured to receive the wicking element (e.g., the wicking element is pressed into the heating element and/or the heating element is held in tension and pulled over the wicking element). The heating element may be bent such that the heating element secures the wicking element between at least two or three portions of the heating element. The heating element may be bent to conform to the shape of at least a portion of the wicking element. The configuration of the heating element allows for more consistent, high quality manufacturing of the heating element. Consistency in manufacturing quality of the heating element is particularly important during scaled and/or automated manufacturing processes. For example, a heating element consistent with embodiments of the present invention helps reduce tolerance issues that may arise during the manufacturing process when assembling a heating element having multiple components.

In some embodiments, the accuracy of the heating element measurements (resistance, current, temperature, etc.) may be improved, at least in part, due to improved consistency in manufacturability of the heating element with reduced tolerance issues. The improved accuracy of the measurements improves the user experience when using the vaporizer device. For example, as described above, the vaporizer 100 can receive a signal to activate the heating element to a full operating temperature to generate an inhalable dose of vapor/aerosol or to a lower temperature to begin heating the heating element. The temperature of the vaporizer heating element can depend on many factors, as described above, some of which become predictable by eliminating potential variations in the manufacturing and assembly of the atomizer parts. A heating element made (e.g., die-cut) from a sheet of material and crimped or bent around at least a portion of the wicking element to provide a preformed element desirably helps minimize heat loss and ensure that the heating element operates predictably to heat to the appropriate temperature.

In addition, as discussed above, the heating element may be fully and/or selectively plated with one or more materials to enhance the heating performance of the heating element. Plating all or a portion of the heating element can minimize heat loss. Plating also helps to concentrate the heating portion of the heating element in the proper location, providing a more efficiently heated heating element, further reducing heat loss. Selective plating helps to direct the current supplied to the heating element to the proper location. Selective plating also helps to reduce the amount of plating material and/or costs associated with manufacturing the heating element.

Once the heating element is formed into the appropriate shape via one or more processes described below, the heating element is crimped around the wicking element and/or bent into the appropriate position to receive the wicking element. The wicking element may be a fibrous wick formed, in some embodiments, as an at least generally flat pad or with other cross-sectional shapes such as a circle, ellipse, etc. A flat pad allows for more precise and/or accurate control of the rate at which vaporizable material is drawn into the wicking element. For example, the length, width, and/or thickness can be adjusted for optimal performance. A wicking element forming a flat pad can provide a larger transfer surface area, which can increase the flow of vaporizable material from the reservoir to the wicking element for vaporization by the heating element (in other words, the transfer of a larger mass of vaporizable material) and the flow of vaporizable material from the wicking element to the air passing through the wicking element. In such configurations, the heating element may contact the wicking element in multiple directions (e.g., on at least two sides of the wicking element) to increase the efficiency of the process of drawing the vaporizable material into the wicking element and vaporizing the vaporizable material. Also, a flat pad may be more easily shaped and/or cut and therefore more easily assembled to the heating element. In some embodiments, as described in more detail below, the heating element may be configured to contact the wicking element on only one side of the wicking element.

The wicking element may include one or more rigid or compressible materials, such as cotton, silica, ceramic, etc. Compared to some other materials, a cotton wicking element may allow for a greater and/or more controllable flow rate of vaporizable material from a reservoir of the vaporizer cartridge to the wicking element to be vaporized. In some embodiments, the wicking element forms an at least approximately flat pad configured to contact the heating element and/or be secured between at least two portions of the heating element. For example, the at least approximately flat pad may have at least a first pair of opposing sides that are approximately parallel to one another. In some embodiments, the at least approximately flat pad may have at least a second pair of opposing sides that are approximately parallel to one another and approximately perpendicular to the first pair of opposing sides.

FIGS. 45-48 show schematic diagrams of a heating element 500 consistent with embodiments of the present invention. For example, FIG. 45 shows a schematic diagram of the heating element 500 in a deployed position. As shown, in the deployed position, the heating element 500 forms a planar heating element. The heating element 500 may first be formed from a substrate material. The substrate material is then cut and/or stamped into the appropriate shape via various mechanical processes, including, but not limited to, punching, laser cutting, photoetching, chemical etching, and the like.

The substrate material may be made of a conductive metal suitable for resistive heating. In some embodiments, the heating element 500 includes a nickel-chromium alloy, a nickel alloy, stainless steel, or the like. As described below, the heating element 500 may be plated with a coating at one or more locations on the surface of the substrate material (which may be all or a portion of the heating element 500) to enhance, limit, or modify the resistivity of the heating element at one or more locations of the substrate material.

The heating element 500 includes one or more teeth 502 (e.g., heating segments) located at the heating portion 504, one or more legs or (e.g., one, two, or more) connectors 506 located at the transition region 508, and cartridge contacts 124 located at the electrical contact region 510 and formed at the respective ends of the one or more legs 506. The teeth 502, legs 506, and cartridge contacts 124 may be integrally formed. For example, the teeth 502, legs 506, and cartridge contacts 124 form portions of the heating element 500 that are stamped and/or cut from the substrate material. In some embodiments, the heating element 500 also includes a heat shield 518 extending from one or more of the legs 506, and may be integrally formed with the teeth 502, legs 506, and cartridge contacts 124.

In some embodiments, at least a portion of the heating portion 504 of the heating element 500 is configured to engage the vaporizable material drawn from the reservoir 140 of the vaporizer cartridge 120 into the wicking element. The heating portion 504 of the heating element 500 can be shaped, sized, and/or otherwise treated to generate a desired resistance. For example, the tines 502 located on the heating portion 504 are designed such that the resistance of the tines 502 corresponds to an appropriate resistance value to affect localized heating at the heating portion 504 to more efficiently and effectively heat the vaporizable material from the wicking element. The tines 502 form heating segments or traces of thin paths in series and/or parallel to provide the desired amount of resistance.

The tines 502 (e.g., traces) may include a variety of shapes, sizes, and configurations. In some configurations, one or more tines 502 may be spaced apart to allow vaporizable material to be forced out of the wicking element and vaporize from the side edges of each tine 502. The shape, length, width, composition, etc., among other characteristics of the tines 502 may be optimized to maximize the efficiency of generating aerosol by vaporizing vaporizable material from within the heating portion of the heating element 500 and maximize electrical efficiency. The shape, length, width, composition, etc., among other characteristics of the tines 502 may additionally or alternatively be optimized to distribute heat evenly across the entire length of the tines 502 (or a portion of the tines 502, such as in the case of the heating portion 504). For example, the width of the tines 502 may be uniform or variable along the length of the tines 502 to control the temperature profile across at least the heating portion 504 of the heating element 500. In some examples, the length of the tines 502 may be controlled to achieve a desired resistance along at least a portion of the heating element 500, such as the heating portion 504. As shown in FIGS. 45-48, the tines 502 each have the same size and shape. For example, the tines 502 may be substantially aligned and include outer edges 503 having a generally rectangular shape, have flat or square outer edges 503 (see also FIGS. 49-53) or have rounded outer edges 503 (see FIGS. 54 and 55). In some embodiments, one or more tines 502 may be misaligned and/or include outer edges 503 of different sizes or shapes (see FIGS. 57-62). In some embodiments, the tines 502 may be evenly spaced or may have variable spacing between adjacent tines 502 (see FIGS. 87-92). The particular geometry of the tines 502 is desirably selected to generate a particular local resistance to heat the heating portion 504 and maximize the performance of the heating element 500 in heating the vaporizable material to generate an aerosol.

The heating element 500 may include portions of wider and/or thicker geometry and/or different composition relative to the tines 502. These portions may form electrical contact areas and/or more conductive portions and/or may include features for mounting the heating element 500 within the vaporizer cartridge. The legs 506 of the heating element 500 extend from the ends of each outermost tine 502A. The legs 506 form a portion of the heating element 500 that typically has a width and/or thickness greater than the width of each of the tines 502. However, in some embodiments, the legs 506 have a width and/or thickness that is the same as or less than the width of each of the tines 502. The legs 506 couple the heating element 500 to the wick housing 178, or another portion of the vaporizer cartridge 120, such that the heating element 500 is at least partially or completely surrounded by the housing 160. The legs 506 provide rigidity that promotes mechanical stability of the heating element 500 during and after manufacturing. The legs 506 also connect the cartridge contacts 124 with the teeth 502 located on the heating portion 504. The legs 506 are shaped and sized to allow the heating element 500 to maintain the electrical requirements of the heating portion 504. As shown in FIG. 48, when the heating element 500 is assembled with the vaporizer cartridge 120, the legs 506 space the heating portion 504 from the end of the vaporizer cartridge 120. As described in more detail below, at least with respect to FIGS. 82-98 and 103-104, the legs 506 can also include a capillary feature 598. The capillary feature 598 limits or prevents the escape of fluid from the heating portion 504 to other portions of the heating element 500.

In some embodiments, one or more of the legs 506 include one or more positioning features 516. The positioning features 516 may be used to mate with other (e.g., adjacent) components of the vaporizer cartridge 120 to relatively position the heating element 500 or portions thereof during and/or after assembly. In some embodiments, the positioning features 516 may be used during or after manufacture to properly position the substrate material to cut and/or stamp the substrate material to form the heating element 500 or for post-processing the heating element 500. The positioning features 516 may be sheared and/or cut prior to crimping or otherwise bending the heating element 500.

In some embodiments, the heating element 500 includes one or more heat shields 518. The heat shields 518 form a portion of the heating element 500 that extends laterally from the legs 506. When folded and/or crimped, the heat shields 518 are positioned offset from the tines 502 in the same plane in a first direction and/or a second direction opposite the first direction. When the heating element 500 is assembled to the vaporizer cartridge 120, the heat shields 518 are configured to be positioned between the tines 502 (and the heating portion 504) and the body (e.g., a plastic body) of the vaporizer cartridge 120. The heat shields 518 can help insulate the heating portion 504 from the body of the vaporizer cartridge 120. The heat shield 518 helps minimize the effects of heat emanating from the heating portion 504 of the body of the vaporizer cartridge 120, protect the structural integrity of the body of the vaporizer cartridge 120, and prevent melting or other deformation of the vaporizer cartridge 120. The heat shield 518 also helps maintain a constant temperature at the heating portion 504 by retaining heat within the heating portion 504, thereby preventing or limiting heat loss while vaporization is occurring. In some embodiments, the vaporizer cartridge 120 may additionally or alternatively include a heat shield 518A that is separate from the heating element 500 (see FIG. 102).

As discussed above, the heating element 500 includes at least two cartridge contacts 124 forming an end of each leg 506. For example, as shown in FIGS. 45-48, the cartridge contacts 124 may form a portion of the leg 506 that is folded along a fold line 507. The cartridge contacts 124 may be folded at an angle of about 90 degrees relative to the leg 506. In some embodiments, the cartridge contacts 124 may be folded at other angles, such as about 15 degrees, 25 degrees, 35 degrees, 45 degrees, 55 degrees, 65 degrees, 75 degrees, or other ranges of angles therebetween, relative to the leg 506. The cartridge contacts 124 may be folded toward or away from the heating portion 504, depending on the embodiment. The cartridge contacts 124 may also be formed on another portion of the heating element 500, such as along the length of at least one of the legs 506. The cartridge contacts 124 are configured to be exposed to the environment when assembled into the vaporizer cartridge 120 (see FIG. 53).

The cartridge contacts 124 may form conductive pins, tabs, posts, receiving holes, or surfaces of the pins or posts, or other contact configurations. Some types of cartridge contacts 124 include a spring or other biasing mechanism that improves physical and electrical contact between the cartridge contacts 124 on the vaporizer cartridge and the receptacle contacts 125 on the vaporizer body 110. In some embodiments, the cartridge contacts 124 include wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or a power source. For example, the wiping contacts may include two parallel but offset protrusions that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

The cartridge contacts 124 are configured to mate with receptacle contacts 125 located near the base of the cartridge receptacle of the vaporizer 100, such that when the vaporizer cartridge 120 is inserted into and mated with the cartridge receptacle 118, the cartridge contacts 124 and the receptacle contacts 125 form an electrical connection. The cartridge contacts 124 can be in electrical communication with the power source 112 of the vaporizer device (e.g., via the receptacle contacts 125, etc.). These electrical connections complete a circuit that can send an electrical current to the resistive heating element to heat at least a portion of the heating element 500, and can further be used for additional functions, such as measuring the resistance of the resistive heating element for use in determining and/or controlling the temperature of the resistive heating element based on the thermal coefficient of resistivity of the resistive heating element, identifying the cartridge based on one or more electrical characteristics of the resistive heating element or other circuitry of the vaporizer cartridge. The cartridge contacts 124 may be treated to provide improved electrical properties (e.g., contact resistance) using, for example, conductive plating, surface treatments, and/or deposition materials, as described in more detail below.

In some embodiments, the heating element 500 may be processed through a series of crimping and/or bending operations to form the heating element 500 into a desired three-dimensional shape. For example, the heating element 500 may be preformed to receive or crimped around the wicking element 162 (such as between opposing portions of the heating portion 504) to secure the wicking element between at least two portions (e.g., substantially parallel portions) of the heating element 500. To crimp the heating element 500, the heating element 500 may be bent toward each other along the fold lines 520. Folding the heating element 500 along the fold lines 520 forms a platform tine portion 524 defined by the area between the fold lines 520 and a side tine portion 526 defined by the area between the fold lines 520 and the outer edge 503 of the tines 502. The platform tine portion 524 is configured to contact one end of the wicking element 162. The side teeth portion 526 is configured to contact both sides of the wicking element 162. The platform teeth portion 524 and the side teeth portion 526 form a pocket shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pocket allows the wicking element 162 to be secured and held by the heating element 500 within the pocket. The platform teeth portion 524 and the side teeth portion 526 contact the wicking element 162 to provide a multi-dimensional contact between the heating element 500 and the wicking element 162. The multi-dimensional contact between the heating element 500 and the wicking element 162 provides a more efficient and/or faster transfer of the vaporizable material to be vaporized (through the wicking element 162) from the reservoir 140 of the vaporizer cartridge 120 to the heating portion 504.

In some embodiments, portions of the legs 506 of the heating element 500 may be bent away from each other along the fold lines 522. By folding the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522, the legs 506 are positioned away from the heating portion 504 (and the tines 502) of the heating element 500 in a first direction (e.g., in the same plane) and/or in a second direction opposite the first direction. Thus, by folding the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522, the heating portion 504 is spaced away from the body of the vaporizer cartridge 120. FIG. 46 shows a schematic diagram of the heating element 500 folded along the fold lines 520 and 522 with respect to the wicking element 162. As shown in FIG. 46, the wicking element is positioned within a pocket formed by folding the heating element 500 along the fold lines 520 and 522.

In some embodiments, the heating element 500 may be folded along fold lines 523. For example, the cartridge contacts 124 may be bent toward each other (toward the front and back of the page shown in FIG. 47) along fold lines 523. The cartridge contacts 124 are exposed to the environment and contact the receptacle contacts, while the remainder of the heating element 500 is disposed within the vaporizer cartridge 120 (see FIGS. 48 and 53).

In use, when the heating element 500 is incorporated into the vaporizer cartridge 120, a user puffs on the mouthpiece 130 of the vaporizer cartridge 120, causing air to enter the vaporizer cartridge and flow along the air path. In conjunction with a user's puff, the heating element 500 may be activated, for example, by automatic detection of the puff via a pressure sensor, detection of a button press by the user, detection of a signal generated from a motion sensor, a flow sensor, a capacitive lip sensor, and/or another approach that may detect that air is entering the vaporizer 100 and moving at least along the air path as the user is puffing or attempting to puff or otherwise inhale. When the heating element 500 is activated, power may be provided to the heating element 500 from the vaporizer device at the cartridge contacts 124.

When the heating element 500 is activated, an electric current flows through the heating element 500, causing it to generate heat and thus increase in temperature. The heat is transferred to a quantity of vaporizable material via heat transfer by conduction, convection, and/or radiation, causing at least a portion of the vaporizable material to vaporize. Heat transfer can occur to vaporizable material in the reservoir and/or to vaporizable material drawn into the wicking element 162 held by the heating element 500. In some embodiments, as described above, the vaporizable material can vaporize along one or more edges of the tines 502. Air entering the vaporizer device flows along an air path across the heating element 500, removing the vaporized vaporizable material from the heating element 500. The vaporized vaporizable material condenses due to cooling, pressure changes, etc., and exits the mouthpiece 130 as an aerosol for the user to inhale.

As mentioned above, the heating element 500 may be made of a variety of materials, such as nichrome, stainless steel, or other resistive heating materials. A combination of two or more materials may be included in the heating element 500, and such combinations may include both a uniform distribution of the two or more materials throughout the heating element, or other configurations in which the relative amounts of the two or more materials are spatially non-uniform. For example, the tines 502 may have a more resistive portion, which is designed to be hotter than the tines or other portions of the heating element 500. In some embodiments, at least the tines 502 (such as in the heating portion 504) may include a material that has high conductivity and heat resistance.

The heating element 500 may be fully or selectively plated with one or more materials. Because the heating element 500 is made of a thermally and/or electrically conductive material, such as stainless steel, nichrome, or other thermally and/or electrically conductive alloy, the heating element 500 may experience electrical or heating losses in the path between the cartridge contacts 124 and the tines 502 of the heating portion 504 of the heating element 500. To help reduce heating and/or electrical losses, at least a portion of the heating element 500 may be plated with one or more materials to reduce the resistance of the electrical path to the heating portion 504. In some embodiments consistent with the present invention, it is beneficial for the heating portion 504 (e.g., the tines 502) to remain unplated and for at least a portion of the legs 506 and/or cartridge contacts 124 to be plated with a plating material that reduces the resistance of those portions (e.g., either or both of the bulk resistance and the contact resistance).

For example, the heating element 500 can include various portions plated with different materials. In another example, the heating element 500 can be plated with layered materials. Plating at least a portion of the heating element 500 helps concentrate the current flowing through the heating portion 504 to reduce electrical and/or thermal losses in other portions of the heating element 500. In some embodiments, it is desirable to maintain a low resistance electrical path between the cartridge contacts 124 and the tines 502 of the heating element 500 to reduce electrical and/or thermal losses in the electrical path and to compensate for voltage drops concentrated across the heating portion 504.

In some embodiments, the cartridge contacts 124 may be selectively plated. Selectively plating the cartridge contacts 124 with a particular material can minimize or eliminate contact resistance at the point where the measurement is made and electrical contact is made between the cartridge contacts 124 and the receptacle contacts. Providing a low resistance at the cartridge contacts 124 can provide more accurate voltage, current, and/or resistance measurements and readings, which can be beneficial in accurately determining the current actual temperature of the heating portion 504 of the heating element 500.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the feet 506 may be plated with one or more outer plating materials 550. For example, at least a portion of the cartridge contacts 124 and/or at least a portion of the feet 506 may be plated with at least gold or another material that provides low contact resistance, such as platinum, palladium, silver, copper, etc.

In some embodiments, the surface of the heating element 500 can be plated with an adhesion plating material to secure the low resistance outer plating material to the heating element 500. In such configurations, the adhesion plating material can be attached to the surface of the heating element 500 and the outer plating material can be attached to the adhesion plating material to define first and second plating layers, respectively. The adhesion plating material includes materials that have adhesion properties when the outer plating material is attached over the adhesion plating material. For example, the adhesion plating material can include nickel, zinc, aluminum, iron, alloys thereof, and the like. FIGS. 79-81 show examples of heating elements 500 in which the cartridge contacts 124 are selectively plated with the adhesion plating material and/or the outer plating material.

In some embodiments, rather than plating the surface of the heating element 500 with an adhesive plating material to deposit an exterior plating material on the heating element 500, the surface of the heating element 500 may be primed using a non-plating primer. For example, the surface of the heating element 500 may be primed using an etch rather than depositing an adhesive plating material.

In some embodiments, all or a portion of the foot 506 and cartridge contact 124 may be plated with an adhesion plating material and/or an outer plating material. In some examples, the cartridge contact 124 may include at least a portion having an outer plating material with a greater thickness compared to the remainder of the cartridge contact 124 and/or the foot 506 of the heating element 500. In some embodiments, the cartridge contact 124 and/or the foot 506 may have a greater thickness compared to the tines 502 and/or the heating portion 504.

In some embodiments, rather than forming the heating element 500 from a single substrate material and plating the substrate material, the heating element 500 may be formed from various materials that are bonded together (e.g., via laser welding, a diffusion process, etc.). The materials of each portion of the heating element 500 that are bonded together can be selected to provide a high resistance at the tines 502 or heating portion 504, and a low or no resistance at the cartridge contacts 124, relative to other portions of the heating element 500.

In some embodiments, the heating element 500 may be electroplated with silver ink and/or spray coated with one or more plating materials, such as an adhesion plating material and an exterior plating material.

As discussed above, the heating element 500 can include a variety of shapes, sizes, and geometries to more efficiently heat the heating portion 504 of the heating element 500 and more efficiently vaporize the vaporizable material.

49-53 show an example of a heating element 500 consistent with an embodiment of the present invention. As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, cartridge contacts 124 formed at the respective ends of the one or more legs 506, and a heat shield 518 extending from the one or more legs 506. In this example, each of the tines 502 has the same or similar shape and size. The tines 502 have a square and/or flat outer edge 503. In FIGS. 49-52, the tines 502 are crimped around the wicking element 162 (e.g., a flat pad) to secure the wicking element 162 within the pocket of the tines 502.

54-55 show another example of a heating element 500 consistent with an embodiment of the present invention in an unbent position (FIG. 54) and a bent position (FIG. 55). As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, cartridge contacts 124 formed at the respective ends of the one or more legs 506, and a heat shield 518 extending from the one or more legs 506. In this example, each of the tines 502 has the same or similar shape and size, and the tines 502 have a rounded and/or semicircular outer edge 503.

FIG. 56 illustrates another example of a heating element 500 in a bent position consistent with an embodiment of the present invention that is similar to the exemplary heating element 500 illustrated in FIGS. 54-55, but in this example, each of the tines 502 have the same or similar shape and size, and the tines 502 have square and/or flat outer edges 503.

57-62 show other examples of heating elements 500 in which at least one tooth 502 has a different size, shape, or location than the remaining teeth 502. For example, as shown in Figs. 57-58, a heating element 500 includes one or more teeth 502 located on a heating portion 504, one or more legs 506 extending from the teeth 502, and cartridge contacts 124 formed at the respective ends of the one or more legs 506. In this example, the teeth 502 include a first set of teeth 505A and a second set of teeth 505B. The first and second sets of teeth 505A, 505B are offset from one another. For example, the outer edges 503 of the first and second sets of teeth 505A, 505B are not aligned with one another. As shown in FIG. 58, when the heating portion 504 is in a bent position, the first set of teeth 505A appears shorter than the second set of teeth 505B on the first portion of the heating element 500, and the first set of teeth 505A appears longer than the second set of teeth 505B on the second portion of the heating element 500.

59-60, the heating element 500 includes one or more teeth 502 located on the heating portion 504, one or more legs 506 extending from the teeth 502, and cartridge contacts 124 formed at the respective ends of the one or more legs 506. In this example, the teeth 502 include a first set of teeth 509A and a second set of teeth 509B. The first and second sets of teeth 509A, 509B are offset from one another. For example, the outer edges 503 of the first and second sets of teeth 509A, 509B are not aligned with one another. Here, the second set of teeth 509B includes a single outermost tooth 502A. As shown in FIGS. 59-60, when the heating portion 504 is in a bent position, the first set of teeth 509A appears to be longer than the second set of teeth 509B. Additionally, in FIGS. 59-60, the teeth 502 are not bent. Rather, the tines 502 are disposed on a first portion of the heating element 500 and a second portion disposed generally parallel to and opposite the first portion. The first set of tines disposed on the first portion of the heating element 500 is spaced from the second set of tines disposed on the second portion of the heating element 500 by a platform portion 530 disposed between and spaced apart from the first and second sets of tines. The platform portion 530 is configured to contact an end of the wicking element 162. The platform portion 530 includes a cutout portion 532. The cutout portion 532 can provide an additional edge along which the vaporizable material can vaporize when the heating element 500 is activated.

61-62, the heating element 500 includes one or more teeth 502 located on the heating portion 504, one or more legs 506 extending from the teeth 502, and cartridge contacts 124 formed at the respective ends of the one or more legs 506. In this example, the teeth 502 include a first set of teeth 509A and a second set of teeth 509B. The first and second sets of teeth 509A, 509B are offset from one another. For example, the outer edges 503 of the first and second sets of teeth 509A, 509B are not aligned with one another. Here, each of the first and second sets of teeth 509A, 509B includes two teeth 502. As shown in FIGS. 61-62, when the heating portion 504 is in a bent position, the first set of teeth 509A appears to be shorter than the second set of teeth 509B. Further, in FIGS. 61-62, the tines 502 are not curved. Rather, the tines 502 are disposed on a first portion and a second portion (opposite and parallel to the first portion) of the heating element 500. The first set of tines disposed on the first portion is spaced from the second set of tines disposed on the second portion by a platform portion disposed between and spaced from both the first and second sets of tines. The platform portion is configured to contact an end of the wicking element 162. The platform portion includes a cutout portion. The cutout portion can provide an additional edge along which the vaporizable material can vaporize when the heating element 500 is activated.

63-68 show another example of a heating element 500 consistent with an embodiment of the present invention in an unbent position (FIG. 63) and a bent position (FIGS. 64-68). As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, cartridge contacts 124 formed at the respective ends of the one or more legs 506, and a heat shield 518 extending from the one or more legs 506. In this example, the heating element 500 is configured to be crimped and/or bent to receive a cylindrical wicking element 162 or a wicking element 162 having a circular cross section. Each of the tines 502 includes an opening 540. The opening 540 can provide an additional edge from which a vaporizable material can vaporize when the heating element 500 is activated. The openings 540 also reduce the amount of material used to form the heating element 500, reducing the weight of the heating element 500 and the amount of material used in the heating element 500, thereby reducing material costs.

69-78 show a heating element 500 consistent with an embodiment of the present invention in which the heating element 500 is pressed against one side of the wicking element 162. As shown, the heating element 500 includes one or more tines 502 located on the heating portion 504, one or more legs 506 extending from the tines 502, and cartridge contacts 124 formed at the respective ends of the one or more legs 506. In these examples, the legs 506 and cartridge contacts 124 are configured to bend in a third direction, rather than in a first-second direction perpendicular to the third direction. In such a configuration, the tines 502 of the heating portion 504 form a planar platform facing outwardly from the heating element 500 and are configured to be pressed against the wicking element 162 (e.g., against one side of the wicking element 162).

FIGS. 71-74 show several examples of heating elements 500 consistent with embodiments of the present invention that include tines 502 configured in various shapes. As discussed above, the tines 502 form a planar platform that presses against one side of the wicking element 162 during use. The legs 506, not the tines 502, bend in the bent position.

FIG. 75 illustrates an example of the heating element 500 shown in FIG. 71 assembled to components of a vaporizer cartridge 120, such as the wicking element 162 and a wick housing (e.g., wick housing 178) that houses the heating element 500, and FIG. 76 illustrates the heating element 500 assembled to an exemplary vaporizer cartridge 120 consistent with embodiments of the present invention. As shown, the cartridge contacts 124 are bent laterally toward one another.

77 and 78 show another example of a heating element 500 in which the tines 502 form a platform configured to press against the wicking element 162. Here, the legs 506 can form a spring-like structure that presses the tines 502 against the wicking element 162 when a lateral inward force is applied to each of the legs 506. For example, FIG. 78 shows an example in which the tines 502 press against the wicking element 162 when power (e.g., current) is applied to the heating element 500, such as via the cartridge contacts 124.

FIGS. 82-86 show another example of a heating element 500 consistent with embodiments of the present invention. As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, and cartridge contacts 124 formed at and/or as part of the ends of the one or more legs 506. In this example, each of the tines 502 has the same or similar shape and size and is spaced equal distances apart from one another. The tines 502 have rounded outer edges 503.

As shown in FIG. 85, the tines 502 are crimped around the wicking element 162 (e.g., a flat pad) to secure the wicking element 162 within the pocket formed by the tines 502. For example, the tines 502 may be folded and/or crimped to define a pocket in which the wicking element 162 resides. The tines 502 include a platform tine portion 524 and a side tine portion 526. The platform tine portion 524 is configured to contact one side of the wicking element 162 and the side tine portion 526 is configured to contact the other opposing side of the wicking element 162. The platform tine portion 524 and the side tine portion 526 form a pocket shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pocket allows the wicking element 162 to be secured and held by the heating element 500 within the pocket.

In some embodiments, the side teeth portion 526 and the platform teeth portion 524 hold the wicking element 162 by compression (e.g., at least a portion of the wicking element 162 is compressed between the side teeth portions 526 and/or the platform teeth portion 524 on both sides). The platform teeth portion 524 and the side teeth portion 526 contact the wicking element 162 to provide multi-dimensional contact between the heating element 500 and the wicking element 162. The multi-dimensional contact between the heating element 500 and the wicking element 162 provides more efficient and/or faster transfer of the vaporizable material to be vaporized (through the wicking element 162) from the reservoir 140 of the vaporizer cartridge 120 to the heating portion 504.

82-86 includes four legs 506. Each of the legs 506 can include and/or define a cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the vaporizer 100. In some embodiments, each pair of legs 506 (and cartridge contact 124) can contact a single receptacle contact 125. The legs 506 can be spring loaded to allow the legs 506 to maintain contact with the receptacle contact 125. The legs 506 can include a portion extending along the length of the legs 506 that is curved to help maintain contact with the receptacle contact 125. The spring-loaded legs 506 and/or the curvature of the legs 506 can help increase and/or maintain a consistent pressure between the legs 506 and the receptacle contact 125. In some embodiments, the legs 506 are coupled with supports 176 that help increase and/or maintain consistent pressure between the legs 506 and the receptacle contacts 125. The supports 176 can include plastic, rubber, or other materials to help maintain contact between the legs 506 and the receptacle contacts 125. In some embodiments, the supports 176 are formed as part of the legs 506.

The legs 506 may contact one or more wiping contacts configured to clean the connection between the cartridge contacts 124 and other contacts or a power source. For example, the wiping contacts may include at least two parallel but offset protrusions that frictionally engage and slide against each other in a direction parallel or perpendicular to the insertion direction.

82-98, one or more legs 506 of the heating element 500 include four legs 506. FIGS. 91-92, 97A-98B, and 109-110 show examples of the heating element 500 in an unbent position. As shown, the heating element 500 has an H-shape defined by the four legs 506 and the tines 502. This configuration allows for a more accurate measurement of the resistance across the heater and reduces the variability of the resistance measurements, thereby improving the efficiency of aerosol generation and improving the quality of the aerosol generation. The heating element 500 includes two pairs of opposing legs 506. The tines 502 join (e.g., intersect) each pair of opposing legs 506 at or near the center of each pair of opposing legs 506. The heating section 504 is disposed between the pairs of opposing legs 506.

109 illustrates an example of a heating element 500 before the heating element 500 is punched and/or otherwise formed from the substrate material 577. The excess substrate material 577A may be bonded to the heating element 500 at one, two, or more bond locations 577B. For example, as shown, the excess substrate material 577A may be bonded to the heating element 500 at two bond locations 577B near the platform portion of the heating element and/or the opposing lateral ends 173 of the heating portion 504 of the heating element 500. In some embodiments, the heating element 500 may first be punched from the substrate material 577 and then removed from the excess substrate material 577A at the bond locations 577B (e.g., by twisting, pulling, punching, cutting the heating element 500, etc.).

As described above, to crimp the heating element 500, the heating element 500 may be bent or otherwise folded toward or away from one another along fold lines 523, 522A, 522B, 520 (see, e.g., FIG. 98A). Although the fold lines are shown in FIG. 98A, the exemplary heating element 500 described and shown in FIGS. 44A-115C may be crimped, folded, or otherwise bent along the fold lines. Folding the heating element 500 along the fold lines 520 forms a platform tine portion 524 defined by the area between the fold lines 520 and/or the side tine portion 526 defined by the area between the fold lines 520 and the outer edge 503 of the tines 502. The platform tine portion 524 may contact and/or support one end of the wicking element 162. The side tine portion 526 may contact both sides of the wicking element 162. The platform teeth portion 524 and the side teeth portion 526 define an interior volume of the heating element that receives the wicking element 162 and/or forms a pocket shaped to conform to the shape of at least a portion of the wicking element 162. The interior volume allows the wicking element 162 to be secured and held by the heating element 500 within the pocket. The platform teeth portion 524 and the side teeth portion 526 contact the wicking element 162 to provide multi-dimensional contact between the heating element 500 and the wicking element 162. The multi-dimensional contact between the heating element 500 and the wicking element 162 provides more efficient and/or faster transfer of the vaporizable material to be vaporized (through the wicking element 162) from the reservoir 140 of the vaporizer cartridge 120 to the heating portion 504.

In some embodiments, portions of the legs 506 of the heating element 500 may be bent along the fold lines 522A, 522B. By folding the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522, the legs 506 are positioned away from the heating portion 504 (and the tines 502) of the heating element 500 in a first direction (e.g., in the same plane) and/or in a second direction opposite the first direction. Thus, by folding the portions of the legs 506 of the heating element 500 away from each other along the fold lines 522, the heating portion 504 is spaced away from the body of the vaporizer cartridge 120. Folding the portions of the legs 506 along the fold lines 522A, 522B forms a bridge 585. In some embodiments, the bridge 585 helps to reduce or eliminate overflow of vaporizable material from the heating portion 504, such as by capillary action. The bridge 585 also helps to insulate the heating portion 504 from the legs 506 so that heat generated in the heating portion 504 does not reach the legs 506. This also helps to localize the heating of the heating element 500 within the heating portion 504.

In some embodiments, the heating element 500 may be bent along fold lines 523 to define cartridge contacts 124. The cartridge contacts 124 are exposed to the environment or are otherwise accessible (and can be located within a portion of the cartridge, such as the outer shell) for contacting the receptacle contacts, while other portions of the heating element 500, such as the heating portion 504, are located in an inaccessible portion of the vaporizer cartridge 120, such as the wick housing.

In some embodiments, the legs 506 include a retaining portion 180 configured to be bent around at least a portion of the wick housing 178 surrounding at least a portion of the wicking element 162 and the heating element 500 (such as the heating portion 504). The retaining portion 180 forms an end of the legs 506. The retaining portion 180 serves to secure the heating element 500 and the wicking element 162 to the wick housing 178 (and the vaporizer cartridge 120). Alternatively, the retaining portion 180 may be bent away from at least a portion of the wick housing 178.

FIGS. 87-92 show another example of a heating element 500 consistent with embodiments of the present invention. As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, and cartridge contacts 124 formed at and/or as part of each of the ends of the one or more legs 506.

The tines 502 may be folded and/or crimped to define a pocket in which the wicking element 162 (e.g., a flat pad) resides. The tines 502 include a platform tine portion 524 and a side tine portion 526. The platform tine portion 524 is configured to contact one side of the wicking element 162 and the side tine portion 526 is configured to contact the other opposing side of the wicking element 162. The platform tine portion 524 and the side tine portion 526 form a pocket shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pocket allows the wicking element 162 to be secured and held by the heating element 500 within the pocket.

In this example, the tines 502 have various shapes and sizes and are spaced apart from one another at equal or varying distances. For example, as shown, each of the side tines 526 includes at least four tines 502. In a first pair 570 of adjacent tines 502, each of the adjacent tines 502 is spaced apart at equal distances from an inner region 576 located near the platform tines 524 to an outer region 578 located near the outer edge 503. In a second pair 572 of adjacent tines 502, the adjacent tines 502 are spaced apart at varying distances from the inner region 576 to the outer region 578. For example, the adjacent tines 502 of the second pair 572 are spaced apart at a greater width in the inner region 576 than in the outer region 578. These configurations can help maintain a constant and uniform temperature along the length of the tines 502 of the heating section 504. By maintaining a constant temperature along the length of the tines 502, the maximum temperature can be maintained more uniformly throughout the heating section 504, thereby providing a higher quality aerosol.

As described above, each of the legs 506 can include and/or define a cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the vaporizer 100. In some embodiments, each pair of legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125. In some embodiments, the legs 506 include a retaining portion 180 that is configured to be bent and generally extends away from the heating portion 504. The retaining portion 180 is configured to be positioned within a corresponding recess in the wick housing 178. The retaining portion 180 forms an end of the legs 506. The retaining portion 180 serves to secure the heating element 500 and the wicking element 162 to the wick housing 178 (and vaporizer cartridge 120). The retaining portion 180 may have a tip portion 180A that extends from the end of the retaining portion 180 toward the heating portion 504 of the heating element 500. This configuration reduces the possibility of the retaining portion coming into contact with another portion of the vaporizer cartridge 120 or with a cleaning device for cleaning the vaporizer cartridge 120.

The outer edge 503 of the tines 502 of the heating portion 504 may include a tab 580. The tab 580 may include one, two, three, four, or more tabs 580. The tab 580 may extend outward from the outer edge 503 and away from the center of the heating element 500. For example, the tab 580 may be disposed along an edge of the heating element 500 surrounding an interior volume defined by at least the side tines portion 526 for receiving the wicking element 162. The tab 580 may extend outward away from the interior volume of the wicking element 162. The tab 580 may also extend away in a direction opposite the platform tines portion 524. In some embodiments, the tabs 580 disposed on opposite sides of the interior volume of the wicking element 162 may extend away from each other. This configuration helps to enlarge the opening to the interior volume of the wicking element 162, thereby helping to reduce the likelihood that the wicking element 162 will snag, tear, and/or be damaged when assembled to the heating element 500. Due to the material of the wicking element 162, the wicking element 162 may easily snag, tear, and/or otherwise be damaged when assembled to (e.g., positioned within or inserted into) the heating element 500. Contact between the wicking element 162 and the outer edge 503 of the tines 502 may also cause damage to the heating element. The shape and/or positioning of the tabs 580 may allow the wicking element 162 to be more easily positioned within or towards a pocket (e.g., the interior volume of the heating element 500) formed by the tines 502, thereby preventing or reducing the likelihood of damage to the wicking element 162 and/or the heating element. Thus, the tabs 580 help reduce or prevent damage caused to the heating element 500 and/or the wicking element 162 when the wicking element 162 comes into thermal contact with the heating element 500. The shape of the tabs 580 also helps minimize the effect on the resistance of the heating portion 504.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 can be plated with one or more outer plating materials 550 to reduce contact resistance at the point where the heating element 500 contacts the receptacle contacts 125.

93A-98B show another example of a heating element 500 consistent with embodiments of the present invention. As shown, the heating element 500 includes one or more tines 502 located on a heating portion 504, one or more legs 506 extending from the tines 502, and cartridge contacts 124 formed at and/or as part of each of the ends of the one or more legs 506.

The tines 502 may be folded and/or crimped to define a pocket in which the wicking element 162 (e.g., a flat pad) resides. The tines 502 include a platform tine portion 524 and a side tine portion 526. The platform tine portion 524 is configured to contact one side of the wicking element 162 and the side tine portion 526 is configured to contact the other opposing side of the wicking element 162. The platform tine portion 524 and the side tine portion 526 form a pocket shaped to receive the wicking element 162 and/or conform to the shape of at least a portion of the wicking element 162. The pocket allows the wicking element 162 to be secured and held by the heating element 500 within the pocket.

In this example, the teeth 502 have the same shape and size and are spaced apart at equal distances from each other. Here, the teeth 502 include a first side tooth portion 526A and a second side tooth portion 526B spaced apart by a platform tooth portion 524. Each of the first and second side tooth portions 526A, 526B includes an inner region 576 located near the platform tooth portion 524 to an outer region 578 located near the outer edge 503. In the outer region 578, the first side tooth portion 526A is disposed substantially parallel to the second tooth portion 526B. In the inner region 576, the first side tooth portion 526A is disposed offset from the second tooth portion 526B, and the first and second side tooth portions 526A, 526B are not parallel. This configuration may help maintain a constant and uniform temperature along the length of the teeth 502 of the heating section 504. By maintaining a constant temperature along the length of the tines 502, the maximum temperature can be maintained more uniformly throughout the heating section 504, thereby providing a higher quality aerosol.

As described above, each of the legs 506 can include and/or define a cartridge contact 124 configured to contact a corresponding receptacle contact 125 of the vaporizer 100. In some embodiments, each pair of legs 506 (and cartridge contacts 124) may contact a single receptacle contact 125. In some embodiments, the legs 506 include a retaining portion 180 that is configured to be bent and generally extends away from the heating portion 504. The retaining portion 180 is configured to be positioned within a corresponding recess in the wick housing 178. The retaining portion 180 forms an end of the legs 506. The retaining portion 180 serves to secure the heating element 500 and the wicking element 162 to the wick housing 178 (and vaporizer cartridge 120). The retaining portion 180 may have a tip portion 180A that extends from the end of the retaining portion 180 toward the heating portion 504 of the heating element 500. This configuration reduces the possibility of the retaining portion coming into contact with another portion of the vaporizer cartridge 120 or with a cleaning device for cleaning the vaporizer cartridge 120.

The outer edge 503 of the tines 502 of the heating portion 504 may include a tab 580. The tab 580 may extend outward from the outer edge 503 and away from the center of the heating element 500. The tab 580 may be shaped to allow the wicking element 162 to be more easily positioned within the pocket formed by the tines 502, thereby preventing or reducing the possibility of the wicking element 162 getting caught on the outer edge 503. The shape of the tab 580 helps to minimize its effect on the resistance of the heating portion 504.

In some embodiments, at least a portion of the cartridge contacts 124 and/or at least a portion of the legs 506 can be plated with one or more outer plating materials 550 to reduce contact resistance at the point where the heating element 500 contacts the receptacle contacts 125.

99-100 show an example of an atomizer assembly 141 with a heating element 500 assembled to a wick housing 178, and FIG. 101 shows an exploded view of the atomizer assembly 141 consistent with an embodiment of the present invention. The wick housing 178 may be made of plastic, polypropylene, or the like. The wick housing 178 includes four recesses 592 in which at least a portion of each of the legs 506 of the heating element 500 may be positioned and secured. As shown, the wick housing 178 also includes an opening 593 that provides access to an interior volume 594 within which at least the heating portion 504 and the wicking element 162 of the heating element 500 are positioned.

The wick housing 178 may also include a separate heat shield 518A, shown in FIG. 102. The heat shield 518A is disposed within an interior volume 594 within the wick housing 178 between the walls of the wick housing 178 and the heating element 500. The heat shield 518A is shaped to at least partially surround the heating portion 504 of the heating element 500 and space the heating element 500 from the sidewalls of the wick housing 178. The heat shield 518A can help to insulate the heating portion 504 from the body of the vaporizer cartridge 120 and/or the wick housing 178. The heat shield 518A helps to minimize the effects of heat emanating from the heating portion 504 of the body of the vaporizer cartridge 120 and/or the wick housing 178, protect the structural integrity of the body of the vaporizer cartridge 120 and/or the wick housing 178, and prevent melting or other deformation of the vaporizer cartridge 120 and/or the wick housing 178. The heat shield 518A also helps maintain a constant temperature in the heating section 504 by retaining heat within the heating section 504, thereby preventing or limiting heat loss.

The heat shield 518A includes one or more slots 590 (e.g., three slots) at one end that align with one or more slots (e.g., one, two, three, four, five, six, or more slots) 596 formed in a portion of the wick housing 178 opposite the opening 593, such as the base of the wick housing 178 (see Figs. 100 and 112). The one or more slots 590, 596 allow for the flow of liquid vaporizable material in the heating section 504 and the relief of pressure caused by the vaporization of the vaporizable material without affecting the liquid flow of the vaporizable material.

In some embodiments, flooding may occur between the heating element 500 (e.g., legs 506) and the outer wall of the wick housing 178 (or between portions of the heating element 500). For example, as shown by liquid path 599, capillary pressure between the legs 506 of the heating element 500 and the outer wall of the wick housing 178 may cause liquid vaporizable material to build up. In such a case, there may be sufficient capillary pressure to draw liquid vaporizable material out of the reservoir and/or heating portion 504. To help limit and/or prevent liquid vaporizable material from escaping the interior volume of the wick housing 178 (or heating portion 504), the wick housing 178 and/or heating element 500 may include a capillary feature that causes a sudden change in capillary pressure, thereby forming a liquid barrier that prevents liquid vaporizable material from passing through the feature without the use of an additional seal (e.g., a hermetic seal). The capillary mechanism may define a capillary break formed by a sharp point, bend, curved surface, or other surface of the wick housing 178 and/or the heating element 500. The capillary mechanism allows the conductive element (e.g., the heating element 500) to be located in both wet and dry regions.

A capillary feature may be disposed on and/or form part of the heating element 500 and/or the wick housing 178, causing an abrupt change in capillary pressure. For example, the capillary feature may include a bend, sharp point, curved surface, angled surface, or other surface feature along the length of the heating element that causes an abrupt change in capillary pressure between the heating element and the wick housing, or between another component of the vaporizer cartridge. The capillary feature may also include a protrusion or other portion of the heating element and/or wick housing that widens a capillary channel, such as a capillary channel formed between portions of the heating element, between the heating element and the wick housing, etc., sufficient to reduce the capillary pressure in the capillary channel such that the capillary channel does not draw liquid into the capillary channel (e.g., the capillary feature moves the heating element away from the wick housing). Thus, the capillary feature prevents or restricts liquid from flowing past the capillary feature and along the liquid path due at least in part to a sudden change and/or drop in capillary pressure. The size and/or shape (e.g., bends, sharp points, curved surfaces, sloped surfaces, protrusions, etc.) of the capillary feature may be a function of the wetting angle formed between materials such as the heating element and the wick housing, or other walls of the capillary channel formed between the components, may be a function of the materials of the heating element and/or wick housing or other components, and/or may be a function of the size of the gap formed between two components such as the heating element and/or wick housing that define the capillary channel, among other properties.

103A and 103B, as an example, show a wick housing 178 having a capillary feature 598 that causes a sudden change in capillary pressure. The capillary feature 598 prevents or restricts liquid from flowing past the capillary feature 598 along the liquid path 599, helping to prevent liquid from pooling between the legs 506 and the wick housing 178. The capillary feature 598 on the wick housing 178 spaces the heating element 500 (e.g., a component made of metal, etc.) from the wick housing 178 (e.g., a component made of plastic, etc.), thereby reducing the capillary strength between the two components. The capillary feature 598 shown in FIG. 103A and 103B also includes a sharp edge at the end of the wick housing's sloped surface that restricts or prevents liquid from flowing past the capillary feature 598.

As shown in FIG. 103B, the legs 506 of the heating element 500 may be angled inward toward the interior volume of the heating element 500 and/or the wick housing 178. The angled legs 506 may form a capillary mechanism that helps restrict or prevent liquid from flowing over the outer surface of the heating element and along the legs 506 of the heating element 500.

As another example, the heating element 500 may be formed with one or more legs 506 and include a capillary feature (e.g., bridge 585) that spaces the legs 506 from the heating portion 504 (see Figs. 82-98). The bridge 585 may be formed by folding the heating element 500 along fold lines 520, 522. In some embodiments, the bridge 585 helps to reduce or eliminate overflow of vaporizable material from the heating portion 504, such as by capillary action. In some examples, such as the exemplary heating element 500 shown in Figs. 93A-98B, the bridge 585 is angled and/or includes bends to help restrict the flow of fluid from the heating portion 504.

As another example, the heating element 500 can include a capillary feature 598 that defines a sharp point to cause a sudden change in capillary pressure, thereby preventing the liquid vaporizable material from flowing past the capillary feature 598. FIG. 104 illustrates an example of a heating element 500 having a capillary feature 598 consistent with an embodiment of the present invention. As shown in FIG. 104, the capillary feature 598 can form an end of a bridge 585 that extends outwardly from the heating portion a distance greater than the distance between the legs 506 and the heating portion 504. The end of the bridge 585 can be a sharp edge that helps to further prevent the liquid vaporizable material from flowing into the legs 506 and/or out of the heating portion 504, thereby reducing leakage and increasing the amount of vaporizable material remaining within the heating portion 504.

105-106 show a variation of the heating element 500 shown in FIGS. 87-92. In this variation of the heating element 500, the legs 506 of the heating element 500 include a bend in a bend region 511. The bend in the legs 506 can form a capillary feature 598, which helps prevent the liquid vaporizable material from flowing past the capillary feature 598. For example, the bend can create a sudden change in capillary pressure, which can help limit or prevent the liquid vaporizable material from flowing past the bend and/or pooling between the legs 506 and the wick housing 178, which can help limit or prevent the liquid vaporizable material from flowing out of the heating portion 504.

107-108 show a variation of the heating element 500 shown in FIGS. 93A-98B. In this variation of the heating element 500, the legs 506 of the heating element 500 include a bend in a bend region 511. The bend in the legs 506 can form a capillary feature 598, which helps to prevent the liquid vaporizable material from flowing past the capillary feature 598. For example, the bend can create a sudden change in capillary pressure, which helps to limit or prevent the liquid vaporizable material from flowing past the bend and/or pooling between the legs 506 and the wick housing 178, which can help to limit or prevent the liquid vaporizable material from flowing out of the heating portion 504.

111A-112 show another example of an atomizer assembly 141 with a heating element 500 assembled to a wick housing 178 and heat shield 518A, and FIG. 113 shows an exploded view of the atomizer assembly 141 consistent with an embodiment of the present invention. The wick housing 178 may be made of plastic, polypropylene, or the like. The wick housing 178 includes four recesses 592 in which at least a portion of each of the legs 506 of the heating element 500 may be positioned and secured. Within the recesses 592, the wick housing 178 may include one or more wick housing retention features 172 (see FIG. 115A) that serve to secure the heating element 500 to the wick housing 178, e.g., via a snap-fit arrangement between at least a portion of the legs 506 of the heating element 500 and the wick housing retention features 172. The wick housing retention mechanism 172 can also help space the heating element 500 away from the surface of the wick housing 178, which can help prevent heat from acting on the wick housing and melting a portion of the wick housing 178.

As shown, the wick housing 178 also includes an opening 593 that provides access to an interior volume 594 within which at least the heating portion 504 and the wicking element 162 of the heating element 500 are disposed.

The wick housing 178 may also include one or more other cutouts that help space the heating element 500 from the surface of the wick housing 178 to reduce the amount of heat that contacts the surface of the wick housing 178. For example, the wick housing 178 may include a cutout 170. The cutout 170 may be formed along the outer surface of the wick housing 178 proximate the opening 593. The cutout 170 may also include a capillary feature, such as capillary feature 598. The capillary feature of the cutout 170 may define a surface (e.g., a curved surface) that breaks the contact points between adjacent (or intersecting) walls (such as walls of the wick housing). The curved surface may have a radius sufficient to reduce or eliminate capillary action formed between adjacent outer walls of the wick housing.

With reference to FIGS. 111A-112, the wick housing 178 can include tabs 168. The tabs 168 can help properly position and/or orient the wick housing during assembly of the vaporizer cartridge relative to one or more other components of the vaporizer cartridge. For example, the added material forming the tabs 168 shifts the center of mass of the wick housing 178. Because of the shifted center of mass, the wick housing 178 can rotate or slide in a particular orientation to align with a corresponding feature of another component of the vaporizer cartridge during assembly.

114A-114C illustrate an exemplary method of forming an atomizer assembly 141 of a vaporizer cartridge 120 including a wick housing 178, a wicking element 162, and a heating element 500 consistent with embodiments of the present invention. As shown in FIG. 114A, the wicking element 162 may be inserted into a pocket formed in the heating element 500 (e.g., formed by the side teeth portion 526 and the platform teeth portion 524). In some embodiments, when vaporizable material is introduced into the wicking element 162, the wicking element 162 expands after being secured to the heating element 500.

114B illustrates a wicking element 162 and a heating element 500 coupled to a wick housing 178, and FIG. 114C illustrates an example of a wicking element 162 and a heating element 500 assembled to a wick housing 178. At least a portion of the heating element 500, such as the heating portion 504, can be disposed within the interior volume of the wick housing 178. The legs 506 (e.g., the retaining portion 180) of the heating element 500 may be coupled to an outer wall of the wick housing 178, for example, via a snap-fit configuration. In particular, the retaining portion 180 of the legs 506 can be coupled to and at least partially disposed within a recess in the wick housing 178.

115A-115C illustrate another exemplary method of forming an atomizer assembly 141 of a vaporizer cartridge 120 including a wick housing 178, a wicking element 162, and a heating element 500, consistent with embodiments of the present invention. As shown in FIG. 115A, the heating element 500 can be coupled to the wick housing 178, for example, by inserting or otherwise disposing at least a portion of the heating element 500, such as the heating portion 504, within the interior volume of the wick housing 178. The legs 506 (e.g., the retaining portion 180) of the heating element 500 may be coupled to an outer wall of the wick housing 178, for example, via a snap-fit configuration. In particular, the retaining portion 180 or another portion of the legs 506 can be coupled to and at least partially disposed within a recess of the wick housing 178, for example, by coupling with the wick housing retention feature 172.

115B, the wicking element 162 may be inserted into a pocket formed in the heating element 500 (e.g., formed by the side teeth portion 526 and the platform teeth portion 524). In some embodiments, when the wicking element 162 is coupled with the heating element 500, the wicking element 162 is compressed. In some embodiments, when a vaporizable material is introduced into the wicking element 162, the wicking element 162 expands after fitting within and being secured to the heating element 500.

FIG. 115C shows an example of a wicking element 162 and a heating element 500 assembled to a wick housing 178 to form an atomizer assembly 141.

FIG. 116 illustrates an exemplary process 3600 for assembling a heating element 500 consistent with an embodiment of the present invention. The process flow chart 3600 illustrates method features that may optionally include some or all of the following: At block 3610, a planar substrate having resistive heating properties is provided. At block 3612, the planar substrate may be cut and/or punched into a desired geometric shape. At block 3614, at least a portion of the heating element 500 may be plated. For example, as described above, one or more layers of plating material (e.g., adhesive plating material and/or exterior plating material) may be deposited on at least a portion of the exterior surface of the heating element 500. At block 3616, the heating portion 504 (e.g., tines 502) may be bent and/or otherwise crimped around the wicking element to conform to the shape of the wicking element and secure the wicking element to the heating element. At block 3618, the cartridge contacts 124, which in some embodiments form the ends of the legs 506 of the heating element 500, can be bent along a first or second direction along a plane, or along a third direction perpendicular to the first or second direction. At block 3620, the heating element 500 can be assembled to the vaporizer cartridge 120 to create fluid communication between the wicking element 162 and a reservoir of vaporizable material. At 3622, the vaporizable material can be drawn into the wicking element 162, which can be positioned to contact at least two surfaces of the heating portion 504 of the heating element 500. At block 3624, a heating means can be provided to the cartridge contacts 124 of the heating element to heat the heating element 500 at least at the heating portion 504. The heating causes the vaporizable material to vaporize. At block 3626, the vaporized vaporizable material is entrained in an airflow to a mouthpiece of the vaporizer cartridge in which the heating element is located.

Condensate Control, Collection, and Recycling Embodiments Figures 117-119C show embodiments of a vaporizer cartridge that include one or more features for controlling, collecting, and/or recycling condensate within a vaporizer device. The features described and illustrated with respect to Figures 117-119C may be included in and/or include one or more features of the various embodiments of the vaporizer cartridge described above, and the vaporizer features described and illustrated with respect to Figures 117-119C may additionally and/or alternatively be included in one or more other exemplary embodiments of a vaporizer cartridge, such as those described below.

A typical approach by which a vaporizer device produces an inhalable aerosol from a vaporizable material involves heating the vaporizable material in a vaporization chamber (or heating chamber) to convert the vaporizable material to the gas (or vapor) phase. The vaporization chamber generally refers to the area or volume within the vaporizer device in which a heat source (e.g., conduction, convection, and/or radiation) heats the vaporizable material, producing a mixture of air and vaporized vaporizable, forming a vapor for inhalation by a user of the vaporizer device.

Since the introduction of vaporizer devices to the market, vaporizer cartridges containing free liquid (i.e., liquid held in a reservoir and not held in a porous material) have gained popularity. Products on the market may include a cotton pad to collect condensation resulting from the vapor generated in the vaporizer device, or they may lack such a mechanism altogether.

Liquid from condensation can form a film on the walls of the airway and migrate up to the mouthpiece and leak into the user's mouth, causing an unpleasant experience. Even if the wall film does not leak through the mouthpiece, it can create large droplets that can be caught in the airflow and drawn into the user's mouth and throat, causing an unpleasant user experience. Problems with using cotton pads to absorb such condensation include inefficiencies as well as the additional manufacturing and assembly costs of integrating the cotton pad into part of the vaporizer device. Furthermore, accumulation and loss of condensation and/or unvaporized vaporizable material can eventually result in not all of the vaporizable material being drawn into the vaporizer chamber, thereby wasting vaporizable material. Therefore, improved vaporizer devices and/or vaporizer cartridges are desired.

As described in more detail below, vaporizing a vaporizable material into an aerosol can cause condensation to collect along one or more of the internal channels and outlets of some vaporizers (e.g., along the mouthpiece). For example, such condensation can include vaporizable material that is drawn from a reservoir, formed into an aerosol, and condensed into a condensate before exiting the vaporizer. Additionally, vaporizable material that avoids the vaporization process can also accumulate along one or more of the internal channels and/or air outlets. This can cause condensate and/or unvaporized vaporizable material to exit the mouthpiece outlet and deposit in the user's mouth, causing both an unpleasant user experience and a reduction in the amount of inhalable aerosol that would otherwise be available. Additionally, the accumulation and loss of condensate can eventually result in not all of the vaporizable material being drawn from the reservoir into the vaporization chamber, thereby wasting the vaporizable material. For example, when particulates of vaporizable material accumulate in the internal channel of the air tube downstream of the vaporizer chamber, the effective cross-sectional area of the airflow passage is narrowed, increasing the air flow rate, thereby exerting a drag force on the accumulated fluid, thereby amplifying the likelihood that the fluid will be drawn from the internal channel through the mouthpiece outlet. Various features and devices that improve or overcome these problems are described below.

As discussed above, drawing vaporizable material from a reservoir and vaporizing the vaporizable material into an aerosol can result in vaporizable material condensation collecting adjacent to and/or within one or more outlets formed in the mouthpiece. This can cause the condensate material to exit the outlet and deposit in the user's mouth, causing both an unpleasant user experience and a reduction in the amount of vapor that would otherwise be available for consumption. Various vaporizer device features that improve or overcome these problems are described below. For example, various features for controlling condensation within a vaporizer device are described herein that provide advantages and improvements over existing approaches and may also introduce additional advantages as described herein. For example, vaporizer device features are described that are configured to collect and contain condensation that forms or collects adjacent to an outlet in the mouthpiece, thereby preventing the condensate from exiting the outlet.

Alternatively or additionally, drawing vaporizable material 102 from reservoir 140 and vaporizing the vaporizable material into an aerosol can cause condensation to collect within one or more tubes or internal channels (e.g., air tubes) of the vaporizer device. As described in more detail below, features of the vaporizer device are described that are configured to trap condensation and prevent vaporizable material particulates from exiting the air outlet of the vaporizer cartridge.

117 illustrates an embodiment of the vaporizer cartridge 120 that includes a finned condensate collector 352 configured to collect and contain condensation that forms or collects adjacent the mouthpiece outlet or other area of the vaporizer cartridge 120, thereby preventing the condensate from exiting the outlet. As shown in FIG. 117, the finned condensate collector 352 may be positioned in a chamber adjacent the outlet 136 of the mouthpiece 130 such that the aerosol passes through the finned condensate collector 352 before exiting the outlet 136.

118 illustrates an embodiment of a mouthpiece 330 including an embodiment of a finned condensate collector 352 having a plurality of microfluidic fins 354. The mouthpiece 330 may be configured for a vaporizer cartridge (such as vaporizer cartridge 120) and/or a vaporizer device (such as vaporizer 100) having microfluidic fins 354 housed in the finned condensate collector 352 to improve collection and containment of condensate in the vaporizer cartridge. As shown in FIG. 118, the microfluidic fins 354 include a set of walls 355 or other protrusions and narrow grooves 353 having microfluidic properties. In an exemplary embodiment, each wall of the set of walls 355 may be arranged parallel or substantially parallel to one another such that the space between each wall creates a groove 353 that defines a capillary channel. The walls 355 define or form one or more capillary channels or grooves configured to collect fluid or other condensate.

118 may improve or modify the collection and containment of condensate in the reservoir such that condensate exiting the air tube outlet 332 (such as the air tube or cannula 128 shown in FIG. 117) is trapped or collected between the microfluidic fins 354 when a user inhales on the vaporizer device. As described above, the microfluidic fins define one or more capillary channels in which fluid is collected via capillary forces formed when fluid is disposed within the capillary channels. To maintain fluid trapped in the finned condensate collector 352 without being drawn out by airflow drag, the capillary forces of the microfluidic fins may be made greater than the airflow drag by providing narrow grooves or channels in which the fluid is disposed. For example, an effective groove width may be 0.3 mm, and/or in the range of about 0.1 mm to about 0.8 mm.

One advantage of this configuration is that it eliminates the need to manufacture additional parts, reducing part count without compromising functionality. In one embodiment, the finned condensate collector and mouthpiece may be manufactured as a monolithic body using one mold (e.g., a plastic mold). Additionally, the finned condensate collector and mouthpiece may be separate structures welded together that collectively form the finned condensate collector. Other manufacturing methods and materials are within the scope of this disclosure.

In other embodiments, the microfluidic fins may be formed as a separate piece and fitted into the mouthpiece. For example, the microfluidic fins may be formed into any portion of the vaporizer device or vaporizer cartridge for collecting and containing condensate. The microfluidic fins may be formed with the mouthpiece or may be formed as a second plastic part and fitted into the mouthpiece.

In addition to collecting at the mouthpiece, condensation of vaporizable material may accumulate within one or more airflow passages or internal channels of the vaporizer device. Various features and devices that improve or overcome these problems are described below. For example, various features are described herein for recycling condensate in the vaporizer device, such as embodiments of a condensate recycler system, as described in more detail below.

FIGS. 119A-119C illustrate an embodiment of a condensate recycler system 360 of a vaporizer cartridge (such as vaporizer cartridge 120) and/or a vaporizer device (such as vaporizer 100). The condensate recycler system 360 can be configured to collect condensate of a vaporizable material and return the condensate to the wick for reuse.

The condensate recycler system 360 may include an internally grooved air tube 334 that forms an air flow passage 338 extending from the mouthpiece toward the vaporization chamber 342 and may be configured to collect vaporizable material condensate and return it (via capillary action) to the wick for reuse.

One function of the grooves may include trapping or disposing vaporizable material condensate within the grooves. Once disposed within the grooves, the condensate is drained to the wick via capillary action generated by the wicking element. Discharge of condensate within the grooves may be achieved at least in part by capillary action. If condensate is present within the air tube, in the absence of the grooves, fine particles of vaporizable material fill the grooves rather than forming or building a wall of condensate within the air tube. Once the grooves are filled sufficiently to establish fluid communication with the wick, the condensate flows through the grooves and out of the grooves, where it can be reused as vaporizable material. In some embodiments, the grooves may be tapered to be narrow toward the wick and wider toward the mouthpiece. Such a tapered shape may encourage the fluid to move toward the vaporization chamber as more condensate collects in the grooves via higher capillary action at the narrower points.

FIG. 119A shows a cross-sectional view of the air tube 334. The air tube 334 includes an air flow passage 338 and one or more internal grooves having a hydraulic diameter that decreases toward the vaporization chamber 342. The grooves are sized and shaped to allow fluid (such as condensate) disposed within the grooves to be transported from a first location to a second location via capillary action. The internal grooves include an air tube groove 364 and a chamber groove 365. The air tube groove 364 is disposed inside the air tube 334 and may be tapered such that the cross-section of the air tube groove 364 at the first end 362 of the air tube is larger than the cross-section of the air tube groove 364 at the second end 363 of the air tube. The chamber groove 365 may be disposed proximate the second end 363 of the air tube and coupled to the air tube groove 364. The internal groove may be in fluid communication with the wick and may be configured to allow the wick to continually drain vaporizable material condensate from the internal groove, thus preventing a film of condensate from building up within the airflow passage 338. Condensate may preferentially enter the internal groove due to capillary drive in the internal groove. The capillary drive gradient within the internal groove directs movement of fluid to the wick housing 346, where the vaporizable material condensate is recycled by resaturating the wick.

119B and 119C show internal views of the condensate recycler system 360 from the first end 362 of the air tube and the second end 363 of the air tube, respectively. The first end 362 of the air tube may be located near the mouthpiece and/or the air outlet. The second end 363 of the air tube may be located proximate the vaporizer chamber 342 and/or the wick housing 346 and may be in fluid communication with the chamber groove 365 and/or the wick. The air tube groove 364 may have a first diameter 366 and a second diameter 368. The second diameter 368 may be narrower than the first diameter 366.

As explained above, as the effective cross-sectional area of the airflow passage narrows due to the buildup of condensation in the airflow passage or due to the designs described herein, the flow rate of air moving through the air tube increases, exerting a drag force on the accumulated liquid (e.g., condensation). If the drag force attracting the fluid towards the user (e.g., in response to inhalation of the vaporizer) is greater than the capillary force pulling the fluid towards the wick, the fluid will exit the air outlet.

To overcome this problem and encourage condensate away from the mouthpiece outlet and back to the vaporizer chamber 342 and/or wick, a tapered airflow passage is provided such that the cross section of the air tube groove 364 proximate the vaporizer chamber 342 is narrower than the cross section of the air tube groove 364 proximate the mouthpiece. Additionally, each of the internal grooves narrows such that the width of the internal groove proximate the first end 362 of the air tube is wider than the width of the internal groove proximate the second end 363 of the air tube. In this manner, the narrowing of the passage increases the capillary drive of the air tube groove 364 and promotes fluid movement of condensate towards the chamber groove 365. Additionally, the chamber groove 365 proximate the second end 363 of the air tube may be wider than the width of the chamber groove 365 proximate the wick. That is, each groove channel narrows gradually as it approaches the wick in addition to the airflow passage itself narrowing towards the wick end.

To maximize the effect of capillary action provided by the condensate recycler system design, the cross-sectional size of the air tube relative to the size of the groove may be considered. A narrower groove width may increase capillary drive, but a smaller groove size may cause condensate to spill out of the groove and clog the air tube. Therefore, the groove width may range from about 0.1 mm to about 0.8 mm.

In some embodiments, the shape or number of grooves may vary. For example, the grooves may not necessarily have a decreasing hydraulic diameter toward the wick. In some embodiments, a decreasing hydraulic diameter toward the wick may improve capillary actuation performance, although other embodiments may be contemplated. For example, the internal grooves and channels may have a substantially straight structure, a tapered structure, a spiral structure, and/or other arrangements.

In some embodiments, the mechanisms required to create the capillary drive may be integrated into the housing structure of the aerosol generation unit (e.g., the vaporizer), the mouthpiece, and/or a separate plastic part (such as the finned condensation collector discussed herein).

(term)
As used herein, when a feature or element is referred to as being "on" another feature or element, it may be directly on the other feature or element, or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements present. When a feature or element is referred to as being "connected,""attached," or "coupled" to another feature or element, it will also be understood that it may be directly connected, attached, or coupled to the other feature or element, or intervening features or elements may be present. In contrast, when a feature or element is referred to as being "directly connected,""directlyattached," or "directly coupled" to another feature or element, there are no intervening features or elements present.

Although described or illustrated with respect to one embodiment, the features and elements so described or illustrated may be applicable to other embodiments. Those skilled in the art will also understand that references to a structure or feature being located "adjacent" to another feature may have portions that overlap or underlie the adjacent feature.

The terms used herein are for the purpose of describing particular embodiments and implementations only and are not intended to be limiting. For example, the singular forms "a," "an," and "the" as used herein are intended to include the plural unless otherwise specified. Furthermore, it should be understood that the term "comprises," as used herein, describes the presence of stated features, steps, operations, elements, and/or components, but does not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The term "and/or" as used herein includes any combination of one or more of the associated listed items and may be abbreviated as "/."

In the above description and in the claims, phrases such as "at least one" or "one or more" may appear followed by a linked list of elements or features. The term "and/or" may also appear in a list of two or more elements or features. Unless implicitly or explicitly contradicted by the context in which it is used, such phrases are intended to mean any of the listed elements or features individually, or any of the listed elements or features in combination with any of the other listed elements or features. For example, the phrases "at least one of A and B," "one or more of A and B," and "A and/or B" mean "A alone, B alone, or A and B together," respectively. A similar interpretation applies to lists containing more than two items. For example, the phrases "at least one of A, B, and C," "one or more of A, B, and C," and "A, B, and/or C" mean "A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together," respectively. Use of the term "based on" above and in the claims is intended to mean "based at least in part on," such that unrecited features or elements are allowed for.

Spatially relative terms such as "forward," "backward," "downward," "below," "lower," "upper," "upper," and the like are used herein to describe the relationship of one element or feature to another element or feature, as shown in the figures, for ease of description. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the figures. For example, if the device in the figures is turned upside down, an element described as "below" or "below" the other element or feature may be oriented "above" the other element or feature. Thus, the exemplary term "below" can include both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or in other directions) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms "upward," "downward," "vertically," "horizontally," and the like are used herein for descriptive purposes only, unless otherwise noted.

Although the terms "first" and "second" may be used herein to describe various features/elements (including steps), these features/elements should not be limited by these terms unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another. Thus, a first feature/element described below may be referred to as a second feature/element, and similarly, a second feature/element described below may be referred to as a first feature/element, without departing from the teachings provided herein.

As used herein and in the claims, including those used in the examples, and unless expressly specified otherwise, all numbers may be read as if preceded by the word "about" or "approximately", even if the term is not expressly indicated. The phrase "about" or "approximately" is used when describing a size and/or location to indicate that the described value and/or location is within a reasonable expected range of value and/or location. For example, a numerical value may have a value that is ±0.1% of the specified value (or range of values), ±1% of the specified value (or range of values), ±2% of the specified value (or range of values), ±5% of the specified value (or range of values), ±10% of the specified value (or range of values), etc. Numeric values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise.

For example, if the value "10" is disclosed, then "about 10" is also disclosed. Any numerical ranges recited herein are intended to include all subranges contained therein. When a value is disclosed, it is understood that "less than or equal to that value," "greater than or equal to that value," and possible ranges between values are also disclosed, as would be well understood by one of ordinary skill in the art. For example, when a value "X" is disclosed, "less than or equal to X" and "greater than or equal to X" (e.g., where X is a number) are also disclosed. It is also understood that throughout this application, data is provided in several different formats, and this data represents endpoints and starting points, and ranges for any combination of data points. For example, when a specific data point "10" and a specific data point "15" are disclosed, it is understood that not only between 10 and 15, but also greater than 10 and greater than 15, greater than or equal to 10 and greater than or equal to 15, less than 10 and less than 15, less than or equal to 10 and less than 15, and equal to 10 and equal to 15 are disclosed. It is also understood that each number between two specific numbers is disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

Although various exemplary embodiments have been described above, any of a number of modifications may be made to the various embodiments without departing from the teachings herein. For example, the order in which the various method steps described are performed may often be changed in alternative embodiments, and in other alternative embodiments, one or more method steps may be skipped entirely. Optional features of the various apparatus and system embodiments may be included in some embodiments and not in other embodiments. Thus, the foregoing description has been provided primarily for illustrative purposes and should not be construed as limiting the scope of the claims.

One or more aspects or features of the invention described herein may be implemented in digital electronic circuitry, integrated circuits, specially designed application specific integrated circuits (ASICs), field programmable gate array (FPGA) computer hardware, firmware, software, and/or combinations thereof. These various aspects or features may include implementation in one or more computer programs executable and/or interpretable on a programmable system including at least one programmable processor, which may be special purpose or general purpose, coupled for transmitting and receiving data and instructions from a storage system, at least one input device and at least one output device. The programmable system or computing system includes clients and servers. Typically, clients and servers are remote from each other and typically interact through a communications network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

These computer programs, which may also be referred to as programs, software, software applications, applications, components, or code, contain machine instructions for a programmable processor and may be implemented in high-level procedural languages, object-oriented programming languages, functional programming languages, logic programming languages, and/or assembly/machine languages.

As used herein, the term "machine-readable medium" refers to a computer program product, apparatus, and/or device, such as, for example, a magnetic disk, optical disk, memory, programmable logic device (PLD), etc., used to provide machine instructions and/or data to a programmable processor that includes a machine-readable medium that receives the machine instructions as a machine-readable signal.

The term "machine-readable signal" refers to a signal used to provide machine instructions and/or data to a programmable processor. The machine-readable medium may store such machine instructions non-transiently, such as, for example, a non-transient solid-state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium may alternatively or additionally store such machine instructions in a transitory manner, such as, for example, a processor cache or other random access memory associated with one or more physical processor cores.

The examples and figures contained herein illustrate, by way of illustration and not limitation, specific embodiments in which the disclosed invention may be practiced. As noted above, other embodiments may be utilized or derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Such embodiments of the disclosed invention may be referred to herein, individually or collectively, by the term "invention" merely for convenience and without any intention of intentionally limiting the scope of this application to any single invention or inventive concept, even though in fact more than one invention or inventive concept is disclosed.

Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiment shown. This disclosure is intended to cover any adaptations or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.

The disclosed invention has been provided herein with reference to one or more features or embodiments. Those skilled in the art will recognize that, regardless of the detailed nature of the exemplary embodiments provided herein, changes and modifications can be applied to said embodiments without limiting or departing from the generally intended scope. These and various other adaptations and combinations of the embodiments provided herein are within the scope of the disclosed invention as defined by the complete set of disclosed elements and features and their equivalents.

Portions of the disclosure of this patent document may contain material that is subject to copyright protection. The owner will not object to reproduction by any of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent file or records, but reserves all copyrights. Certain marks referenced herein may be common law or registered trademarks of the applicant, assignee, or third parties affiliated or unaffiliated with the applicant or assignee. The use of these marks is intended to provide an authorizing disclosure by way of example and shall not be construed as exclusively limiting the scope of the disclosed invention to the material associated with such marks.

Claims (14)

1. A collector component of a vaporizer for use with a liquid vaporizable material, said collector component comprising:
an overflow volume including a fluid passageway through which the liquid vaporizable material contained in the reservoir flows due to one or more factors;
an exterior port disposed at a first end of the fluid passage and configured to be in fluid communication with ambient air exterior to the vaporization device;
a gate disposed at a second end of the fluid passageway distal to the first end and configured to manage flow between the fluid passageway and the reservoir of the vaporizer, the reservoir configured to contain the liquid vaporizable material, the gate comprising:
a V-shaped structure having a low capillary drive channel on a first side and a high capillary drive channel on a second side, the low capillary drive channel and the high capillary drive channel cross each other to form a pinch-off point, each channel connecting to the reservoir and configured to receive the liquid vaporizable material;
when the reservoir is at a first pressure state, the low capillary drive channel and the high capillary drive channel maintain a liquid seal to prevent air from entering the reservoir through the gate;
a gate, when the reservoir is at a second pressure state, whereby one or more gas bubbles from the fluid passage are formed at the pinch-off point and directed through the lower capillary driven channel to the reservoir;
a first wick supply including a first channel that allows the liquid vaporizable material stored in the storage chamber to flow toward a wick located in a wick housing disposed in the overflow volume;
Equipped with
The gate maintains equilibrium within the reservoir chamber to prevent pressure within the reservoir chamber from building up to a point where the liquid vaporizable material would flood the wick housing, a collector component. The collector component of claim 1, wherein the equilibrium condition is maintained by establishing the liquid seal at the opening of the gate where the reservoir communicates with the fluid passage. The collector component of claim 2, wherein the liquid seal is established and maintained at the gate by maintaining a capillary pressure for one or more meniscuses between the liquid vaporizable material and air at a level sufficient for the meniscus to form at a portion of the gate that opens into the fluid passageway. The collector component of claim 3, wherein the low capillary drive channel and the high capillary drive channel are tapered, and as the meniscus continues to recede, the capillary drive of the low capillary drive channel decreases at a greater rate than the capillary drive of the high capillary drive channel. The collector component of claim 4, wherein the capillary drive of the low capillary drive channel and the high capillary drive channel is gradually reduced to reduce the partial headspace vacuum maintained in the reservoir chamber. The collector component of claim 5, wherein the capillary drive of the lower capillary drive channel and the higher capillary drive channel gradually decreases relative to one another such that the drainage pressure of the lower capillary drive channel falls below the drainage pressure of the higher capillary drive channel. The collector component of claim 6, wherein the meniscus of the low capillary drive channel continues to drain as the drainage pressure of the low capillary drive channel changes, but the meniscus of the high capillary drive channel remains stationary. The collector component of claim 7, wherein the drainage pressure associated with a retreating contact angle of the lower capillary driven channel can be lower than the flooding pressure associated with an advancement of the contact angle of the higher capillary driven channel, thereby causing the lower capillary driven channel and the higher capillary driven channel to fill with the liquid vaporizable material. The collector component of claim 8, wherein the liquid vaporizable material flows through the gate into the fluid passage in response to an increase in pressure within the reservoir, and the gate is configured to maintain the liquid seal at all times. 1. A collector for a vaporizer for use with a liquid vaporizable material, the collector comprising:
a secondary passageway configured to hold a volume of liquid vaporizable material in fluid contact with the reservoir;
a microfluidic gate disposed at an end of the secondary passage and configured to control a flow of the liquid vaporizable material between the secondary passage and the reservoir;
Equipped with
a collector, the microfluidic gate including a plurality of openings connecting the reservoir and the secondary passage and a pinch-off point between the plurality of openings, the plurality of openings including a first channel and a second channel, the first channel having a higher capillary driving force than the second channel. a primary passageway through which at least a portion of the liquid vaporizable material flows from the reservoir toward a wicking element;
The collector of claim 10 , wherein the primary passageway provides a fluid connection between the reservoir and the wicking element and is formed through a structure of the collector. the primary passageway includes a wick supply channel configured to allow the liquid vaporizable material to flow from the reservoir toward the wicking element;
12. The collector of claim 11, wherein the wick supply channel has a cross-sectional shape with at least one irregularity configured to allow liquid in the wick supply channel to bypass an air bubble blocking a remainder of the wick supply channel. The collector of any one of claims 10 to 12, wherein the secondary passage comprises a plurality of spaced constriction points having a smaller cross-sectional area than the portions of the secondary passage between the constriction points, the constriction points having flat surfaces oriented along the secondary passage toward the reservoir and rounded surfaces oriented along the secondary passage away from the reservoir. A collector according to any one of claims 10 to 13, insertably received within the monolithic hollow structure of a cartridge housing.

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