US20240260659A1

US20240260659A1 - Ceramic vaping core with surface treatment

Info

Publication number: US20240260659A1
Application number: US18/434,296
Authority: US
Inventors: Eric C. Scribben
Original assignee: Next Level Ventures LLC
Current assignee: Next Level Ventures LLC
Priority date: 2023-02-07
Filing date: 2024-02-06
Publication date: 2024-08-08

Abstract

This disclosure relates generally to vaporizing devices that can include a radially graded porous ceramic structure. Disclosed devices can include center post having proximal and distal ends and a body extending therebetween. In some embodiments, the distal end of the center post includes a proximal portion defining one or more voids in fluid communication with the internal channel. The distal end of the center post also includes a distal portion, and a median flange between the proximal and distal portions, with the median flange extending radially outward from a longitudinal axis of the distal end of the center post (e.g., a longitudinal axis of the center post). The distal portion can define a cavity to receive an atomizer (e.g., a core and/or heating element) and a wick. In some embodiments, the atomizer includes a radially graded porous ceramic structure with a surface treatment.

Description

CROSS-REFERENCE TO RELATED APPLICATION

A claim for priority to the Feb. 7, 2023 filing date of U.S. Provisional Patent Application No. 63/443,906, titled CERAMIC VAPING CORE WITH SURFACE TREATMENT (“the '906 Provisional Application”), is hereby made pursuant to 35 U.S.C. § 119(e). The entire disclosure of the '906 Provisional Application is hereby incorporated herein.

TECHNICAL FIELD

This disclosure relates generally to vaporizing devices and, particularly, to vaporizing devices having surface treated ceramic cores.

SUMMARY

In various aspects, embodiments of the present disclosure provide for atomizers for vaporizing or aerosolizing devices. Disclosed atomizers may include a radially graded porous ceramic structure and a surface coating or treatment disposed on the radially graded porous ceramic structure. In some embodiments, the radially graded porous ceramic structure is embedded with a heating element. The atomizer can be received by a vaporizing device to generate vapor from a fluid contained within a reservoir of the vaporizing device, where the fluid flows from the reservoir into one or more pores of the radially graded porous ceramic structure to be atomized by the embedded heating element. The surface treatment can include a carbon surface treatment. In some embodiments, the surface treatment includes graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.
In some embodiments, disclosed devices include a center post having proximal and distal ends and a body extending therebetween. The body defines an internal channel. The distal end of the center post includes a proximal portion defining one or more voids in fluid communication with the internal channel, a distal portion, and a median flange between the proximal and distal portions. The median flange extends radially outward from a longitudinal axis of the distal end of the center post (e.g., a longitudinal axis of the center post). The distal portion can define a cavity to receive an atomizer (e.g., a core and/or heating element) and a wick. In some embodiments, the atomizer includes a radially graded porous ceramic structure.
The disclosed devices further include a cartridge for receiving the center post within an interior of the cartridge. The proximal end of the center post can extend proximally beyond the proximal end of the cartridge. Additionally, the proximal end of the center post can include a lip and a pair of proximal flanges or engaging a mouthpiece. The disclosed devices can also include a base associated with the distal ends of both the center post and the cartridge.
In some embodiments, disclosed vaporizing devices include a center post defining an internal channel extending between proximal and distal ends of the center post. The distal end of the center post can include a proximal portion defining one or more voids in fluid communication with the internal channel, a distal portion defining a cavity to receive an atomizer, and a median flange between the proximal and distal portions, with the median flange extending radially outward from a longitudinal axis of the distal end of the center post. The atomizer can include an atomizer surface treatment. The disclosed devices can also include a cartridge for receiving the center post within an interior of the cartridge.
In some embodiments, disclosed vaporizing devices include a cartridge having proximal and distal ends, with a base unit associated with the distal end. In some embodiments, the distal end of the cartridge defines the base unit. Alternatively, the base unit is attached to the distal end of the cartridge. The base unit can receive and/or house an atomizer (e.g., a core and/or heating element), where the atomizer includes a radially graded porous ceramic structure and a surface coating or treatment disposed on the radially graded porous ceramic structure. A heating element (e.g., a coil) can be embedded or otherwise received within the radially graded porous ceramic structure.
The cartridge defines an internal reservoir for holding a fluid to be vaporized, and the base unit can be located below the internal reservoir. The base unit and/or the internal reservoir may include (e.g., define) apertures placing the base unit and the internal reservoir in fluid communication. That is, a fluid (e.g., oil or liquid) can flow from the internal reservoir through the apertures and into the base unit. As the fluid enters the base unit, the fluid will contact the atomizer and flow into one or more pores of the radially graded porous ceramic structure, where the oil will be heated and vaporized by the atomizer. In embodiments where the cartridge defines the internal reservoir, the vaporizing device may not have (i.e., may lack) a center post. As a user pulls on the vaporizing device for a “hit” (e.g., a volume of vaporized oil), vaporized oil will be pulled proximally through the internal reservoir for inhalation by the user. In some embodiments, the vaporizing device may not have a wick.
Also disclosed are methods of manufacturing a radially graded porous ceramic atomizer. In some embodiments, a method includes depositing a first layer of ceramic material on a substrate, where the first layer has at least a first porosity. The method can also include depositing a second layer of ceramic material on the first layer, where the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method can also include depositing a third layer of ceramic material on the second layer, where the third layer has a third porosity that may be different than the second porosity and/or the first porosity. The method can further include embedding a heating element within the first, second, and/or third layers.
In some embodiments, a method includes depositing a first layer of ceramic material on a substrate, where the first layer has at least a first porosity. The method can also include depositing a second layer of ceramic material on the first layer, where the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method can also include depositing a third layer of ceramic material on the second layer, where the third layer has a third porosity that, in some embodiments, is different than the second porosity and/or the first porosity.
Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS In the Drawings:

FIG. 1 illustrates a diagram of a transport section of a porous media.

FIG. 2 schematically illustrates capillary rise in an inclined and cylindrical tube.

FIG. 3 schematically illustrates heat transfer among components of a vaporizing device or system, according to embodiments of the present disclosure.

FIG. 4 graphically illustrates a heated section and transport section of a vaporizing device, according to embodiments of the present disclosure.

FIGS. 5A and 5B graphically illustrate temperature and vaporization rates as a function of time and input power.

FIG. 6 schematically illustrates particle formation and growth in various phases of matter.

FIG. 7 illustrates a perspective view of an embodiment of a vaporizing device, according to embodiments of the present disclosure.

FIG. 8A illustrates a first close-up view of the vaporizing device of FIG. 7 .

FIG. 8B illustrates a second close-up view of an atomizer of FIG. 7 and FIG. 8A.

FIG. 9A illustrates a top view and FIG. 9B illustrates a lateral cross-section view of an embodiment of radially graded porous structure.

FIG. 10A illustrates a perspective view of an untreated material and FIG. 10B illustrates a perspective view of a treated material.

FIGS. 11-13 illustrate flowcharts of embodiments of methods, according to the present disclosure.

DETAILED DESCRIPTION

Vaporizing or aerosolizing devices generally apply heat to a substance (i.e., a liquid or oil) in order to vaporize or aerosolize the substance for inhalation. As used herein, “vapor” and “aerosol” are used interchangeably. That is, any vapor or aerosol generated by heating a liquid is referred to as a “vapor” or “aerosol,” even though a vapor is a substance in the gas phase whereas an aerosol is a suspension of tiny particles of liquid, solid or both within a gas. Similarly, “vaporizing devices” and “aerosolization devices” are used interchangeably, and a device can be referred to as a “vaping device” enough though it may produce an aerosol and not a vapor. Vaping devices are often typically easier to use than conventional smoking devices (e.g., cigarettes). Additionally, vaporizing or aerosolizing substances for inhalation rather than burning them provides a more pleasing flavor of the substance.
Typically, during assembly of vaporizing devices, the heating element (e.g., an atomizer, a heating core, a coil, etc.) is disposed inside an internal cavity of the vaporizing device. Oils or liquids are delivered to the heating element to be atomized and/or vaporized, and the produced vapor is pulled proximally through the vaporizing device for inhalation by a user. This is often referred to as “a hit.” However, if the heating element is insufficiently saturated with oil or liquid, the resulting hit will be dry—that is, no oil or liquid has been vaporized (or too little oil or liquid has been vaporized), resulting in the user inhaling burnt residues or, simply, hot air. Getting a “dry hit” is undesirable in taste and can harm the user's mouth or throat with the hot air.
FIG. 1 illustrates a diagram of a transport section of a porous media, where the liquid level line illustrates a transient boundary between remaining oil and the vapor at time t. The flow rate of oils or liquid delivered to the heating element can affect the hit a user inhales. Generally, the flow rate of oils or liquids from the reservoir is equal to the oil or hit delivered to the user, oil or liquid within a wick and the heating element, or oil or liquid condensed on walls of the vapor channel or internal channel. The volumetric flow rate of oil from the reservoir can be approximated by:
$\dot{V} = \frac{Δ V}{Δ t} = \frac{A Δ h}{Δ t}$
where h is the oil in the reservoir at time t. The mass flow rate of oil from the reservoir can substantially be approximated by:
$\dot{m} = \dot{V} \overline{ρ}$
with the average density of the oil being approximated by:
$\overline{ρ} = \frac{1}{\frac{ω_{A}}{ρ_{A}} + \frac{ω_{B}}{ρ_{B}} + \dots + \frac{ω_{x}}{ρ_{x}}}$
where ω_Ais the mass fraction of component A, ω_Bis the mass fraction of component B, etc. The mass flow rate of the individual components (A, B, . . . X, etc.) is approximated by:
${\dot{m}}_{A} = {\dot{m}}_{tot} ω_{A}$
As the oil level in the reservoir decreases, a vacuum is created in the reservoir, which results in air flowing through other components of the vaporizing device (e.g., the atomizer or wicks) to backfill and equilibrate the pressure. This can result in increased oxygen levels within the reservoir, concomitantly increasing the potential for the oil to be oxidized. Oxidization of the oil within the reservoir can impact the overall composition of the oil that will ultimately be vaporized as a hit delivered to a user.
Often, oil is transported from the reservoir to the heating element via capillary action. FIG. 2 schematically illustrates capillary rise in an inclined and cylindrical tube. The magnitude of capillary pressure is usually described by the Laplace equation:
$P = \frac{2 γ_{LA} \cos θ}{r}$
where γ_LAis the surface tension of the oil, θ is the oil-solid contact angle, and r is the capillary radius. Additionally, Darcy's law models single-phase flow in a porous media:
$\dot{V} = - A \frac{K}{μ L} (Δ P)$
where {dot over (V)} is the volumetric flow rate, A is the cross-sectional area of the porous media, K is the permeability of the porous media, μ is the dynamic viscosity of the oil, L is the distance, and ΔP is the difference in pressure.
Permeability is a measure of the ease of passage of liquids or gases through a material. Permeability depends on the material's porosity (the fraction of void spaces over the total volume) as well as pore shape and network. Therefore, the porous media directly influences the rate of capillary flow and the amount of oil near the heated element (which may be referred to herein as “saturation”). An air pressure gradient occurs with a user inhalation that drives oil movement (that is not maintained due to reservoir backfilling) while viscous forces resist oil movement.
In addition to the transport of oil playing a role in the overall efficiency of a vaporizing device, the efficiency and consistency of the heating element also plays a role. Often, the heating element is held in place within an internal cavity of the vaporizing device by means of an insulating ring. Inclusion of the insulating ring, however, decreases production efficiency and increases production difficulty in manufacturing these devices, complicating the automatic production process and increasing the ultimate cost of the vaporizing devices. Additionally, the insulation ring can increase buildups or blockages (e.g., debris, un-vaporized oil or components of the oil, etc.) in and around the heating element. These blockages impact the flow and stability of airflow through the device and contribute to leakage of the liquid from the device. The buildups or blockages can also impact the heating efficiency and consistency of the heating element, impacting the likelihood of a user receiving a dry hit.
FIG. 3 schematically illustrates heat transfer among components of a vaporizing device or system. FIG. 4 graphically illustrates a heated section and transport section of a vaporizing device. Generally, energy of a system follows this relationship:
$\dot{Q} + {\dot{W}}_{ε} = Δ \dot{H} + Δ {\dot{E}}_{k} + Δ {\dot{E}}_{p}$
where {dot over (Q)} is the energy transferred to the system as heat and Δ{dot over (H)} is the specific enthalpy. {dot over (W)}_sis the shaft work, ΔE_kis the kinetic energy, and ΔE_pis the potential energy—all of which can be neglected. The specific enthalpy can be approximated by:
$Δ \dot{H} = {\dot{Q}}_{i n} - ({\dot{Q}}_{iat} + {\dot{Q}}_{conv} + {\dot{Q}}_{cond} + {\dot{Q}}_{heating}) = C \frac{dT}{dt}$
where C is the effect heat capacity of the system and dT/dt is the change in temperature over time. {dot over (Q)}_inis the input power (watts, W). Additionally,
${\dot{Q}}_{i n t} = {\dot{m}}_{out} h_{f g}$
is the latent heat associated with the phase change from liquid to vapor, where {dot over (m)}_outis the vaporization rate and h_fgis the latent heat of vaporization. Further,
${\dot{Q}}_{conv} = h_{a} A_{s} (T - T_{0})$
where h_ais the heat transfer coefficient, A_sis the surface area of the heated section, T is the oil temperature, and T₀is the ambient air temperature. Still further,
${\dot{Q}}_{cond} = 2 {kA}_{i n} (T - T_{0}) / L_{t}$
is the heat transfer due to conduction, where k is the effective thermal conductivity, A_inis the surface area, and L_tis the length of the transport section. Additionally,
${\dot{Q}}_{heating} = e_{p} m (T - T_{0}) t_{a}$
is the energy expending rate for heating, where c_pis the heat capacity, m is the total mass, and t_ais the puff duration.
When a user inhales or “pulls” on their vaporizing device to produce a hit, the heating element is triggered. An electrical source (e.g., power source) applies energy to the heating element and electrical energy is converted into thermal energy. The transient heating can be expressed by:
$V_{r} ρ_{r} C_{v_{r}} \frac{{dT}_{r} (t)}{dt} = {\dot{Q}}_{i n} - {hS}_{r} (T_{r} (t) - T_{0})$
where V_ris the volume of the resistor, ρ_ris the metal cC_p _rity, is the metal heat capacity, {dot over (Q)}_inis the input power or power delivered, h is the external heat coefficient, S_ris the external surface of the resistor, T_ris the temperature of the resistor, and T₀is the ambient air temperature.
Thermal energy heats the core surrounding the heating element, which heats the wick surrounding the core, and heats oil contained or absorbed within the core and/or the wick. There is a slight latency in the heat transfer as a result of the core and the wick being insulating materials and/or as a result of any gaps between the materials. That is, a certain amount of time is required to heat up the core. During the heat transfer, there is a potential of residue formation inhibiting the heat transfer and affecting the fluid (e.g., oil) flow. The thermal energy also heats air that passes over the core and the heating element. Conduction along the heating element, the core, and the wick can result in heat losses to a component of the vaporizing device. For example, heat may be lost to a cartridge body.
As the oil is heated, it is converted into vapor, where the vapor is composed of a mixture of varying amounts of components. For example, the vapor can be composed of varying amounts of nicotine, water, flavorings, or other components/ingredients of the oil. As another nonlimiting example, the vapor can be composed of varying amounts of cannabinoids, water, flavorings, or other components/ingredients of the oil. FIGS. 5A and 5B graphically illustrate temperature and vaporization rates as a function of time and input power.
Oil vaporization rate is a function of vapor pressures (P*), mole fractions and masses of evaporating species (x and M), mass transfer coefficient (h), surface area where vaporization occurs (A), and the heat transfer rate. Whether the device attains boiling depends on the power input, puff duration, and the thermal inertia of the heating assembly.
Due to different volatilities of the evaporating species, oil composition in the porous media will tend to become enriched in less volatile species during a puff, causing a higher effective boil point. This is because species having a higher volatility will evaporate faster than the remaining, low volatile species. During each individual puff, the vapor composition will change from being enriched in the most volatile species to being enriched in the least volatile species, relative to the parent oil, due to a higher concentration of this species (e.g., the least volatile) at the heated interface. Both temperature and concentration of evaporating species at the heated interface impact the consistency of vaporized oil.
The vaporization of a component can be approximated by:
${\dot{m}}_{i} = h_{m, i} A \frac{M_{i}}{Ru} \frac{x_{i} P_{i}^{*}}{T}$
where Ru is the universal gas coefficient. The total vaporization rate can be approximated by:
${\dot{m}}_{v} = \sum {\dot{m}}_{i}$
FIG. 6 schematically illustrates particle formation and growth in various phases of matter. Combustion of the oil or a component of the oil may occur depending on the heating temperature, causing decomposition of the oil. Decomposition of the oil increases risks of clogging the vaporizing device or negatively impacting the flavor profile of the generated vapor. One solution is to create an aerosolized spray resembling a cloud at low temperatures.
As a user inhales, the vaporized components are carried out of the device with the inhaled vapor. As the hot vapor comes into contact with cool air drawn into the device, the vapor can re-condense to form an aerosol mist that visually resembles smoke. However, if the condensate flows back to the heated section of the device, or is further heated via conduction, the repeated heating can increase the risk of oxidation, and negatively impact the flavor profile and user experience.
The present disclosure addresses these and other issues. For example, embodiments of the present disclosure provide devices that are substantially leakproof and prevent liquid or oil contained within the device from leaking out. Additionally, embodiments of the present disclosure are provided with components (e.g., surface coated and/or porous components) that produce consistent, low temperature vaporization of oils or liquidsz. Consistent, low temperature vaporization reduces the risk and potential of decomposing the oil and/or various components of the oil. Some embodiments are provided with components that improve adhesion of an oil or liquid to components of the vaporizing device. This improved adhesion promotes saturation of a core or heating element contained within, for example, a center post of the device. Greater saturation of the core or heating element prevents a user from inhaling “dry hits.”
In some embodiments, disclosed atomizers include a radially graded porous ceramic structure and a surface coating or treatment disposed on the radially graded porous ceramic structure. The radially graded porous ceramic structure may be embedded with a heating element. The atomizer can be received by a vaporizing device to generate vapor from a fluid contained within a reservoir of the vaporizing device, where the fluid flows from the reservoir into one or more pores of the radially graded porous ceramic structure to be atomized by the embedded heating element.
In some embodiments, disclosed vaporizing devices include a cartridge having proximal and distal ends, with a base unit associated with the distal end. The distal end of the cartridge may define the base unit, or, the base unit can be attached to the distal end of the cartridge. The base unit can receive and/or house an atomizer (e.g., a core and/or heating element), where the atomizer includes a radially graded porous ceramic structure and/or a surface coating or treatment disposed on the radially graded porous ceramic structure. In some embodiments, a heating element (e.g., a coil) can be embedded or otherwise received within the radially graded porous ceramic structure.
The cartridge may define an internal reservoir for holding a fluid to be vaporized. The base unit can be located below the internal reservoir. In some embodiments, the base unit and/or the internal reservoir include (e.g., define) apertures placing the base unit and the internal reservoir in fluid communication. That is, a fluid (e.g., oil or liquid) can flow from the internal reservoir through the apertures and into the base unit. As the fluid enters the base unit, the fluid will contact the atomizer and flow into one or more pores of the radially graded porous ceramic structure, where the oil will be heated and vaporized by the embedded heating element. In embodiments where the cartridge defines the internal reservoir, the vaporizing device may not have (i.e., may lack) a center post. As a user pulls on the vaporizing device for a hit, vaporized oil will be pulled proximally through the internal reservoir for inhalation by the user. In some embodiments, the vaporizing device may not have a wick.
Also disclosed are methods of manufacturing a radially graded porous ceramic atomizer. In some embodiments, a method includes depositing a first layer of ceramic material on a substrate, where the first layer has at least a first porosity. The method can also include depositing a second layer of ceramic material on the first layer, where the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method can also include depositing a third layer of ceramic material on the second layer, where the third layer has a third porosity that, in some embodiments, is different than the second porosity and/or the first porosity. The method can further include embedding a heating element within the first, second, and/or third layers.
In some embodiments, a method includes depositing a first layer of ceramic material on a substrate, where the first layer has at least a first porosity. The method can also include depositing a second layer of ceramic material on the first layer, where the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method can also include depositing a third layer of ceramic material on the second layer, where the third layer has a third porosity that, in some embodiments, is different than the second porosity and/or the first porosity. In some embodiments, the surface treatment includes a carbon surface treatment. In some embodiments, the surface treatment includes graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.
In some embodiments, disclosed devices include a center post having proximal and distal ends and a body extending therebetween. The body defines an internal channel, and the proximal end of the center post can include a lip and a pair of proximal flanges for engaging a mouthpiece. The distal end of the center post includes a proximal portion defining one or more voids in fluid communication with the internal channel. The distal end of the center post also includes a distal portion, and a median flange between the proximal and distal portions, with the median flange extending radially outward from a longitudinal axis of the distal end of the center post (e.g., a longitudinal axis of the center post). The distal portion can define a cavity to receive an atomizer (e.g., a core and/or heating element) and a wick. In some embodiments, the atomizer includes a radially graded porous ceramic structure.
The disclosed devices further include a cartridge for receiving the center post within an interior of the cartridge. The proximal end of the center post can extend proximally beyond the proximal end of the cartridge. The disclosed devices can also include a base associated with the distal ends of both the center post and the cartridge.
In some embodiments, disclosed vaporizing devices include a center post defining an internal channel extending between proximal and distal ends of the center post. The distal end of the center post can include a proximal portion defining one or more voids in fluid communication with the internal channel, a distal portion defining a cavity to receive an atomizer, and a median flange between the proximal and distal portions. The median flange extends radially outward from a longitudinal axis of the distal end of the center post. In some embodiments, the atomizer can include an atomizer surface treatment. The disclosed devices can also include a cartridge for receiving the center post within an interior of the cartridge.
The disclosed vaporizing devices may also include a controller for monitoring a temperature and tau (e.g., a circuit resistance and capacitance) of the vaporizing device and/or the heating element/atomizer of the vaporizing device. The controller can provide an alarm or visual indicator that (a) the vaporizing device is activated and/or (b) the vaporizing device and/or heating element are running too hot.
FIG. 7 illustrates a perspective view of one embodiment of a vaporizing device 100, according to embodiments of the present disclosure. As illustrated, the vaporizing device 100 includes a cartridge or tank 10 having a proximal end 12 and a distal end 14, a base 16 abutting the distal end 14 of the cartridge 10, and a center post 20. In some embodiments, the base 16 includes a threaded attachment point that may facilitate attachment of the vaporizing device 100 to, for example, a power source such as a battery. The center post 20 extends proximally beyond the proximal end 12 of the cartridge 10. In some embodiments, the base 16 is in connection with a distal end 25 of the center post 20.
In some embodiments, the cartridge 10 can be constructed from a polyresin or a polyresin blend. In other embodiments, the cartridge 10 can be formed of glass or any other suitable material. The cartridge 10 can be substantially transparent to permit a user to view a level of oil or liquid contained within the cartridge 10. This allows a user to determine when the cartridge 10 is empty and needs to be refilled or replaced.
In some embodiments, the cartridge 10 includes an internal reservoir 17. The internal reservoir 17 is defined by an inner wall 17 a of the cartridge 10 and bounded at a bottom of the internal reservoir 17 by the median flange 26 (see FIGS. 8A and 8B), with the reservoir 17 having an open top so oil or liquid can be added to the internal reservoir 17. That is, the median flange 26 together with the cartridge 10 creates a floor for the internal reservoir 17. The floor of the internal reservoir 17 prevents oil or liquid from undesirably seeping out of the internal reservoir 17 and into other components of the vaporizing device 100. In some embodiments, the interior of the cartridge 10 is the internal reservoir 17. In some embodiments, the internal reservoir 17 is disposed within the interior of the cartridge 10 (e.g., in a double-walled manner), as described.
FIG. 8A illustrates a first close-up view of the vaporizing device 100 of FIG. 7 Specifically, as illustrated in FIG. 8A, the center post 20 has a body 23 with a proximal end 21 and a distal end 25. The body 23 defines an internal channel (not illustrated) that extends between the proximal and distal ends 21, 25.
The distal end 25 of the center post 20 includes a proximal portion 2, a distal portion (not illustrated), and a median flange 26 disposed between the proximal portion 2 and the distal portion. In some embodiments, the median flange 26 is disposed substantially in a middle between the proximal 2 and distal portions. The distal end 25 of the center post 20 defines one or more voids 28 that are in fluid communication with the internal channel. In some embodiments, the distal end 25 of the center post 20 defines a cavity or housing 22 to receive, for example, an atomizer 30. The atomizer 30 is illustrated as housed within the cavity 22.
In some embodiments, the atomizer 30 includes a heating element 27 and a core 24, such as a porous ceramic structure. The cavity 22 also houses or receives components to facilitate the transfer of oil or liquid through the one or more voids 28 to the heating element 24. For example, the cavity 22 can house a wick to facilitate the transfer of oil or liquid to the heating element 27. In some embodiments, the proximal portion 2 defines the one or more voids 28 that are in fluid communication with the internal channel. The one or more voids 28 facilitate the transfer of oil or liquid contained within a reservoir 17 of the cartridge 10 to a heating element 27 contained within the cavity 22 defined by the distal end 25 of the center post 20.
FIG. 8B illustrates a second close-up view of the atomizer 30 of FIG. 7 and FIG. 8A. Specifically, FIG. 8B illustrates a close-up view of the atomizer 30 contained within the cavity 22 of the distal portion 25 of the center post 20. As illustrated, the atomizer 30 includes a core (e.g., a porous ceramic structure) 24 and a heating element 27 which can be a coil. In some embodiments, the heating element 27 (e.g., the coil) is embedded, either entirely or partially, in the core 24. That is, the heating element 27 may be embedded within a porous ceramic structure. In some embodiments, a headspace or gap 29 exists or is disposed between turns of the coil 27 within the porous ceramic structure 24. Inclusion of the headspace 29 prevents turns of the coil 27 from being too close to each other, which can undesirably lead to overheating of the vaporizing device 100. As discussed more fully below with respect to FIGS. 9A and 9B, the porous ceramic structure 24 can be a radially graded porous ceramic structure.
In some embodiments, the porous ceramic structure 24 includes aluminum oxide, silicon dioxide, zinc oxide, boron nitride, aluminum nitride, silicon carbide, or combinations thereof. In some embodiments, the porous ceramic structure 24 also includes gold, silver, aluminum, copper, or combinations thereof. A wick may be included, where the wick is a porous media, such as cotton, line, cotton-blends, a woven fabric, a non-woven fabric, or another appropriate porous media to facilitate the transfer of oil from the reservoir 17 of the cartridge 10 to the atomizer 30 housed within the distal end 25 of the center post 20.
The vaporizing device 100 can include a controller (not illustrated) to control heating of the heating element 27. The controller can monitor and/or measure a temperature and/or resistance of the heating element 27. Based on the monitored and measured temperature and/or resistance, the controller can trigger an alarm for the user. For example, if the temperature of the heating element 27 is too high, the controller can trigger a visual or auditory alarm to the user to reduce the temperature. Similarly, if the measured resistance of the heating element 27 is too high, the controller can trigger a visual or auditory alarm to the user to reduce the temperature.
In some embodiments, the wick (not illustrated) and/or the ceramic structure 24 can include a surface treatment or coating. Including a surface treatment or coating on the wick and/or the ceramic structure 24 can increase a heat transfer rate between the wick, the ceramic structure 24, the heating element 27, and/or oil within pores of the ceramic structure 24. The surface treatment can also reduce conductive losses dissipated to the cartridge 10 or other components of the vaporizing device 100. Reducing conductive losses can improve vaporization of components in the oil (e.g., the least volatile species) during an individual puff or hit.
For example, including a surface treatment or coating on the porous ceramic structure 24 can improve the heat transferred from the heating element 27 to the porous ceramic structure 24. This means the porous ceramic structure 24 is more evenly and uniformly heated throughout an entirety of the porous ceramic structure 24 (i.e., throughout each pore, a thickness of the ceramic, etc.) and at a surface of the porous ceramic structure 24. As oil contacts the porous ceramic structure 24, either at its surface or throughout the pores, it is heated and vaporized. By having the porous ceramic structure 24 evenly and uniformly heated, the oil is evenly and uniformly vaporized, providing a consistent vaporization and hit to the user. Additionally an even and uniformly heated porous ceramic structure 24 reduces hot spots of the porous ceramic structure 24, meaning decomposition and/or combustion of the oil is reduced or eliminated. This delivers a more pleasing flavor profile of the vaporized oil to the user.
In some embodiments, the surface treatment can be deposited on the wick and/or the porous ceramic structure 24 via chemical vapor deposition, plasma-enhanced chemical vapor deposition, a combination thereof, or another suitable deposition method. In some embodiments, the surface treatment can be deposited on the wick and/or the porous ceramic structure 24 via electrospinning, vacuum filtration, spraying, coating, 3D printing, and/or chemical coupling.
FIG. 10A illustrates a perspective view of an untreated material and FIG. 10B illustrates a perspective view of a treated material. Specifically, FIG. 10A illustrates an atomic force microscopy (AFM) surface profile of untreated nylon filament and FIG. 10B illustrates an AFM surface profile for a 60 s Helium (He)-plasma treated nylon filament. As described, providing a surface treatment on either the wick and/or the porous ceramic structure 24 can improve the heating efficiency and heat transfer throughout the vaporizing device 100. In some embodiments, the surface treatment includes a carbon surface treatment. In some embodiments, the surface treatment includes graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, boron nitride, metallic nanofibers, and conductive polymers, such as polypyrrole, polyaniline (PANI), and polyacetylene or combinations thereof. Known application methods (such as electrospinning, vacuum filtration, spraying, coating, 3D printing, and chemical coupling) can be used to apply thermally conductive materials to either the wick, and/or the ceramic core 24. In some embodiments, the thermally conductive ceramic structure 24 of the atomizer 30 can have one or more thermally conductive materials integrated into the ceramic structure 24 and/or applied to the surface to accelerate the rate of heat dissipation to the surroundings.
Surface treatment of porous media can also impact surface area or roughness, which may strengthen the interaction between the surface and oil, resulting in greater oil absorption. According to one aspect, a plasma treatment of the ceramic structure 24 of the atomizer 30 can be used to increase oil absorption to improve liquid mass transfer rate and prevent leaking/clogging via flooding. Plasma treatment of textiles has been used to increase the wettability, dyeability, adhesion to other materials, and to impart different functional finishes. A plasma treatment can be used for improvement in hydrophilicity of the ceramic structure 24 of the atomizer 30. Plasma treatment may impose several modifications on the surface, including cleaning, activation, grafting, etching, and polymerization. By precise selection of the treatment gas and the process variables such as pressure, flow rate, power, frequency, and duration, the type and extent of the modification can be tuned according to known methods. According to another aspect of the disclosure, locally tailored properties of the ceramic structure 24 of the atomizer 30 can be achieved using functionally graded materials.
FIG. 9A illustrates a top view and FIG. 9B illustrates a lateral cross-section view of a radially graded porous structure. As described, the porous ceramic structure 24 can be a radially graded porous ceramic structure. This means that a pore size throughout the porous ceramic structure 24 varies from a core or center 40 of the porous ceramic structure 24 to an outer edge, perimeter, or circumference 45 of the porous ceramic structure 24. Varying the pore size throughout the porous ceramic structure 24 improves the uniform heating of the porous ceramic structure 24.
In some embodiments, the pore size is varied uniformly or consistently from the center 40 to an edge or perimeter 45 of the porous ceramic structure 24. In some embodiments, the pore size additionally varies along a length or height of the porous ceramic structure 24. In some embodiments, the radially graded pore size of the porous ceramic structure 24 produces an aerosolized puff having a smaller particle size contained within it. The smaller particle size can provide a more pleasing experience for the user.
In some embodiments, radially grading the porous ceramic structure 24 provides more consistent heating of oil throughout the porous ceramic structure 24. An increased number of pores within the porous ceramic structure 24 provides more surface area for the oil to adhere to. Again, this improves the heating efficiency of the oil, as thinner layers of the oil are being heated by the heating element 27. This also means that the heating element 27 can vaporize the oil using a lower temperature, as more oil is interfacing with the porous ceramic structure 24 at any given point of the porous ceramic structure 24. Vaporizing oil at lower temperatures reduces decomposition of the oil and improves the overall flavor profile for a puff or hit delivered to the user.
In some embodiments, the porous ceramic structure 24 can have a decreased porosity near the center 40 to prevent leaking and clogging of the internal channel of the center post 20. The porous ceramic structure 24 can have increased porosity at an edge or perimeter 45 of the porous ceramic structure 24 (and near the reservoir) to improve a liquid mass transfer rate of the oil. Additionally, increased porosity at the edge 45 of the porous ceramic structure 24 can prevent decomposition of the oil.
According to another aspect of the disclosure, the internal channel of the center post 20 may have a graded composition. Functionally graded additive manufacturing can gradually alter the material composition for multi-phase materials. By spatially varying compositions of the internal channel, desired performance across the entire internal channel is optimized. Functionally graded materials have a graded interface between the two dissimilar materials rather than a sharp interface (such as from traditional composite materials). The graded chemical composition minimizes the differences in the properties from one material to another, which may otherwise result in failure. For example, the internal channel can include a metal-rich phase at the distal end 25 for high heat transfer to prevent insulation and thermal decomposition of the oil. The internal channel could also include a ceramic-rich phase near the proximal end 21 and/or along the body 23 to provide a thermal barrier and reduce heat transfer from the ceramic/heating element to the vapor channel.
As illustrated in FIGS. 9A and 9B, the porous ceramic structure 24 is substantially circular, puck, or disk shaped. In some embodiments, the puck or disk can have multiple sides, such as a pentagonal, hexagonal, etc. shaped puck or disk. In some embodiments, the porous ceramic structure 24 can be substantially cuboid in shape, such as a cube or block shape. In some embodiments, the porous ceramic structure 24 can have a cone, triangular prism, square-based pyramid, or a triangular-based pyramid shape. In some embodiments, the porous ceramic structure 24 can be substantially cylindrical or have a pill shape (e.g., a rounded, elongated cylinder). Other suitable shapes can also be used, and the atomizer 30 disclosed herein is not limited to a particular shape. Regardless of the shape of the porous ceramic structure 24, the pore size and/or shape can vary from a core or center 40 of the porous ceramic structure 24 to an outer edge, perimeter, or circumference 45 of the porous ceramic structure 24.
FIG. 11 illustrates a flowchart of a method 200 of manufacturing an atomizer, such as atomizer 30 illustrated in FIGS. 8A and 8B. The method 200 includes depositing a first layer of ceramic material on a substrate, at 205, where the first layer has at least a first porosity. The method 200 can also include depositing a second layer of ceramic material on the first layer, at 210, where the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method 200 can also include depositing a third layer of ceramic material on the second layer, at 215. The third layer can have a third porosity that may be different than the second porosity and/or the first porosity. The method 200 can further include embedding a heating element within the first, second, and/or third layers, at 220. In some embodiments, the heating element is a coil.
In some embodiments, the method 200 may include depositing layers of metallic material within or between layers of ceramic material. This can produce a graded metal-to-ceramic atomizer, providing a thermal barrier and reducing an overall temperature of the produced vapor. The metal rich phases of the atomizer can improve heat transfer to the oil, preventing thermal decomposition of the oil.
FIG. 12 illustrates a flowchart of a method 300 of manufacturing a radially graded porous ceramic material, according to embodiments of the present disclosure. The method 300 includes depositing a first layer of ceramic material on a substrate, at 305, where, as before, the first layer has at least a first porosity. The method 300 can also include depositing a second layer of ceramic material on the first layer, at 310. In some embodiments, the second layer has at least a second porosity. In some embodiments, the second porosity is different than the first porosity. The method 300 can also include depositing a third layer of ceramic material on the second layer, at 315. The third layer can have a third porosity that, in some embodiments, is different than the second porosity and/or the first porosity.
FIG. 13 illustrates a flowchart of a method 400 of monitoring a temperate of a heating element and/or a vaporizing device. In some embodiments, the method 400 includes measuring resistance at the heating element or measuring resistance of the heating element, at 405. In some embodiments, the heating element is embedded in a surface coated radially graded porous ceramic structure. The method 400 can also include calculating a temperature based on the measured resistance, at 410. The method 400 further includes calculating tau based on the calculated temperature, at 415. In some embodiments, the method 400 includes monitoring tau and the temperature, at 420, and triggering an alarm when tau satisfies a threshold value, at 425. Tau is a heat transfer time constant, defined by:
$Tau = \frac{- t}{\ln (\frac{T (t) - T_{f}}{T_{s} - T_{f}})}$
where T(t) is temperature at time t, Tf and Ts are the final and start temperatures, respectively.
Other embodiments can include one or more aspects to improve the transport of oil, including pressure-driven flow of oil and/or drag flow with batch vaporization. With pressure-driven flow, a collapsible reservoir with a passive variant to prevent backflow could be used. According to another aspect, alternate configurations and geometries can be used to achieve uniform but rapid heating at the vaporization surface. Atomization can be used to achieve the desired vapor generation, including the use of a nebulizer.
Embodiment A. A method of manufacturing a radially graded porous ceramic structure, the method comprising depositing a first layer of ceramic material on a substrate, the first layer having at least a first porosity; depositing a second layer of ceramic material on the first layer, the second layer having at least a second porosity, the second porosity being different than the first porosity; and depositing a third layer of ceramic material on the second layer, the third layer having a third porosity, the third porosity being different than the second porosity and/or the first porosity.
Embodiment B. The method of Embodiment A, wherein the substrate comprises a heating element, such as a coil.
Embodiment C. The method of Embodiment B, further comprising establishing a headspace within or between the coil and the radially graded porous ceramic structure.
Embodiment D. The method of any one of Embodiments A, B, or C, wherein the ceramic material of the first, second, and/or third layers comprises aluminum oxide, silicon dioxide, zinc oxide, boron nitride, aluminum nitride, silicon carbide, or combinations thereof.
Embodiment E. The method of Embodiment any one of Embodiments A, B, C, or D, wherein the ceramic material of the first, second, and/or third layers further comprises gold, silver, aluminum, copper, or combinations thereof.
Embodiment F. The method of any one of Embodiments A, B, C, D, or E, wherein the ceramic material of the first, second, and/or third layers further comprises carbon fiber, graphene, graphite, carbon nanotubes, or combinations thereof.
Embodiment G. The method of any one of Embodiments A, B, C, D, E, or F, wherein the ceramic material of the first, second, and/or third layers further comprises carbon fiber, graphene, graphite, carbon nanotubes, or combinations thereof.
Embodiment H. The method of any one of Embodiments A, B, C, D, E, F, or G, further comprising depositing additional layers of ceramic material as needed to produce a radially graded porous ceramic structure having a length of 0.5 mm to about 10 mm, a width of from about 0.5 mm to about 10 mm, and a height of from about 0.5 mm to about 10 mm.
Embodiment I. The method of any one of Embodiments A through H, further comprising embedding a heating element within the first, second, and/or third layers.
Embodiment J. The method of any one of Embodiments A through I, wherein a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the first layer of ceramic material.
Embodiment K. The method of any one of Embodiments A through J, wherein a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the second layer of ceramic material.
Embodiment L. The method of any one of Embodiments A through K, wherein a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the third layer of ceramic material.
Embodiment M. A method of monitoring a temperate of a heating element, the method comprising measuring resistance at the heating element, the heating element embedded in a surface coated radially graded porous ceramic structure; calculating a temperature based on the measured resistance; calculating tau based on the calculated temperature; monitoring tau and the temperature; and triggering an alarm when tau satisfies a threshold value.
Embodiment N. The method of Embodiment M, wherein triggering an alarm comprises delivering a sound through a vaporizing device in which the heating element is contained.
Embodiment O. The method of Embodiment M or N, wherein triggering an alarm comprises providing a visual signal through a vaporizing device in which the heating element is contained.
Embodiment P. A vaporizing device comprising a center post having proximal and distal ends and a body extending therebetween, the body defining an internal channel, the proximal end of the center post comprising a lip and a pair of proximal flanges, the distal end of the center post comprising a proximal portion defining one or more voids in fluid communication with the internal channel, a distal portion defining a cavity to receive an atomizer and a wick, the atomizer comprising a radially graded porous ceramic structure, and a median flange between the proximal and distal portions, the median flange extending radially outward from a longitudinal axis of the distal end of the center post; a cartridge for receiving the center post within an interior of the cartridge; and a base in association with the distal end of the center post and a distal end of the cartridge.
Embodiment Q. The vaporizing device of Embodiment P, wherein the cavity in the distal portion of the distal end of the center post is in fluid communication with the internal channel of the center post via the one or more voids.
Embodiment R. The vaporizing device of Embodiment P or Q, wherein the atomizer further comprises a coil embedded within the radially graded porous ceramic structure.
Embodiment S. The vaporizing device of Embodiment R, wherein the atomizer further comprises a headspace within or between the coil and the radially graded porous ceramic structure.
Embodiment T. The vaporizing device of any one of Embodiments P, Q, R, or S, wherein the radially graded porous ceramic structure has a porosity ranging from 10% to 85%.
Embodiment U. The vaporizing device of any one of Embodiments P, Q, R, S, or T, wherein the radially graded porous ceramic structure has a permeability ranging from 1 to 100 millidarcy.
Embodiment V. The vaporizing device of any one of Embodiments P, Q, R, S, T, or U, wherein the wick comprises a porous media, such as cotton, linen, a woven fabric, a non-woven fabric, or another suitable porous media.
Embodiment W. The vaporizing device of any one of Embodiments P, Q, R, S, T, U, or V, wherein the wick comprises a surface treatment.
Embodiment X. The vaporizing device of Embodiment W, wherein the surface treatment comprises graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.
Embodiment Y. The vaporizing device of Embodiment W or X, wherein the surface treatment is applied to the wick via electrospinning, vacuum filtration, spraying, coating, 3D printing, and/or chemical coupling.
Embodiment Z. The vaporizing device of any one of Embodiments P, Q, R, S, T, U, V or X, wherein a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure.
Embodiment AA. A vaporizing device comprising a center post defining an internal channel and having proximal and distal ends, the distal end of the center post comprising a proximal portion defining one or more voids in fluid communication with the internal channel, a distal portion defining a cavity to receive an atomizer, the cavity also being in fluid communication with the one or more voids, the atomizer comprising an atomizer surface treatment, and a median flange between the proximal and distal portions, the median flange extending radially outward from a longitudinal axis of the distal end of the center post; a reservoir to receive the center post within an interior of the reservoir, the proximal end of the center post extending proximally beyond a proximal end of the reservoir and the distal end of the center post extending distally beyond a distal end of the reservoir; and a base in association with the distal end of the center post, the base abutting the distal end of the reservoir.
Embodiment BB. The vaporizing device of Embodiment AA, wherein the atomizer surface treatment comprises a carbon surface treatment, such as graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.
Embodiment CC. The vaporizing device of Embodiment AA or BB, wherein the atomizer further comprises a radially graded porous ceramic structure.
Embodiment DD. The vaporizing device of Embodiment CC, wherein a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure.
Embodiment EE. The vaporizing device of any one of Embodiments AA through CC, wherein the reservoir is in fluid communication with the internal channel via the one or more voids defined in the proximal portion of the distal end of the center post.
Embodiment FF. The vaporizing device of any one of Embodiments AA through CC or Embodiment EE, wherein the cavity of the distal portion further receives a wick for facilitating a transfer of fluid contained within the reservoir to the atomizer to be heated via the one or more voids.
Embodiment GG. The vaporizing device of Embodiment FF, wherein the wick comprises a porous media.
Embodiment HH. The vaporizing device of Embodiment FF, wherein the wick comprises a porous media and a surface treatment.
Embodiment II. The vaporizing device of Embodiment HH, wherein the surface treatment comprises a carbon surface treatment.
Embodiment JJ. A vaporizing device comprising a cartridge defining an internal reservoir and having proximal and distal ends; and a base unit in association with the distal end of the cartridge and housing an atomizer, the atomizer comprising a radially graded porous ceramic structure and a heating element embedded within the radially graded porous ceramic structure, wherein the base unit and/or the internal reservoir defines a plurality of apertures placing the base unit and the internal reservoir in fluid communication, such that a fluid contained within the internal reservoir flows through the plurality of apertures to contact the base unit and the atomizer housed therein.
Embodiment KK. The vaporizing device of Embodiment JJ, wherein the vaporizing device does not include a center post.
Embodiment LL. The vaporizing device of Embodiment JJ or Embodiment KK, wherein the vaporizing device does not include a wick.
Embodiment MM. The vaporizing device of any one of Embodiments JJ through LL, wherein the radially graded porous ceramic structure further comprises a surface coating or treatment, such as a carbon surface treatment comprising graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.
Embodiment NN. The vaporizing device of Embodiment MM, wherein the surface coating or treatment is disposed on the radially graded porous ceramic structure via chemical vapor deposition or plasma-enhanced chemical vapor deposition.
Embodiment OO. The vaporizing device of any one of Embodiments JJ through MM, wherein the heating element embedded within the radially graded porous ceramic structure comprises a coil.
Embodiment PP. The vaporizing device of Embodiment OO, wherein atomizer further comprises a headspace within or between the coil and the radially graded porous ceramic structure.
Embodiment QQ. The vaporizing device of any one of Embodiments JJ through OO, wherein the radially graded porous ceramic structure has a porosity ranging from 10% to 85%.
Embodiment RR. The vaporizing device of any one of Embodiments JJ through OO or Embodiment QQ, wherein the radially graded porous ceramic structure has a permeability ranging from 1 to 100 millidarcy.
Embodiment SS. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ to RR, wherein the radially graded porous ceramic structure has a disk shape.
Embodiment TT. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ to SS, wherein the radially graded porous ceramic structure has a cuboid shape.
Embodiment UU. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ through TT, wherein the radially graded porous ceramic structure has a cone shape.
Embodiment VV. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ through UU, wherein the radially graded porous ceramic structure has an elongated, rounded cylindrical shape.
Embodiment WW. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ through VV, wherein a pore size and/or shape of the radially graded porous ceramic structure varies from a center of the radially graded porous ceramic structure to a perimeter, circumference, and/or outer edge of the radially graded porous ceramic structure.
Embodiment XX. The vaporizing device of any one of Embodiments JJ through OO or Embodiments QQ through WW, wherein the base unit is in fluid communication with the internal reservoir of the cartridge such that a vaporized fluid flows from the base unit proximally through the internal reservoir to be inhaled by a user.
While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. Portions of a vaping device that are closer to a user when the vaping device is in use are referred to as more “proximal” (i.e., the proximal mouthpiece which is within a user's mouth when the vaping device is in use) while surfaces that are farther away from the user when the device is in use are referred to as “distal.”
In one embodiment, the terms “about” and “approximately” refer to numerical parameters within 10% of the indicated range. The terms “a,” “an,” “the,” and similar referents used in the context of describing the embodiments of the present disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the embodiments of the present disclosure and does not pose a limitation on the scope of the present disclosure. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the embodiments of the present disclosure.
Groupings of alternative elements or embodiments disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
Certain embodiments are described herein, including the best mode known to the author(s) of this disclosure for carrying out the embodiments disclosed herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The author(s) expects skilled artisans to employ such variations as appropriate, and the author(s) intends for the embodiments of the present disclosure to be practiced otherwise than specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
Specific embodiments disclosed herein may be further limited in the claims using consisting of or consisting essentially of language. When used in the claims, whether as filed or added per amendment, the transition term “consisting of” excludes any element, step, or ingredient not specified in the claims. The transition term “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s). Embodiments of this disclosure so claimed are inherently or expressly described and enabled herein.
Although this disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

Claims

What is claimed:

1. An atomizer comprising:

a radially graded porous ceramic structure having a heating element at least partially embedded therein; and

a surface treatment disposed on the radially graded porous ceramic structure, the atomizer to be received by a vaporizing device to generate vapor from a fluid contained within a reservoir of the vaporizing device, wherein the fluid flows from the reservoir into one or more pores of the radially graded porous ceramic structure to be atomized by the embedded heating element.

2. The atomizer of claim 1, wherein the radially graded porous ceramic structure has a length of from about 0.5 mm to about 10 mm, a width of from about 0.5 mm to about 10 mm, and a height of from about 0.5 mm to about 10 mm.

3. The atomizer of claim 1, wherein the radially graded porous ceramic structure has at least one of a pre-defined porosity and a pre-defined permeability.

4. The atomizer of claim 1, wherein the heating element comprises a coil.

5. The atomizer of claim 1, wherein the surface treatment comprises a carbon surface treatment.

6. The atomizer of claim 5, wherein the carbon surface treatment comprises pyrolytic carbon.

7. The atomizer of claim 5, wherein the carbon surface treatment comprises graphite.

8. The atomizer of claim 5, wherein the carbon surface treatment comprises graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.

9. The atomizer of claim 1, wherein the surface coating or treatment is disposed on the radially graded porous ceramic structure via chemical vapor deposition or plasma-enhanced chemical vapor deposition.

10. A method of manufacturing a porous ceramic atomizer having a surface treatment, the method comprising:

depositing a first layer of ceramic material on a substrate, the first layer having a first porosity;

depositing a second layer of ceramic material on the first layer, the second layer having a second porosity, the second porosity being different than the first porosity;

depositing a third layer of ceramic material on the second layer, the third layer having a third porosity, the third porosity being different than the second porosity and/or the first porosity;

embedding a heating element within the first, second, and/or third layers; and

depositing a surface treatment on an outermost layer of ceramic material, the surface treatment comprising a carbon surface treatment.

11. The method of claim 10, wherein embedding the heating element comprises providing the heating element and depositing a first, second, and/or third layer of ceramic material around the heating element.

12. The method of claim 11, wherein a space exists between the heating element and the first, second, and/or third layer of ceramic material.

13. The method of claim 10, wherein depositing a surface treatment on an outermost layer of ceramic material comprises depositing the carbon surface treatment through chemical vapor deposition or plasma-enhanced chemical vapor deposition.

14. The method of claim 10, wherein the carbon surface treatment comprises graphite, synthetic graphite, pyrolytic carbon, graphene, carbon black, carbon nanotubes, or combinations thereof.

15. The method of claim 10, wherein the porous ceramic atomizer is a radially graded porous ceramic structure and a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure.

16. The method of claim 10, wherein the porous ceramic atomizer is a radially graded porous ceramic structure and a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the first layer of ceramic material.

17. The method of claim 10, wherein the porous ceramic atomizer is a radially graded porous ceramic structure and a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the second layer of ceramic material.

18. The method of claim 10, wherein the porous ceramic atomizer is a radially graded porous ceramic structure and a pore size at a center of the radially graded porous ceramic structure is smaller than a pore size at an edge or perimeter of the radially graded porous ceramic structure in the third layer of ceramic material.

19. An atomizer comprising:

a heating element at least partially embedded within a ceramic structure; and

a carbon-based surface treatment disposed on the ceramic structure, the atomizer to be received by a vaporizing device to generate vapor from a fluid contained within a reservoir of the vaporizing device, wherein the fluid flows from the reservoir into one or more pores of the ceramic structure to be atomized by the embedded heating element.