阅读说明：本技术 混合电子蒸汽烟筒、包含混合电子蒸汽烟筒的电子蒸汽烟装置以及其制造方法 (Hybrid e-vaping cartridges, e-vaping devices including hybrid e-vaping cartridges, and methods of making the same ) 是由 E·卡迪厄 W·J·克劳威 B·S·史密斯 N·特朗 C·S·塔克 于 2017-12-29 设计创作，主要内容包括：电子蒸汽烟筒(70)包含壳体主体,其具有在所述壳体主体内纵向延伸并限定中心过道(20、20a)的第一/中心管(8),所述第一管(8)进一步限定至少一个第一孔(8a)。一个或多个吸收材料层(10、12)围绕所述第一管(8)的至少一部分定位在内环形储存器(4b)内。芯(28)与所述中心过道(20a)连通,其中所述芯(28)的远端穿越所述第一孔(8a),并且与所述内环形储存器(4b)连通。加热器(14)被配置成汽化从所述内环形储存器(4b)传递到所述芯(28)的蒸汽前调配物。电子蒸汽烟装置(71)包含可连接到电力区段(72)的所述筒(70)。(An e-vaping cartridge (70) includes a housing body having a first/center tube (8) extending longitudinally within the housing body and defining a center passageway (20, 20a), the first tube (8) further defining at least one first aperture (8 a). One or more layers (10, 12) of absorbent material are positioned within the inner annular reservoir (4b) around at least a portion of the first tube (8). A wick (28) is in communication with the central passageway (20a), wherein a distal end of the wick (28) passes through the first aperture (8a) and is in communication with the inner annular reservoir (4 b). A heater (14) is configured to vaporize pre-vapor formulation transferred from the inner annular reservoir (4b) to the wick (28). An e-vaping device (71) includes the cartridge (70) connectable to a power section (72).)

1. An e-vaping cartridge comprising:

a housing main body;

a first tube extending longitudinally within the housing body, the first tube at least partially defining a central passageway within a central tube, the first tube further defining at least one first aperture providing fluid communication between the central passageway and a first annular reservoir defined between the housing body and the first tube;

one or more layers of absorbent material positioned within the inner annular reservoir and around at least a portion of the first tube;

a wick in communication with the central passageway, a distal end of the wick traversing the at least one first aperture of the first tube and in communication with the first annular reservoir; and

a heater configured to vaporize pre-vapor formulation delivered by the wick from the first annular reservoir.

2. The e-vaping cartridge of claim 1, further comprising:

a second tube extending longitudinally within the housing body and partially defining a second annular reservoir between the housing body and the second tube, the second tube defining at least one second aperture providing fluid communication between the first and second annular reservoirs,

the absorbent material is at least one of gauze and fibrous material.

3. The e-vaping cartridge of claim 2, further comprising:

a third tube connected to an end of the first tube, the third tube defining the central passageway with the first tube,

the distal end of the core is in direct contact with a portion of the one or more layers of absorbent material.

4. The e-vaping cartridge of claim 3, further comprising:

a first electrical lead electrically connected to connectors on a first end of the heater and a first end of the barrel;

a second electrical lead electrically connected to a second end of the heater and the third tube, the third tube being electrically conductive.

5. The e-vaping cartridge of claim 4, wherein the connector on the first end of the cartridge is a female threaded connector, a portion of the female threaded connector extending beyond the confines of the housing body and defining at least one air inlet in communication with the central passageway of the cartridge.

6. The e-vaping cartridge of claim 5, wherein an outer surface of a portion of the female threaded connector defines a groove, a first adhesive fills at least a portion of the groove to connect the distal end of the housing body to the base of the female threaded connector, and a sealant at least partially covers a junction between the distal end of the second tube and the proximal end of the female threaded connector.

7. The e-vaping cartridge of any of claims 2-6, further comprising:

a mouth-end insert on the second end of the barrel,

wherein ends of the first and second tubes contact the mouth-end insert.

8. The e-vaping cartridge of any of claims 2-7, wherein the second tube has a diameter of between about 4-6 millimeters, the at least one second aperture defined by the second tube having a total cross-sectional area of between about 3.14 and 9.42 square millimeters.

9. The e-vaping cartridge of any of claims 2-8, wherein the at least one second aperture defined by the second tube includes four separate apertures, each aperture having a diameter of between about 1 millimeter and 4 millimeters.

10. The e-vaping cartridge of any of the preceding claims, wherein at least a portion of the housing body is one of transparent and translucent.

11. An electronic vaping device, comprising:

a cartridge comprising, in combination,

a first shell body which is provided with a first shell body,

a first tube extending longitudinally within the housing body, the first tube at least partially defining a central passageway within the central tube, the first tube further defining at least one first aperture providing fluid communication between the central passageway and a first annular reservoir defined between the housing body and the first tube,

one or more layers of absorbent material positioned within the inner annular reservoir and around at least a portion of the first tube,

a wick in communication with the central passageway, a distal end of the wick passing through the at least one first aperture of the first tube and in communication with the first annular reservoir; and

a heater configured to vaporize pre-vapor formulation delivered by the wick from the first annular reservoir; and

a power section connectable to the cartridge, the power section including,

a sensor configured to detect one or more internal vaping conditions within the power section and, if the power section is connected to the canister, detect one or more internal vaping conditions within the canister,

a power supply, and

a control circuit configured to send current from the power source to the heater if the sensor detects the one or more vapor smoke conditions.

12. The e-vaping device of claim 11, wherein the cartridge further includes,

a second tube extending longitudinally within the housing body and partially defining a second annular reservoir between the housing body and the second tube, the second tube defining at least one second aperture providing fluid communication between the first and second annular reservoirs,

the absorbent material is at least one of gauze and fibrous material.

13. The e-vaping device of claim 12, wherein the cartridge further includes,

a third tube connected to an end of the first tube, the third tube defining the central passageway with the first tube,

the distal end of the core is in direct contact with a portion of the one or more layers of absorbent material,

wherein the second tube of the cartridge has a diameter of between about 4 millimeters and 6 millimeters and the at least one second aperture defined by the second tube has a total cross-sectional area of between about 3.14 square millimeters and 9.42 square millimeters.

14. The e-vaping device of claim 12 or 13, wherein the cartridge further includes

A first electrical lead electrically connected to connectors on a first end of the heater and a first end of the barrel;

a second electrical lead electrically connected to a second end of the heater and the third tube, the third tube being electrically conductive.

15. A method of manufacturing an e-vaping cartridge, comprising:

cutting at least one first hole through a first tube and connecting a distal end of the first tube to a connector, the first tube at least partially defining a central passageway within the first tube;

inserting a wick and a heater through the at least one first aperture of the first tube;

wrapping one or more layers of absorbent material around at least a portion of the first tube;

sliding a housing body over the first tube and connecting a proximal end of the housing body to the connector, the housing body partially defining a first annular reservoir;

filling the first annular reservoir with a pre-vapor formulation; and

a mouth-end insert is attached to the distal end of the housing body.

16. The method of claim 15, wherein the connecting of the distal end of the first tube to the connector includes connecting a second tube to the connector and connecting the distal end of the first tube to the second tube.

17. The method of claim 15 or 16, further comprising:

cutting at least one second hole in a third tube and sliding the first tube over at least a portion of the one or more layers of absorbent material and the first tube until a distal end of the third tube fits over a proximal end of the connector, the distal end of the wick communicating with a second annular reservoir defined at least in part by the third tube, the housing body being common with the third tube and defining in part the first annular reservoir,

the absorbent material is at least one of a scrim and a fibrous material, the distal end of the core directly contacting a portion of the one or more layers of absorbent material.

18. The method of claim 17, further comprising:

controlling the wicking rate of the wick by adjusting a total cross-sectional area of the at least one second hole in the third tube, the total cross-sectional area of the at least one second hole being between about 3.14 square millimeters and 9.42 square millimeters.

19. The method of claim 17 or 18, further comprising:

cutting a groove on an outer surface of the connector and at least partially filling the groove with an adhesive, the connecting of the proximal end of the housing body to the connector including adhering the proximal end of the housing body to the connector with the adhesive; and

applying a sealant at a junction between the distal end of the third tube and a portion of the proximal end of the connector.

20. The method of any of claims 15 to 19, further comprising:

connecting a first electrical lead to a first end of the heater and the connector and a second electrical lead to a second end of the heater and the second tube before the one or more layers of absorbent material are wrapped around at least a portion of the first tube, the second tube being electrically conductive; and is

Wherein the distal end of the first tube is positioned between the first and second electrical leads and the outer surface of the second tube.

Technical Field

Example embodiments generally relate to a hybrid e-vaping cartridge and an e-vaping device including a hybrid e-vaping cartridge. Example embodiments also include a method of manufacturing a hybrid e-vaping cartridge, an e-vaping device, or both.

Background

An electronic vaping (e-vaping) device may be used to vaporize the pre-vapor formulation to "vapor". E-vaping devices typically include a heater that vaporizes the pre-vapor formulation. The heater may be included in a section of the e-vaping device, where this section may typically be in the form of an e-vaping canister or cartridge that also contains a pre-vapor formulation reservoir. The power source to energize the heating coil may be included in another section of the e-vaping device. The e-vaping device may also require a single section or two or more sections.

E-vaping cartridges typically include a sealed pre-vapor formulation reservoir. The heater may be in communication with a chimney positionable within the cartridge. For example, the heater may be in fluid communication with the reservoir via a wick (or other structure that provides capillary action). The reservoir is sealed from the standpoint that the pre-vapor formulation within the cartridge is generally depleted during use until the reservoir is empty. Also, once emptied, the cartridge can be discarded because the cartridge cannot be refilled with pre-vapor formulation. A gauze or other suitable fibrous material may be included within the reservoir to help retain the pre-vapor formulation within the reservoir. However, gauze, fibrous material, or neither are contained in, around, or both the chimney.

An e-vaping canister typically contains an unsealed pre-vapor formulation reservoir and may be essentially an empty container that allows manual refilling. Similar to the cartridge, the heater may be in communication with a chimney that may be positioned within the tank. For example, the heater may be in fluid communication with the reservoir via a wick (or other structure that provides capillary action). Unlike the cartridge, the reservoir of the e-vaping canister may be unsealed. Thus, once the pre-vapor formulation from the reservoir is depleted during use, at least a portion of the reservoir may be accessed in order to allow the reservoir to be manually filled again with the pre-vapor formulation prior to additional use of the e-vaping canister. The gauze, fibrous material, or neither are located within the chimney nor are the gauze, fibrous structure, or both located within the reservoir.

Disclosure of Invention

At least one example embodiment relates to an e-vaping cartridge.

In one example embodiment, the e-vaping cartridge includes a housing body; a first tube extending longitudinally within the housing body, the first tube at least partially defining a central passageway within the central tube, the first tube further defining at least one first aperture providing fluid communication between the central passageway and a first annular reservoir defined between the housing body and the first tube; one or more layers of absorbent material positioned within the inner annular reservoir and around at least a portion of the first tube; a wick in communication with the central passageway, a distal end of the wick traversing the at least one first aperture of the first tube and in communication with the first annular reservoir; and a heater configured to vaporize pre-vapor formulation delivered by the wick from the first annular reservoir.

In one example embodiment, the e-vaping cartridge further comprises a second tube extending longitudinally within the housing body and partially defining a second annular reservoir between the housing body and the second tube, the second tube defining at least one second aperture providing fluid communication between the first annular reservoir and the second annular reservoir, the absorbent material being at least one of a gauze and a fibrous material.

In one example embodiment, the e-vaping cartridge further includes a third tube connected to an end of the first tube, the third tube and the first tube collectively defining the central passageway, the distal end of the core being in direct contact with a portion of the one or more layers of absorbent material.

In one example embodiment, the e-vaping cartridge further includes a first electrical lead electrically connected to a first end of the heater and a connector on a first end of the cartridge; a second electrical lead electrically connected to a second end of the heater and the third tube, the third tube being electrically conductive.

In one example embodiment, the e-vaping cartridge further includes a mouth-end insert on a second end of the cartridge, wherein ends of the first tube and the second tube contact the mouth-end insert.

In one example embodiment, the second tube has a diameter of between about 4 millimeters and 6 millimeters, and the at least one second aperture defined by the second tube has a total cross-sectional area of between about 3.14 square millimeters and 9.42 square millimeters.

In one example embodiment, the at least one second aperture defined by the second tube comprises four individual apertures, each aperture having a diameter of between about 1 millimeter and 4 millimeters.

In one example embodiment, the connector on the first end of the cartridge is a female threaded connector, a portion of which extends beyond the grains of the housing body and defines at least one air inlet in communication with the central passageway of the cartridge.

In one example embodiment, an outer surface of a portion of a female threaded connector defines a groove, a first adhesive fills at least a portion of the groove to connect the distal end of the housing body to a base of the female threaded connector, and a sealant at least partially covers a junction between the distal end of the second tube and the proximal end of the female threaded connector.

In an example embodiment, at least a portion of the housing body is one of transparent and translucent.

At least one other example embodiment relates to an electronic vaping device.

In one example embodiment, the e-vaping device includes a cartridge including a first housing body; a first tube extending longitudinally within the housing body, the first tube at least partially defining a central passageway within a central tube, the first tube further defining at least one first aperture providing fluid communication between the central passageway and a first annular reservoir defined between the housing body and the first tube; one or more layers of absorbent material positioned within the inner annular reservoir and around at least a portion of the first tube; a wick in communication with the central passageway, a distal end of the wick traversing the at least one first aperture of the first tube and in communication with the first annular reservoir; and a heater configured to vaporize pre-vapor formulation delivered by the wick from the first annular reservoir; and a power section connectable to the cartridge, the power section including a sensor configured to detect one or more internal vaping conditions within the power section and, if the power section is connected to the cartridge, detect one or more internal vaping conditions within the cartridge; a power source; and control circuitry configured to send current from the power source to the heater if the sensor detects the one or more vapor smoke conditions.

In one example embodiment, the cartridge further includes a second tube extending longitudinally within the housing body and partially defining a second annular reservoir between the housing body and the second tube, the second tube defining at least one second aperture providing fluid communication between the first annular reservoir and the second annular reservoir, the absorbent material being at least one of a gauze and a fibrous material.

In one example embodiment, the cartridge further includes a third tube connected to an end of the first tube, the third tube defining the central passageway in cooperation with the first tube, the distal end of the core being in direct contact with a portion of the one or more layers of absorbent material, wherein the diameter of the second tube of the cartridge is between about 4 millimeters and 6 millimeters, the at least one second aperture defined by the second tube having a total cross-sectional area between about 3.14 square millimeters and 9.42 square millimeters.

In one example embodiment, the cartridge further comprises: a first electrical lead electrically connected to a first end of the heater and a connector on a first end of the cartridge; a second electrical lead electrically connected to a second end of the heater and the third tube, the third tube being electrically conductive.

At least one example embodiment relates to a method of manufacturing an e-vaping cartridge.

In one example embodiment, the method includes cutting at least one first hole through a first tube and connecting a distal end of the first tube to a connector, the first tube at least partially defining a central passageway within the first tube; inserting a wick and a heater through at least one first hole of the first tube; wrapping one or more layers of absorbent material around at least a portion of the first tube; sliding a housing body over the first tube and connecting a proximal end of the housing body to the connector, the housing body partially defining a first annular reservoir; filling the first annular reservoir with a pre-vapor formulation; and attaching a mouth-end insert to the distal end of the housing body.

In one example embodiment, the connecting of the distal end of the first tube to the connector includes connecting a second tube to the connector and connecting the distal end of the first tube to the second tube.

In one example embodiment, the method further comprises cutting at least one second hole in a third tube, and sliding the first tube over at least a portion of the one or more layers of absorbent material and the first tube until a distal end of the third tube fits over a proximal end of the connector, a distal end of the core communicating with a second annular reservoir defined at least in part by the third tube, the housing body and the third tube collectively and in part defining the first annular reservoir, the absorbent material being at least one of gauze and fibrous material, the distal end of the core directly contacting a portion of the one or more layers of absorbent material.

In one example embodiment, the method further comprises connecting a first electrical lead to the first end of the heater and the connector, and connecting a second electrical lead to the second end of the heater and the second tube, the second tube being electrically conductive, prior to wrapping the one or more layers of absorbent material around at least a portion of the first tube; and wherein the distal-most end of the first tube is positioned between the first and second electrical leads and the outer surface of the second tube.

In one example embodiment, the method further includes controlling the wicking rate of the wick by adjusting a total cross-sectional area of the at least one second hole in the third tube, the total cross-sectional area of the at least one second hole being between about 3.14 square millimeters and 9.42 square millimeters.

In one example embodiment, the method further comprises cutting a groove on an outer surface of the connector, and at least partially filling the groove with an adhesive, the connecting of the proximal end of the housing body to the connector comprising for the adhesive to adhere the proximal end of the housing body to the connector; and applying a sealant to a junction between the distal end of the third tube and a portion of the proximal end of the connector.

Drawings

The above and other features and advantages of example embodiments will become more apparent by describing in detail example embodiments with reference to the attached drawings. The drawings are intended to depict example embodiments and should not be construed as limiting the intended scope of the claims. The drawings are not to be considered as drawn to scale unless explicitly indicated.

FIG. 1 shows a perspective view of a hybrid e-vapor chimney according to an example embodiment;

FIG. 2 shows a cross-sectional view of a hybrid e-vapor chimney, according to an example embodiment;

FIG. 3 shows an exploded view of a hybrid e-vapor cartridge according to an example embodiment;

FIG. 4 illustrates steps of assembling a hybrid e-vapor chimney according to an example embodiment;

FIG. 5 illustrates another step of assembling a hybrid e-vapor chimney according to an example embodiment;

FIG. 6 illustrates another step of assembling a hybrid e-vapor chimney according to an example embodiment;

FIG. 7 illustrates another step of assembling a hybrid e-vapor chimney according to an example embodiment;

FIG. 8 illustrates another step of assembling a hybrid e-vapor chimney according to an example embodiment;

FIG. 9 illustrates another step of assembling a hybrid e-vapor chimney according to an example embodiment;

figure 10 illustrates an e-vaping device with a hybrid e-vaping cartridge, according to an example embodiment; and is

Figure 11 illustrates a cross-sectional view of an e-vaping device with a hybrid e-vaping cartridge, according to an example embodiment.

Detailed Description

Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the embodiments set forth herein.

Accordingly, while example embodiments are capable of various modifications and alternative forms, embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but on the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.

It will be understood that when an element or layer is referred to as being "on," "connected to," "coupled to," or "covering" another element or layer, it can be directly on, connected to, coupled to, or covering the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to" or "directly coupled to" another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers or sections, these elements, components, regions, layers or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of example embodiments.

Spatially relative terms (e.g., "under," "below," "lower," "above," "upper," etc.) may be used herein to describe one element or feature's relationship to another element or feature as illustrated 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 depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the example embodiments. Thus, it is contemplated that the shapes of the illustrations will vary, for example, due to manufacturing techniques or tolerances. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of example embodiments.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Fig. 1 shows a perspective view of a hybrid e-steam cartridge 70 according to an example embodiment. As shown in fig. 1, the cartridge may comprise an outer housing. The end of the canister 70 may have an electrical terminal 212a (e.g., an anode terminal 212 a). The end of the cartridge 70 may also include threads 205a, which may be capable of mating with one or more additional sections of the e-vaping device. For example, the threads 205a may be on the male connector 205 (see fig. 2), wherein the threads 205a may be configured to mate with the threads 205d on the female connector 206 of another segment, such as the power segment 72 (see fig. 11) of the e-vaping device 71. It should be understood that the threads 205a of the mixing cartridge 70 may also be on a male connector (not shown) of the cartridge 70 such that the threads 205a can mate with a female connector of another section of the e-vaping device.

The end of the cartridge 70 may also include one or more air vents 44, which may be positioned near the distal end of the connector 205, wherein the one or more vents 44 may be capable of communicating ambient air (outside the cartridge 70) with the interior air passageway of the cartridge 70, as further described herein.

Fig. 2 shows a cross-sectional view of a hybrid e-steam chimney 70 (view '2' of fig. 1) according to an example embodiment. As shown in fig. 2, the housing 6 may extend along a majority of the longitudinal length of the cartridge 70. Nevertheless, the distal end of the connector 205 may extend beyond the confines of the housing 6, thereby allowing the one or more vents 44 and the outer surface of the connector 205 to be visible and open to ambient air after the fully assembled e-vaping device 71 is formed with the canister 70.

The mixing drum 70 may define a central air passageway 20 in communication with another air path 20a, which may allow for a flow of air to be maintained within the drum 70 (where the central air passageway 20 and the air path 20a may collectively be considered a central passageway 20, 20 a). In particular, the central air passageway 20 may be defined by an end tube 210 (which may be a conductive tube, or "live tube") that may be held in place by the connector 205, wherein the insulator 15 may be used to electrically isolate the live tube 210 from the connector 205. The distal end of the charged tube 210 may form an electrical contact 212a, which may be, for example, an anode contact 212 a. The heater 14 with wick 28 may be positioned in communication with the tube 210, for example, near the end of the tube 210. The electrical leads 26a, 26b may be electrically connected to the ends of the heater 14. For example, the cathode electrical lead 26b may be electrically connected to the connector 205 and the end of the heater 14, and the anode electrical lead 26a may be electrically connected to the other end of the live tube 210 and the heater 14.

The inner tube 4 may help define an inner annular portion 4b, wherein the inner annular portion 4b may communicate with the outer annular region 6 a. For example, the end of the inner tube 4 may be affixed to the proximal end 205b by pressing on the proximal end 205b of the connector 205 such that the inner tube 4 may compress the proximal end 205 b. The other end of the inner tube 4 may be connected to a mouth-end insert 9 of the cartridge 70, wherein the insert 9 may contain an outlet 24, e.g., one or more diverging outlets 24. The center tube 8 may be compression fit over the end of the live tube 210, wherein the end of the tube 8 may be pressed against the mouth-end insert 9 so that the center tube 8 defines an air path 20a in communication with the central air passageway 20.

One or more layers of absorbent gauze, high density gauze, sponge, or another suitable form of fibrous absorbent material may be positioned within the inner tube 4 to also assist in defining the air path 20 a. For example, an inner layer of gauze 10 and an outer layer of gauze 12 may be positioned between the inner tube 4 and the central tube 8. It should be noted that more or fewer layers of gauze may be positioned within the inner tube 4. By way of example, the inner layer of the scrim 10 and the outer layer of the scrim 12 may alternatively be a single layer of scrim. By providing one or more layers of gauze inside the inner tube 4, wherein the annulus 6a lacks any gauze, the mixing drum 70 combines the advantages from a section of the tank type that can hold the pre-vapor formulation 22 in the outer annulus 6a for easy viewing of pre-vapor formulation content, and that can optionally be refilled with stability of the drum (wherein the gauze 10, 12 can prevent leakage and provide consistent flow of the pre-vapor formulation 22 to the wick 28 and heater 14).

In one embodiment, each gauze layer 10, 12 may be formed of the same material or different materials. The gauze layers 10, 12 may be made, for example, of cotton, polyethylene, polyester, rayon, another polymeric material, another filamentary material, or a combination thereof containing a dense number of interstitial spaces that may effectively absorb and retain the pre-vapor formulation 22 before the pre-vapor formulation 22 is drawn into the heater 14 by capillary action of the wick 28. In one embodiment, each gauze layer 10, 12 may be rectangular in shape and may be about 18 millimeters wide and 22 millimeters long.

An annular region 6a may be defined between the outer shell 6 and the inner tube 4. The annular region 6a may be configured to contain the pre-vapor formulation 22. One or more apertures 4a within the inner tube 4 may allow for the transfer of pre-vapor formulation between the annular region 6a and the inner annular region 4b, where the inner annular region 4b may be defined in part by the inner tube 4, the center tube 8, the connector 205, and the mouth-end insert 9. The end of the wick 28 may extend away from the heater 14 and through a hole 8a (shown more clearly in fig. 3 and 4) in the central tube 8 to communicate with the inner annular region 4 b. In particular, this wick 28 may be configured to draw pre-vapor formulation from the inner annular portion 4b toward the heater 14 so that the heater may vaporize the pre-vapor formulation when the cartridge 70 is in operation. In one embodiment, the length of the core 28 may be between about 20 millimeters and 32 millimeters over the total length.

It will be appreciated that by providing the gauze layers 10, 12 in the inner annular space 4b of the cartridge, the wicking rate of the core 28 can be better controlled in order to obtain the desired flow of the pre-vapor formulation 22 to the heater 14. Further, the gauze layers 10, 12 may be oriented fibers capable of directing the flow of the pre-vapor formulation 22 (rather than simply retaining the pre-vapor formulation 22). In particular, if the wicking rate of the pre-vapor formulation 22 is too high, the vapor formation at the heater 14 may be too great. This steam overproduction may serve to saturate the air stream exiting the air path 20a, thereby imparting an undesirable taste to the steam that may be vented from the cartridge 70 (or causing the exiting air path 20a to contain a pre-steam formulation 22 that is not properly vaporized, or both). Meanwhile, if the wicking rate of the pre-vapor formulation is too low, then vapor formation at the heater 14 may be too low. This lower steam throughput may cause the steam exiting the drum 70 to not contain a sufficient amount of steam, which is also undesirable.

The sizing of the holes 4a in the inner tube 4 and the total number of holes 4a in the inner tube 4 can be adjusted to also adjust the wicking rate of the wick 28. That is, the total cross-sectional area of the combined number of holes 4a can be adjusted to affect the wicking rate. In an example embodiment, the total cross-sectional area of the apertures 4a may be between about 3.14 square millimeters and 9.42 square millimeters, where this total cross-sectional area may be provided by including four individual apertures 4a in the tube 4, where each tube has a diameter between about 1 millimeter and 4 millimeters, for example, an inner tube diameter of about 4 millimeters to 6 millimeters.

The heater 14 may be in the form of a coil of wire, a planar body, a ceramic body, a single wire, a disk, a cage of resistive wire, or any other suitable form. Further, the heater 14 may also be in the form of a coiled heater or a serpentine heater, as disclosed in both of these patent applications which are hereby incorporated by reference into the present application: U.S. application No. 15/223,857, "Method of Making a Heater for an Electronic Vaping Device (Method of Making an Electronic Vaping Device"), filed by Christopher s.tucker et al on 29/7/2016, "; and U.S. application No. 15/224,866, "Cartridge with Snake Heater and electronic vapor Smoke Device with Serpentine Heater (card and E-Vaping Device with Serpentine Heater)" filed by Shmuel Gavrielov et al on 8.1.2016. The wick 28 may extend longitudinally through the coil of the heater 14, or the wick 28 may otherwise be in communication with the heater 14 so as to allow the heater 14 to vaporize the pre-vapor formulation 22, which pre-vapor formulation 22 may be drawn by the wick 28 toward the heater 14. The core 28 may be constructed of a fibrous and flexible material. The wick 28 may include at least one filament having the ability to draw the pre-vapor formulation 22. For example, the core 28 may comprise a bundle of filaments, which may comprise glass (or ceramic) filaments. In an embodiment, a bundle comprising a set of windings of glass filaments (e.g., three of such windings) may be arranged to form the wick 28 so as to draw the pre-vapor formulation 22 to the heater 14 by capillary action of the interstitial spaces within the filaments.

The pre-vapor formulation 22 may have a boiling point suitable for use in the cartridge 70. If the boiling point is too high, the heater 14 will not be able to vaporize the pre-vapor formulation 22 in the wick 28. However, if the boiling point is too low, the pre-vapor formulation 22 may vaporize without activating the heater 14.

The pre-vapor formulation 22 may comprise a tobacco-containing material that includes volatile tobacco flavorant compounds that are released from the pre-vapor formulation 22 upon heating. The pre-vapor formulation 22 can also be a tobacco flavor-containing material or a nicotine-containing material. Alternatively or additionally, the pre-vapor formulation 22 may include a non-tobacco material. For example, the pre-vapor formulation 22 may include water, solvents, active ingredients, alcohols, plant extracts, and natural or artificial flavors. The pre-vapor formulation 22 may further comprise a vapor smoke former. Examples of suitable vapour forming agents are glycerol, propylene glycol and the like.

Fig. 3 shows an exploded view of a hybrid e-vapor chimney 70 according to an example embodiment. Specifically, FIG. 3 depicts the basic assembly of the elements of the cartridge 70. At a first end of the cartridge 70, the insulator sleeve 15 may be fitted over the live tube 210, wherein the connector 205 may then be fitted over the insulator sleeve 15. One of the electrical leads 26a, 26b (e.g., the cathode electrical lead 26b) may be inserted into the proximal end 205b of the connector 205, while the other of the electrical leads 26a, 26b (e.g., the anode electrical lead 26b) may be connected to the live tube 210. Both electrical leads may be connected to respective ends of the heater.

The center tube 8 may define a bore 8a through the tube 8, wherein the bore 8a may receive the wick 28 and the heater 14. Such a tube 8 may be made of glass fibre, hydrophilic polyethylene oxide or an organic thermoplastic polymer, for example, in order to provide a more robust structure, as such a tube 8 may in essence form a "chimney" structure, which acts as a barrier between the inner annulus 4b and the air path 20 a. An inner layer of gauze 10 and optionally an outer layer of gauze 12 (or even another layer of at least one of gauze and fibers) may be inserted into the inner tube 4. Once the proximal end of tube 210 is inserted through connector 205, inner tube 4 may be slid over charged tube 210.

The outer shell 6 may be fitted over the inner tube 4 and then the mouth-end insert 9 fitted to the proximal end of the shell 6.

Fig. 4 shows the steps of assembling a hybrid e-steam cartridge 70 according to an example embodiment. Note that in this depicted step, the energizing tube 210 has been inserted completely through the connector 205, where the anode electrical lead 26a may be connected to one side of the tube 210 and the cathode electrical lead 26b may be connected to the proximal end 205b of the connector 205. It should be noted that the placement of the electrical leads 26a, 26b extending longitudinally near the outer surface of the charged tube 210 allows the electrical leads 26a, 26b to be contained within the inner tube 4 (see fig. 6 showing the inner tube 4 fitted over the pledgets 10, 12 and the electrical leads 26a, 26 b).

The heater 14 may be inserted into a bore 8a defined by the central tube 8, wherein the wick 28 may be fitted through the coil of the heater 14. The tube 8 and the inner layer of gauze 10 may be slid over the charged tube 210.

Fig. 5 shows another step of assembling a hybrid e-steam cartridge 70 according to an example embodiment. During this step, the distal end of the wick 28 may emanate from the bore 8a of the central tube 8. The inner layer of gauze 10 may then be slid over the proximal end of the tube 8 so that the distal end of the intermediate gauze may be positioned near (but not overlapping) the location of the core 28. The outer scrim 12 may then be fitted over both the inner scrim 10 and the tube 8 such that the outer scrim 12 may encapsulate, or at least partially encapsulate, the inner scrim layer 10.

Note that annular groove 205C may be present near the distal end of the connector. This groove 205C may be used to secure the housing to the connector 205, as explained in more detail in fig. 7 (below).

Fig. 6 shows another step of assembling a hybrid e-steam cartridge 70 according to an example embodiment. In this step, the inner tube 4 may be fitted over each layer of gauze 10, 12, wherein any number of gauze layers may be utilized. It is noted that the effective diameter of the wound gauze layers 10, 12 and the diameter of the inner tube 4 may be coordinated so as to ensure that the inner tube 4 provides a snug fit for the gauze layers 10, 12 so as to mitigate the gauze layers 10, 12 from spreading, unraveling, or spreading and unraveling over time.

Fig. 7 shows another step of assembling a hybrid e-steam cartridge 70 according to an example embodiment. In this step, an adhesive layer (sealant) 7a may be applied to the joint where the inner tube 4 contacts the connector 205. The sealant 7a may be a silicon-based adhesive or another suitable sealant. After pressing the distal end of the inner tube 4 on the proximal end 205b of the connector 205, a sealant 7a may be added to the junction between the inner tube 4 and the connector 205. In an environment where the sealant 7a may be submerged in the pre-vapor formulation 22, the sealant 7a may provide a liquid-impermeable seal between the distal end of the inner tube 4 and the connector 205. The sealant 7a may also help securely affix the distal end of the inner tube 4 to the connector 205.

Another adhesive (sealant) 7b may be applied to the groove 205 before seating the housing 6 on the connector 205. Such adhesive 7b may also be a silicon-based adhesive or another suitable sealant that may securely affix the distal end of the housing 6 to the connector 205, wherein the adhesive 7b may form a liquid-impenetrable seal to mitigate the pre-vapor formulation from escaping the housing 6 at this interface with the connector 205.

Fig. 8 shows another step of assembling a hybrid e-steam cartridge 70 according to an example embodiment. In this step, the pre-vapor formulation 22 may be added to the annular space 6a between the housing 6 and the inner tube 4. It should be appreciated that after the pre-vapor formulation is added within the annular space 6a, the pre-vapor formulation 22 may then flow through the holes 4a in the inner tube 4, allowing the pre-vapor formulation to flow into the inner annular space 4 b. In the annular space 4b, the pre-vapor formulation 22 may become absorbed and permeate through the layers of the pledgets 10, 12.

Fig. 9 shows another step of assembling a hybrid e-steam cartridge 70 according to an example embodiment. In this step, the mouth-end insert 9 may be affixed to the proximal end of the barrel 70. The insert 9 may be affixed by use of an adhesive, mating threads, friction fit, snap fit, ultrasonic welding, or the like. This engagement of the insert 9 with the housing 6 may create a liquid impermeable seal to ensure that the pre-vapor formulation may not escape the confines of the cartridge 70.

The mouth-end insert 9 may optionally be configured to be removed for refilling of the formulation 22 prior to vapor within the cartridge. This may allow the cartridge 70 to be selectively reusable rather than disposable.

Figure 10 shows an e-vaping device 71 having a hybrid e-vaping cartridge 70 according to an example embodiment. In this embodiment, another section 72 may be connected to the barrel 70. The other section 72 may be a power section of the device 71, as shown in more detail in fig. 11 (described below).

In the present embodiment, it is noted that the housing 6 or both the outer shell 6 and the inner tube 4 may be made of a transparent or translucent material. The transparent material, translucent material, or both may be made of glass, acrylic, polycarbonate, quartz, silica, or other suitable material that allows viewing of the interior of the cartridge 70. In particular, the transparent, translucent, or both transparent and translucent nature of the housing 6 (or the housing 6 and the inner tube 4) may allow for the determination of the remaining content of the pre-vapor formulation.

It should be noted that with the presence of the gauze layers 10, 12, and particularly with respect to the relatively thick layers of gauze 10, 12, towards the end of the useful life of the cartridge 70, the cartridge 70 may appear to lack a visible amount of the pre-vapor formulation 22. However, given the absorbent nature of the pledgets 10, 12, the cartridge 70 may continue to operate successfully for a substantially extended period of time despite the lack of any visible presence of the pre-vapor formulation 22.

Figure 11 shows a cross-sectional view of an e-vaping device 71 with a hybrid e-vaping cartridge 70 according to an example embodiment (view '11' of figure 10). The cartridge 70 may be connected to the other section 72, which may be the power section 72, by mating threads 205a, 205 d. Specifically, the power section 72 may include an outer housing 6a, and a male connector 206, which may have threads 205d on the connector 206. The connector 206 may be configured to mate with a female connector 205 that also includes threads 205 a. Other means of connecting the segments 70, 72 may also be used, such as friction fit, snap fit, adhesive, removable pins and at least one of insertable pins, or other suitable means of engaging the segments 70, 72. Further, the power section 72 may be permanently connected to the cartridge 70 such that the power section 72 may be an integral part of the cartridge 70.

The power section 72 may include a power source 1, such as a battery. The battery may be a lithium ion battery or one of its variants, for example a lithium ion polymer battery. Alternatively, the battery may be a nickel-metal hydride battery, a nickel-cadmium battery, a lithium-manganese battery, a lithium-cobalt battery, or a fuel cell. In that case, the power section 72 may be used when the energy in the power source 1 is depleted. Alternatively, the power supply 1 may be rechargeable and contain circuitry that allows the battery to be chargeable by an external charging device. In that case, the circuitry may provide power for a desired (or predetermined) number of puffs when charged, after which the circuitry must be reconnected to an external charging device.

The power supply 1 may have electrical connections 1a, 1b emanating from the power supply 1. For example, the power supply 1 may have an anode connection 1a and a cathode connection 1b that help create a circuit to power the operation of the device 71. For example, the power source 1 may be electrically connected to the sensor 16, and the control circuit 300 may control the operation of the device 71. The control circuit 300 may be disposed on a rigid printed circuit board 302. The circuit board 302 may be connected to a first electrical connection 1a of the power supply 1 by electrical leads 308, and the circuit board 302 may be connected to a second electrical connection 1b by electrical leads 310. The power supply 1 may also send current to the heater 14 of the cartridge 70 (as explained in more detail below).

Upon engaging the sections 70, 72 of the e-vaping device 71, an airflow path may exist to pass the airflow between the sections 70, 72. Specifically, the anode electrical post 78 and the post rod 78a may define an air passageway 78a extending through the post 78. One or more side vents 78b may emanate from the air passageway 78 a. The side vents 78b may be in fluid communication with the air vents 44 and one or more passageways 78c that may exist between the anode posts 78 and the anode terminal 212A of the cartridge 70. The one or more passageways 78c may be in fluid communication with the central air passageway 20.

In the assembled state, the e-vaping device 71 may be formed as an electrical circuit that powers the operation of the device 71. The circuit may include the power source 1, the sensor 16, the control circuit 300, the electrical leads 308, 310, the connector 206 (which may be made of an electrically conductive metal), the electrical lead 26c in electrical contact with both the connector 206 of the power section 72 and the connector 205 of the cartridge 70, and the heater 14 in electrical contact with the connector 205 (through electrical lead 26a) and in electrical contact with the electrical post 78 of the power section 72 (through electrical lead 26a and the live tube 210).

Based on an understanding of the e-vaping device 71 (above), the operation of the assembled device 71 with the mixing drum 70 is explained herein. The airflow through the device 71 may be caused by air being drawn into the cartridge 70 primarily from the air inlet 44, wherein the air may flow through the one or more passages 78c, into the central air passage 20, and into the air passage 20a, wherein the airflow may become entrained by steam generated by the heating of the pre-vapor formulation 22 absorbed by the wick 28 by the heater 14, and then the airflow and entrained steam is discharged from the device 71 at the mouth-end insert 9. Because the passageway 78c may be in fluid communication with the side vents 78b and the air passageway 78a extending through the post 78, the sensor 16 may then be able to detect a vapor smoke condition (discussed below) such that the control circuit 300 may provide current from the power supply 1 to the heater 14. In an embodiment, when activated, heater 14 may heat a portion of wick 28 in less than about 10 seconds.

The flow of air through the device 71 may be used to activate the device 71. Specifically, the sensor 16 may be configured to generate an output indicative of the magnitude and direction of the airflow, wherein the control circuit 300 may receive the sensor 16 output and determine whether the following vaping conditions are present: (1) the direction of airflow indicates suction on the mouth-end insert 9 (as compared to blowing air through the insert 9), and (2) the magnitude of airflow exceeds a threshold. If these internal vapor smoke conditions of the device 71 are met, the control circuit 300 may electrically connect the power source 1 to the heater 14, thus activating the heater 14. That is, the control circuit 300 may electrically connect the first lead 310 with the electrical connection 1b (e.g., by activating a heater power control transistor forming part of the control circuit 300) so that the heater 14 may become electrically connected to the power supply 1. In an alternative embodiment, the sensor 16 may generate an output indicative of a voltage drop thereacross, and the control circuit 300 may activate the heater 14 in response thereto.

In an embodiment, the control circuit 300 may also include a light 304 that the control circuit 300 may activate to emit light when the heater 14 is activated, when the power supply 1 is recharged, or both. The light 304 may comprise one or more Light Emitting Diodes (LEDs). The LEDs may comprise one or more colors (e.g., white, yellow, red, green, blue, etc.). Further, the light 304 may be arranged to be visible by an adult vaper during smoking of the vaping, wherein the light 304 may be positioned near an end cap 306 of the power section 72 of the e-vaping device 71. The light 304 may also be used for e-vaping system diagnostics. The light 304 may also be configured such that an adult vaper may activate, deactivate, or both activate and deactivate the heater activation light 304 for privacy.

In an embodiment, the control circuit 300 may include a time period limiter. In another example embodiment, the control circuit 300 may include a manually operable switch for an adult vaper to initiate heating. The time period for which current is supplied to the heater 14 may be set or preset depending on the amount of pre-vapor formulation 22 that is desired to be vaporized.

Having thus described the example embodiments, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the intended scope of example embodiments, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.