METHOD OF FORMING CONNECTOR WITH FLANGE AND SHAFT

Abstract

The method includes first defining a longitudinal channel in a major body, the major body including a first portion, a second portion and a flange, the flange being located between the first portion and the second portion, the longitudinal channel traversing through a longitudinal length of the major body from the first portion through the second portion, the first portion including a shaft, and second defining a first side end of the flange, the first side end at least partially defining a first segment of at least one first airflow inlet, the first segment being in communication with the longitudinal channel.

Claims

1. (canceled)

2. A method of forming a connector, comprising: first defining a longitudinal channel in a major body, the major body including a first portion, a second portion and a flange, the flange being located between the first portion and the second portion, the longitudinal channel traversing through a longitudinal length of the major body from the first portion through the second portion, the first portion including a shaft; and second defining a first side end of the flange, the first side end at least partially defining a first segment of at least one first airflow inlet, the first segment being in communication with the longitudinal channel.

3. The method of claim 2, wherein the first side end faces the first portion.

4. The method of claim 3, wherein the second defining defines a step that faces the shaft, a part of the step at least partially defining the first segment.

5. The method of claim 3, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being in communication with the first segment and the longitudinal channel.

6. The method of claim 3, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being between the first segment and the longitudinal channel.

7. The method of claim 5, wherein the third defining defines such that the second segment is an aperture that is at least partially defined within a sidewall of the shaft.

8. The method of claim 5, wherein the at least one first airflow inlet includes a first airflow inlet and a second airflow inlet, and the second defining defines a step that at least partially defines the first segment for the at least one first airflow inlet and the second airflow inlet.

9. The method of claim 8, wherein the third defining defines the second segment of the first airflow inlet and the second airflow inlet within the shaft, the second segment of the first airflow inlet and the second airflow inlet being evenly spaced apart along a circumference of the shaft.

10. The method of claim 2, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft.

11. The method of claim 10, wherein the third defining defines such that the second segment is an aperture that is at least partially defined within a sidewall of the shaft.

12. The method of claim 10, wherein the third defining defines the second segment to be in communication with the first segment and the longitudinal channel.

13. The method of claim 11, wherein the at least one first airflow inlet includes a first airflow inlet and a second airflow inlet, and the second defining defines the first segment of the first airflow inlet and the second airflow inlet with the first side end of the flange, the first airflow inlet and the second airflow inlet being in communication with the longitudinal channel.

14. The method of claim 13, wherein the third defining defines the second segment of the first airflow inlet and the second airflow inlet within the shaft, the second segment of the first airflow inlet and the second airflow inlet being in communication with the first segment of the first airflow inlet and the second airflow inlet, respectively, the second segment of the first airflow inlet and the second airflow inlet being evenly spaced apart along a circumference of the shaft.

15. The method of claim 2, wherein a first diameter of the first portion of the major body is smaller than a second diameter of the second portion of the major body, and a third diameter of the flange is larger than the second diameter.

16. The method of claim 2, further comprising: connecting a first section to a second section with the connector to form an assembled e-vaping device, the first section and the second section being e-vaping elements.

17. The method of claim 16, wherein the second defining defines a step that faces the shaft, a part of the step defining the first segment, the first side end facing the first portion.

18. The method of claim 16, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being fluidly connected to the first segment and the longitudinal channel within the assembled e-vaping device.

19. The method of claim 18, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the first segment and the second segment fluidly connecting the longitudinal channel to ambient air within the assembled e-vaping device.

20. The method of claim 16, wherein the connecting connects such that a first external surface of the flange forms a portion of an outer surface of the assembled e-vaping device.

21. The method of claim 20, wherein the connecting connects such that the second portion and the first portion of the major body fits at least partially within a first end of the first section and a second end of the second section, respectively, and a second side edge of the second end of second section further defines the first segment of the at least one first airflow inlet.

22. The method of claim 21, further comprising: third defining a second segment of the at least one first airflow inlet within the shaft, the second segment being in fluid communication with the first segment and the longitudinal channel once the first section is connected to the second section with the connector.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0017] FIG. 1 is an assembled view of a typical two-piece electronic cigarette.

[0018] FIG. 2 is a disassembled view of a typical two-piece electronic cigarette.

[0019] FIG. 3 is a cross-sectional view of an electronic cigarette in the prior art showing inhaled and exhaled air paths.

[0020] FIG. 4 is a cross-sectional view of an electronic cigarette using the novel connector herein described showing inhaled and exhaled air paths.

[0021] FIGS. 5-13 are alternative embodiments of the connector of the present invention showing various arrangements of side vent apertures.

[0022] FIGS. 14-15 illustrate an alternative embodiment of a connector of the present invention with a battery post of the present invention.

[0023] FIG. 16 is a cross-sectional view of an electronic cigarette using the connector and battery post shown in FIGS. 13-15.

[0024] FIG. 17 illustrates an alternative embodiment of a battery post of the present invention.

[0025] FIG. 18 is a cross-sectional view of an electronic cigarette using the connector of FIG. 13 and the battery post of FIG. 17.

DETAILED DESCRIPTION

[0026] The present invention concerns various embodiments of a Battery-Cartomizer connector for an Electronic Cigarette that creates an air-intake path that enters through the male connector (i.e. the Battery section), without the need to modify the female connector (i.e. the Cartomizer section) thereof. Accordingly, the present invention permits flexibility of design and product diversification for the E-cigarette manufacturer, maintains ease of manufacture and mass-production, and creates additional advantages such as reducing noise and hissing during air-intake (i.e. a puff or drag).

[0027] FIGS. 5-13 depict various embodiments of the connector of the present invention. It is understood that these figures depict a sectional view of an E-cigarette connector 1, which joins the Battery section to the Cartomizer section by a threaded engagement. As shown in FIGS. 5-13, it is intended that the male Battery connector M at the proximal end 3 of the connector mates to a female portion of a Cartomizer, and the distal end 5 of the connector is attached, through a pressure or friction fit, or through other suitable means, to the Battery portion B (not shown) and functions as a cap thereof.

[0028] In some embodiments of the present invention, an air intake path starts at the outer circumference of the connector 1 between the Battery and the Cartomizer of the E-cigarette, running inside notch 9 on connector 1. The air is thus brought into the Battery through grooves 10 formed on the attachment (i.e., non-threaded) distal end 5 of the connector. Once inside the battery, the air path loops around and exits the Battery housing towards the Cartomizer, via a hole along the central axis of connector 1. In accordance with the desired air-intake path, notch 9 is cut out on the side of connector 1 at strategic location and with strategic geometry.

[0029] In most E-cigarettes, connector 1 has a flange 7 that appears from the outside as a metallic ring when the separate parts of the E-cigarette are screwed together, like that shown in FIG. 1. The resulting ring is usually very thin, and has little purpose other than cosmeticto create a decorative divider between the two major parts of the E-cigarette (i.e. the Battery section and the Cartomizer section) and to cover the inside edge of the Battery housing. Cutting into this ring or removing a portion of it to create the desired air-intake characteristics of the present invention would expose the dull edge of the Battery housing and detracts from the esthetics of the product. However, in some embodiments of the present invention, the thickness of the flange is increased so that a portion of it can be cut or milled away, resulting in notch 9, while the remaining portion of the flange thickness will still retain the aesthetic design and still cover the internal edge of the housing.

[0030] Accordingly, as shown in FIG. 5, in some embodiments of connector 1, notch 9 begins at the outer perimeter of the flange 7, toward distal end 5 and travels toward the center axis of flange 7, resulting in a rectangular shape.

[0031] In some embodiments, such as in FIG. 6, aperture 11 is bored through the wall of the distal end 5 of connector 1 at substantially the same radial location as notch 9. This configuration increases the air-intake volume, permitting less-constricted air flow through the connector 1 and the Battery section.

[0032] In some embodiments, such as in FIG. 7, slot 13 is milled along the curved wall of the distal end 5 of connector 1, with notch 9 located substantially across from the center of slot 13, radially. As shown, slot 13 is oriented perpendicular to the longitudinal axis of connector 1.

[0033] In some embodiments, such as in FIG. 8, channel 15 is milled across the outer surface of the distal end 5 of connector 1, beginning at notch 9 and terminating at the end of distal end 5. In this configuration, notch 9 has a substantially curved profile that transitions uniformly into channel 15. In this configuration, channel 15 is milled substantially parallel to the longitudinal axis of connector 1.

[0034] In some embodiments, such as in FIG. 9, fanned channel 17 is milled across the outer surface of the distal end 5 of connector 1, beginning at notch 9 and terminating at the end of distal end 5. Notch 9 has a substantially curved profile that transitions into fanned channel 17. Fanned channel 17 is milled substantially parallel to the longitudinal axis of connector 1.

[0035] In some embodiments, such as in FIG. 10, channel 19 is milled away all around the outer circumference of flange 7, along its distal edge. The purpose of channel 19 is to allow for air intake even when a user happens to hold his finger over notch 9 during smoking. When that happens, air enters channel 19 and runs along the channel until it reaches and enters notch 9.

[0036] In some embodiments, such as in FIG. 11, channel 21 is milled away all around the outer circumference of flange 7, substantially in the middle of the flange. Several apertures 23 are bored through the wall of the flange. The purpose of channel 21 is to allow for air intake even when a user holds his finger over an aperture 23 during smoking. When that happens, air enters channel 21 and runs along the channel until it reaches and enters an aperture 23.

[0037] In some embodiments, such as in FIG. 12, notch 25 is cut out through the wall of flange 7 on the side of connector 1 at strategic location and with strategic geometry. Slot 27 is cut out of the distal end 5 of connector 1, beginning at notch 25 and terminating at the end of distal end 5. In this configuration, notch 25 has a rectangular profile that transitions uniformly into slot 27.

[0038] Another embodiment of the connector of the present invention is shown in FIGS. 13-15. FIG. 13 shows the connector without a battery post, FIG. 14 shows the battery post and FIG. 15 shows the battery post and connector assembled. As shown in FIG. 13, instead of a notch in the outer perimeter of the flange 7, toward distal end 5, perpendicular surface channels 30 are drilled on shelf 31 of flange 7. The channels continue and penetrate through the shaft 32 of connector 1 (in which threads are not shown for purposes of clarity) at orifices 33 and continue through inner shelf 45. The engaging battery post 34, shown in FIG. 14, includes a longitudinal orifice 35 (beginning on the surface of post head 37 and continuing longitudinally completely through the post) that forms the pressure differential channel, as well as a groove 36 which assists in guiding air inhaled or exhaled through perpendicular surface channel 30 and orifice 33.

[0039] It should be noted here that although in FIG. 15 groove 36 is shown aligned with perpendicular surface channel 30 and orifice 33, because the outer diameter of post head 37 is smaller than the inner diameter of shaft 32, such alignment is not necessary to allow for unimpeded air flow through connector 1.

[0040] The airflow 104 through the connector and battery post combination shown in FIGS. 13-15 is illustrated in FIG. 16. As shown in FIG. 16, one possible draw-back of this arrangement is that upon exhalation, any excess fluid 116 (vapor, saliva, etc.) could be blown through orifice 35, into the pressure differential channel and into the Battery B.

[0041] An alternative embodiment for a battery post designed to minimize this problem is shown in FIG. 17. As shown in this figure, there is no orifice drilled through post head 37. Rather, the air path to the pressure differential channel is created by channel 38 which is drilled beneath groove 36 on the side 39 of post head 37. Channel 38 perpendicularly intersected by the pressure differential channel (not shown) which is drilled longitudinally from battery post end 40.

[0042] The airflow through a connector such as that shown in FIG. 13 using the battery post shown in FIG. 17 is illustrated in FIG. 18. As is shown in this figure, there is no direct path for excess liquid 116 to migrate into the Battery compartment B.

[0043] The connector 1 of the present invention has an additional major advantage in that those embodiments shown in FIGS. 5-18 allow for a substantially silent air-intake without the excessive hissing or noise associated with other known E-cigarettes. Another major advantage of the present invention is its application in newly introduced V-Go and E-go (large-capacity electronic cigarettes) E-cigarettes. V-go and E-go E-cigarettes, which almost always have a side-intake, cannot be used with non-vented female Cartomizers. Heretofore manufacturers always had to resort either to vented female Cartomizers or non-vented male Cartomizers. However, with the present invention, it is possible to create V-go and E-go E-cigarettes that will be interchangeable with Tip-Intake E-cigarettes so that they are compatible with the same existing female unvented Cartomizers, without the need to modify the Cartomizers.

[0044] It should be appreciated that although the above-described embodiments demonstrate that some embodiments of the present invention are designed such that the Battery comprises the male connection and the Cartomizer comprises the female connection, the reverse configuration may be equally suitable, depending on design requirements. Accordingly, the Cartomizer may comprise the male connection and the Battery may comprise the female connection.

[0045] It will be understood that the preferred embodiments of the present invention have been disclosed by way of example and that other modifications and alterations may occur to those skilled in the art without departing from the scope of the disclosure herein.