Vaping Pod with Pressure Regulator Protection

Abstract

To avoid e-liquid being expelled from a pod due to air pressure differentials between the interior and exterior of a pod, a pressure regulator such as a valve can be introduced into the pod. To prevent e-liquid moving adjacent to the pressure regulator and being expelled during pressure regulation, a barrier impermeable to the e-liquid is introduced into the pod to prevent movement of the e-liquid. This barrier may be air permeable and e-liquid impermeable, and may in some embodiments take the form of a mesh with apertures small enough that the surface tension of the e-liquid does not permit movement of the e-liquid through the mesh under normal circumstances.

Claims

1. A pod for storing an atomizable e-liquid for use in a vaping system, the pod comprising: a reservoir for storing the e-liquid; a pressure regulator within the reservoir for allowing equalization of pressure inside the reservoir with pressure outside the reservoir; and a membrane, impermeable to the e-liquid in at least one direction, positioned within the reservoir to allow for separation of the e-liquid from an air pocket within the reservoir, and for keeping the air pocket within the reservoir within fluid communication with the pressure regulator.

2. The pod of claim 1 wherein the e-liquid comprises at least one of vegetable glycerine, propylene glycol, nicotine and a flavoring.

3. The pod of claim 1 wherein the e-liquid comprises a cannabinoid.

4. The pod of claim 1 wherein the pressure regulator allows an air pressure within the reservoir to be regulated down to an air pressure outside the reservoir.

5. The pod of claim 1 wherein the pressure regulator is a vent.

6. The pod of claim 1 wherein the pressure regulator is a valve for allowing air to flow from inside the reservoir to outside the reservoir.

7. The pod of claim 1 wherein the membrane is permeable to air.

8. The pod of claim 1 wherein the membrane is positioned within the reservoir at a level at or above the level of the e-liquid stored within the pod.

9. The pod of claim 1 wherein the membrane is permeable to the e-liquid in one direction, and impermeable to the e-liquid in the other direction.

10. The pod of claim 9 wherein the membrane is impermeable to the e-liquid in the direction of the pressure regulator.

11. The pod of claim 1 wherein the membrane is formed of filaments spaced apart no greater than a threshold distance.

12. The pod of claim 11 wherein the threshold distance is determined in accordance with physical properties of the e-liquid.

13. The pod of claim 12 wherein the physical properties include at least one of a density of the e-liquid, a viscosity of the e-liquid and a surface tension of the e-liquid.

14. The pod of claim 11 wherein the threshold distance is determined in accordance with at least one of a maximum storage temperature and a volume of e-liquid to be stored in the reservoir.

15. The pod of claim 1 wherein the membrane is impermeable to the e-liquid in at least one direction under a defined set of conditions.

16. A vaping device for atomizing an atomizable liquid, the device comprising: a battery for storing power; control circuitry for controlling the delivery of power from the battery to a heater engaged with a wick; a reservoir for storing the e-liquid for delivery to the wick; a pressure regulator within the reservoir for allowing equalization of pressure inside the reservoir with pressure outside the reservoir; and a membrane, impermeable to the e-liquid in at least one direction, positioned within the reservoir to allow for separation of the e-liquid from an air pocket within the reservoir, and for keeping the air pocket within the reservoir within fluid communication with the pressure regulator.

16. The vaping device of claim 15 wherein the e-liquid comprises at least one of vegetable glycerine, propylene glycol, nicotine and a flavoring.

17. The vaping device of claim 15 wherein the e-liquid comprises a cannabinoid.

18. The vaping device of claim 15 wherein the pressure regulator is one of a vent and a valve for allowing air to flow from inside the reservoir to outside the reservoir.

19. The vaping device of claim 15 wherein the membrane is permeable to the e-liquid in one direction, and impermeable to the e-liquid in the other direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Embodiments of the present invention will now be described in further detail by way of example only with reference to the accompanying figure in which:

[0025] FIG. 1A is a front view of a prior art pod for use in an electronic nicotine delivery system;

[0026] FIG. 1B is a side view of the pod of FIG. 1A;

[0027] FIG. 1C is a bottom view of the pod of FIG. 1A;

[0028] FIG. 2 is a cross section of the pod of FIGS. 1A and 1B along cut line A in FIG. 1B;

[0029] FIG. 3 is a cross section of a prior art pod with a pressure regulator;

[0030] FIG. 4 is a cross section of an alternate prior art pod design with a pressure regulator;

[0031] FIG. 5 is a cross section of a pod having a pressure regulator and a membrane for separating e-liquid from an air bubble;

[0032] FIG. 6 illustrates the pod of FIG. 5 inverted;

[0033] FIG. 7 is a cross section of an alternate design of a pod having a pressure regulator and a membrane for separating e-liquid from an air bubble;

[0034] FIG. 8 illustrates a cross section of the pod of FIG. 7 taken along cut line B in FIG. 7;

[0035] FIG. 9A illustrates an example of a membrane preventing movement of an e-liquid in one direction; and

[0036] FIG. 9B illustrates the membrane of FIG. 9A allowing movement of e-liquid across the membrane in the other direction.

[0037] In the above described figures like elements have been described with like numbers where possible.

DETAILED DESCRIPTION

[0038] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. Disclosure of numerical range should be understood to not be a reference to an absolute value unless otherwise indicated. Use of the terms about or substantively with regard to a number should be understood to be indicative of an acceptable variation of up to ±10% unless otherwise noted.

[0039] As noted earlier, the addition of valves of various types have been disclosed with respect to addressing the problems associated with pressure relief within a pod. Because the valve should permit flow of trapped air, but should not allow e-liquid to be exhausted, valved pods are often recommended for shipping in a defined orientation, so that the air pocket is adjacent to the valve. However, for a conventional pod without a valve, shipping the pod in an orientation that keeps the air pocket between e-liquid and the end cap may also find success as expansion of the air pocket is more likely to push air out of the pod instead of pushing e-liquid out. However, even if packed in a specific orientation, it should be understood that pods are likely to be moved around during transit, and there is no guarantee that a pod will end up in the orientation that is indicated as correct (e.g. a container labelled “This Side Up” may not in fact spend most of its shipping time with the indicated side facing up.)

[0040] In embodiments of the present invention, a mechanism is provided to ensure that the air pocket and valve are maintained in a configuration so that they are adjacent to each other regardless of the orientation of the pod. This is done through the introduction of a barrier within the pod that is located at or above the level at which the e-liquid should reach in a filled pod. This barrier is preferably permeable to air, but largely impermeable to the e-liquid. This mix of permeabilities with respect to the two fluids allows the fixed position of the valve to be adjacent to an air pocket at all times. This allows the venting of air from the air pocket so that pressure can be equalized between the interior and exterior of the pod.

[0041] FIG. 5 illustrates a cross section view of a pod 100 of an embodiment of the present invention. Pod 100 is comprised of a reservoir 102 which defines a post-wick airflow passage 104 and an end cap 106. The end cap 106 defines wick feedlines 108 that allow for e-liquid stored within reservoir 102 to flow into end cap 106. Between end cap 106 and the walls of reservoir 102 are seals 110, that in some embodiments are implemented as o-rings or other resilient seals. Electrical contacts 112 allow for an electrical connection to a vaping device that allows for power to be delivered across electrical contacts 112 and through the heater 120. Aligned with the post-wick airflow passage 104 is a pre-wick airflow passage 114 (in this illustrated embodiment, but it should be understood that this vertical alignment is not essential and is only specific to this discussed embodiment). Air can enter a filled pod through pre-wick airflow passage 114, and enter into atomization chamber 116. Within the atomization chamber is a segment of wick 118, which extends across the atomization chamber and ends in the wick feed lines 108. This allows wick 108 to be in fluid contact with the e-liquid within the reservoir. Wick 118 draws e-liquid across from the feedlines 108 towards the center of the wick 118, which is generally aligned with an airflow path through pre-wick airflow passage 114, the atomization chamber 116 and the post wick airflow passage 104. The wick 118 is also in contact with heater 120, and when power is delivered across electrical contacts 112, the heater 120 atomizes e-liquid carried across wick 116. The atomized e-liquid is entrained in an airflow and continues into post wick airflow passage 104 for delivery to the user.

[0042] As before, above e-liquid 122 is an air pocket 124, as well as a valve 126. The particular implementation of valve 126 is not necessarily germane to the following discussion so long as it allows outflow of liquids when the pressure inside the pod exceeds the pressure outside the pod by a cracking pressure associated with the valve 126. The valve 126 may be implemented in any of a number of different fashions as would be understood by those skilled in the art. Additionally, a membrane 128 is positioned inside reservoir 102 at a level at or above the level of e-liquid 122. Membrane 128 is designed to be permeable to air, but largely impermeable to the e-liquid. This means that the membrane 128 will allow air to pass through it (in either direction) and it will resist the passage of the e-liquid through the membrane in at least one direction. It should be noted that the membrane being completely impermeable to the e-liquid in either direction is not a requirement, and as such, while the positioning of the membrane 128 has been described as being at or above the level of the e-liquid within the reservoir 102 is optional. In some embodiments, membrane 128 may have pores that are small enough so that e-liquid 122 cannot pass through, but large enough to allow air from the air pocket 124 to pass through. Depending upon the viscosity and other characteristics of the e-liquid in question, this may allow membrane 128 to be implemented as a screen.

[0043] FIG. 6 illustrates the pod 100 of FIG. 5 in an inverted orientation. The e-liquid 122 within reservoir 102 falls towards the mouthpiece end of pod 100. It rests atop membrane 128 as the membrane is impermeable to the e-liquid (at least in the illustrated direction). Below membrane 128, air pocket 124 is maintained. Valve 126 is in fluid communication with air pocket 124 and not with e-liquid 122. This allows any over pressurization of the inside of reservoir 102 to be vented safely without expelling e-liquid. It should be understood that there may be a second air pocket 130 that is formed at the top of the e-liquid 124. Over pressurization of air pocket 130 can be safely accommodated by venting through the feed lines 108, the wick and either of pre-wick airflow passage 114 or post wick airflow passage 104. Thus, membrane 128 prevents e-liquid from migrating into an area adjacent to the valve 126, allowing for valve 126 to allow for regulation of the pressure within reservoir 102 without expelling e-liquids.

[0044] In some embodiments, the outward face of valve 126 can be covered by an absorbent material, such as cotton. This absorbent material may be the absorbent pad illustrated in FIG. 1. This would further protect from valve 126 expelling e-liquid in an unexpected situation.

[0045] The membrane 126 can be formed in any of a number of different fashions, as will be explained in discussions of subsequent figures. But, at this moment it is important to understand that the membrane 126 should prevent movement of the e-liquid across the membrane in the direction of the valve 126. In the disclosed embodiments of FIGS. 5 and 6, the membrane 126 permits air to pass through the membrane in both directions. This allows for an air bubble that straddles both sides of the membrane to have its air pressure consistent in both sections. If the membrane can be designed so that it allows e-liquid 122 to pass through the membrane in the direction away from the valve 126, this allows e-liquid 122 to be effectively drained into the larger volume of e-liquid 122 through the use of the pod 100.

[0046] FIG. 7 illustrates an embodiment of an alternate design of the pod 100. In place of seals 110, pod 100 in FIG. 7 makes use of a resilient cap 134 that engages with end cap 106 to provide a sealing interface between the end cap 106 and reservoir 102. In some embodiments, resilient cap 134 is formed from silicone and is compressible so that it is distorted when end cap 106 is inserted into reservoir 102. This distortion of the resilient cap 134 provides a high degree of sealing to prevent egress of e-liquid from the endcap-reservoir interface. Airflow feature 132 can optionally be included in the post wick airflow passage 104 or within the resilient cap 134, as illustrated in this embodiment. In some embodiments, the airflow feature 132 may be a blunt shaped object, such as a rod perpendicular to the airflow path. This optional airflow feature 132 can induce turbulence in the airflow which may result in vortices forming in the post wick airflow path 104 that encourage droplets over a threshold size to be directed into the walls of the post wick airflow path 104. Valve 126 and membrane 128 are situated within the reservoir, at the mouthpiece end distal to the end cap 106. As with the previously described figures, the air bubble within pod 100 may be divided into two air pockets when the pod 100 is stored within this inverted position. The air pocket 124 is kept at the mouthpiece end of pod 100 due to the presence of membrane 128, while air pocket 130 can migrate through the pod 100 with changes in the orientation of pod 100. Valve 126 is maintained in fluid communication with air pocket 124 in all orientations as a result of the placement of membrane 128. Also shown in FIG. 7 is a cut line B, that defines the perspective position used to show the cross section illustrated in FIG. 8.

[0047] FIG. 8 is a cross section view of pod 100 (shown without e-liquid) along section line B in FIG. 7. From this view, pod 100 has a reservoir 102 and post wick airflow passage 104, along with membrane 128. The membrane is mounted so that it connects with the sidewalls of reservoir 102. The illustrated embodiment of membrane 128 is a mesh made of filaments 136 with an interfilament spacing 138. Although illustrated here with just horizontal and vertical filaments 136, it should be understood that other patterns can be used as well. Furthermore, there is no requirement for the vertical and horizontal filaments to be the same diameter or have other similar characteristics. The interfilament spacing 138 has a maximum size that is determined in accordance with physical characteristics of the e-liquid being used within pod 100. The surface tension of the e-liquid defines a minimum size of aperture through which the e-liquid can pass in accordance with a number of factors including an expected temperature range and the mass of the e-liquid that will be supported on membrane 128. When these factors are taken into account, a maximum interfilament spacing can be determined that prevents the movement of the e-liquid across the membrane 128 under a set of expected conditions. Thus, in operation, if e-liquid resides on one side of the membrane, even under the weight of the entire allotment of a full pod, the e-liquid will not pass through the membrane 128, allowing the air pocket to remain adjacent to the valve.

[0048] FIGS. 9A and 9B illustrate an embodiment of membrane 128. Instead of embodiments in which the membrane is symmetrical on either side, this embodiment of membrane 128 is directional. As shown in FIG. 9A, filaments of the membrane are formed so that they have two different faces. In the illustrated embodiment, membrane 128 has triangular filaments that allow air 125 or other gasses to pass through membrane 128 in both directions. As shown in FIG. 9A, a mass of e-liquid 122 can pass through the membrane 128 in one orientation. The e-liquid 122 is able to come through the membrane 128 as droplets, which can reduce the amount of the e-liquid above the membrane 128.

[0049] In FIG. 9B, the membrane has been inverted, and due to the asymmetry of the filaments within membrane 128, the e-liquid 122 has too much surface tension to allow for passing through the membrane 128 in this direction. As such, membrane 128 is able to prevent movement of the e-liquid 122 in one direction but it also can allow movement of the e-liquid across the membrane in the other direction. Use of such a membrane 128 would allow for the placement of the membrane 128 within pod 100 at or below the fill level of the e-liquid. As e-liquid is used, the e-liquid would be drained and would migrate to below the membrane 128. Over pressurization of the pod 100 could still be prevented through the use of valve 126, with the understanding that this would find its greatest effect after the pod 100 had been used and e-liquid level had dropped below the level of the membrane 128.

[0050] In the above embodiments valve 126 has been discussed as a mechanism to allow for the regulation of pressure between the inside and outside of reservoir 102 in pod 100. It should be noted that so long as the membrane is sufficiently impermeable to the e-liquid, valve 126 could be replaced by a vent. This would function as a perpetually open valve, and would avoid over pressurization of the reservoir. It should be understood that this may have some effects including an increased rate of oxidation of the e-liquid, but this may be offset by an ease of implementation. Thus, a vent or a valve may be used as a pressure regulator within the pod 100. Thus, the pressure regulator and membrane, allow a pod to equalize pressure between the air pocket separated from the e-liquid by the membrane through the pressure regulator.

[0051] It should also be understood that while discussed above within the context of a pod for use with a distinct vaping device, the above embodiments may also be employed in disposable devices that integrate the reservoir and heating systems within a device that does not use a replaceable pod. In discussing such devices it should be understood that an integrated pod may simply be referred to as by its constituent components. It should also be understood that although the above descriptions have addressed pre-filled pods, some of the above described embodiments may be used in systems that make use of refillable pods which have a port that allows for user refilling of the reservoir.

[0052] Although presented below in the context of use in an electronic nicotine delivery system such as an electronic cigarette (e-cig) or a vaporizer (vape) it should be understood that the scope of protection need not be limited to this space, and instead is delimited by the scope of the claims. Embodiments of the present invention are anticipated to be applicable in areas other than ENDS, including (but not limited to) other vaporizing applications.

[0053] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. The sizes and dimensions provided in the drawings are provided for exemplary purposes and should not be considered limiting of the scope of the invention, which is defined solely in the claims.