WO2024031104A1 - Systems and methods for optimizing heating in an aerosol generating system - Google Patents
Systems and methods for optimizing heating in an aerosol generating system Download PDFInfo
- Publication number
- WO2024031104A1 WO2024031104A1 PCT/US2023/071800 US2023071800W WO2024031104A1 WO 2024031104 A1 WO2024031104 A1 WO 2024031104A1 US 2023071800 W US2023071800 W US 2023071800W WO 2024031104 A1 WO2024031104 A1 WO 2024031104A1
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- assembly
- consumable
- heating element
- aerosol
- layer
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Classifications
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- A61M2207/00—Methods of manufacture, assembly or production
Definitions
- the present disclosure generally relates to the field of aerosol generation.
- the present disclosure is directed to systems and methods for optimizing heating in an aerosol generating system.
- Smoking and inhaling aerosolized substances is a commoditized activity for many users. Most methods of heating tobacco, cannabis, or the like using heat-not-burn devices are inefficient due to their use of insulating material optimized for combustion heating methods. While electronic aerosol generating systems can be integrated into electronic devices to enable inhalation-based delivery of cannabis components, nicotine, and other substances in more efficient and less wasteful manners, the complications of integrating electronics to stimulate smoking can pose risk in the aerosolization of certain substances and the safe inhalation of such substances.
- an apparatus includes a heater assembly configured to be disposed proximate to a consumable.
- the heater assembly includes a set of heating elements, a processor operatively coupled to each heating element of the set of heating elements, and a memory operatively coupled to the processor.
- the memory stores instructions to cause the processor to receive a request for delivering an aerosol of the consumable, the request including at least one of a user preference and a desired amount of the aerosol of the consumable, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable so as to produce varying amounts of the aerosol based on the request.
- a system includes a consumable assembly and a heater assembly.
- the consumable assembly includes at least one segment, the at least one segment including a consumable material.
- the heater assembly includes at least one heating element, the at least one segment of the consumable assembly being in direct contact with the at least one heating element.
- the heater assembly further includes a controller operatively coupled to the at least one heating element.
- the controller is configured to receive a request for an aerosol of the consumable material, the request including at least one of a user preference and a desired amount of the aerosol of the consumable.
- the controller is also configured to activate the at least one heating element to heat the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
- a system includes a pen assembly and a cartridge assembly.
- the cartridge assembly is configured to be removably coupled to the pen assembly.
- the pen assembly includes a heater assembly, the heater assembly including a set of heating elements.
- the pen assembly further includes a controller operatively coupled to the heater assembly.
- the cartridge assembly includes a container defining an airflow path and a consumable assembly disposed in the container, the consumable assembly including a consumable material.
- the cartridge assembly is configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly.
- the controller of the pen assembly is configured to receive a pressure data from a draw sensor disposed in the pen assembly and receive a preference input from a control interface provided in the pen assembly.
- the controller is further configured to selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
- a system includes a cartridge assembly and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly.
- the cartridge assembly includes a consumable assembly including at least one segment, where the consumable assembly includes a consumable material.
- the cartridge assembly includes at least one heating element in direct contact with the at least one segment of the consumable assembly.
- the pen assembly includes a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly.
- the pen assembly further includes a controller operatively coupled to the heater assembly, the controller configured to receive a request for an aerosol of the consumable material, the request including at least one of a user preference and a desired amount of the aerosol of the consumable.
- the controller is also configured to selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
- the techniques described herein relate to an apparatus, including: a heater assembly configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element; a processor operatively coupled to each heating element of the set of heating elements; and a memory operatively coupled to the processor, the memory storing instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
- the techniques described herein relate to a system, including: a consumable assembly including at least one segment, the at least one segment including a consumable material; and a heater assembly including: a first heating element and a second heating element, the first heating element and the second heating element being in thermal communication with the at least one segment including a consumable material, and a controller operatively coupled to the at least one heating element, the controller configured to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
- the techniques described herein relate to a system, including: a pen assembly, including: a heater assembly, the heater assembly including a set of heating elements, and a controller operatively coupled to the heater assembly; a cartridge assembly configured to be removably coupled to the heater assembly, the cartridge assembly including: a container defining an airflow path and a heater chamber, and a consumable assembly disposed in the container, the consumable assembly including a consumable material, the cartridge assembly configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly, and the controller being configured to: receive a pressure data from a draw sensor disposed in the pen assembly, receive a preference input from a control interface provided in the pen assembly, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
- a pen assembly including: a heater assembly, the heater assembly including
- the techniques described herein relate to a system including: a cartridge assembly, including: a consumable assembly including at least one segment, the consumable assembly including a consumable material, and at least one heating element being in direct contact with the at least one segment of the consumable assembly; and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly, the pen assembly including: a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly, and a controller operatively coupled to the heater assembly, the controller configured to: receive a request for an aerosol of the consumable material, the request including a user preference or a desired amount of the aerosol of the consumable, and selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
- the techniques described herein relate to a system, including: an electrically-conductive layer having a first side and a second side opposite the first side; a first aerosol-substance generating layer having a first side and a second side opposite the first side, the first side of the first aerosol-substance generating layer disposed in contact with the first side of the electrically-conductive layer; a second aerosol-substance generating layer having a first side and a second side opposite the first side, the second side of the second aerosol-substance generating layer disposed in contact with the second side of the electrically- conductive layer; a first membrane layer disposed on the second side of the first aerosolsubstance generating layer; and a second membrane layer disposed on the first side of the second aerosol-substance generating layer.
- the techniques described herein relate to a system, including: a first rolling assembly configured to dispose a portion of a continuous elongated first aerosolsubstance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; a second rolling assembly configured to dispose a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; a tube-forming assembly configured to transition the second planar layered assembly into a continuous tubular layered assembly; and a cutting assembly configured to separate the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
- the techniques described herein relate to a method, including: disposing a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; transitioning the second planar layered assembly into a continuous tubular layered assembly; and separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
- FIG. 1 is a schematic block diagram of an aerosolization system, according to an embodiment.
- FIG. 2 is a schematic illustration of a portion of a heater assembly including a set of heating elements disposed proximate to a portion of a consumable assembly, according to an embodiment.
- FIG. 3A is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3B is a side cross-section view of the consumable assembly of FIG. 3 A taken along the line A-A in FIG. 3 A.
- FIG. 3C is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3D is a side cross-section view of the consumable assembly of FIG. 3C taken along the line B-B in FIG. 3C.
- FIG. 3E is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3F is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3G is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3H is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 31 is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3J is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 3K is a schematic illustration of a consumable assembly, according to an embodiment.
- FIG. 4A is a schematic illustration of a portion of a vaporizer pen, where a heater assembly is contained in the vaporizer pen, according to an embodiment.
- FIG. 4B is a schematic illustration of a cartridge assembly configured to be coupled to the vaporizer pen of FIG. 4A with a consumable assembly being disposed in a housing of the cartridge assembly, according to an embodiment.
- FIG. 4C is a schematic illustration of a portion of a vaporizer pen assembly that can be used in the with the cartridge of the system of FIG. 4A-4B, according to an embodiment.
- FIG. 4D is a schematic illustration of a portion of a vaporizer pen assembly that can be used in the with the cartridge of the system of FIG. 4A-4B, according to an embodiment.
- FIG. 5 A is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly of FIG. 4A-4B coupled to the vaporizer pen assembly of FIG. 4C or 4D.
- FIG. 5B is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly of FIG. 4B coupled to the vaporizer pen assembly of FIG. 4C, and indicating the direction of aerosol flow through the system, according to an embodiment.
- FIG. 6A is a schematic illustration of a portion of a vaporizer pen assembly that can be used in an aerosolization system, according to an embodiment.
- FIG. 6B is a side cross-section of a portion of a system that includes the vaporizer pen assembly of FIG. 6 A coupled to a cartridge assembly, according to an embodiment.
- FIG. 7A and FIG. 7B are side cross-section views of portions of aerosolization systems including a cartridge assembly coupled to a vaporizer pen, according to various embodiments.
- FIG. 8 is a schematic illustration of a consumable assembly including a consumable formed into a sheet having multiple segments, and a heating element including a susceptor sheet configured to be disposed on and contact the consumable sheet, according to an embodiment.
- FIG. 9A is a schematic illustration of a consumable assembly that includes a sheet of a consumable that is in contact with a susceptor, and rolled or wound into a spool or coil, according to an embodiment.
- FIG 9B is a top of view of the consumable assembly of FIG. 9A wound into a flat coil, according to an embodiment.
- FIG. 9C is a top view of the consumable assembly of FIG. 9A wound into a circular coil, according to an embodiment
- FIG. 9D is a schematic illustration of a cartridge assembly including the consumable assembly of FIG. 9A wound into a spool or coil, according to an embodiment.
- FIG. 10A is a side cross-section view of a portion of an aerosolization system that includes a cartridge assembly that includes a consumable assembly with a consumable sheet and susceptor, coupled to a vaporizer pen assembly that includes multiple inductor coils, according to an embodiment.
- FIG. 10B is a side cross-section view of a portion of an aerosolization system that includes a cartridge assembly that includes a consumable assembly with a consumable sheet and susceptor, coupled to a vaporizer pen assembly that includes an injector coil mounted on an actuator, according to an embodiment.
- FIG. 11 A-l IB is an aerosolization system including a portion of vaporizer pen with a heater assembly including a susceptor with wicks on both sides of the susceptor, according to an embodiment.
- FIG. 11C is a front view of an assembly including a susceptor with wicks on both sides of the susceptor formed into a tube, according to an embodiment.
- FIG. 12A is a schematic illustration of an aerosolization system including a cartridge assembly coupled to a vaporizer pen assembly, according to an embodiment.
- FIG. 12B is a schematic illustration of the cartridge assembly of FIG. 12A, according to an embodiment.
- FIG. 12C a schematic illustration of the vaporizer pen assembly of FIG. 12 A, according to an embodiment.
- FIG. 12D is a side cross-section view of the cartridge assembly of FIG. 12A-1 IB.
- FIG. 12E is a side cross-section view of the vaporizer pen assembly of FIG. 12A and 12C.
- FIG. 12F is a side cross-section view of the cartridge assembly of FIGS. 12A-1 IB, and 1 ID coupled to the vaporizer pen assembly of FIGS. 12A, 12C, and 12E.
- FIG. 13 A is a plot showing power management of a set of heating elements included in a heater assembly of an aerosolization system, according to an embodiment.
- FIG. 13B is a plot showing temperature profiles of three heating elements of a heater assembly that are sequentially activated, and associated temperature of a consumable that is located proximate to or in contact with each of the three heating elements of the heater assembly.
- FIG. 14 is a schematic block diagram of a controller that can be configured to selectively activate each of a set of heating elements included in a heater assembly, according to an embodiment.
- FIG. 15 A- 15E are various views of a heater assembly that includes a wick including a flat porous layer and a set of heating elements arranged in a flat configuration, and that can be used to aerosolize a liquid consumable, according to an embodiment.
- FIG. 15F is an exploded view of the heater assembly of FIGS. 15A-14E, an associated heater assembly housing and a base, according to an embodiment.
- FIG. 16A-16D are various views of a heater assembly that includes a wick including a cylindrical porous layer and a set of heating elements provided as coils, and that can be used to aerosolize a liquid consumable, according to an embodiment.
- FIG. 17 is a schematic flow diagram of a method for aerosolizing a consumable via a heater assembly that includes a set of heating elements, according to an embodiment.
- FIG. 18 is a schematic illustration of a system for manufacturing a consumable assembly, according to an embodiment.
- FIG. 19 is a schematic illustration of a system for manufacturing a consumable assembly, according to an embodiment.
- FIG. 20 is a schematic illustration of an implementation of the system of FIG. 1, according to an embodiment.
- FIG. 21 is a schematic flow diagram of a method for manufacturing a consumable assembly, according to an embodiment.
- Embodiments described herein relate to systems and methods for aerosolizing solid, liquid, gel, and other consumables.
- embodiments described herein relate to aerosol generating systems that include a vaporizer pen configured to heat a consumable assembly via a heater assembly included in the vaporizer pen or a cartridge coupled to the vaporizer pen to produce aerosol for inhalation.
- the techniques described herein relate to an apparatus, including: a heater assembly configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element; a processor operatively coupled to each heating element of the set of heating elements; and a memory operatively coupled to the processor, the memory storing instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
- the techniques described herein relate to an apparatus, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
- the techniques described herein relate to an apparatus, wherein the first power and the second power are substantially equal.
- the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
- the techniques described herein relate to an apparatus, wherein the heater assembly further includes a third heating element, and the memory stores instructions to cause the processor to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
- the techniques described herein relate to an apparatus, wherein the first power, the second power, and the third power are substantially equal.
- the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
- the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element are disposed in contact with the consumable during a heating operation.
- the techniques described herein relate to an apparatus, wherein the heater assembly extends axially along a longitudinal axis of the consumable.
- the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element extend parallel to a longitudinal axis of the consumable, the first heating element and the second heating element being separated from each other along a circumferential direction about the longitudinal axis.
- the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element extend in a circumferential direction about a longitudinal axis of the consumable, the first heating element and the second heating element being axially separated from each other along the longitudinal axis.
- the techniques described herein relate to an apparatus, wherein the heater assembly defines an axial channel therethrough.
- the techniques described herein relate to an apparatus, wherein the heater assembly is configured to be disposed at least one of radially outward or radially inward of the consumable. [0077] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly has at least one of a flat, a circular, a star, a cylindrical, a polygonal, a tubular, a coiled, or an asymmetric shape.
- the techniques described herein relate to an apparatus, wherein: the heater assembly includes one or more inductor coils, the consumable includes at least one susceptor and an aerosol-generating substance disposed proximate to or in contact with the at least one susceptor, and activating the first heating element includes activating at least a portion of the one or more inductor coils so as to heat an associated portion of the at least one susceptor and thereby, an associated portion of the aerosol-generating substance.
- the techniques described herein relate to an apparatus, wherein the at least one susceptor includes a porous sheet, the aerosol-generating substance includes a consumable sheet, and the at least one susceptor and the consumable sheet are coiled into a spool.
- the techniques described herein relate to an apparatus, wherein the at least one susceptor includes an electrically-conductive sheet and the aerosolgenerating substance includes one or more of a layer of a porous consumable sheet, a layer of an aerosol-producing gel, or a layer of an aerosol-producing paste.
- the techniques described herein relate to an apparatus, wherein the consumable includes the layer of a porous consumable sheet, and the aerosolgenerating substance includes one of a layer of an aerosol-producing gel or a layer of an aerosol-producing paste disposed between the layer of the porous consumable sheet and the electrically-conductive sheet.
- the techniques described herein relate to an apparatus, wherein: the consumable includes a liquid, and the heating element further includes a wick at least one of presoaked with the liquid or configured to draw the liquid from a reservoir.
- the techniques described herein relate to a system, including: a consumable assembly including at least one segment, the at least one segment including a consumable material; and a heater assembly including: a first heating element and a second heating element, the first heating element and the second heating element being in thermal communication with the at least one segment including a consumable material, and a controller operatively coupled to the at least one heating element, the controller configured to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
- the techniques described herein relate to an apparatus, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
- the techniques described herein relate to an apparatus, wherein the first power and the second power are substantially equal.
- the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
- the techniques described herein relate to an apparatus, wherein the heater assembly further includes a third heating element, and controller configured to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
- the techniques described herein relate to an apparatus, wherein the first power, the second power, and the third power are substantially equal.
- the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
- the techniques described herein relate to a system, wherein: the consumable assembly includes a plurality of segments, and each of the first heating element and the second heating element is associated with at least one segment of the plurality of segments.
- the techniques described herein relate to a system, wherein: the controller is configured to selectively activate one of the first heating element or the second heating element to heat the at least one segment of the plurality of segments associated with the one of the first heating element or the second heating element.
- the techniques described herein relate to a system, wherein the controller is configured to activate each of the first heating element and the second heating element concurrently and intermittently so as to control a rate of the aerosol generated based on the request.
- the techniques described herein relate to a system, wherein the consumable assembly is aligned with and co-extensive with the set of heating elements of the heater assembly.
- the techniques described herein relate to a system, wherein the consumable assembly includes a sheet having a thickness in a range of about 0.05 mm to about 5 mm.
- the techniques described herein relate to a system, wherein the consumable assembly includes a sheet having a plurality of layers, each layer having a thickness in a range of about 0.05 mm to about 5 mm.
- each of the layers is formed as one of a solid or a gel.
- the techniques described herein relate to a system, wherein the consumable assembly and at least one of the first heating element and the second heating element are each assembled as a flat sheet, a tube, a spooled coil, or having complex shape such that the at least one segment of the consumable is in direct contact and aligned with the at least one heating element.
- the techniques described herein relate to a system, wherein the at least one heating element of the set of heating elements are disposed radially outward or radially inward of the at least one segment of the consumable assembly.
- each of the first heating element and the second heating element includes at least one inductor coil
- the consumable assembly includes at least one susceptor
- activating the first heating element includes activating the at least one inductor coil of the first heating element to heat a first portion of the at least one susceptor
- activating the second heating element includes activating the at least one inductor coil of the second heating element to heat a second portion of the at least one susceptor .
- each of the first heating element and the second heating element includes at least one inductor coil
- the consumable assembly includes at least one susceptor
- the heater assembly includes an actuator
- the at least one inductor coil of the first heating element being coupled to the actuator
- the controller configured to actuate the actuator to cause the actuator to displace the inductor coil axially relative to the at least one susceptor so as to position the at least one inductor coil proximate to a portion of the susceptor such that activation of the at least one inductor coil causes heating of the portion of the susceptor.
- the techniques described herein relate to a system, wherein: the consumable material is a liquid, and the consumable assembly includes a porous material at least one of presoaked with the liquid or in fluid communication with a reservoir of the liquid.
- the techniques described herein relate to a system, including: a pen assembly, including: a heater assembly, the heater assembly including a set of heating elements, and a controller operatively coupled to the heater assembly; a cartridge assembly configured to be removably coupled to the heater assembly, the cartridge assembly including: a container defining an airflow path and a heater chamber, and a consumable assembly disposed in the container, the consumable assembly including a consumable material, the cartridge assembly configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly, and the controller being configured to: receive a pressure data from a draw sensor disposed in the pen assembly, receive a preference input from a control interface provided in the pen assembly, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
- a pen assembly including: a heater assembly, the heater assembly including
- the techniques described herein relate to a system, wherein each heating element of the set of heating elements includes a mesh configured to allow the aerosol to pass through each heating element of the set of heating elements and the airflow path.
- the techniques described herein relate to a system, wherein the container includes a porous material disposed therein such that the produced aerosol flows through the porous material.
- the techniques described herein relate to a system, wherein the heater assembly includes a heater matrix including each heating element of the set of heating elements, the heater matrix being configured as a sheet, and the consumable assembly includes a consumable sheet such that selective activation of the portion of the set of heating elements by the controller causes an associated portion of the consumable sheet to be aerosolized.
- the techniques described herein relate to a system including: a cartridge assembly, including: a consumable assembly including at least one segment, the consumable assembly including a consumable material, and at least one heating element being in direct contact with the at least one segment of the consumable assembly; and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly, the pen assembly including: a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly, and a controller operatively coupled to the heater assembly, the controller configured to: receive a request for an aerosol of the consumable material, the request including a user preference or a desired amount of the aerosol of the consumable, and selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
- the techniques described herein relate to a system, wherein: the heating element includes a susceptor, the susceptor being aligned with and co-extensive with the at least one segment of the consumable assembly, and selectively activating the at least one heating element includes selectively activating the at least one inductor coil so as to heat an associated portion of the susceptor.
- the techniques described herein relate to a system, including: an electrically-conductive layer having a first side and a second side opposite the first side; a first aerosol-substance generating layer having a first side and a second side opposite the first side, the first side of the first aerosol-substance generating layer disposed in contact with the first side of the electrically-conductive layer; a second aerosol-substance generating layer having a first side and a second side opposite the first side, the second side of the second aerosol-substance generating layer disposed in contact with the second side of the electrically- conductive layer; a first membrane layer disposed on the second side of the first aerosolsubstance generating layer; and a second membrane layer disposed on the first side of the second aerosol-substance generating layer.
- the techniques described herein relate to a system, wherein the electrically-conductive layer is formed by a metal sheet.
- the techniques described herein relate to a system, wherein the electrically-conductive layer is formed by at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
- the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length.
- the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length and width.
- the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have a circular cross-section and a tubular shape.
- each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
- the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
- the techniques described herein relate to a system, wherein at least one of the first membrane layer and the second membrane layer are at least one of permeable or perforated.
- the techniques described herein relate to a system, further including an elongated hollow tube defining an annular space between an outer surface of the second membrane layer and an inner surface of the elongated hollow tube.
- the techniques described herein relate to a system, including: a first rolling assembly configured to dispose a portion of a continuous elongated first aerosolsubstance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; a second rolling assembly configured to dispose a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; a tube-forming assembly configured to transition the second planar layered assembly into a continuous tubular layered assembly; and a cutting assembly configured to separate the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
- the techniques described herein relate to a system, further including a third rolling assembly configured to dispose a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly, the second rolling assembly configured to disposed the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosolsubstance generating layer and the portion of the continuous elongated second membrane layer.
- the techniques described herein relate to a system, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
- the techniques described herein relate to a system, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
- the techniques described herein relate to a system, wherein the tube-forming assembly is configured to couple a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
- the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
- each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
- the techniques described herein relate to a method, including: disposing a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; transitioning the second planar layered assembly into a continuous tubular layered assembly; and separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
- the techniques described herein relate to a method, further including: disposing a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly; and disposing the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosol-substance generating layer and the portion of the continuous elongated second membrane layer.
- the techniques described herein relate to a method, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
- the techniques described herein relate to a method, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings. [0129] In some embodiments, the techniques described herein relate to a method, further including coupling a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
- each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
- each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
- the techniques described herein relate to a method, further including disposing a consumable assembly of the plurality of consumable assemblies within a cartridge having a housing, a filter, and defining an airflow channel from the consumable assembly through a proximal opening of the cartridge.
- the consumable assembly can include a thin dense sheet of a solid consumable material that can be formed into a flat sheet, formed into a cylindrical shape, wound into a spool or coil, or formed into any other polygonal or complex three dimensional surface shape and disposed in a cartridge assembly configured to be coupled to the vaporizer pen such that one or more heating elements of the heater assembly are disposed proximate to the consumable.
- the one or more heating elements can be in direct contact with the consumable assembly such that a surface of the thin dense sheet is mated with a surface area of the heating elements of the heater assembly.
- the consumable assembly can include a solid consumable, for example, a pressed plant-based material.
- the thin dense sheet of the consumable material can be mated with an equal size or larger heating element(s) to transfer heat through the mass of the consumable quickly and efficiently.
- the thin dense sheet can consist of one or more segments where one or more segments of the consumable are associated with one or more segments of a heating element, or one or more heating elements of the heater assembly so as to heat the thin dense sheet and/or its segments at the same time or separately, sequentially, intermittently, or in any desired order.
- the desired order of activating the set of heating elements can be based on at least one of a user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and a desired amount of the aerosol of the consumable (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, amount of consumable material remaining, etc.).
- a user preference e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.
- a desired amount of the aerosol of the consumable e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, amount of consumable material remaining, etc.
- the consumable assembly can include a porous material, for example, a wick presoaked with a liquid consumable and/or in fluid communication with a reservoir of the liquid consumable.
- the vaporizer pen can be optimized to support multiple consumable materials.
- the vaporizer pen can support multiple types of nicotine consumables such as e-juice, enabling safe and accurate aerosolization of substances other than burnable substances such as cannabis and traditional tobacco.
- the controller can be configured to heat the consumable at various rates for combustible and/or vaporizable consumable materials.
- the heater assembly can also support sublimation of solid consumables, such as glycerin / propylene glycol based gels/solids.
- the vaporizer pen can include a controller (e.g., the processor 125) configured to selectively activate one or more heating elements included in the heater assembly to allow for accurate dosing of aerosolized consumable and increase efficiency of aerosolization of the consumable.
- the controller can control the aerosolization rate and/or the volume of aerosol produced based on user inputs or preferences by increasing surface area of active heating, not increasing the temperature to which the consumable is heated.
- the heater assembly can be configured to aerosolize a consumable that does not include additives, thereby reducing and/or eliminating harmful by-products delivered to a user in the consumable aerosol.
- the cartridge assembly can be removably coupled to the vaporizer pen, allowing for a used cartridge assembly to be removed from the vaporizer pen and replaced with a new cartridge assembly containing the same or a different consumable to be used with the vaporizer pen.
- the vaporizer pen can be implemented to support the consumable in a variety of shapes and forms such as, but not limited to, flat, circular, star, cylindrical, polygonal, tubular, coiled, asymmetric shapes, or complex three dimensional (“3D”) shapes.
- the vaporizer pen can also be implemented to include a heater assembly with the same (or similar) shapes and forms as the consumable, where the heater assembly mates (directly or proximate to) with a consumable and/or consumable assembly in the cartridge assembly when coupled to the heater assembly of the vaporizer pen.
- the consumable can be sandwiched in between a surface of the heater assembly and a surface of the cartridge assembly to hold the consumable in place and in direct (or proximate) contact with the heater assembly.
- the consumable can include a solid thin dense sheet between about 0.01 millimeters and about 2.5 millimeters thick, inclusive, mated with the heater assembly, and that can be about equal size, shape, or form with the heater assembly.
- the thin dense sheet mated to the heater assembly in equal size is beneficial because the heater assembly can transfer heat to the thin dense sheet quickly and efficiently, thereby resulting in quick and efficient aerosolization and inhalation.
- the heating element can include one or more susceptors (e.g., solid sheets, porous sheets, meshes, etc.) that are configured to be energized to generate heat via electromagnetic energy provided by inductor(s).
- the inductor(s) can include any solid inductor such as, but not limited to, coils, flat plate inductors, etc.
- the susceptors can be mated with the consumable, i.e., provided in direct contact with the consumable sheet in the consumable assembly, and disposed in the cartridge assembly along with the consumable assembly.
- the heater assembly can include one or more heating elements, which can form a heater matrix.
- the consumable can include a thin dense sheet, where the thin dense sheet includes one or more consumable segments, where the one or more heating elements corresponds to the surface area of the one or more consumable segments.
- the multiple consumable segments can be beneficial in dosing and volume control of aerosolization as each consumable segment can include a precise quantity of a desired consumable, where the one or more heating elements corresponding to the one or more consumable segments can deliver precise or predefined dose(s) and/or enable adjustability of the rate of aerosol delivery of a desired consumable in each consumable segment.
- the heater assembly with multiple heating elements significantly enhances the surface area of the consumable that is heated.
- the vaporizer pen can be implemented to include a power source that can conserve power consumption by intermittently powering each heating element such that fewer heating elements are on at any one time.
- the process of heating the consumable can focus higher energy on a smaller surface of the consumable, or one or more consumable segments, at a time.
- the power source of the vaporizer pen can be configured to cycle each heating element with peak power output, enabling a user to vary the volume of aerosol produced.
- the power source of the vaporizer pen can be configured to cycle each heating element with or without uniform power output to enable the user to vary the volume of aerosol produced.
- Embodiments of the systems and methods described herein for aerosolizing a consumable can provide one or more benefits including, for example: (1) providing a thin dense sheet of a solid consumable material that can be selectively heated and aerosolized to allow better aerosolization of the solid consumable material; (2) providing multiple heating elements in a heater assembly that can be selectively activated in any suitable configuration to optimize aerosolization of multiple consumable materials, thereby increasing heating surface area, increasing aerosolization rate, and providing aerosolization of greater than 50% of the consumable; (3) enabling accurate dosing via aerosolization of a thin dense sheet of the solid consumable material (4) reducing power consumption and extending power source life by allowing activation of less than all heating elements included in the heater assembly at a given time; (5) allowing generation of consumable aerosols at a rate of greater than 7 mg/sec that is greater than 2 times the maximum vapor generated by cigarettes including the same consumable material; (6) providing all electronics in a vaporizer pen allowing cartridges configured to be coupled to the vaporizer
- FIG. 1 is a schematic block diagram of an aerosolization system 100, according to an embodiment.
- the aerosolization system 100 can be referred to as an “electronic aerosol delivery system,” “aerosol generating system,” or “electronic vapor delivery system.”
- the aerosolization system 100 can be a heat-not-bum system.
- the aerosolization system 100 includes a cartridge 110 and a vaporizer pen 140.
- the cartridge 110 can also be referred to and/or formed as a “cartridge assembly,” a “cartridge portion,” a “container,” a “capsule,” a “capsule assembly,” a “pack,” a “pod,” a “consumable,” a “stick,” or a “consumable portion.”
- the vaporizer pen 140 can also be referred to as a “pen assembly,” a “vape pen,” a “vaporizer pen assembly,” a “pen portion,” a “pen housing,” a “vaporizer body,” a “reusable,” a “reusable portion,” a “reusable device,” a “battery portion,” a “heating control assembly,” or a “heating control device.”
- the cartridge 110 can be removably coupled to the vaporizer pen 140 such that the vaporizer pen 140 can control aerosolization of one or more aerosol-generating substances included in the cartridge 110.
- the cartridge 110 can include at least one heating element 170 (also referred to as at least one “heat-emitting elements”) and at least one aerosol-generating substance (e.g., a first aerosol-generating substance portion 160), and the vaporizer pen 140 can include a heater assembly 150 operatively coupled to a power supply 124.
- aerosol-generating substance can also be referred to as a “consumable substance” or a “consumable material,” and can refer to any substance that can be vaporized, combusted, and/or aerosolized for inhalation.
- the heater assembly 150 and the least one heating element 170 can be configured such that, when the cartridge 110 is engaged with the vaporizer pen 140, the heater assembly 150 can operate to initiate a temperature increase of the least one heating element 170 sufficient such that the at least a portion of the at least one aerosol-generating substance is heated by the least one heating element 170 and aerosolized for inhalation by a user of the aerosolization system 100.
- the vaporizer pen 140 can include a housing 142 defining a cartridge receptacle 141 configured to receive the cartridge 110 such that aerosolization of at least one aerosolgenerating substance included in the cartridge 110 can be controlled by the heater assembly 150.
- the cartridge 110 can include a proximal end (e.g., a mouth end) and a distal end.
- the cartridge receptacle 141 can be configured to receive at least a portion of the cartridge 110 such that the distal end of the cartridge 110 is disposed within the cartridge receptacle 141.
- the cartridge receptacle 141 is configured to receive a portion of the cartridge 110 such that a proximal end of the cartridge 110 is accessible by a user (e.g., for engagement with a user’s mouth) when the cartridge 110 is operatively engaged with the vaporizer pen 140 for an aerosolization operation.
- the cartridge 110 can include a consumable assembly 130 including the first aerosol-generating substance portion 160 and the at least one heating element 170.
- the consumable assembly 130 can include a second aerosol -generating substance portion 162.
- the consumable assembly 130 can include a first membrane layer 164 and/or a second membrane layer 166.
- the first aerosol-generating substance portion 160 and the second aerosol -generating substance portion 162 can be formed as independent segments or portions that can be independently aerosolized by the heater assembly 150 (e.g., via an associated portion of heater element of the heater assembly 150).
- Each of the segments or portions of the consumable assembly 130 can include the same consumable material or different consumable materials in any suitable combination.
- the cartridge 110 can include three or more aerosol-generating substance portions having similar characteristics to first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162.
- the at least one heating element 170 can be disposed between the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162.
- the at least one heating element 170 can include a plurality of heating elements disposed between the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162.
- the first aerosol -generating substance portion 160 can be disposed between the at least one heating element 170 and the first membrane layer 164.
- the second aerosol-generating substance portion 162 can be disposed between the at least one heating element 170 and the second membrane layer 166.
- the consumable assembly 130 can include the at least one heating element 170, the first aerosol-generating substance portion 160, the second aerosol-generating substance portion 162, and the first membrane layer 164. In some implementations, the consumable assembly 130 can include the at least one heating element 170, the first aerosolgenerating substance portion 160, the second aerosol -generating substance portion 162, the first membrane layer 164, and the second membrane layer 166. In some implementations, the at least one heating element 170 can include a first heating element and a second heating element.
- the first heating element can be disposed on a first side of the first aerosol-generating substance portion 160 and the second heating element can be disposed on a second side of the first aerosol-generating substance portion 160, and the second aerosol-generating substance portion 162 can or can not be included in the consumable assembly 130.
- the first aerosol -generating substance portion 160 and/or the second aerosol -generating substance portion 162 is disposed in direct contact with the at least one heating element 170.
- the first membrane layer 164 is disposed in direct contact with the first aerosol -generating substance portion 160 and/or the second membrane layer 166 is disposed in direct contact with the second aerosol -generating substance portion 162.
- a thin membrane layer (not shown in FIG.
- the thin membrane layer can be formed as a thin, paper-like substrate. In some implementations, the thin membrane layer can be the same or similar in structure and/or function as the first membrane layer 164 and/or the second membrane layer 166.
- the consumable assembly 130 can be formed as a hollow tube such that a channel 131 is defined by the consumable assembly 130 from a distal end to a proximal end of the consumable assembly 130 (e.g., along a central axis of the consumable assembly 130).
- aerosol produced by the first aerosol -generating substance portion 160 and/or the second aerosol -generating substance portion 162 can travel through the channel 131 toward the proximal end of the consumable assembly 130 and/or the mouth end of the cartridge 110.
- the consumable assembly 130 can be formed as a flat, planar multi-layered sheet having a thickness significantly smaller than a length and width of the consumable assembly 130.
- each of the components of the consumable assembly 130 e.g., the first aerosol-generating substance portion 160, the at least one heating element 170, and the optional second aerosol-generating substance portion 162, the optional second aerosol-generating substance portion 162, the optional first membrane layer 164, and/or the optional second membrane layer 166) can be formed to have the same perimeter shape (e.g., a rectangular shape) and stacked to form a multi-layered sheet such that one of the components (e.g., the first membrane layer 164, the first aerosol-generating substance portion 160, or the at least one heating element 170) forms an outermost layer on a first side including a first surface and another of the components (e.g., at least one heating element 170, the second aerosolgenerating substance portion 162, or the second membrane layer 166) forms an outermost layer on a second
- the consumable assembly 130 can have any suitable overall shape and/or cross-sectional shape.
- the cross-sectional shape of the at least one heating element 170 and/or the consumable assembly consumable assembly 130 can be rectangular, circular, star-shaped, polygonal, spiraled, coiled, asymmetric, and/or a complex three dimensional (“3D”) shape.
- the consumable assembly 130 can be flexible or malleable to form multiple distinct shapes or configurations further described in FIG. 3 A-K.
- the one or more segments or portions of the consumable substance can be in direct contact or configured to be in direct contact with one or more heating elements of the heater assembly 150.
- the one or more heating elements of the heater assembly 150 can be aligned with and/or substantially corresponding in area (e.g., have about the same area or a slightly larger area than a surface area of the sheet of consumable assembly 130) with the consumable assembly 130 and/or the one or more segments or portions of the consumable substance therein (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162).
- the consumable assembly 130 can include, or be formed from a consumable material (e.g., a solid consumable material) that is configured (e.g., disposed, shaped, and/or sized) to be directly aerosolized by the heater assembly 150 (e.g., via direct and/or indirect contact with the heater assembly 150).
- a consumable material e.g., a solid consumable material
- the heater assembly 150 e.g., via direct and/or indirect contact with the heater assembly 150.
- each of the components of the consumable assembly 130 can have the same length (e.g., taken along a line parallel to or coaxial with a central axis of the consumable assembly 130), the same width, and/or the same perimeter shape and/or size as adjacent components.
- the cross- sectional shape and size of each component of the consumable assembly 130 can be the same (e.g., constant and continuous) from the distal end to the proximal end of the consumable assembly 130 (e.g., taken along a central axis of the consumable assembly).
- each of the components of the consumable assembly 130 can have the same thickness.
- the first aerosolgenerating substance portion 160, the at least one heating element 170, and the second aerosolgenerating substance portion 162 can have the same thickness.
- the first membrane layer 164 and the second membrane layer 166 can each have a thickness less than a thickness of the first aerosol-generating substance portion 160, the at least one heating element 170, and/or the second aerosol-generating substance portion 162.
- surfaces of the at least one heating element 170, the first aerosol-generating substance portion 160, and the optional at least one heating element 170 that directly abut or face other surfaces of the at least one heating element 170, the first aerosolgenerating substance portion 160, and the optional at least one heating element 170 have substantially the same perimeter shape and size and substantially the same area as the surface that is abutted or faced.
- the at least one heating element 170 can be formed as a planar sheet or hollow tube having a first surface and a second surface opposite the first surface.
- the first surface can be an interior surface and the second surface can be an exterior surface.
- the first aerosol-generating substance portion 160 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the at least one heating element 170.
- the second surface of the first aerosolgenerating substance portion 160 and the first surface of the at least one heating element 170 can have the same length, the same or substantially (e.g., in the case of abutting non-planar surfaces) the same area, the same perimeter shape, and/or the same or substantially the same (e.g., in the case of abutting non-planar surfaces) perimeter size.
- the second aerosol -generating substance portion 162 which can be included in the consumable assembly 130 in addition to the first aerosol-generating substance portion 160 or in the alternative to the first aerosol -generating substance portion 160) can have a first surface in contact with and/or facing the second surface of the at least one heating element 170 and a second surface opposite the first surface.
- the first surface of the second aerosol-generating substance portion 162 and the second surface of the at least one heating element 170 can have the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size.
- the first membrane layer 164 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the first aerosol-generating substance portion 160.
- the second surface of the first membrane layer 164 and the first aerosol-generating substance portion 160 can have the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size.
- the second membrane layer 166 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the second aerosol-generating substance portion 162.
- the second surface of the second membrane layer 166 and the second aerosol-generating substance portion 162 can have the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size.
- the at least one heating element 170 can include a coil heating element, rod-shaped heating element, a pancake heating element, a chemical heating element, a ceramic heating element, a resistive heating element, a wick heating element (or wicks), a ceramic wick heating element, an electromagnetic heating element such as at least one susceptor configured to be heated by inductor coils, infrared light, a radiant heater such as an infrared heater, and/or any other heating element or combination thereof that is sized, dimensioned, and constituted of material suitable for heating the consumable substance in the consumable assembly 130.
- an electromagnetic heating element such as at least one susceptor configured to be heated by inductor coils, infrared light, a radiant heater such as an infrared heater, and/or any other heating element or combination thereof that is sized, dimensioned, and constituted of material suitable for heating the consumable substance in the consumable assembly 130.
- the heating element(s) 170 can include a resistive element (e.g., coil or serpentine solid state heaters such as ceramic heaters) that can be solid or have a porosity of at least about 25% (e.g., at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%, inclusive).
- a resistive element e.g., coil or serpentine solid state heaters such as ceramic heaters
- the heating element(s) 170 can include one or more susceptor(s) in the form of a solid foil, or a perforated foil or a mesh with porosity of at least about 25% (e.g., at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%, inclusive).
- the solid or porous heating element 170 can be in direct contact with a largest surface area of the consumable substance (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) of the consumable assembly 130.
- the pores or openings through the heating element(s) 170 can allow air and, thus, aerosol, to flow through the pores or openings of the heating element(s) 170.
- the at least one heating element 170 can be formed of one or more solid sheets, solid sheets with perforations, and/or porous sheets.
- the at least one heating element 170 can be formed of a single sheet-like heating element (e.g., foil). As described above, the single sheet-like heating element can be used in a planar multi-layer consumable assembly 130 or can be formed into a hollow tube for use in a tubular consumable assembly 130.
- the at least one heating element 170 can be formed of a mesh or a web that can optionally allow aerosol-generating substance or aerosol produced therefrom to flow therethrough.
- the at least one heating element 170 can include a plurality of thin rods, wires, strips, or other elements that are disposed adjacent to neighboring elements in series to form a layer (e.g., a tubular or flat, planar layer).
- the at least one heating element 170 can include a plurality of heating elements, with each heating element arranged in contact with an adjacent heating element or spaced from an adjacent heating element a distance of less than a thickness of the individual heating elements.
- the at least one heating element 170 can have a constant cross-sectional shape and size along a central axis of the consumable assembly 130 and can extend from the distal end to the proximal end of the consumable assembly 130.
- the at least one heating element 170 can include a thin heating layer (e.g., a sheet).
- the at least one heating element 170 can have a thickness of less than 2 mm, less than 1 mm, and/or less than 0.2 mm.
- the thin heating layer can have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 0.3 mm, about 0.9 mm, about 1.2 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive).
- the thin heating layer can have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive. In some implementations, the thin heating layer can have a thickness less than 5 mm (e.g. less than 4.5 mm, less than 4.0 mm, less than 3.5 mm, less than 3.0 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm). In some implementations, the thin heating layer can have a thickness in range of about 0.2 mm to about 1 mm, inclusive. In some embodiments, the thin heating layer can have a thickness of about 0.3 mm.
- the at least one heating element 170 can be formed to function as or include one or more susceptors that is energized by electromagnetic energy provided by an external inductor (e.g., included in the heater assembly 150 of the vaporizer pen 140) such that the at least one heating element 170 increases in temperature and generates heat that is transferred to the first aerosol -generating substance portion 160, the second aerosolgenerating substance portion 162, the first membrane layer 164, and/or the second membrane layer 166.
- the at least one heating element 170 can be formed of an electrically- conductive material (e.g., metal).
- the at least one heating element 170 can include any material configured to be heated by a magnetic induction system.
- the at least one heating element 170 can be ferro-magnetic.
- the at least one heating element 170 can be formed of, for example, ceramic, graphite, and/or a composite.
- the at least one heating element 170 can include a susceptor including solid sheet, perforated sheet, porous sheet, mesh sheet, or plurality of elongated wires that is formed to define a central passageway (e.g., formed as a tube) to allow aerosol to pass therethough and through fluidic channels defined in the cartridge 110 following an airflow path to and through a proximal end of the cartridge 110 for inhalation by a user.
- the at least one susceptor can be heated via induction by one or more inductor coils (e.g., included in the vaporizer pen 140) to cause aerosolization of consumable substance within the consumable assembly 130 and heating of air passing through a central portion of the cartridge 110 along a longitudinal axis of the vaporizer pen 140 and/or the cartridge 110.
- the susceptor(s) included in the at least one heating element 170 can include a porous sheet and the first aerosol-generating substance portion 160 and/or the second aerosolgenerating substance portion 162 can include a sheet including consumable substance (e.g., a sheet formed of a solid or gel consumable material or a porous sheet soaked with a liquid consumable).
- the porous sheet susceptor(s) and the consumable substance sheet(s) can be coiled together into a spool (e.g., as shown in FIGS. 9A-C).
- the cartridge 110 can include one or more susceptor(s) in addition to or as an alternative to the one or more susceptors that can be included in the at least one heating element 170 within the consumable assembly 130.
- the at least one heating element 170 can include at least one resistive heating element including two or more electrical pads or contacts (e.g., forming or included in an input/output (I/O) module 136 of the cartridge 110) and one or more active heating sections.
- the resistive heating element can be formed as a porous, perforated, or solid sheet.
- the at least one heating element 170 can be configured to be resistively heated under the control of the heater assembly 150 of the vaporizer pen 140 when the electrical contacts of the at least one heating element 170 are electrically coupled to the heater assembly 150.
- the electrical contacts can be disposed relative to the cartridge 110 such that the electrical contacts are accessible from an exterior of the cartridge 110 (e.g., disposed on or project from an outer surface thereof).
- the first aerosol -generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can be formed as a thin layer.
- the first aerosol-generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can each have a thickness of less than 2 mm, less than 1 mm, and/or less than 0.2 mm.
- the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 0.3 mm, about 0.9 mm, about 1.2 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive).
- the first aerosol-generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can each have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive.
- the first aerosol-generating substance portion 160 and/or the optional second aerosolgenerating substance portion 162 can each have a thickness less than 5 mm (e.g. less than 4.5 mm, less than 4.0 mm, less than 3.5 mm, less than 3.0 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm). In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness in range of about 0.2 mm to about 1 mm, inclusive. In some embodiments, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness of about 0.3 mm.
- the consumable substance(s) included in the consumable assembly 130 can have a consistency of a liquid, a gel, a solid, a paste, a gel that functions as a paste, a gel that hardens at room temperature and functions as an adhesive, or a substance between a gel and a solid (e.g., a semi-solid) (e.g., at room temperature).
- the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can include a consumable substance including a mixture of vegetable glycerin (VG) and propylene glycol (PG) in any suitable proportion, such as about 10% VG to about 90% PG, more than about 50% VG, more than about 60% VG, or more than about 65% VG.
- the first aerosol-generating substance portion 160 and/or the optional second aerosolgenerating substance portion 162, in addition to the VG and PG can include a consumable substance including about 0.5% to about 10% water.
- the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can include a consumable substance including one or more gelling agents such as, for example, food-grade additives such as xanthate gum, xanthan gum, carboxymethyl-cellulose, microcrystalline cellulose, methyl cellulose, Arabic gum, guar gum, lambda carrageenan, chitosan, hydroxymethylcellulose, cellulose derivatives or starch in the range of about 0.1 to about 5.0 w/w% of the total mixture, of about 0.5 to about 3.5 w/w% of the total mixture, or of about 1 to about 2.0 w/w% of the total mixture.
- food-grade additives such as xanthate gum, xanthan gum, carboxymethyl-cellulose, microcrystalline cellulose, methyl cellulose, Arabic gum, guar gum, lambda carrageenan, chitosan, hydroxymethylcellulose, cellulose derivatives or starch in the range of about 0.1 to about 5.0
- the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can optionally include a consumable substance including nicotine (e.g., freebase or salt), such as Nicotine Benzoate, Nicotine Lactate, Nicotine Levulinate, Nicotine Malate, Nicotine Pyruvate, Nicotine Salicylate, Nicotine Tartrate, or any other Nicotine derivative, cannabis, tetrahydrocannabinol (THC), any individual cannabinoids / terpenes, other pharmaceutical substances, one or more flavoring agents, one or more flavor modifying agents, aromatics, binders, solidifying agents, any other substance suitable for aerosol delivery, and/or water and/or any other suitable nontoxic solvents.
- nicotine e.g., freebase or salt
- nicotine e.g., freebase or salt
- nicotine e.g., freebase or salt
- nicotine e.g., freebase or salt
- nicotine e.g., freebase or salt
- nicotine e
- the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can optionally include a consumable substance including tobacco.
- the consumable substance can be a liquid that includes, for example, one more of a nicotine extract, a cannabis extract, glycerin, vegetable oil, flavorants, additives, and/or water.
- the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can be porous or can include or included in a porous material.
- the first aerosolgenerating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can include any of the mixtures and/or ingredients described above, be formed as a liquid or a gel, and can be suspended in one or more wick(s) 122 formed of an absorbent and/or wicking substrate.
- the wick(s) 122 can be or include, for example, silica, borosilicate, foam, cotton, cellulose, and/or tobacco and be formed as a thin absorbent sheet.
- the wicking substrate can be or include, for example, any other thin wicking material (e.g., less than 2 mm, less than 1 mm, or less than 0.5 mm thick) with high heat resistance that remains non-reactive at temperatures of 250 C or higher.
- the wick(s) 122 can have sufficient porosity while being sufficiently heat resistant so as to allow the liquid consumable imbued therein (e.g., PG/VG, nicotine, tobacco extract, cannabis extract, other plant extract, or any other substance that is appropriate for aerosolization) to be aerosolized without itself undergoing phase transformation or burning.
- the consumable assembly 130 can include wick(s) 122 that can be disposed in and/or have a surface facing and/or forming a boundary of an air flow path within the cartridge 110, and, in some implementations, the heater assembly 150 can include one, two, or more heating elements of the heater assembly 150 disposed or configured to be disposed in direct contact with the wick(s) 122.
- the wick(s) 122 can include a porous ceramic wick that is configured to be heated by at least one heating element 170 and/or at least one heating element of the heater assembly 150 (e.g., when the cartridge 110 is coupled to the vaporizer pen 140).
- the wick(s) 122 can be formed as a cylindrical stick analogous to a traditional cigarette stick intended to be heated through combustion. In some implementations, the wick(s) 122 can also be wrapped around foam and structured to be in contact with one or more heating elements of the heater assembly 150 (e.g., when the cartridge 110 is coupled to the vaporizer pen 140).
- the wick(s) 122 can include a porous material that is presoaked with a liquid or gel consumable substance or can be in fluid communication with a reservoir 138 including a liquid or gel consumable substance.
- Various configurations of cartridges 110 that include a liquid consumable are described in detail in U.S. Application No. PCT/CA2022/050455, filed March 25, 2022, and entitled “Methods and Systems for Variable Viscosity Carrier Vaporizers,” the entire disclosure of which is hereby incorporated by reference herein.
- a drug component can be applied to the wick(s) 122 of the consumable assembly 130 or included in the liquid or gel consumable imbued or soaked therein (e.g., through nozzle application or dipping during manufacturing of the consumable assembly 130 or the cartridge 110).
- the consumable assembly 130 can include one or more segments or portions of a consumable substance, similar the one or more segments or portions of a consumable substance formed of a solid material described above.
- the consumable segment(s) of the consumable assembly 130 can be in direct contact with the heater assembly 150 (e.g., one or more heating elements of the heater assembly 130), where the heater assembly 150 can include the wick(s) 122 having wicking material pressed or divided into the consumable substance to delineate individual consumable segments.
- each consumable segment can be separated by completely separating the wicking material, and disposing the wicking material in the consumable substance such that the wicking material is pressed or quilted therein, to prevent movement of the consumable assembly 130 and its materials between consumable segments.
- a portion of the heater assembly 150 can be disposed in the cartridge 110.
- one or more heating elements of the heater assembly 150 can be disposed in the cartridge 110 (e.g., as at least one heating element 170), and can be disposed proximate to or in contact with the consumable assembly 130 (e.g., a porous consumable assembly 130).
- one or more heating elements of the heater assembly 150 can be aligned with and/or corresponding in area to the consumable assembly 130 including the liquid consumable.
- each consumable segment can be physically separate.
- the consumable assembly 130 can be configured as a flat sheet, a tube, a spooled coil, or any complex shape equal to, substantially equal to, or slightly larger than the size and/or the surface area of the heater assembly 150 of the vaporizer pen 140.
- the consumable substance(s) included in the consumable 130 can include solid consumable materials.
- the solid consumable materials can include a densely pressed plant or synthetic consumable material such as, for example, tobacco, or cannabis products and extracts made from plant material, such as crystal or solid extractions reconstituted into a sheet format.
- the sheet can be made using a dehydration processes, reconstitution processes, extraction processes, or the like, and can contain additives such as propylene glycol (PG) or vegetable glycerin (VG) to create desirable constitution and/or physical attributes.
- PG propylene glycol
- VG vegetable glycerin
- the processes used to form the consumable assembly 130 can also increase visible aerosol feedback and/or delivery of active components such as, but not limited to, nicotine, THC and other individual cannabinoids or terpenes for effect delivery, as well as flavoring agents.
- the solid consumable materials and/or sheets made therefrom can include any ingredients described with respect to any of the consumable substances described herein.
- the optional first membrane layer 164 and/or the optional second membrane layer 166 can each be formed as a thin layer.
- the first membrane layer 164 and/or the second membrane layer 166 can have a thickness of less than 1 mm, less than 0.5 mm, and/or less than 0.3 mm.
- the first membrane layer 164 and/or the second membrane layer 166 can be paper-like. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can be porous and/or perforated to allow aerosol to pass therethrough. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can form outermost layers of the consumable assembly 130 or an innermost layer and an outermost layer of the consumable assembly 130 (e.g., in the case of a tubular consumable assembly 130).
- the first membrane layer 164 and/or the second membrane layer 166 can be configured to prevent aerosol-generating substance (e.g., gel) included in the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162 from flowing or migrating away from the at least one heating element 170 and/or through the first membrane layer 164 and/or second membrane layer 166 before aerosolization of the aerosol-generating substance.
- aerosol-generating substance e.g., gel
- the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a reconstituted tobacco sheet.
- the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a paper sheet.
- the paper sheet can be formed from natural and/or synthetic materials, such as silica or cotton, that are able to withstand temperatures greater than 160 C.
- the paper sheet can optionally include a coating that includes flavoring agents, flavor modifying agents, and/or one or more active ingredients (e.g., nicotine, cannabinoids, and/or any pharmaceutical-use active ingredient appropriate for heated aerosol delivery).
- the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a sheet formed of a plant-based material including one or more active ingredients that can be delivered via inhalation, such as, for example, cannabis.
- the first membrane layer 164 and/or the second membrane layer 166 can each be perforated.
- the perforations can each have a diameter less than, for example, 1 mm or 0.3 mm.
- the number and size of the perforations can allow for increased airflow of aerosol through the reconstituted tobacco sheet, such as at least about 5% more airflow or at least about 15% more airflow.
- the consumable assembly 130 can have a length that is shorter than the overall length of the cartridge 110.
- the distal end of the consumable assembly 130 can be disposed at, near, or adjacent to a distal end of the cartridge 110 and the proximal end of the consumable assembly 130 can be disposed closer to the proximal end of the cartridge 110 than the distal end of the consumable assembly 130 is disposed relative to the proximal end of the cartridge 110.
- the consumable assembly 130 can be disposed within the consumable assembly 130 such that the consumable assembly 130 and the overall cartridge 110 are coaxial.
- the cartridge 110 includes a housing 114 (also referred to as a “membrane”) forming an outer surface of the cartridge 110.
- the housing 114 can define a container within which the consumable assembly 130 and any other components of the cartridge 110 can be disposed.
- the cartridge 110 can include one or more structural elements, filters, ventilation features, dilution features, tipping papers, fluid channel(s) 135, tubes, and/or other elements configured to provide structure, airflow, ventilation, temperature management, flavoring, anti-sticking, tracking, anti-leaking, antibreakage, and/or any other features, each of which can be disposed within the housing 114.
- the cartridge 110 can include structures to facilitate positioning of the consumable assembly 130 within the housing 114 and to guide the flow of aerosol from the consumable assembly 130 to the proximal end of the cartridge 110 (e.g., to the opening of a mouthpiece 133 described below) for inhalation by a user.
- FIG. 20 is a schematic illustration of an implementation of the system 100 in which the consumable assembly 130 is disposed within the housing 114 of the cartridge 110.
- the cartridge 110 is partially disposed within a cartridge receptacle 141 of the pen assembly 140.
- the consumable assembly 130 is formed as a hollow tube and optionally has multiple tubular layers such as a tubular first aerosol-generating substance portion 160, a tubular at least one heating element 170, a tubular second aerosolgenerating substance portion 162, a tubular first membrane layer 164, and a tubular second membrane layer 166, as further described herein.
- each of the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162 can be formed of an aerosol-generating gel or paste configured to be heated by the at least one heating element 170, and each of the first membrane layer 164 and the second membrane layer 166 can optionally be configured to be indirectly heated by the at least one heating element 170 via the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162, respectively, such that the first membrane layer 164 and second membrane layer 166 are heated at a lower temperature.
- the housing 114 can have any suitable shape, such as a shape corresponding to an inner and/or outer shape of the consumable assembly 130.
- the housing 114 can have a tubular shape and can be arranged coaxially with the consumable assembly 130 formed as a tube.
- the housing 114 can be open at both the proximal end and the distal end such that components disposed within the housing 114 at the proximal end and the distal end of the cartridge 110 are exposed.
- the housing 114 can have a tubular shape and the consumable assembly 130 can have a flat multi-layer planar shape.
- the housing 114 can be elongated and can have a rectangular, oblong, or any other suitable cross-section such that the housing 114 has a constant cross-sectional shape and size from the distal end to the proximal end of the housing 114.
- the housing 114 can be formed as a coating for the internal components (e.g., disposed on the outer surface of other components) of the cartridge 110.
- the housing 114 can be wrapped around the internal components (e.g., around the outer surface of other components) of the cartridge 110.
- the housing 114 can include a thin sheet of material such as a paper sheet formed of natural and/or synthetic materials. In some implementations, the housing 114 can be configured and arranged to provide structure for the cartridge 110 such that the cartridge 110 is maintained in a particular overall shape and the components of the cartridge 110 are held together for transport and use. In some implementations, the housing 114 can be include material similar to the material forming an outer surface of a traditional cigarette stick intended to be heated through combustion. In some implementations, the housing 114 and the cartridge 110 can be shaped and/or configured to mimic the feel of a traditional cigarette stick intended to be heated through combustion (e.g., can be cylindrical). In some implementations, the housing 114 can be liquid impermeable to serve as a barrier to any liquids, gels, or semisolids disposed within the cartridge 110 (e.g., within the consumable assembly 130).
- the cartridge 110 can include porous materials (e.g., foams and/or filters) disposed within the housing 114 such that any produced aerosols flow through the porous materials.
- porous materials e.g., foams and/or filters
- an inner surface of the housing 114 can include, contain, or be formed from the porous materials.
- the housing 114 can function as filter or a liquid isolator (e.g., in the case of liquid aerosol- generating material being included in the cartridge 110) to prevent liquid from leaking out of the cartridge 110.
- the housing 114 can define an opening coated and/or covered by a membrane.
- the aerosol-generating substance e.g., the first aerosol-generating substance portion 160
- the cartridge 110 can include one or more reservoirs 138 configured to contain the liquid aerosol-generating substance (also referred to as a precursor reservoir) which can be in fluid communication with the mouthpiece 133, one or more vapor chambers (e.g., vapor expansion chambers), and/or one or more fluidic channels, to facilitate the heating and drawing of aerosol and/or vapor from the cartridge 110.
- the at least one heating element 170 and the wick(s) 122 can be arranged and configured such that the wick(s) 122 can deliver the liquid aerosolgenerating substance from the one or more reservoirs 138 to the at least one heating element 170 and the at least one heating element 170 can heat and aerosolize the liquid aerosolgenerating substance.
- the wick(s) 122 and/or the at least one heating element 170 can include a porous ceramic and can be configured to be heated under control of the heater assembly 150.
- the wick(s) 122 can include a porous ceramic material and the at least one heating element 170 can include coils directly coupled to the wick(s) 122 and configured to be operatively coupled to the heater assembly 150 for heating of the coils and the porous ceramic material to aerosol liquid consumable disposed in the porous ceramic.
- the at least one heating element 170 can include the wick(s) 122 (e.g., presoaked in liquid or gel consumable substance or configured to draw liquid or gel consumable substance from the reservoir 138).
- the opening and the membrane can be arranged such that a consumable substance, such as a liquid consumable, can be supplied to the reservoir(s) 138 of the cartridge 110 via the opening (e.g., via insertion of a needle through the membrane or via delivery through the opening before closing the opening with the membrane or while the membrane is temporarily removed).
- the membrane can include a valved impermeable or semi-permeable material, such as, for example, rubber, polyvinyl chloride (PVC), and/or silicone.
- the membrane can be resealable (e.g., automatically after removal of a needle).
- the cartridge 110 can be formed from biodegradable material a to allow the cartridge 110 that can be disposable, to have minimal impact on the environment when disposed after being used.
- the housing 114 can be disposed such that the housing 114 and an outer surface of the consumable assembly 130 define an annular space forming a fluid channel 135 through which aerosol produced by the consumable assembly 130 can flow to reach the proximal end of the cartridge 110.
- the cartridge 110 can include a mouthpiece 133.
- the mouthpiece 133 of the cartridge 110 can include one or more of ceramic, heat-resistant plastic, anodized aluminum, and/or any other suitable material, and can define one or more mouthpiece openings through which a user can draw fluid (e.g., air) through the cartridge 110 and through the mouthpiece opening(s) and can draw aerosol produced within the cartridge 110 through the mouthpiece opening(s).
- the mouthpiece 133 can be coupled to a proximal end of the housing 114.
- the mouthpiece 133 can be spaced from a proximal end of the consumable assembly 130.
- the proximal end of the housing 114 can include a mouthpiece portion.
- the mouthpiece portion can, for example, be formed of a similar of the same material as the housing 114 (e.g., reconstituted tobacco or paper) and/or can have the same outer diameter as the remainder of the housing 114, similar to a traditional cigarette stick.
- the vaporizer pen 140 can include a processor 125 (which can also be referred to as a “controller” and/or included in a controller) and a memory 123 operatively coupled to the processor.
- the processor 125 can be operatively coupled to the heater assembly 150 and/or the power supply 124 such that the processor 125 can control heating operations of the heater assembly 150.
- the heater assembly 150 is configured to be disposed proximate to (e.g., aligned with and/or coupled to) the consumable assembly 130 when the cartridge 110 is coupled to the vaporizer pen 140 (e.g., properly received within the cartridge receptacle 141).
- a “heater assembly,” as used herein, can refer to a combination of components and/or devices to initiate, provide, and/or enable heating.
- the heater assembly 150 can include a set of heating elements.
- the heater assembly 150 can form a heater matrix, such as is described, for example, with respect to FIG. 2.
- the set of heating elements can also be referred to as “heating elements” or “vaporizer device heating elements.”
- Each heating element of the set of heating elements of the heater assembly 150 can also be referred to as “heater segments,” “individual heaters,” or “heaters.”
- the heating elements are configured to be disposed proximate to (e.g., sufficiently aligned with or coupled to such that the heating elements of the heater assembly 150 can heat the at least one heating element 170) the at least one heating element 170 of the consumable assembly 130, and spaced from (i.e., not in contact with) the consumable assembly 130, when the cartridge 110 is coupled to the vaporizer pen 140 (e.g., properly received within the cartridge receptacle 141).
- the processor 125 of the vaporizer pen 140 is operatively coupled to each heating element of the set of heating elements of the heater assembly 150 such that the processor 125 can individually control the operation (e.g., heating activation and deactivation) of each heating element of the set of heating elements of the heater assembly 150.
- the heater assembly 150 and/or the set of heating elements thereof can extend axially along a longitudinal axis parallel to or coaxial with a central axis of the cartridge receptacle 141 and/or a central axis of the cartridge 110 when the cartridge 110 is engaged with the vaporizer pen 140.
- the cartridge receptacle 141 of the vaporizer pen 140, the heater assembly 150 of the vaporizer pen 140, and the cartridge 110 can have a cylindrical shape, similar to the shape of a traditional cigarette stick heatable via combustion.
- the heater assembly 150 can be configured to be disposed at least one of radially outward or radially inward of the consumable assembly 130 and/or at least one segment of the consumable assembly 130.
- the heater assembly 150 can be disposed radially outward (e.g., around an outer circumferential surface of the consumable assembly 130 as shown in FIG. 5B) or radially inward (e.g., disposed within an inner circumferential surface of the consumable assembly 130 as shown in FIG. 5 A) relative to the cartridge 110 and/or the at least one heating element 170.
- the set of heating elements of the heater assembly 150 can be arranged to form a cylindrical structure.
- the heating elements can each be formed as an elongated member arranged circumferentially around a central axis (e.g., the central axis of the cartridge receptacle 141) (e.g., as shown in FIG. 4C) or can be formed as annular rings arranged along the central axis (e.g., as shown in FIG. 4D).
- each of the heating elements can be spaced from adjacent heating elements of the heater assembly 150 (e.g., separated from one another along a circumferential path around the central axis or along a longitudinal axis parallel to the central axis).
- the heater assembly 150 is configured to be received within an interior portion of the cartridge 110 (e.g., within an interior portion of the consumable assembly 130), such as within the central channel 131, with the set of heating elements of the heater assembly 150 disposed within and aligned with the at least one heating element 170 of the cartridge 110.
- the set of heating elements of the heater assembly 150 can be arranged to define an axial channel therethrough, which can function as an airflow path that extends along the central axis, through the cartridge 110, and through the mouthpiece 133 for inhalation by a user.
- the heater assembly 150 is disposed outside of and/or at least partially defines the cartridge receptacle 141 such that the heater elements of the heater assembly 150 are disposed radially outward of and/or surround the cartridge receptacle 141 and the at least one heating element 170 of the cartridge 110 when the cartridge 110 is received within the cartridge receptacle 141.
- the heater assembly 150 and/or the heating elements of the heater assembly 150 can have at least one of a flat, circular, star, cylindrical, polygonal, tubular, coiled, complex three-dimensional surface, asymmetric shape, or any other suitable shape, and can be similar (e.g., about equal) in size and/or shape to the consumable assembly 130.
- the surface area of a side of the heater assembly 150 and/or heating elements facing the consumable assembly 130 can be substantially similar to or the same as the surface area of a portion of the consumable assembly 130 (e.g., of the at least one heating element 170) facing the side of the heater assembly 150 and/or heating elements (e.g., disposed radially inward or radially outward of the consumable assembly 130).
- the surface a side of the heater assembly 150 and/or heating elements facing the consumable assembly 130 can be in direct contact with or proximate to the surface of a portion of the cartridge 110 (e.g., of the consumable assembly 130 or of the at least one heating element 170) facing the side of the heater assembly 150 and/or heating elements (e.g., disposed radially inward or radially outward of the consumable assembly 130).
- the consumable assembly 130 which can be aligned with at least one heating element of the heater assembly 150, can be formed as or include a component formed to complement or mate with the heater assembly.
- the consumable assembly 130 can be formed as or include a component formed as a flat sheet, a tube, a spooled coil, and/or a complex 3D shape such that at least one segment of the consumable assembly 130 remains in direct contact and/or aligned with the at least one heating element of the set of heating elements of the heater assembly 150.
- the heater assembly 150 includes one or more inductive heating elements (also referred to as inductors) configured to generate electromagnetic energy (e.g., radiofrequency and/or microwave radiation) in response to being activated by the processor 125.
- the heater assembly 150 can include one or more solid inductors such as inductor coils or flat plate inductors.
- the inductor element(s) e.g., coil(s)
- the inductor element(s) are disposed within the housing 142 of the vaporizer pen 140 and surround the cartridge receptacle 141.
- the at least one heating element 170 of the consumable assembly 130 can be disposed proximate to or in contact with aerosol-generating substances (e.g., first aerosol-generating substance portion 160 and/or second aerosol-generating substance portion 162) included in the consumable assembly 130 (e.g., as shown in FIGS. 7A-B).
- aerosol-generating substances e.g., first aerosol-generating substance portion 160 and/or second aerosol-generating substance portion 162
- the at least one heating element 170 can be located in direct contact with a sheet including an aerosol-generating substance, a segmented sheet including an aerosol-generating substance, a porous layer including an aerosol-generating substance, or a wick soaked with a liquid or gel including an aerosol-generating substance.
- the at least one heating element 170 can include, for example, a metallic solid foil, a metallic porous or perforated sheet, a metallic wire mesh, or elongated metallic rods, wires, or threads, and the at least one heating element 170 can generate heat when energized by the inductor elements (e.g., inductor coil(s)) of the heater assembly 150.
- the inductor elements e.g., inductor coil(s)
- the vaporizer pen 140 can include an input/output (I/O) module 126.
- the I/O module can be configured to electrically engage with electrical contacts of the cartridge 110.
- the I/O module 126 of the vaporizer pen 140 can include, for example, contacts or connectors (e.g., pogo pins) operatively coupled to the processor 125 and/or the heater assembly and configured to engage with the contacts or pads of the cartridge assembly 110.
- the processor 125 can control the heater assembly 150 and/or the power supply 124 to provide current to the at least one heating element 170 via the I/O module 126 and the pads or contacts of the cartridge 110 to cause the at least one heating element 170 to increase in temperature and aerosolize the first aerosol-generating substance portion 160 and/or the second aerosolgenerating substance portion 162.
- the processor 125 can be configured to receive a request (e.g., via a draw sensor 121 of the vaporizer pen 140 and/or via a user actuator included in the I/O module 136) for delivery of an aerosol from the cartridge 110.
- the processor 125 can send an instruction to the heater assembly 150 to activate.
- One or more heating elements and/or portions of heating elements of the heater assembly can activate to cause an increase in temperature of the at least one heating element 170 of the cartridge 110 and aerosolization of at least a portion of the consumable substance of the cartridge 110 based on the instructions.
- the processor 125 can be configured to individually and/or selectively activate one or more heating elements of the heater assembly 150 and/or one or more portions of one or more heating elements of the heater assembly 150.
- each heating element of a set of heating elements of the heater assembly 150 can be individually and/or selectively activated and/or controlled by the processor 125.
- each heating element of the set of heating elements of the heater assembly 150 can be individually and/or selectively caused to change in temperature to a temperature different from a temperature of one or more other heating elements of the set of heating elements.
- the processor 125 can individually control the heating elements based on various inputs and/or pre-set heating instructions, such as, for example, based on type of consumable substance included in the consumable assembly 130, one or more predetermined temperatures or heating profiles (e.g., associated with a heating element, the heater assembly 150, and/or the consumable substance(s) disposed in the cartridge 110), an amount of consumable substance (e.g., portion of the first aerosol-generating substance portion 160 and/or second aerosol -generating substance portion 162 of the cartridge 110) previously aerosolized and/or remaining, a draw pressure, and/or a user setting (e.g., as inputted via the I/O module 136 and/or via interaction with a compute device (e.g., a mobile device) in communication with the vaporizer pen 140.
- a compute device e.g., a mobile device
- individual portions of a heating element of the heater assembly 150 can be individually and/or selectively activated and/or controlled by the processor 125.
- a controller separate from the processor 125 (e.g., included in or coupled to the heater assembly 150) or a controller including the processor 125 can be used to control the operations of the heater assembly 150 and/or the heating element(s) of the heater assembly 150.
- An example controller that can be used to control the operations of the heater assembly 150 is described with respect to FIG. 14.
- the set of heating elements of the heater assembly 150 can include at least a first heating element, a second heating element, and a third heating element.
- the processor 125 (or a controller separate from or including the processor 125) can be configured to selectively activate the first heating element at a first time and/or for a first time period.
- the processor 125 (or a controller separate from or including the processor 125) is further configured to selectively activate the second heating element at a second time and/or for a second time period.
- the first time can optionally be different from the second time and the first time period can optionally have a different duration than the second time period.
- the first time, first time period, second time, and/or second time period can be selected based on, for example, a user input, a desired amount or rate of aerosol desired by the user, or a portion of consumable substance (e.g., a portion of the first aerosolgenerating substance portion 160 and/or second aerosol-generating substance portion 162) known to be remaining in the cartridge 110 (e.g., based on known characteristics and/or previous usage of the cartridge 110).
- the processor 125 (or a controller separate from or including the processor 125) can be further configured to selectively activate the third heating element at a third time and/or for a third time period (e.g., based on similar inputs as described above).
- the third time can optionally be different from the first time and/or second time and the third time period can optionally have a different duration than the first time period and/or the second time period.
- the first time period, the second time period, and/or the third time period can be in a range of about 0.1 seconds to about 3 seconds (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, or 3 seconds, inclusive).
- the second time period can be immediately subsequent to the first time period, or commence after a first gap period between the first time period and the second time period.
- the third time period can be immediately subsequent to the second time period, or commence after a second gap period between the second time period and the third time period.
- the second heating element can be located adjacent to the first heating element or one or more heating elements can be located between the first heating element and the second heating element.
- the third heating element can be located adjacent to the second heating element or one or more heating elements can be located between the second heating element and the third heating element.
- the processor 125 (or a controller separate from or including the processor 125) can be configured to cycle through multiple heating elements (e.g. the first heating element, the second heating element, and/or the third heating element) of the heater assembly 150 to cause the consumable substance of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) and/or the at least one heating element 170 to increase in temperature.
- the processor 125 (or a controller separate from or including the processor 125) can be configured to control the heater assembly 150 such that the heating of one or more portions of the at least one heating element 170 is cycled.
- a user can prefer activating a smaller number or portions of heating elements to generate a smaller volume aerosol or to generate aerosol at a lower rate, or can prefer activating a larger number or portions of heating elements to generate a larger volume aerosol or to generate aerosol at a higher rate.
- a user can set the aerosolization system 100 to activate only one heating element in a set of three heating elements included in the heater assembly 150 to produce aerosol at a rate of 2.5 mg/s.
- a user can set the aerosolization system 100 to activate two heating elements to produce aerosol at a rate of 5 mg/s. In some implementations, for example, a user can set the aerosolization system 100 to activate all three heating elements to produce aerosol at a rate of equal to or greater that than 7 mg/s.
- consumable substance disposed in contact with or near a heating element e.g., of the at least one heating element 170 and/or of the heater assembly 150
- a heating element e.g., of the at least one heating element 170 and/or of the heater assembly 150
- consumable substance disposed in or near a wick such as a ceramic wick thermally coupled to a heating coil
- other heating elements can solidify (e.g., transition from a liquid state to a solid state), increase in thickness, and/or obstruct an aerosol flow path within the aerosolization system 100.
- the flow of liquid consumable substance in the consumable assembly 130 can be managed via cycling the activation and/or heating profiles of multiple heating elements of the heater assembly 150 to cause the cycling of heating of the consumable substance (e.g., via the at least one heating element 170).
- the flow of liquid consumable substance in the consumable assembly 130 can be managed via cycling the activation and/or heating profiles of the at least one heating element 170 and/or portions thereof under control by the heater assembly 150.
- the heating elements of the heater assembly 150 or portions thereof and/or portions of the at least one heating element 170 can function as wicks for managing the flow of liquid consumable substance in one or more inactive sections or areas of the consumable assembly 130.
- the processor 125 can cycle or activate the three heating elements one at a time to remove built up flow of consumable substance (e.g., liquid) at the surface of the three heating elements (e.g., when a liquid consumable is used). If the user sets the aerosolization system 100 to activate two heating elements (or to generate aerosol in a volume or rate associated with the activation of two heating elements), the processor 125 can cycle or activate the three heating elements so that two are activated at a time.
- consumable substance e.g., liquid
- the processor can cycle all three heaters at the same time and/or intermittently.
- the processor 125 can also cycle the heating elements and/or more than three heating elements in multiple different variations.
- the processor 125 (or the controller including the processor 125) can be configured to activate any one of the first, second, or third heating elements, or any number of heating elements included in the heater assembly 150 in any suitable order or combination so as to generate a desired amount of aerosol at a desired rate.
- Using a set of heating elements that can be independently activated and controlled can allow for a larger surface area of the heating surface compared to a system in which the heating elements are not independently controllable, thereby increasing vapor volume and allow more efficient consumption of the entire mass or volume of the consumable material included in the consumable assembly 130.
- the processor 125 can selectively activate each heating element of the heater assembly 150 sequentially, intermittently, and/or more than one at a time, and/or can activate a subset of the set of heating elements with each heating element being activated at a different heating power to control aerosolization rate, volume, and/or ensure substantially complete consumption of the consumable substance included in the cartridge 110 over the life of the cartridge 110.
- the selective activation can be based on at least one of a user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and a desired amount of the aerosol of the consumable (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, and/or amount of consumable material remaining).
- a user preference e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.
- a desired amount of the aerosol of the consumable e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, and/or amount of consumable material remaining.
- Example configurations of activating the heating elements based on the request can include: i) subsequent activation of heating elements located adjacent to each other with each being activated for a given time period with each being activated one at a time; ii) subsequent activation of heating elements that are not located adjacent to each other with each being activated for a given time period and being activated one at a time; iii) activating two heating elements of the set of heating elements at any given time in any suitable sequence or order; iv) activating more than one but less than all heating elements at different power levels (e.g., some in a range of about 10% to about 50% power, and others in a range about 60% to about 100% power); or v) activating all heating elements with each heating element being activated at a different power level (e.g., in a range of about 0% to about 100% power).
- power levels e.g., some in a range of about 10% to about 50% power, and others in a range about 60% to about 100% power
- a first heating element can be activated at 80% power
- a second heating element can be activated at 20% power at a first time point for a first time period
- the activation of power level of the first heating element and the second heating element can be alternated during the first time period (e.g., selectively switched such that the second heating element is operated at 80% power and the first heating element is operated at 20% power.
- the each of the set of heating elements can be activated in any suitable sequence, at any suitable time, and any suitable power based on the request.
- the cartridge 110 can define one or more airflow paths from the distal end to the proximal end of the cartridge 110.
- the airflow path(s) can include the channel 131 through the consumable assembly 130, which can also be referred to and function as a heater chamber.
- the cartridge 110 can also define an airflow path including an annular space defined between an inner surface of the housing 114 and an outer surface of the consumable assembly 130 (e.g., a fluid channel 135) such that aerosol can be drawn toward and through the proximal end of the cartridge 110 from both a first side of the consumable assembly 130 (e.g., an interior when the consumable assembly 130 is formed as a hollow tube) and a second side of the consumable assembly 130 (e.g., an exterior when the consumable assembly 130 is formed as a hollow tube).
- a first side of the consumable assembly 130 e.g., an interior when the consumable assembly 130 is formed as a hollow tube
- a second side of the consumable assembly 130 e.g., an exterior when the consumable assembly 130 is formed as a hollow tube
- the vaporizer pen 140 can include a draw sensor 121 operably coupled to the processor 125 such that the processor 125 can activate the heater assembly 150 (e.g., to heat the at least one heating element 170 of the cartridge 110) in response to the draw sensor 121 sensing a decrease in pressure (e.g., within the cartridge receptacle).
- the processor 125 can activate the heater assembly 150 (e.g., to heat the at least one heating element 170 of the cartridge 110) in response to the draw sensor 121 sensing a decrease in pressure (e.g., within the cartridge receptacle).
- heating of the at least one heating element 170 to generate aerosol from the consumable assembly 130 can be triggered in response to a user sucking or drawing on the proximal end of the cartridge 110 (e.g., on an opening of the mouthpiece 133) and causing a drop in pressure at the draw sensor 121.
- the draw sensor 121 In response to the draw sensor 121 sensing a drop in pressure beyond a threshold pressure or change in pressure beyond a threshold change within the cartridge receptacle 141 and/or within the cartridge 110 (e.g., within the channel 131), the draw sensor 121 can send a signal to the processor 125 indicating the sensed pressure change. In response to receiving the signal from the draw sensor 121, the processor 125 can activate the heater assembly 150.
- the draw sensor 121 can be configured to be used periodically by the user as a spirometer. For example, the user can blow into an opening of the vaporizer pen 140 (e.g., an opening of the cartridge receptacle 141) without the cartridge 110 being coupled to the vaporizer pen 140.
- the draw sensor 121 can sense an increase in pressure within the vaporizer pen 140 (e.g., within the cartridge receptacle), and send one or more signals to the processor 125 indicating the amount of change in pressure (e.g., relative to particular pre-set thresholds or ranges).
- the processor 125 can then send an instruction including the sensed pressure data to another device (e.g., a mobile device or server) for processing and/or can determine an exhalation pressure associated with the lungs of a user based on the signal(s) received from the draw sensor 121 as an indicator of the user’s lung function or capacity.
- another device e.g., a mobile device or server
- the processor 125 can adjust the volume of aerosol produced based on the air pressure or change in air pressure detected by an inhalation from the user. For example, the processor 125 can selectively activate more heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a larger drop in pressure and can selectively activate fewer heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a relatively smaller drop in pressure. The activation of more heating elements can cause a larger portion of the at least one heating element 170 to be heated, causing a larger portion or volume of the aerosol-generating substance in the cartridge 110 (e.g., in the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) to be aerosolized.
- the processor 125 can selectively activate more heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a larger drop in pressure and can selectively activate fewer heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a relatively smaller drop in pressure.
- the processor 125 can be configured to selectively activate one or more of the heating elements based on at least one of a pre-set or indicated user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and/or based on a predetermined target amount or volume of aerosol to be generated per draw or per a time period (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, a type of consumable material, and/or an amount of consumable material remaining).
- a pre-set or indicated user preference e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.
- a predetermined target amount or volume of aerosol to be generated per draw or per a time period e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, a type of consumable material, and/or an amount of consumable material remaining.
- the vaporizer pen 140 can include a volume control feature based on a threshold change in pressure and/or a threshold pressure that is associated with higher or lower volumes of aerosol produced.
- the volume control can include an engagement features, such as a pressure-sensitive button or toggle included in the vaporizer pen 140. For example, a user can actuate a pressure-sensitive button by applying a higher force (e.g., with a finger) to the button to indicate that a higher aerosol volume output is desired and by applying a relatively lower force to the button to indicate that a lower aerosol volume output is desired.
- a pressure sensor associated with the button can send a signal to the processor 125 indicative of the pressure or force applied, and the processor 125 can control the heater assembly 150 to apply an amount and/or duration of heat to the cartridge 110 associated with the amount of pressure or force and associated aerosol volume.
- the volume control can include multiple buttons associated with higher or lower volumes of aerosol production (e.g., per drag).
- buttons can include pressure or volume control buttons (also referred to herein as “+/- buttons”), where activation of the + button causes a signal to be sent to the processor 125 indicating an increase in pressure and/or volume of aerosol to be produced and activation of the - button causes a signal to be sent to the processor 125 indicated a decrease in pressure and/or volume of aerosol to be produced.
- the aerosol produced can vary in volume and/or rate of aerosolization.
- the processor 125 can be configured to enable easier and/or more difficult aerosolization of the consumable assembly 130 based on the air pressure detected from the inhalation of the user by the draw sensor 121. For instance, if the user wants more aerosolization of the consumable assembly 130 using less air pressure for inhalation, the user can press the + button to trigger aerosolization based on a lower threshold pressure.
- the processor 125 can be configured to deliver a higher or lower volume and/or pressure of the aerosol of the consumable material in response to the draw sensor 121 detecting a higher or lower draw pressure, respectively, based on a higher or lower draw pressure exerted on the mouthpiece 133 by the user.
- the vaporizer pen 140 can control the volume of aerosol produced by cycling the heater assembly 150 including one or more heating elements.
- an interface used to control and/or vary the volume of aerosol produced can be integrated on a web application (e.g., accessible via a remote compute device).
- the buttons, the volume control, and/or the interface used to control the volume of aerosol produced can be used to control the aerosolization of any consumable including solid consumables, liquid consumables, and/or the like.
- the cartridge 110 can be manufactured, shipped and/or sold separately from the vaporizer pen 140, and assembled by a user to form the aerosolization system 100.
- the consumable assembly 130 can be manufactured, shipped, and/or sold separately from the cartridge 110 and, for example, a manufacturer can assembly the cartridge 110 including the consumable assembly 130 before commercial sale of the cartridge 110 to a user.
- a user can, prior to use (e.g., upon purchase of a new cartridge 110), couple the cartridge 110 to the vaporizer pen 140.
- the cartridge 110 can be configured to be received within a cartridge receptacle 141 of the vaporizer pen 140.
- the cartridge 110 and the vaporizer pen 140 can be configured to be mechanically connected, for example by one or more of screw attachment, press-fit attachment, snap-fit attachment, magnetic attachment, or any other suitable connection means.
- the cartridge 110 can be received loosely within the cartridge receptacle 141.
- the vaporizer pen 140 can be considered the reusable portion of the vaporizer system 100, and the cartridge 110 can be considered a disposable or “replaceable” portion of the vaporizer system 100.
- the vaporizer pen 140 can be configured to be used with a plurality of cartridges 110, with each cartridge 110 being replaceable with a new cartridge after use.
- the cartridge 110 can optionally include a processor 132 and a memory 137 operatively coupled to the processor 132, where the memory 137 stores instructions configured to be executed by the processor 132.
- the processor 132 of the cartridge 110 can be configured to receive information from the processor 125 of the vaporizer pen 140, provide information to the processor 125 of the vaporizer pen 140, and/or receive operational power from the power supply 124 of the vaporizer pen 140.
- the cartridge 110 can draw operational power from the power supply 124 of the vaporizer pen 140 (e.g., to power a heater included in the cartridge 110) via, for example, a control interface 128 of the vaporizer pen 140 (e.g., under control of the processor 132 of the cartridge 110).
- the processor 132 can be configured to receive the signal from the draw sensor 121 (e.g., via the processor 125 of the vaporizer pen 140) and communicate an activation signal to the heater assembly 150 via the control interface 128.
- the cartridge 110 can include one or more optional sensors 134 (e.g., operatively coupled to the optional processor 132).
- the one or more optional sensors 134 can include, for example, a pressure sensor, a temperature sensor, a position sensor, a light sensor, a magnetic sensor (e.g., a hall or strip), an orientation sensor, or the like.
- the one or more optional sensors 134 can additionally, or alternatively, be disposed in the vaporizer pen 140 and operatively coupled to the processor 125.
- the processor 125 and/or the processor 132 can each include one or more of: a general purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a controller, a microcontroller, a state machine and so forth.
- a “processor” can include an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable gate array (FPGA), etc.
- ASIC application specific integrated circuit
- PLD programmable logic device
- FPGA field programmable gate array
- the term “processor” can refer to a combination of processing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core or any other such configuration.
- the processor 125 of the vaporizer pen 140 can be in electronic communication with the memory 123 of the vaporizer pen 140 and can be configured to read information from and/or write information to the memory 123.
- the processor 125 and the memory 123 can be included on a common tracking component or in a control assembly of the vaporizer pen.
- the tracking component or control assembly can be, for example, an integrated circuit (e.g., Application-Specific Integrated Circuits (ASICs)).
- the memory 123 and/or the memory 137 can each include any electronic component capable of storing electronic information.
- the term memory can refer to various types of processor-readable media such as random access memory (RAM), read-only memory (ROM), non-volatile random access memory (NVRAM), programmable read-only memory (PROM), erasable programmable read only memory (EPROM), electrically erasable PROM (EEPROM), flash memory, magnetic or optical data storage, registers, etc.
- RAM random access memory
- ROM read-only memory
- NVRAM non-volatile random access memory
- PROM programmable read-only memory
- EPROM erasable programmable read only memory
- EEPROM electrically erasable PROM
- flash memory magnetic or optical data storage, registers, etc.
- the memory 123 of the vaporizer pen 140 is operational to store instructions (e.g., code, algorithm, data, etc.) configured to cause the processor 125 to perform the functions of the vaporizer pen 140 described herein.
- the power supply 124 of the vaporizer pen 140 can include any suitable battery or fuel cell configured to provide operational power to the vaporizer pen 140 components.
- the power supply 14 can have high-drain characteristics.
- the vaporizer pen 140 can include a mechanical interface (e.g., a button) as part of the I/O module 126 that the user can actuate (e.g., engage) to trigger the heating and vaporization of the consumable assembly 130.
- the I/O module 126 can include one or more of: a push-button control for causing vapor generation (as an alternative, or in addition to, activating the heater assembly 150 based on a signal received from the draw sensor 121), a battery status indicator, an electromechanical connector for charging and/or data communication, a light source (e.g., one or more light-emitting diodes), etc.
- the vaporizer pen 140 can include indicator(s) such as, but not limited to, an illumination source (e.g., one or more lightemitting diodes), a speaker, a display screen, a haptic feedback (e.g., vibration) component (e.g., a vibration motor or a piezoelectric vibrating element), etc.
- one or more of the indicator(s) can be included in or controlled by a component of the I/O module 126.
- the processor 125, the memory 123, the I/O module 126, the power supply 124, and/or other electronic components of the vaporizer pen 140 can be included in, be part of, or associated with a controller or a control unit.
- the vaporizer pen 140 can include one or more of a GPS receiver, one or more antennae, and/or a transmitter or transceiver for wireless (e.g., Bluetooth, WI-FI®, ZigBee, NFC, or WAN/LTE) communication with a command center (e.g., a cloudbased server, a centralized server and/or the like) and/or with one or more other remote compute devices (e.g., a mobile device, such as a smartphone or tablet, or a smart connected accessory, such as a base or hub device such as a connected charger/dock or a home connected unit which can also be configured for direct contact with the vaporizer pen 140 for data exchange and/or charging).
- a command center e.g., a cloudbased server, a centralized server and/or the like
- a smart connected accessory such as a base or hub device such as a connected charger/dock or a home connected unit which can also be configured for direct contact with the vaporizer pen 140 for data exchange and/
- the vaporizer pen 140 can communicate with the command center and/or other remote compute devices as part of a cartridge 110 identification process and/or a cartridge 110 and/or vaporizer pen 140 activation process (e.g., as an additional or alternative method of communicating with a command center regarding identifiers and activation as described herein).
- the vaporizer pen 140 can communicate various statuses of the cartridge 110, the vaporizer pen 140, or of a user action via any of the communication methods disclosed herein (e.g., consumable supply level, draw frequency, draw duration, draw volume, draw pressure level, and/or blow pressure level).
- the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to selectively activate a portion of the heater assembly 150 (e.g., a portion of the heating elements) to selectively heat the consumable assembly 130.
- the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to selectively activate a portion of the inductor coil(s) of the heater assembly 150 to heat the susceptor(s) of the at least one heating element 170 and, thereby, the consumable substance (e.g., the first aerosolgenerating substance portion 160 and/or second aerosol-generating substance portion 162) of the consumable assembly 130.
- the processor 125 can be configured to selectively activate at least a portion of the one or more inductor coils so as to heat an associated portion of the at least one susceptor and thereby, the consumable substance included in the consumable assembly 130 and associated with (e.g., directly coupled to) the portion of the at least one susceptor.
- the processor 125 can control a set of induction coils so that a first induction coil heats a first portion of a susceptor to cause aerosolization of a first portion of the consumable substance in contact with or adjacent to the first portion of the susceptor for a first time period and a second induction coil heats a second portion of the susceptor to cause aerosolization of a second portion of the consumable substance in contact with or adjacent to the second portion of the susceptor for a second time period.
- a third induction coil can be controlled by the processor 125 to heat a third portion of the susceptor to cause aerosolization of a third portion of the consumable substance in contact with or adjacent to the susceptor for a third time period, etc.
- the system 100 can direct more energy to a smaller aerosolization area, and the quantity of aerosol produced during one heating session (e.g., one draw or series of draws in a session) can be controlled.
- one portion of the consumable substance can be aerosolized at a time such that consistent quantities of aerosol can be generated per session (e.g., per draw or series of draws in a session). Such a feature can be used for consistent dosing of the aerosol material generated.
- each induction coil can be heated for the period of time associated with aerosolization of the portion of the consumable substance associated with the portion of the susceptor heated by the induction coil.
- the portions of the consumable material are aerosolized in linear, serial order (e.g., starting with the distal- most portion), so the induction coils are activated by the processor 125 serially starting with the distalmost induction coil.
- the processor 125 can activate each induction coil for a pre-set number of draws or a pre-set volume of air drawn through the system 100 (e.g., determined based on data from the draw sensor 121) associated with the cartridge 110 before no longer activating that induction coil and activating the next induction coil.
- the heater assembly 150 can include an actuator (not shown) such as, for example, a lead screw and associated nut or any other suitable actuator.
- the at least one inductor coil can be coupled to the actuator and the processor 125 can be configured to selectively actuate the actuator to displace the inductor coil axially relative to the at least one susceptor of the at least one heating element 170 of the cartridge 110 so as to position the at least one inductor coil proximate to a particular portion of the at least one susceptor such that selective activation of the at least one inductor coil causes heating of the associated portion of the susceptor.
- initial aerosolization and draws from the cartridge 110 can be associated with a consumable substance portion disposed distally of subsequent draws.
- the at least one inductor coil can be moved proximally by the actuator under the control of the processor 125 to aerosolize the consumable substance of the cartridge 110 linearly (e.g., serially, section by section in a linear direction toward the proximal end of the consumable assembly 130.
- the heating element of the heater assembly 150 can include a radiant heater.
- the heating element can include one or more infrared (IR) heater (e.g., an IR light emitting diode (LED)) configured to deliver radiant heat to the consumable assembly 130.
- IR infrared
- LED IR light emitting diode
- the heating element(s) can be located proximate to the consumable assembly 130 but with a gap (e.g., an annular space) defined therebetween.
- the at least one heating element 170 can optionally not be included in the cartridge 110.
- the consumable assembly 130 can include a plurality of segments, and the at least one heating element of the heater assembly 150 can be configured to selectively direct heat to or on the at least one segment of the plurality of segments.
- the heater assembly 150 can include a set of heating elements, each of which is contact with at least one associated segment of the plurality of segments of the consumable assembly 130.
- the processor 125 (or a controller including the processor 125) can be configured to selectively activate a portion of the set of heating elements to heat the at least one associated segment of the plurality of segments of the consumable assembly 130.
- the processor 125 (or a controller including the processor 125) can be configured to activate each element of the set of heating elements concurrently or intermittently in any suitable order so as to control a rate of the aerosol generated based on the request received from the user or the draw sensor 121.
- the processor 125 can receive pressure data from the draw sensor 121 included in the vaporizer pen 140, and can receive a preference input from a control interface (e.g., the I/O module 126) provided in the vaporizer pen 140 (e.g., provided by a user) associated with a volume of aero.
- a control interface e.g., the I/O module 126
- the processor 125 can selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable based on the pressure data and a volume preference input to produce aerosol based on a preference of the user, for example, based on a draw pressure exerted by the user on the mouthpiece and measured by the draw sensor 121, and/or based on a user setting entered by the user via the +/- buttons.
- each element of the set of heating elements can include a mesh configured to allow the aerosol to pass through each heating element of the set of heating elements and the airflow path.
- the housing 114 of the cartridge 110 can include or be formed from a porous material or include a porous material disposed therein such that the produce aerosol produced aerosol flows through the porous material.
- the heater assembly 150 can include a heater matrix including each heating element of the set of heating elements.
- the heater matrix can be configured, shaped, or formed a sheet and the consumable can include a consumable sheet such that selective activation of the portion of the set of heating elements by the processor 125 (or a controller including the processor 125) such that selective activation of the portion of the set of heating elements by the controller causes an associated portion of the consumable sheet to be aerosolized.
- the heating element(s) can include a susceptor that is aligned with and coextensive with at least one segment of the consumable assembly.
- the heater assembly 150 can include at least one inductor coil and the processor 125 (or a controller including the processor 125) can be configured to selectively activate the at least one inductor coil so as to heat an associated portion of the susceptor(s) and thereby, the associated segment(s) of the consumable assembly 130.
- the memory 123 of the vaporizer pen 140 can store instructions for the processor 125 to receive a request for delivering an aerosol of the consumable material (e.g., a signal from the draw sensor 121), and interpret the request to deliver a suitable or desired amount of aerosol of the consumable material to the user.
- the vaporizer pen 140 can include an interface, input devices, or the like, to transmit a signal representing the request for aerosol delivery to the processor 125.
- the request can include a request by the user to inhale a specific dose or volume of aerosol, specific type of consumable material, or the like.
- the memory 123 can further stores instructions to cause the processor 125 to selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable assembly 130 based on the request.
- At least a portion consumable segment of the consumable assembly 130 can include a predetermined amount of the consumable material (e.g., tobacco, cannabis, PG/VG, a flavored drug, etc.), for example, in a range of about 2 mg to about 30 mg, inclusive, (e.g., about 5 mg, 10 mg, 15 mg, 20 mg, 25 mg, or 30 mg, inclusive of the consumable material in each segment of the consumable material 130).
- a predetermined amount of the consumable material e.g., tobacco, cannabis, PG/VG, a flavored drug, etc.
- the consumable material e.g., tobacco, cannabis, PG/VG, a flavored drug, etc.
- the heating element(s) of the heater assembly 150 can be configured to heat the consumable assembly so as to generate in a range of about 1 mg/sec to about 10 mg/sec of the consumable material to the user (e.g., about 2.5 mg/sec, about 5.0 mg/sec, about 6.0 mg/sec, about 6.5 mg/sec, about 7.0 mg/sec, about 7.5 mg/sec, about 8.0 mg/sec, about 8.5 mg/sec, about 9.0 mg/sec, about 9.5 mg/sec, or about 10.0 mg/sec, inclusive of the aerosol of the consumable material).
- about 1 mg/sec to about 10 mg/sec of the consumable material to the user e.g., about 2.5 mg/sec, about 5.0 mg/sec, about 6.0 mg/sec, about 6.5 mg/sec, about 7.0 mg/sec, about 7.5 mg/sec, about 8.0 mg/sec, about 8.5 mg/sec, about 9.0 mg/sec, about 9.5 mg/sec, or about 10.0 mg/sec, inclusive of the aerosol of the consum
- the user can interact with the I/O module 126 and/or interface any other interface of the vaporizer pen 140 to select an amount of aerosol that is desired by the user.
- the user can also select the type of consumable, drug, flavor, and/or the like, to be aerosolized for inhalation.
- the vaporizer pen 140 including the power source 124 can be implemented to conserve power consumption by intermittently and/or concurrently powering each heating element such that fewer heating elements are on at any one time so as to control the rate of the aerosol generated based on the request provided by the user.
- the process of heating the consumable assembly 130 can focus higher energy on a smaller surface of the consumable assembly 130, or one or more consumable segments, at a time to reduce or eliminate latency of heating.
- the power source 124 of the vaporizer pen 140 can be configured to cycle each heating element with uniform peak power output, enabling the user to vary the volume of aerosol produced.
- the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to receive pressure data from the draw sensor 121 disposed in the vaporizer pen 140.
- the processor 125 can receive a signal including a measured pressure or force, and can send an instruction to cause the heater assembly 150 to heat the consumable assembly 130 based on the signal.
- the processor 125 can send instructions to cause the heater assembly 150 to produce more aerosol volume and/or produce aerosol at a faster rate in response to receiving a signal including a higher measured pressure or force.
- the processor 125 can send instructions to cause the heater assembly 150 to produce less aerosol volume and/or produce aerosol at a slower rate in response to receiving a signal including a relatively lower measured pressure or force.
- the memory 123 can also store instructions to cause the processor 125 to receive a preference input from the draw sensor 121 and/or the other sensor(s) 134 and send an instruction to the heater assembly 150 based on the received input.
- the processor 125 can be configured to selectively activate the portion of the set of heating elements to aerosolize the at least a portion of the consumable assembly 130 based on the pressure data and the preference input so as to produce aerosol and/or produce aerosol of the consumable material.
- the cartridge 110 will not operate when coupled to the vaporizer pen 140 unless the cartridge 110 has first been validated and/or activated.
- a user can use a mobile device (not shown) to communicate with a command center to retrieve information associated with the cartridge 110 by sending data such as cartridge identifying information, the pressure data from the draw sensor 121 and/or a preference input from the processor 125 to the command center.
- the mobile device can present a presentation (e.g., a webpage or an application) on a display of the mobile device (e.g., automatically) including at least some of the information associated with the cartridge 110.
- the user can view information associated with the cartridge 110, such as a source of the contents of the consumable assembly 130, reservoir 138, concentration, dosage, or the like thereof.
- the vaporizer pen 140 can include a display that shows fill and/or usage data associated with the cartridge 110 (e.g., the type of consumable disposed in the cartridge 110, amount of consumable remaining, aerosol delivery rate, etc.).
- the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 of the vaporizer pen 140 to transmit the fill and/or usage data to the mobile device.
- the fill and/or usage data can include, for example, one or more of consumable materials and/or ingredients, consumable formulation, nicotine concentration, nicotine plant genetics, nicotine provenance data (e.g., the tobacco plant(s) from which the nicotine was derived, the grow location of the nicotine plant(s), the grow and/or harvesting date of the nicotine plant(s), etc.) cannabinoid concentration(s), cannabinoid provenance data (e.g., the cannabis plant(s) from which the cannabinoid(s) were derived, the grow location of the cannabis plant(s), seed information associated with the cannabis plant(s), the date on which the cannabis seeds were planted, the grow and/or harvesting date of the cannabis plant(s), the dispensary from which the cannabinoid(s) were obtained, etc.), active ingredient (e.g., drug) concentration, extraction method(s) (and details thereof) used when converting the cannabis plant(s) into carrier material, inactive ingredient concentration, functionality of the vaporizer (e.g., nicotine proven
- the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 of the vaporizer pen 140 to communicate the fill and/or usage data to the processor 132 of the cartridge 110.
- the processor 132 can transition the cartridge 110 from a deactivated status to an activated status (e.g., activate the cartridge 110) (e.g., in response to receiving an activation signal from the vaporizer pen 140).
- the cartridge 110 can be used by the user for aerosolization of the contents of the consumable assembly 130 (e.g., a solid or gel consumable substance included in the consumable assembly 130 and/or a liquid consumable substance soaked in the consumable assembly 130 or stored in the reservoir 138).
- the processor 132 of the cartridge 110 or the processor 125 of the vaporizer pen 140 can include a fraud mitigation feature to avoid a brute force activation in which the user can attempt to activate the cartridge 110 by aligning a light sensor (not shown) on the vaporizer pen 140 with the display displaying or flashing a color or series of colors (e.g., button(s), a button code, a randomized display, etc.). For instance, a combination of button presses can enable and/or disable the fraud mitigation control.
- the fraud mitigation feature can include a lock-out feature such that, in the event of a certain number of failed activation attempts (e.g., one, two, three).
- the memory 137 / 121 can store instructions to cause the processor 132 / 125 to pause or lock the cartridge 110 and the vaporizer pen 140 for a predetermined period of time (e.g., thirty seconds, two minutes, three minutes) before another activation attempt can be initiated.
- the predetermined period of time can progressively increase with each failed activation attempt, such that the first pause of lock period is shorter than the duration of the second, which is shorter than the duration of the third, etc.
- the first pause period can be thirty seconds
- the second can be two minutes
- the third can be ten minutes
- the fourth can be an hour
- the fifth can be six hours, etc.
- the lockout period can be permanent.
- the sensor(s) 134 of the cartridge 110 and/or the light sensor of the vaporizer pen 140 can be configured to read an indication generated by the remote compute device (e.g., a mobile device or a remote server).
- the remote compute device can include an indication generator configured to present the indication.
- the indication generator of the remote compute device can include a display (e.g., liquid-crystal display (LCD)), organic light-emitting diode (OLED), active-matrix organic light emitting diodes (AMOLED), Super AMOLED, a thin film transistor technology (TFT) LCD, an in-place switching (IPS) LCD, a resistive touchscreen LCD, a capacitive touchscreen LCD display) configured to generate a visual or optical indication.
- the indication generator can be a speaker configured to generate an auditory indication.
- the indication generator can be a vibration component (e.g., a vibration motor or a piezoelectric vibrating element) configured to generate a vibratory indication.
- the indication can be at least one of a visual indication, an auditory indication, or a vibratory indication.
- the vaporizer pen 140 can include a lock, for example, a mechanical or electronic lock.
- the operation of the vaporizer pen 140 and the cartridge 110 together can be a locking or unlocking operation.
- the lock can optionally be a mechanical lock.
- the lock status of the vaporizer pen 140 can be a lock status of the mechanical lock and the mechanical lock can be in a locked configuration when the lock status is locked, and the mechanical lock can be in an unlocked configuration when the lock status is unlocked.
- the interior space of a housing of the vaporizer pen 140 can be inaccessible when the mechanical lock is in the locked configuration and can be accessible when the mechanical lock is in the unlocked configuration.
- the vaporizer pen 140 will not unlock, operate, or perform one or more particular operations unless the aerosolization system 100 has first been activated, validated and/or instructed (e.g., via data or instructions provided via the indication generated by the indication generator of the remote compute device).
- a calibration sequence can be presented in conjunction with the indication.
- the calibration sequence and the indication can both be presented as part of the remote compute device presentation presented by the indication generator.
- the calibration sequence can be used to ensure that the indication sensed by the sensor(s) 134 is accurately understood by the processor 125 or 132 regardless of the variation or distortion in the indication generator compared to other indication generators.
- the calibration sequence can include a predetermined sequence of colors (e.g., including each color used in the indication (e.g., in the portion of the compute device presentation associated with the key indicator)) displayed on the display of the cartridge 110.
- the processor 125 or 132 can be configured to recognize the colors in the calibration sequence based on the predetermined sequence.
- the processor 125 or 132 can be configured to understand the indication (e.g., to identify the key indicator in the portion of the compute device presentation associated with the key indicator) based on the colors in the calibration sequence.
- the processor 125 of the cartridge 110 can then actuate the heater assembly 150 to pass a current through one or more of heating element(s) that is in contact with, or in sufficiently close proximity to, the carrier material or a wick material containing at least a portion of the carrier material, so as to cause the aerosolization of the portion of the consumable assembly 130.
- One or more characteristics of the current or affecting the delivery of the current passed through the heating element(s) can be controlled by the processor 125 based on, for example, an ambient temperature measured by a temperature sensor of the sensor(s) 134, a resistance of the heating element, and/or a heating profile or target temperature range associated with the consumable material (e.g., as determined by the processor 125 and/or provided to the processor 125 and/or stored in the memory 123 prior to use).
- the volatilized consumable material, aerosol, and/or vapor travels toward the mouthpiece 133 of the cartridge 110 via one or more of the expansion chamber(s), the heater chamber 131, or one or more of the fluidic channels until it exits a mouthpiece opening for inhalation by the user.
- the cartridge 110 and/or the vaporizer pen 140 can be coupled to the mobile device (e.g., a mobile phone, tablet, external connected hub, smart charger or dock, or computer) via, for example, Bluetooth or Wi-Fi, such that the mobile device can control one or more operations of the cartridge and/or the vaporizer pen 140.
- the mobile device can lock and/or unlock the cartridge 110 such that the processor 125 does not actuate the heater assembly 150 when locked and the processor 125 can actuate the heater assembly 150 when unlocked.
- the memory 137 can include or store a second identifier of the cartridge 110.
- a command center can include a database in a memory of the command center associating the first identifier, the second identifier, and consumable material data (e.g., mass data, volume data, or fill data) associated with the cartridge 110.
- the second identifier is unique to only one cartridge 110. In some embodiments, the second identifier can be used in more than one cartridge 110.
- the second identifier can be used in more than one cartridge 110, but used in only a small portion of manufactured cartridges 110 (e.g., less than 5%, less than 1%).
- the consumable data can include, for example, one or more of carrier ingredients, carrier formulation, nicotine concentration, nicotine plant genetics, nicotine provenance data (e.g., the tobacco plant(s) from which the nicotine was derived, the grow location of the nicotine plant(s), the grow and/or harvesting date of the nicotine plant(s), etc.) cannabinoid concentration(s), cannabinoid provenance data (e.g., the cannabis plant(s) from which the cannabinoid(s) were derived, the grow location of the cannabis plant(s), seed information associated with the cannabis plant(s), the date on which the cannabis seeds were planted, the grow and/or harvesting date of the cannabis plant(s), the dispensary from which the cannabinoid(s) were obtained, etc.), active ingredient (e.g., drug) concentration, extraction method(s
- FIG. 2 is a schematic illustration of a portion of a heater assembly 250 including a set of heating elements disposed proximate to a portion of a consumable assembly 230, according to an embodiment.
- the heater assembly 250 can be the same or similar in structure and/or function to the heater assembly 150 and/or the at least one heating element 170 described with respect to FIG. 1.
- the heater assembly 250 can include a matrix of heating elements (e.g., heating element 252a / 252b) collectively forming the heater assembly 250.
- the heating elements e.g., 252a / 252b
- the heating elements can be configured in a geometrically uniform shape or form.
- the heater assembly 250 and/or the heating elements can mate with the consumable assembly 230.
- the heater assembly 250 can directly contact the consumable assembly 230 and/or be densely pressed onto the consumable assembly 230.
- the consumable assembly 230 includes a solid, semi-solid, or gel consumable substance.
- the consumable assembly 230 can also be referred to as a “consumable.”
- the consumable assembly 230 can be the same or similar in structure and/or function to the consumable assembly 130 described with respect to FIG. 1.
- the consumable assembly 230 can be configured as a sheet.
- the sheet can have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 2.0 mm, about 2.5 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive).
- consumable assembly 230 can have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive.
- the consumable 230 can have a thickness less than 5 mm (e.g.
- the consumable assembly 230 can have a thickness in range of about 0.2 mm to about 1 mm, inclusive.
- the consumable assembly 230 can also be flexible or malleable to form multiple distinct shapes or configurations further described in FIG. 3A-K.
- the consumable assembly 230 can include, or be formed from a solid, semi-solid, or gel consumable material configured to be directly aerosolized by the heater assembly 250 and/or the heating elements (e.g. 252a / 252b).
- the consumable assembly 230 can have several different configurations and include various materials.
- solid consumable materials used in the consumable assembly 230 can be a densely pressed plant or synthetic consumable material such as, for example, tobacco, or cannabis products and extracts made from plant material, such as crystal or solid extractions reconstituted into a sheet format.
- the sheet can be made using a dehydration processes, reconstitution processes, extraction processes, or the like, and can contain additives such as propylene glycol (PG) or vegetable glycerin (VG) to create desirable constitution and/or physical attributes of the consumable assembly 230.
- PG propylene glycol
- VG vegetable glycerin
- the consumable assembly 230 can include a sheet having multiple segments.
- Each of the segments (e.g. consumable segment 260 / 262) of the consumable assembly 230 can include the same consumable material or different consumable materials in any suitable combination.
- the one or more segments of the consumable assembly 230 can be in direct contact and/or proximate with the one or more heating elements of the heater assembly 250.
- each corresponding heating element e.g. heating element 252a / 252b
- directly contacts with a corresponding segment e.g. segment 260 / 262
- the heating element 252a directly contacts the segment 260 and the heating element 252b directly contacts the segment 262.
- Each heating element of the heater assembly 250 directly contacts an associated segment of the consumable segment 230.
- the heater assembly 250 (and the heating elements) share a similar configuration as the consumable assembly 230 (and the segments), for example, have about the same size and shape (e.g., have about the same surface area and/or axial extents), and can be aligned with the consumable assembly 230.
- the heater assembly 250 can be in direct contact with the consumable assembly 230, as described herein.
- FIG. 3A is a schematic illustration of a consumable assembly 330, according to an embodiment.
- the consumable assembly 330 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 330 includes a heater assembly 350 disposed proximate to and radially outward of an aerosol-generating substance portion 360 having a circular cross-sectional shape.
- the heater assembly 350 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1.
- the heater assembly 350 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 330). In some implementations, the heater assembly 350 can include a single heating element, such as a solid metal sheet.
- the aerosol-generating substance portion 360 and the heater assembly 350 are formed as (e.g., rolled into) a hollow tube shape having a circular crosssection.
- An outer surface area of the heater assembly 350 is in direct contact with an inner surface area of the aerosol-generating substance portion 360.
- an inner diameter of the aerosol-generating substance portion 360 is about equal to or slightly larger than an outer diameter of the heater assembly 350.
- the aerosolization of the aerosol-generating substance portion 360 can occur on the side that is directly interfacing with the heater assembly 350.
- the heater assembly 350 can aerosolize the aerosol-generating substance portion 360 by applying heat to the inner surface of the aerosol-generating substance portion 360, thereby aerosolizing the aerosol-generating substance portion 360 from an inner surface thereof.
- aerosolization can occur on either side of the aerosolgenerating substance portion 360 via the side that is directly interfacing with the heater assembly 350.
- the aerosol-generating substance portion 360 and/or the heater assembly 350 can include features that allow for air to flow through the consumable assembly 330.
- the aerosol-generating substance portion 360 and/or the heater assembly 350 can include a surface pattern for perforations, be porous, or define apertures therethrough.
- FIG. 3B is a side cross-section view of the consumable assembly 330 taken along the line A-A in FIG. 3 A.
- the heater assembly 350 and the aerosol-generating substance portion 360 can be directly in contact, forming a thin configuration, where the aerosol -generating substance portion 360 is on top of and/or in direct contact with the outer surface of the heater assembly 350 as shown in FIG. 3B.
- FIG. 3C is a schematic illustration of a consumable assembly 430, according to an embodiment.
- the consumable assembly 430 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 430 includes a heater assembly 450 disposed proximate to and radially inward of an aerosol-generating substance portion 460 having a circular cross-sectional shape.
- the heater assembly 450 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1.
- the heater assembly 450 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 430). In some implementations, the heater assembly 450 can include a single heating element, such as a solid metal sheet.
- the aerosol-generating substance portion 460 and the heater assembly 450 are formed as (e.g., rolled into) a hollow tube shape having a circular crosssection.
- An inner surface area of the heater assembly 450 is in direct contact with an outer surface area of the aerosol-generating substance portion 460.
- an inner diameter of the heater assembly 450 is about equal to or slightly larger than an outer diameter of the aerosolgenerating substance portion 460.
- the aerosolization of the aerosol-generating substance portion 460 can occur on the side that is directly interfacing with the heater assembly 450.
- the heater assembly 450 can aerosolize the aerosol-generating substance portion 360 by applying heat to the outer surface of the aerosol-generating substance portion 460, thereby aerosolizing the aerosol-generating substance portion 460 from an outer surface thereof.
- FIG. 3D is a side cross-section view of the consumable assembly 430 taken along the line B-B in FIG. 3C.
- the heater assembly 450 and the aerosol-generating substance portion 460 can be directly in contact, forming a thin configuration, where the heater assembly heater assembly 450 is on top of and/or in direct contact with the outer surface area of aerosolgenerating substance portion 460 as shown in FIG. 3C.
- FIG. 3E is a schematic illustration of a consumable assembly 530.
- the consumable assembly 530 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 530 includes a heater assembly 550 including a first heating element 552a and a second heating element 552b.
- the first heating element 552a is disposed proximate to and radially outward of an aerosol-generating substance portion 560 having a circular cross-sectional shape
- the second heating element 552b is disposed proximate to and radially inward of the aerosol-generating substance portion 560.
- the heater assembly 550 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1.
- each of the first heating element 552a and the second heating element 552b can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 530).
- each of the first heating element 552a and the second heating element 552b can include a single heating element, such as a solid metal sheet.
- the aerosol-generating substance portion 560, the first heating element 552a, and the second heating element 552b are formed as (e.g., rolled into) a hollow tube shape having a circular cross-section.
- An inner surface area of the first heating element 552a is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
- An outer surface area of the second heating element 552b is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
- FIG. 3F is a schematic illustration of a consumable assembly 630, according to an embodiment.
- the consumable assembly 630 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 630 includes a heater assembly 650 disposed proximate to (e.g., in contact with) and outward of an aerosolgenerating substance portion 660.
- Each of the heater assembly 650 and the aerosol-generating substance portion 660 have a star cross-sectional shape.
- the heater assembly 650 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1.
- the heater assembly 650 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 630).
- the heater assembly 650 can include a single heating element, such as a solid metal sheet.
- the configuration (e.g., cross-sectional shape and elongated shape) of the heater assembly 650 and the aerosol-generating substance portion 660 can be in any radially symmetrical shape or form.
- FIG. 3G is a schematic illustration of a portion of a consumable assembly 730, according to an embodiment.
- the consumable assembly 730 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 730 includes a heater assembly 750 disposed proximate to (e.g., contacting) and having a cross- sectional shape corresponding to an aerosol-generating substance portion 760.
- the heater assembly 750 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. As shown in FIG.
- the heater assembly 750 and the aerosol-generating substance portion 760 can be formed to define an asymmetric curve and the aerosol-generating substance portion 760 can be disposed on an outer or upper surface of the heater assembly 750.
- the heater assembly 750 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 730).
- the heater assembly 750 can include a single heating element, such as a solid metal sheet.
- FIG. 3H is a schematic illustration of a portion of a consumable assembly 830, according to an embodiment.
- the consumable assembly 830 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 830 includes a heater assembly 850 disposed proximate to (e.g., contacting) and having a cross- sectional shape corresponding to an aerosol-generating substance portion 860.
- the heater assembly 850 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. As shown in FIG.
- the heater assembly 850 and the aerosol-generating substance portion 860 can be formed to define an asymmetric curve and the aerosol-generating substance portion 860 can be disposed on an inner or lower surface of the heater assembly 850.
- the heater assembly 850 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 830).
- the heater assembly 850 can include a single heating element, such as a solid metal sheet.
- the heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include any suitable heating element(s).
- the heating element(s) and/or heating assemblies described with respect to FIGS. 3A-3H can include a direct resistive heater such as the metallic coil, a printed coil circuit, or the like.
- the heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include an embedded indirect heater such as a ceramic diffuser and a coil, a printed sheet heater, and/or any conductive foil/mesh in contact with any of the aerosolgenerating substance portions described with respect to FIGS. 3A-3H.
- the heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include or be formed as susceptors.
- FIG. 31 is a schematic illustration of a portion of a consumable assembly 930 including a heater assembly 950 including one or more heating elements 952 disposed in contact with an aerosol-generating substance portion 960.
- the heating assembly 950 includes a susceptor 956 radially spaced apart from the one or more heating elements 952 and the aerosol-generating substance portion 960.
- the one or more heating elements 952 can include a metallic sheet or foil in contact with the aerosol-generating substance portion 960.
- the susceptor 956 is configured to be energized by an inductor coil (not shown) located proximate thereto and to generate heat so as to heat an associated portion of the metallic foil 952 and, thereby, the aerosol-generating substance portion 960.
- the configuration shown in FIG. 31 includes the susceptor 956 located proximate to the one or more heating elements 952, but, in some implementations, the susceptor 956 can be in direct contact with the 960 such that the metallic foil 952 can be excluded.
- the susceptor 956 can include any material that absorbs electromagnetic energy (via the associated portion of the metallic foil) and converts the electromagnet energy into heat, where the susceptor 956 then applies heat to the metallic foil in contact with the consumable assembly aerosol-generating substance portion [0245] FIG.
- 3J is a schematic illustration of a portion of a consumable assembly 1030 including an aerosol -generating substance portion 1060 disposed proximate to a set of heating elements 1052 of a heater assembly 1050, each of which is configured to provide radiant heat to an associated portion of the aerosol -generating substance portion 1060.
- Each of the heating elements 1052 can include a radiant heater and/or an infrared (IR) heater that is not in direct contact with the consumable assembly 1030, but is in proximity to the consumable assembly 1030.
- Each heating element 1052 can radiate heat on a surface of aerosol-generating substance portion 1060 facing the heating element 1052.
- the heating elements 1052 and/or the heater assembly 1050 can apply heat to the aerosol-generating substance portion 1060 using a laser, a magnetron, a heated air jet, or the like.
- FIG. 3K is a schematic illustration of a consumable assembly 2130.
- the consumable assembly 2130 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1.
- the consumable assembly 2130 includes heater element(s) 2170, a first aerosol-generating substance portion 2160, and a second aerosol-generating substance portion 2162.
- the second aerosol -generating substance portion 2162 is disposed proximate to (e.g., contacting) and radially outward of the heater element(s) 2170 and the first aerosolgenerating substance portion 2160 is disposed proximate to (e.g., contacting) and radially inward of the heater element(s) 2170.
- the heater element(s) 2170 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1.
- the heater element(s) 2170 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 2130).
- the heater element 2170 can include a single heating element, such as a solid metal sheet. As shown in FIG.
- the heater element(s) 2170, the first aerosol -generating substance portion 2160, and the second aerosolgenerating substance portion 2162 are each formed as hollow tubes having a constant circular cross-section along the length of the consumable assembly 2130.
- the consumable assembly 2130 includes a first membrane layer 2164 (e.g., disposed on an interior surface of the first aerosol-generating substance portion 2160) and a second membrane layer 2164 (e.g., disposed on an exterior surface of the second aerosol -generating substance portion 2162) that can be the same or similar to the first membrane layer 164 and/or the second membrane layer 166 described with respect to FIG. 1. [0247] As shown in FIG.
- the aerosol-generating substance portion 560, the first heating element 552a, and the second heating element 552b are formed as (e.g., rolled into) a hollow tube shape having a circular cross-section.
- An inner surface area of the first heating element 552a is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
- An outer surface area of the second heating element 552b is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
- FIG. 4A-5B are schematic illustrations of various configurations of an aerosolization system 1100 that includes a cartridge 1110 and a vaporizer pen 1140 configured to be coupled to the cartridge 1110, according to an embodiment.
- FIG. 4A is a schematic illustration of a portion of a vaporizer pen 1140, according to an embodiment.
- the vaporizer pen 1140 can be the same or similar in structure and/or function to any of the vaporizer pens described herein, such as the vaporizer pen 140.
- the vaporizer pen 1140 includes a heater assembly 1150 that can be the same or similar in structure and/or function to any of the heater assemblies described herein, such as the heater assembly 150.
- the heater assembly 1150 can be inserted or positioned in a cartridge holder 1141 located at one end of the vaporizer pen 1140. As shown in FIG. 4A, the vaporizer pen 1140 and the heater assembly 1150 includes a radially symmetrical shape such as a tube, cylinder, stick, or the like.
- the heater assembly 1150 can include on one end a housing and/or opening defining a receptacle shaped and sized to receive the cartridge 1110.
- FIG. 4B is a schematic illustration of the cartridge assembly 1110 configured to be coupled to the vaporizer pen 1140 shown in FIG. 4 A.
- the cartridge assembly 1110 can be the same or similar in structure and/or function to any of the cartridges described herein, such as the cartridge 110.
- the cartridge assembly 1110 includes a consumable assembly 1130 disposed within a housing 1114 of the cartridge assembly 1110.
- the housing 1114 can also be referred to as a “container.”
- the housing 1114 can provide structure for holding or securing the consumable assembly 1130.
- the housing 1114 can be used as a filter or liquid isolator to prevent liquid or gel from leaking out of the housing 1114, such as in implementations in which the consumable assembly 1130 includes a liquid and/or a high concentration of glycerin or similar contained in a wick.
- the housing 1114 can include a single container or multiple parts forming the container.
- the housing 1114 can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like.
- an outer surface area of the housing 1114 can be coated with a membrane such as any of the coatings or membranes described with respect to the housing 114 described in FIG. 1.
- the housing 1114 can also function as a heating chamber consistent with the heating chamber described with respect to the cartridge 100 shown in FIG. 1.
- the housing 1114 of the cartridge assembly 1110 includes a hollow housing that defines an airflow path towards a mouthpiece opening (not shown) at a top end of an airflow path 1115.
- the consumable assembly 1130 can also include a channel 1132 extending through one or both ends of the consumable assembly 1130 such that aerosol produced by the consumable assembly 1130 can travel upwards through the channel 1132 and into the mouthpiece opening for inhalation.
- the channel 1132 can act as a heater chamber to facilitate and/or draw aerosol through the housing 1114 of the cartridge assembly 1110, along the airflow path 1115, and into the mouthpiece opening for inhalation.
- the housing 1114 can define a heater chamber located radially inwards of the consumable assembly 1130.
- FIG. 4C is a schematic illustration of a portion of a vaporizer pen assembly 1140a that can be used in conjunction with the cartridge assembly 1110 of the system 1100 of FIG. 4A-4B, according to an embodiment.
- the cartridge assembly 1130 can be coupled to the vaporizer pen assembly 1140a, where the vaporizer pen assembly 1140a includes the cartridge holder 1141 to hold and/or house the cartridge assembly 1130.
- the cartridge holder 1141 can include a heater assembly 1150a that can be coupled to the consumable assembly 1130 of the cartridge assembly 1130 of the system of FIG. 4B.
- the heater assembly 1150a extends axially along a longitudinal axis AL.
- the heater assembly 1150a includes a set of heating elements such as heating element 1152al and heating element 1152a2.
- the heater assembly 1150a having a cylindrical body can include of multiple heating elements (e.g. heating element 1152al / 1152a2) where each heating element extends axially parallel to the longitudinal axis A L of the heater assembly 1150a, with the set of heating elements being separated from each other along a circumferential direction about the longitudinal axis AL.
- the configuration of the heater assembly 1150a can form an axial channel 1154a therethrough as shown in FIG. 4C.
- the axial channel 1154a can also be referred to as an “inner axial channel,” which can be configured to allow passage of air or aerosol therethrough.
- FIG. 4D is a schematic illustration of a portion of a vaporizer pen assembly 1140b that can be used in the with the cartridge assembly 1110 of the system 1100 of FIG. 4A-4B, according to an embodiment.
- the cartridge assembly 1130 can be coupled to the vaporizer pen assembly 1140b, where the vaporizer pen assembly 1140b includes the cartridge holder 1141 to hold and/or house the cartridge assembly 1130.
- the cartridge holder 1141 can include a heater assembly 1150b that can be coupled to the consumable assembly 1130 of the cartridge assembly 1130 of the system of FIG. 4B.
- the heater assembly 1150b extends in a circumferential direction about the longitudinal axis AL, where the heating elements of the set of heating elements are axially separated from each other along the longitudinal axis AL.
- the heater assembly 1150b having a cylindrical body can include multiple heating elements (e.g. heating element 1152b 1 / 1152b2) where each heating element (e.g. heating element 1152b 1 / 1152b2) of the set of heating elements extends in a circumferential direction about the longitudinal axis AL A L , with the heating elements being axially separated from each other along the longitudinal axis AL.
- the configuration of the heater assembly 1150b can form an axial channel 1154b therethrough as shown in FIG. 4D.
- the axial channel 1154b can also be referred to as an “inner axial channel,” which can be configured to allow passage of air or aerosol therethrough.
- the heater assembly 1150b can also be formed in between the inner axial channel 1154b located radially inward of the heater assembly 1150b and an outer axial channel 1143b located radially outward of the heater assembly 1150b.
- the inner axial channel 1154a / 1154b and/or the outer axial channel 1143a / 1143b can act as a holder for the consumable assembly 1130, where either side of the consumable assembly 1130 is in direct contact with and/or proximate to the heater assembly 1150a / 1150b as shown in the configurations 350 and 450 in FIG. 3A and FIG. 3C, respectively.
- the heater assembly 1150a / 1150b can also be disposed at least one of radially outward or radially inward of the consumable assembly 1130.
- the cartridge assembly 1110 can couple to the vaporizer pen assembly 1140a / 1140b by inserting the cartridge assembly 1110 into the outer axial channel 1143a / 1143b, where the consumable assembly 1130 in the cartridge assembly 1110 is subsequently inserted in the inner axial channel 1154a / 1154b.
- the consumable assembly 1130 can be in direct contact with and/or proximate to the inner surface area of the heater assembly 1150a / 1150b, where the heater assembly 1150a / 1150b and/or at least one of the heating elements (e.g. heating element 1152al / 1152bl) can apply heat to the consumable assembly 1130, to produce aerosol.
- the produced aerosol can travel upwards along the longitudinal axis AL through an airflow path defined by the inner axial channel 1154a / 1154b.
- FIG. 5 A is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly 1110 of FIG. 4A-4B coupled to the vaporizer pen assembly 1140a / 1140b of FIG. 4C or 4D, respectively.
- the cartridge assembly 1110 including the consumable assembly 1130 can be coupled to the vaporizer pen assembly 1140a / 1140b of FIG. 4C or 4D, respectively where the consumable assembly 1130 and the cartridge assembly 1110 is placed in the outer axial channel 1143a / 1143 b of FIG. 4C or 4D.
- the heater assembly 1150a / 1150b can apply heat to the consumable assembly 1130 through the inner surface area of the consumable assembly 1130 to produce aerosol.
- the produced aerosol can then travel upwards along an airflow path 1115 and through the mouthpiece opening for inhalation.
- the cartridge assembly 1110 can also include the housing 1114 previously described in FIG. 4B.
- the housing 1114 and/or the cartridge assembly 1110 can also be wrapped with a membrane 1111 on the outer surface area of the housing 1114 and/or the cartridge assembly 1110.
- the housing 1114 can be consistent with the housing or membrane 114 described in FIG. 1.
- the membrane 1111 can include a thin sheet such as paper or a synthetic form sheet to provide further structure for the housing 1114 and/or the cartridge assembly 1110.
- the membrane 1111 can also include paper to imitate the texture and feel of a cigarette stick.
- the membrane 1111 cannot include any water and/or liquid permeable material as to serve as a barrier for any liquid that can be contained inside the consumable assembly 1130.
- the cartridge assembly 1110 can also include a consumable holder 1157 that serves to hold the consumable assembly 1130 in place and stably.
- the consumable holder 1157 can also include a continuous cleaning mechanism to clean the heater assembly 1150a / 1150b for each use of the consumable assembly 1130, such as replacing the cartridge assembly 1110 with a new cartridge assembly and/or each time the heater assembly 1150a / 1150b applies heat to the consumable assembly 1130.
- FIG. 5B is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly 1110 of FIG. 4B coupled to the vaporizer pen assembly 1140a of FIG. 4C, and indicating the direction of aerosol flow F through the system, according to an embodiment.
- the consumable assembly 1130 can directly contact and/or be proximate to the heater assembly 1150a, where the heater assembly 1150a includes the set of heating elements (e.g., heating element 1152al / 1152a2) extending axially along the longitudinal axis of the heater assembly 1150a.
- the heater assembly 1150a can include material that allows for aerosol flow F to pass through the heater assembly 1150a (e.g., perforation) and along the airflow path 1115 towards the mouthpiece opening.
- the heater assembly 1150a can include a mesh heater, a set of mesh heaters, printed filament with porous substrate, and/or any other heating element that allows for aerosol to pass through it.
- FIG. 6A is a schematic illustration of a portion of a vaporizer pen assembly 1240 that can be used in an aerosolization system 1200, according to an embodiment.
- the vaporizer pen assembly 1240 includes a cartridge holder 1241 at one end of the vaporizer pen assembly 1240.
- the portion of the vaporizer pen assembly 1240 is consistent with or substantially similar to the portion of the vaporizer pen assembly 1140b of FIG. 4D.
- the vaporizer pend assembly 1240 includes a heater assembly 125 that extends in a circumferential direction about the longitudinal axis AL, where the heating elements (e.g., heating elements 1252a / 1252b) of the set of heating elements are axially separated from each other along the longitudinal axis AL.
- the heater assembly 1250 having a cylindrical body can include multiple heating elements (e.g. heating element 1252a / 1252b) where each heating element (e.g. heating element 1252a / 1252b) of the set of heating elements extends in a circumferential direction about the longitudinal axis AL, where the heating elements are axially separated from each other along the longitudinal axis AL,
- the configuration of the heater assembly 1250 can form an outer axial channel 1243 located radially outward of the heater assembly 1250 as shown in FIG. 6A.
- the set of heating elements (e.g. heating element 1252a / 1252b) extending in the circumferential direction about the longitudinal axis AL can include a set of mesh heaters as further described in FIG. 6B.
- FIG. 6B is a side cross-section of a portion of the aerosolization system 1200 that includes the vaporizer pen assembly 1240 of FIG. 6A couped to a cartridge assembly 1210, according to an embodiment.
- the cartridge assembly 1210 and a consumable assembly 1230 included in the cartridge assembly 1210 can be inserted into the outer axial channel 1243, where the consumable assembly 1230 is in direct contact with and/or proximate to the heater assembly 1250 and/or the set of heating elements (e.g. heating element 1252a / 1252b) as shown in FIG. 6B.
- the set of heating elements and/or the heater assembly 1250 can include a mesh heater, at least one or more segments of a mesh, printed filament, embedded ceramic element, filament embedded into ceramic substrate or any other heating element that can be constructed as a rod (e.g. round, square, etc.), or the like.
- the housing 1214 can include a porous material such as cellulose or cotton that allows aerosol to pass directly through the housing 1214 as directed by the airflow path F, where aerosolization of the consumable assembly 1230 occurs on all sides of the consumable assembly 1230.
- the cartridge assembly 1210 can also include a housing 1214 that allows for an aerosol flow F out of the consumable assembly 1230 and through the housing 1214.
- the heater assembly 1250 can include a portion 1253 at one end of the heater assembly 1250.
- the portion 1253 can be inserted into a heater chamber 1215 defined by the cartridge assembly 1210.
- the heater chamber 1215 can include an opening and/or space for the heater assembly 1250 to occupy while applying heat to the consumable assembly 1230.
- the cartridge assembly 1210 also includes a membrane 1211 wrapped around the outer surface of the housing 1214 and/or the cartridge assembly 1210, where the membrane is consistent with any membrane as described in the entirety of this disclosure. As shown in FIG.
- the heater chamber 1215 can be closed at an end distal from heater assembly 1250.
- the housing 1214 can be formed from a porous material such that aerosol produced due to heating of the consumable assembly 1230 flows through the porous material of the housing 1214 towards a user.
- FIG. 7 A is side cross-section view of a portion of an aerosolization system 1300a including a cartridge assembly 1310a coupled to a housing 1341a of a vaporizer pen 1340a, according to various embodiments.
- the cartridge assembly 1310a includes an assembly 1329a including a consumable assembly 1330a and heating element(s) 1339a that include a susceptor disposed on a radially outer surface of the consumable assembly 1330a.
- the aerosolization system 1300a produces aerosol by using at least one susceptor.
- the at least a susceptor can also be referred to as a “susceptor,” a “susceptor material,” or “susceptor(s) .”
- the heater assembly 1350a can include at least one induction segment or inductor coils (e.g. induction segment 1352al / 1352a2 / 1352a3).
- the at least one induction segment can also be referred to as “induction segment.”
- multiple induction segments 1352al / 1352a2 / 1352a3 can include at least a coil.
- the heater assembly 1350a and/or the set of heating elements 1339a can include a susceptor 1339a that can include perforated metallic foil or mesh that is contact with a consumable assembly 1330a of the cartridge 1310a, and is configured to be heated by the induction segments (e.g., the induction segments 1352al / 1352a2 / 1352a3), where the at least a induction segments can be wrapped around the heater assembly 1350a and/or the set of heating elements 1339a.
- the inductor segments 1352al / 1352a2 / 1352a3 can be configured to selectively apply electromagnetic energy to an associated segment of the susceptor 1339a to heat the susceptor 1339a to aerosolize the consumable assembly 1330a.
- the heater assembly 1350a can be configured to include pairs of induction segments. For instance, a pair of coils can be placed through and around the cartridge 1310a when the cartridge 1310a is coupled to the vaporizer pen assembly 1340a.
- the inductor segments 1352al / 1352a2 / 1352a3 can be powered by a power source in the vaporizer pen 1340a (not shown) to heat the heater assembly 1350a, where the heater assembly 1350a can apply the heat via the heating elements 1339a (e.g., susceptor(s)) to the consumable assembly 1330a.
- a set of heating elements 1339a of the heater assembly 1350a can be located radially outward of the consumable assembly 1330a, aerosolizing the consumable assembly 1330a from the outside, where the produced aerosol follows the aerosol flow F through the airflow path 1315a.
- the cartridge assembly 1310 can also include a housing 1313a, where the housing 1313a is consistent with any housing as described in the entirety of this disclosure.
- the housing 1311a and/or the cartridge assembly 1310 can also be wrapped around by a membrane 1313a, where the membrane 1313a is consistent with any membrane as described in the entirety of this disclosure.
- FIG. 7B is a side cross-section views of portions of aerosolization system 1300b including a cartridge assembly 1310b coupled to a housing 1341b of a vaporizer pen 1340b, according to embodiments.
- the cartridge assembly 1310b includes an assembly 1329b that includes a consumable assembly 1330b and heating element(s) 1339b that include a susceptor disposed on a radially inner surface of the consumable assembly 1330b.
- the aerosolization system 1300b produces aerosol by using at least one susceptor, similar to the at least one susceptor of FIG. 7A.
- the heater assembly 1350b can include at least an induction segment or inductor section (e.g.
- induction segment 1352b 1 / 1352b2 / 1352b3 The at least an induction segment can also be referred to as “induction segment.”
- induction segment multiple induction segments 1352b 1 / 1352b2 / 1352b3 can include inductor coils, elements or “coils”.
- the heater assembly 1350b and/or the set of heating elements 1339b can include a susceptor (e.g., solid sheet, perforated metallic foil or mesh) configured to be heated by the induction segment including the at least a coil (e.g., in response to receiving electromagnetic radiation from the induction segment), where the at least a coil can be disposed around the heater the set of heating elements 1339b and thus, the cartridge 1310b when the cartridge 1310b is coupled to the vaporizer pen assembly 1340b.
- a susceptor e.g., solid sheet, perforated metallic foil or mesh
- the inductor segments 1352b 1 / 1352b2 / 1352b3 can apply electromagnetic radiation to the set of heating elements 1339b (e.g., susceptors) to cause at least an associated portion of the set of heating elements 1339b to generate heat to aerosolize the consumable assembly 1330b or at least an associated portion of the consumable assembly 1330b (e.g., associated segments of the consumable assembly 1330b).
- the heater assembly 1350b can be configured to include sections of induction segments.
- a section of induction segments can include one, two, or three segments of coils and/or any solid inductors placed through and around the heater assembly 1350b and/or the set of heating elements 1339b.
- the set of heating elements 1339b of the heater assembly 1350b can be located radially inward 1329b of the consumable assembly 1330b, and configured to aerosolize the consumable assembly 1330b or segments thereof from the inner surface area of the consumable assembly 1330a closer to the center of the cartridge assembly 1310, where the produced aerosol follows the aerosol flow F through the airflow path 1315b.
- the radially inward set of heating elements 1339b can apply heat to the inner surface area of the consumable assembly 1330b, where the set of heating elements 1339b can include or define perforations via the heat to allow produced aerosol to pass through the set of heating elements 1339b for the aerosol flow F to travel along the airflow channel 1315b.
- the cartridge assembly 1310 can also include a housing 1313b, where the housing 1313b is consistent with any housing as described in the entirety of this disclosure.
- the housing 1313b and/or the cartridge assembly 1310 can also be wrapped around by a membrane 1313b, where the membrane 1313b is consistent with any membrane as described in the entirety of this disclosure.
- FIG. 8 is a schematic illustration of an assembly 1429 that includes consumable assembly 1430 including a consumable formed into a sheet having multiple segments, and a heating element 1439 including a susceptor sheet configured to be disposed on and contact the consumable sheet, according to an embodiment.
- the heating element 1439 includes any heating element and/or a set of heating elements as described in the entirety of this disclosure.
- the heating element 1439 includes a perforated metallic foil and/or mesh acting as a susceptor, heated by at least one induction segment (e.g., at least one of the induction segment 1352al / 1352b 1 , 1352a2 / 1352b2, and/or 1352a3 / 1352b3 as described in FIGS.
- the heating element 1439 can be applied directly to the consumable assembly 1430 formed into a sheet having multiple consumable segments, where the consumable segments are consistent with the consumable segments described in FIG. 2.
- the heating element 1439 can be directly applied to the consumable sheet 1430, where the heating element 1439 and the consumable sheet 1430 are in direct contact with and/or proximate to each other.
- the heating element 1439 including the susceptor sheet can include a thin sheet formed from any ferromagnetic material and/or any material excitable by an electromagnetic radiation. Such materials can include, but are not limited to, Nichrome, Series 400 Stainless Steel, or the like.
- the heating element 1439 can include a thickness between about 0.005 mm and about 0.2 mm, inclusive. In some embodiments, the heating element 1439 can have a porosity of at least 30% (e.g., at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90%, inclusive).
- the heating element 1439 or any other heating element described herein can be coupled to or placed in contact with the consumable sheet 1430 or any other consumable sheet described herein to form an assembly that is spooled into a cylindrical coil.
- FIG. 9A is a schematic illustration of a spooled assembly 1429 that includes a consumable assembly that includes a sheet of a consumable that can be in contact with a susceptor, and rolled or wound into a spool or coil, according to an embodiment.
- the spooled assembly 1429 can include an empty spiral channel located in the gap between the successive layers of the spool assembly 1429 that allow for aerosol flow F through and/or between the successive layers of the spool assembly 1429.
- the spool is wound with at least minimal airflow between the surfaces of each layer of the spool.
- the spooled assembly 1429 can include the consumable assembly and/or the susceptor (e.g. heating element) disposed onto the consumable assembly.
- the consumable assembly can include a quilt like feature to allow for aerosol flow F through one end of the spooled assembly and out the other end.
- the susceptor and/or the heating element disposed on the consumable assembly can include a mesh with three- dimensional features that create the aerosol flow F to travel in an X or Y dimension.
- the susceptor and/or the heating element can be incorporated into a heater assembly in a vaporizer pen assembly, where the susceptor is spooled or coiled to form a cylindrical shape.
- a cartridge assembly can be configured to house a spooled consumable assembly including a thin sheet, where the spooled consumable assembly can be inserted into an empty spiral channel located in the gap between the successive layers of spool. The cartridge assembly and the spooled consumable assembly can be coupled to the heater assembly and the vaporizer pen.
- FIG 9B is a top of view of the assembly 1429 of FIG. 9A wound into a flat coil, according to an embodiment.
- the spooled assembly 1429 comprising the consumable assembly and the susceptor disposed onto the consumable assembly can be foldable as shown in FIG. 9B.
- the spooled assembly 1429 can form any shape that is foldable.
- FIG. 9C is a top view of the assembly 1429 of FIG. 9A wound into a circular coil, according to an embodiment.
- the spooled assembly 1429 comprising the consumable assembly and the susceptor disposed onto the consumable assembly can be spooled to form a coil having circular cross section (e.g., as shown in FIG. 4C).
- FIG. 9D is a schematic illustration of a cartridge assembly 1410 including the spooled assembly 1429 of FIG. 9A disposed in a housing or a membrane 1411 according to an embodiment.
- the spooled assembly 1429 includes a spooled thin consumable sheet and can optionally, include a susceptor coupled to the consumable sheet.
- the spooled assembly 1429 and/or the spooled consumable assembly can be coupled to a heating element, where the heating element includes a spooled/coiled thin perforated metallic foil or mesh acting as a susceptor.
- the spooled assembly 1429 is disposed inside the cartridge assembly 1410, where the cartridge assembly 1410 includes a housing 1411 that can be surrounded and/or wrapped in a membrane.
- the housing 1411 and/or the membrane can be consistent with any membrane as described in the entirety of this disclosure.
- the spooled assembly 1429 can include an empty spiral channel located in the gap between the successive layers of the spool that allow for aerosol flow F through and/or between the successive layers of the spool, where the aerosol flow F travels through an airflow path 1415 upwards and towards a mouthpiece opening (not shown).
- the consumable assembly can include a quilt like feature to allow for aerosol flow F through one end of the spooled assembly 1429 and out the other end.
- the susceptor and/or the heating element disposed on the consumable assembly can include a mesh with three-dimensional features that create the aerosol flow F to travel in an X or Y dimension.
- FIG. 10A is a side cross-section view of a portion of an aerosolization system 1400a that includes a cartridge assembly 1410a that includes a spooled assembly 1429a that includes consumable assembly 1430a (e.g., a consumable sheet) and a heating element 1439a, coupled to a housing 1441a of vaporizer pen assembly 1440a that includes multiple induction segments 1452al / 1452a2 / 1452a3, such as inductor coils, according to an embodiment.
- the multiple induction segments 1452al / 1452a2 / 1452a3 can be consistent with the multiple induction segments as described in FIG. 7 A or 7B.
- the consumable assembly 1430a can be spooled or coiled to form a spooled consumable assembly 1429a as described in FIG. 9A-D.
- the heating element 1439a can be disposed in contact with the consumable assembly 1430a, where the heating element 1439a is also spooled so as to form the spooled assembly 1429.
- the spooled heating element can include a thin metallic foil that can form perforations when heat is applied.
- the consumable assembly 1430a and the heating element 1439a disposed on the consumable assembly 1430a can form a spooled assembly 1429a, where the spooled assembly 1429 can be consistent with any spooled assembly as described in the entirety of this disclosure.
- the heater assembly 1450a and/or the set of heating elements 1439a can include a perforated metallic foil or mesh and heated by the induction segment 1452al / 1452a2 / 1452a3 including the at least a coil (e.g., an inductor coil), where the at least a coil can be disposed around the set of heating elements 1439a or otherwise, the cartridge assembly 1410a when it is coupled to the vaporizer pen assembly 1440.
- the inductor segments 1452al / 1452a2 / 1452a3 can apply heat to the at least a susceptor of the heater assembly 1450a and/or the set of heating elements 1439a to aerosolize the consumable assembly 1430a.
- the produced aerosol can pass through perforations formed in the set of heating elements 1439a along an airflow path 1415a.
- the cartridge assembly 1410a can include a housing 1413a that provides structure for the consumable assembly 1430a.
- the housing 1413a can be consistent with any housing of a cartridge assembly as described in the entirety of this disclosure.
- the housing 1413a can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like.
- the housing 1413a can define an airflow path 1415a for aerosol flow F.
- an outer surface area of the housing 1413a can be coated with a membrane 1411a, where the membrane 1411a can be consistent with any membrane as described herein.
- FIG. 10B is another side cross-section view of a portion of an aerosolization system 1400b that includes a cartridge assembly 1410b that includes a spooled assembly including a consumable assembly 1430b (e.g., a consumable sheet) that is in contact with and spooled with a heating element 1439b (e.g., a susceptor).
- the cartridge assembly 1410b is configured to be coupled to a vaporizer pen assembly that includes a heater assembly 1450b.
- the heater assembly 1450b includes an inductor coil 1452b mounted on a mounting arm 1453b (e.g., a lead screw) that is coupled to an actuator 1455b, according to an embodiment.
- the actuator 1455b can include a linear motor, stepper motor, or the like.
- the inductor coil 1452b is disposed parallel to a longitudinal axis of the vaporizer pen assembly.
- the inductor coil 1452b included is configured to provide electromagnetic radiation to a corresponding or associated portion of the heating element 1439 so as to heat the corresponding or associated portion, and thereby, aerosolize a corresponding or associated portion of the consumable assembly 1430.
- the actuator 1455b is configured to be selectively actuated to linear displace the inductor coil 1452b along the mounting arm 1453b so as to heat different associated portions of the heating element 1439b, and thereby the consumable assembly 1430b. In this manner, more efficient aerosolization of the consumable assembly 1430b can be achieved such that substantially all of the consumable assembly 1430 can be aerosolized over an operational life of the cartridge assembly 1410b.
- FIG. 11A-11B is a side cross-section view of an aerosolization system 1500 including a portion of vaporizer pen 1540 with a heater assembly 1550 including a susceptor 1553 with wicks 1551 on both sides of the susceptor 1553.
- the susceptor 1553 can include a single sheet susceptor.
- the vaporizer pen 1540 can include induction segments 1552a / 1552b / 1552c which can be powered by a power source in the vaporizer pen 1540 (not shown) to heat the heater assembly 1550, where the heater assembly 1550 can apply the heat via the susceptor 1553 which then heats the wicks 1551 located on both sides of the susceptor 1553.
- the wicks 1551 can include ceramic wicks, any other any wicks as described herein.
- the susceptor 1553 and the wicks 1551 can form a single flat shape or have a flat profile, where the wicks 1551 are disposed on both sides of the single flat shape.
- the susceptor 1553 can be a flat sheet with a first layer of the wick 1551 assembly disposed on a first side thereof, and a second layer of the wick 1551 or any other consumable assembly disposed on a second side thereof, with the wicks 1551 having a flat shape.
- the vaporizer pen 1540 can be coupled to a cartridge assembly 1510 containing a consumable assembly (not shown), where the consumable assembly can be configured to have any structure that directly contacts with and/or is proximate with the wicks 1551, where the wicks 1551 can aerosolize the consumable assembly.
- FIG. 11C is a top view of an assembly 1529a that can be included in a cartridge assembly (e.g., the cartridge assembly 1510) including a susceptor 1553a with wicks 1551a disposed on both sides of the susceptor 1553a, where the susceptor 1553a and the wicks 1551a are formed into a tube.
- the cartridge assembly e.g., the cartridge assembly 1510) including the assembly 1529a can be configured to couple to the vaporizer pen 1540, where the consumable assembly is disposed radially outwards of an outer wick (e.g., as shown in FIG. 3A).
- the cartridge assembly (e.g., the cartridge assembly 1510) including the assembly 1529a can be configured to be coupled to the vaporizer pen 1540, where the consumable assembly is disposed radially inward of an inner wick (e.g., as shown in FIG. 3C).
- the cartridge assembly 1410b can include a housing that provides structure for the consumable assembly 1430b.
- the housing can be consistent with any housing of a cartridge assembly as described in the entirety of this disclosure.
- the housing can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like.
- the housing can define an airflow path 1415b for aerosol flow F.
- an outer surface area of the housing can be coated with a membrane 1411b, where the membrane 1411b can be consistent with any membrane as described herein.
- FIG. 12A is a schematic illustration of an aerosolization system 1600 including a cartridge assembly 1610 coupled to a housing 1641 of vaporizer pen assembly 1640, according to an embodiment.
- the aerosolization system 1600 can include a configuration where the shape of the vaporizer pen assembly 1641 and/or the cartridge assembly 1610 is flat and/or stretched as shown in FIG. 12A-11C.
- the configuration of the cartridge assembly 1610 can be referred to as a “pack” or “pod.”
- FIG. 12A also shows the cartridge assembly 1610, where the cartridge assembly 1610 can be inserted into the vaporizer pen assembly 1640.
- the cartridge assembly is a schematic illustration of an aerosolization system 1600 including a cartridge assembly 1610 coupled to a housing 1641 of vaporizer pen assembly 1640, according to an embodiment.
- the aerosolization system 1600 can include a configuration where the shape of the vaporizer pen assembly 1641 and/or the cartridge assembly 1610 is flat and/or stretched as shown in FIG. 12A-11C.
- the configuration of the aerosolization system 1600 can support a consumable assembly comprising a large thin sheet and a heater assembly comprising a set of heating elements.
- FIG. 12B is a schematic illustration of the cartridge assembly 1610 of a FIG. 12A, according to an embodiment.
- the cartridge assembly 1610 can include a housing 1611 configured to house a consumable assembly 1630, where the housing can define the airflow path 1615 for aerosol produced from the consumable assembly 1630.
- the housing of the cartridge assembly 1610 can be consistent with any housing as described in the entirety of this disclosure.
- the housing 1611 including a hollow area, can house the consumable assembly 1630, where the consumable assembly 1630 includes two large thin sheets such as a first consumable sheet 1630a and a second consumable sheet 1630b.
- the housing 1611 can be formed from plastic or folded paper.
- the housing 1611 can be formed from plastic or folded paper.
- the membrane 1611 can be surrounded by the membrane, where the membrane includes at least a layer of impermeable material to separate the membrane from the first consumable sheet 1630a and/or the second consumable sheet 1630b.
- both the first consumable sheet 1630a and the second consumable sheet 1630b can be applied to the two longer sides of the housing as shown in FIG. 12B.
- a heater assembly 1650 of the vaporizer pen assembly 1640 can be coupled to the cartridge assembly 1610 and/or the consumable assembly 1630, where the heater assembly sits in between the first consumable sheet 1630a and the second consumable sheet 1630b, where the heater assembly 1650 comes into contact with and/or proximate to the first consumable sheet 1630a and the second consumable sheet 1630b (e.g., as shown in FIG. 12F).
- FIG. 12C is a schematic illustration of the vaporizer pen assembly 1640 of FIG. 12 A, according to an embodiment.
- the vaporizer pen assembly 1640 can include a hollow housing configured to receive at least a portion of the cartridge assembly 1630 of FIG. 12B.
- the heater assembly 1650 is disposed in the housing and configured to be disposed onto the consumable assembly 1630, for example, between the first consumable sheet 1630a and the second consumable sheet 1630b, when the cartridge assembly 1610 is inserted in the housing 1641 as shown in FIG. 12A.
- the heater assembly 1650 can include a flat sheet including one or more heating elements, which is configured to be disposed between the first consumable sheet 1630a and the second consumable sheet 1630b so that the heating assembly 1650 can establish contact with the first consumable sheet 1630a on one side of the heater assembly 1650 and establish contact with the second consumable sheet 1630b on a second side of the heater assembly 1650 opposite the first side.
- the heater assembly 1650 can include or be connected to a battery.
- the heater assembly 1650 can be include porous elements, define pores or apertures therethrough, or be generally porous, to allow for aerosolization of the consumable assembly 1630 to occur through the heater assembly 1650 and through the center of the consumable assembly 1630.
- FIG. 12D is a side cross-section view of the cartridge assembly 1610 of FIG. 12A- 12B.
- the cartridge assembly 1610 and/or the housing 1611 can define an airflow path such as a tortuous path 1618 to filter the aerosol produced by the aerosolization of the first consumable sheet 1630a and the second consumable sheet 1630b prior to inhalation.
- the tortuous path 1618 can include a zigzagged structure disposed or formed in the housing 1611.
- the housing 1611 can include a filter that defines the tortuous path 1618.
- FIG. 12E is a side cross-section view of the vaporizer pen assembly 1640 of FIG. 12A and 12C.
- the vaporizer pen 1640 of the aerosolization system 1600 includes the housing 1641.
- the vaporizer pen 1640 includes the heater assembly 1650 of FIG. 12C.
- the heater assembly 1650 can be operatively connected to a power source (not shown) of the vaporizer pen assembly 1640, where at least a portion of the heater assembly 1650 is configured to disposed inside the cartridge assembly 1610.
- the housing 1641 can also provide housing and/or protection for the heater assembly 1650.
- the housing 1641 includes a cartridge channel 1643, where the cartridge channel 1643 can include an exposed area between the inner surface area of the cartridge holder 1641 and the outer surface area of the heater assembly 1650.
- the cartridge assembly 1610 of FIG. 12B or 11D can be coupled to the vaporizer pen assembly 1640 such that the cartridge assembly 1610 is inserted in the cartridge channel 1643 of the housing 1641 and/or the vaporizer pen assembly 1640.
- FIG. 12F is a side cross-section view of the aerosolization system 1600 including the cartridge assembly 1610 of FIGS. 12A-12B, and 12D coupled to the vaporizer pen assembly 1640 of FIGS. 12A, 12C, and 12E.
- the aerosolization system 1600 includes the cartridge assembly 1610 located in the cartridge holder 1641 of the vaporizer pen assembly 1640.
- the cartridge assembly 1610 is coupled to the vaporizer pen assembly 1640 and/or the housing 1641 where the heater assembly 1650 is in contact with and/or proximate to the consumable assembly 1630 housed inside the cartridge assembly 1610.
- the cartridge assembly 1610 can include a membrane coated or disposed around the housing 1611 of the cartridge assembly 1610 where the membrane can allow for smooth coupling of the cartridge assembly 1610 to housing 1641 of the vaporizer pen assembly 1640.
- the heater assembly 1650 can be located outward of the consumable assembly 1630, aerosolizing the consumable assembly 1630 from the outside, where the produced aerosol follows upwards and through the tortuous path 1618.
- the heater assembly 1650 can include multiple heating elements and/or a set of heating elements (e.g. the heating elements 1652a / 1652b).
- the consumable assembly 1630 can also include multiple consumable segments, where the heater assembly 1650 and/or the set of heating elements (e.g., the heating elements 1652a / 1652b) can apply heat to associated consumable segments to produce aerosol.
- the configuration of the aerosolization system 1600 which includes the consumable assembly 1650 including larger sheets (e.g. first consumable sheet 1652a and/or second consumable sheet 1652b), can be used instead of a liquid pod.
- the aerosolization system 1600 and/or the consumable assembly 1600 can remove the need for an embedded heater and resolves the issues of liquid material leaking and/or clogging of a liquid pod.
- the configuration of the consumable assembly 1630 can also be cheaper and/or simpler to manufacture than the liquid pod.
- the aerosolization system 1600 can provide finite control of aerosol flow, rate of aerosolization, and/or volume of aerosol produced from the consumable assembly 1630 containing multiple consumable segments such as the first consumable sheet 1652a and/or the second consumable sheet 1652b.
- FIG. 13 A is a plot showing power management of a set of heating elements included in a heater assembly of an aerosolization system, according to an embodiment.
- the aerosolization system can be consistent with any aerosolization system as described herein.
- Current multi heater designs can multiple the surface area being heated, but also increase power consumption.
- the heater assembly as described herein can include multiple heating elements that can be powered intermittently, such that fewer heater elements (in some cases only one) are on at any one time.
- the heater assembly reduces or stops the supply of power to the heater assembly (including three heating elements Hl / H2 / H3) to a plateau power to maintain the desired aerosolization temperature for multiple consumable segments (a larger area of aerosolization) at a time as shown in the plot of FIG. 13 A.
- the heater assembly including multiple heating elements can each be powered to reach a desired aerosolization temperature. In some cases, some heating elements can be powered to reach different temperatures than that of other heating elements.
- the aerosolization system can also include smaller and more powerful heating elements making up the heater assembly to apply heat to a variable size surface area of the consumable assembly more efficiently. For instance, smaller heating elements can be powered and apply heat over a large surface area of the consumable assembly multiple times to allow for faster powering and/or heating time and reduced latency to aerosolization.
- FIG. 13B is a plot showing temperature profiles of three heating elements (e.g. heating element Hl / H2 / H3) of a heater assembly for an aerosolization system that are sequentially activated, and associated temperature of a consumable assembly that is located proximate to or in contact with each of the three heating elements of the heater assembly.
- the surface of the consumable assembly can create multiple consumable segments, where some consumable segments have a less viscous liquid at the surface of the consumable assembly as a result of intermittent heating of the consumable assembly by the heater assembly.
- consumable segments that have viscous liquid at the surface of the consumable segment can experience leaking and/or dripping, where the heater assembly can be configured to mitigate the leaking and/or dripping by optimizing the timing of powering on/off the intermittent heating of heating elements Hl, H2, and/or H3, individually or concurrently.
- the aerosolization system can include a cartridge assembly that can support a liquid consumable assembly such as a liquid pod.
- the cartridge assembly can include a wick with a large surface area and in contact with a liquid consumable in the liquid consumable assembly.
- the wick can be included in a wick assembly containing multiple heating coils that can apply heat to the liquid consumable drawn by the wick.
- the heating coils can include ceramic coils.
- the heating coils and/or the wick can also be powered on/off to optimize the timing of the intermittent heating of the liquid consumable assembly to mitigate leaking and/or dripping of liquids. This is so, at least in part, to control the volume of aerosol produced, the rate of delivery, the optimization of power consumption, and/or the wick management.
- FIG. 14 is a schematic block diagram of a controller 1770 of a vaporizer pen assembly 1770 that can be configured to selectively activate each of a set of heating elements or heaters 1752a, 1752b, 1752c, 1752d, 1752e (together referred to herein as “heaters 1752”). included in a heater assembly 1750, according to an embodiment.
- the controller 1770 can be part of the heating assembly 1750. In other embodiments, the controller 1770 can be operatively coupled to the heating assembly 1750 but physically separate therefrom.
- the controller 177- include a power supply 1774, a processor 1775, and a set of transistors 1776a, 1776b, 1776c, 1776d, 1776e (together referred to herein as “transistors 1776”), operatively coupled to the heaters 1752a, 1752b, 1752c, 1752d, 1752e, respectively.
- the controller 1770 can include any controller as described herein.
- the transistors 1776 can include a field effect transistor (FET).
- FET field effect transistor
- the processor 1775 can be consistent with any processor as described in the entirety of this disclosure.
- the power supply 1774 can include a rechargeable battery (e.g., a Li-ion battery, a Li-sulfur battery, a Li-air battery, or any other suitable rechargeable power source), or a disposable battery that is configured to provide electrical power to the processor 1775, the transistors 1776, and/or the heaters 1752.
- a rechargeable battery e.g., a Li-ion battery, a Li-sulfur battery, a Li-air battery, or any other suitable rechargeable power source
- a disposable battery that is configured to provide electrical power to the processor 1775, the transistors 1776, and/or the heaters 1752.
- the controller 1770 can allow for aerosol volume control.
- the controller 1770 can include a memory (not shown) that includes instructions to cause the processor 1775 to power the heaters 1752a, 1752b, 1752c, 1752d, and/or 1752e intermittently or selectively provide electrical energy thereto.
- a user can control the volume of aerosol produced based on the user’s preference.
- the user can interact with the controller 177- and/or the control interface of the vaporizer pen assembly 1770 including a physical digital toggle to select the aerosol production from a consumable assembly to a desired level. Based on the desired level and/or the user preference, fewer or more heaters 1752a, 1752b, 1752c, 1752d, and/or 1752e can be powered concurrently by activating a corresponding one of the transistors 1776.
- a flow or pressure sensor (not shown) can be used to intuitively provide a larger or smaller volume of aerosol by inhaling more or less powerfully by the user.
- the flow or pressure sensor can be used to trigger the activation of the heater assembly and can also measure the strength of inhalation.
- the memory can store instructions to cause the processor 1775 to adjust the number of heaters 1752 (e.g. heater 1752a / 1752b / 1752c / 1752d / 1752e) being activated, and in turn adjust the number of heaters 1752 acting in unison to increase or decrease the power in applying heat to the consumable assembly and/or the volume of aerosol produced.
- the controller 1770 can also be configured to communicate with features included in the vaporizer pen assembly that support haptic and/or visual feedback to indicate the cadence and/or rate of flow of aerosol being produced.
- the haptic and/or visual feedback can also indicate increasing and decreasing frequency in the rate of aerosol production.
- the haptic and/or visual feedback can include an LED light that can buzz and/or blink for every 2 mg of aerosol produced.
- the user can set a low or high setting for the haptic and/or visual feedback, where the blinking and/or buzzing can occur every second at the low setting or every 1/3 of a second at the high setting.
- a heater assembly can be configured to aerosolize liquid consumables.
- FIG. 15A-15E are various views of a heater assembly 1850 such as a wick assembly 1851 including a flat porous layer and a set of heating elements arranged in a flat configuration, and that can be used to aerosolize a liquid consumable, according to an embodiment.
- the wick assembly 1850 includes heating coils (e.g. heating coil 1852a / 1852b / 1852c) located on an inner cup portion and/or surface area of the wick assembly 1851 as shown in FIG. 15B or 15E.
- the heating coils are configured in a geometrically snake-like pattern to cover a larger surface area of the wick assembly 1851.
- the wick assembly 1851 can be consistent with any wick assembly and/or wick as described in the entirety of this disclosure.
- the heater assembly 1850 can include a flat heater operatively connected to the wick assembly 1851, where the wick assembly 1853 includes the heating coils 1852a, 1852b, and/or 1852c and wicks 1853 protruding and/or extending away from the inner surface area of the wick assembly 1851 as shown in FIG. 15 A, 15B, or 15D.
- Heater assembly 1850 and the wick assembly 1851 can be coupled to a liquid cartridge assembly (not shown) such as a liquid pod, where a liquid consumable is in contact with the wicks 1853.
- the wick assembly 1851 can include multiple heating coils 1852a, 1852b, and/or 1852c (together referred to herein as “heating coils 1852c”), where the heating coils 1852 are disposed within (e.g. partially or fully embedded within) the wick assembly 1851 of the heater assembly 1850.
- the wick assembly 1851 can include a cup portion where the cup portion includes a sidewall (e.g., cylindrical or tubular) and can have a porous bottom.
- the wick assembly 1851 can be formed of ceramic, stainless steel, and/or cotton.
- the cup portion can be formed of ceramic
- the contact pins 1853 can be formed of cotton
- the heating coils can be formed of stainless steel.
- the liquid consumable is configured to be vaporized and removed from the bottom surface of the cup portion and to travel laterally away from the bottom surface of the cup portion of the wick assembly 1851.
- the wick assembly 1851 can include three separate heating coils 1852a, 1852b, and 1852c as shown in FIG. 15B and 15E disposed proximate to different portions of a top surface of the wick assembly 1851.
- selective activation of one or more of the heating coils 1852 aerosolizes a liquid consumable absorbed in an associated portion or segment of the top surface of the wick assembly 1851.
- the individual heating coils 1852a, 1852b, and/or 1852c allow for two or three times the volume of aerosol produced relative to convention heaters that heat an entire surface of an associated therewith, without compromising ideal heating temperature.
- the heater assembly 1850 can cause the heating coils 1852a, 1852b, and/or 1852c to apply heat to the liquid consumable absorbed in associated portions of the wick assembly 1851 individually and/or concurrently to optimize heating and power consumption.
- the heater assembly 1850 and the wick assembly 1851 can fit into a pod configuration.
- the heater assembly 1850 can use cylindrical heater, coil heaters, and/or wicks, such as silica wick and coil, cotton wick and coil, wick and mesh, or the like.
- the heater assembly 1850 can include the wick assembly 1851 and a chimney component (not shown).
- the chimney component can be formed of a metal such as, for example, brass.
- the wick assembly 1851 can include the wicks 1853 component and the heating coils 1852a, 1852b, and 1852c coupled to and/or disposed within (e.g., partially or fully embedded within) the wick assembly.
- the wick assembly 1851 can include a flexible wick and a cylindrical portion defining a central passageway (not shown).
- the chimney component can define a number of openings (e.g., two, three, or four openings) such that a reservoir defined by the mouthpiece and/or the cartridge assembly (e.g., the cartridge assembly 110 of FIG. 1) and the housing of the cartridge assembly is in fluid communication with an outer surface area of the wick assembly via the openings when the wick assembly is disposed within an interior of the chimney component.
- liquid consumable can travel from the reservoir, through the openings, through the flexible wick portion, and into the ceramic portion of the wick assembly 1851.
- the heating coils 1852a, 1852b, and/or 1852 the temperature of the ceramic portion rises and the liquid consumable within the ceramic portion can heat and transition to vapor or aerosol.
- Air can be drawn through the central passageway of the wick assembly 1851, combine with heated vapor inside the wick assembly, and travel to the mouthpiece opening of the cartridge assembly via the chimney component.
- the wick assembly 1851 and/or the cartridge assembly can include at least one filter for the aerosol prior to exiting out of the mouthpiece of the cartridge assembly.
- FIG. 15F is an exploded view of the heater assembly 1850 of FIGS. 15A-15E, an associated heater assembly housing 1886 and a base 1885 according to an embodiment.
- the heater assembly 1850 and/or the wick assembly 1851 can be part of a cartridge assembly (not shown).
- the heater assembly housing 1886 is configured to receive the heater assembly 1850 within a recess of the heater assembly housing 1886 such that a bottom surface of an interior of the flat heating elements 1852 included in the wick assembly 1851 can be accessed through an opening of the heater assembly housing 1886.
- the heater assembly housing 1886 and/or the heater assembly 1850 can couple to the base 1884 via the heating subassembly 1885.
- the sidewalls of the cup portion of the wick assembly 1851 can be disposed in the recess of the heater assembly housing 1886.
- the heater assembly housing 1886 can include at least one opening 1887, where the at least one opening 1887 that can be sized and/or shaped to control the rate at which the liquid consumable travels from the reservoir of the cartridge assembly into the wick assembly 1851 of the heater assembly 1850.
- the at least one opening 1887 can be about 2 mm long by about 1 mm wide.
- the heater assembly housing 1887 can include three openings as shown in FIG. 15F, where each opening is identical in size, but in some embodiments, can be different in size or shape.
- the heater assembly housing 1886 can be formed of any suitable material, such as a food grade elastomeric membrane material such as silicone.
- the heater assembly housing 1886 can include a flange portion disposed around the perimeter of the heater assembly housing 1886 and configured to function as a sealing ring (e.g., an O-ring) to seal the heater assembly housing 1886 relative to the base 1885 (e.g., an inner surface of the base 1885 defining the space within which the wick assembly 1851 and/or the heater assembly 1850 and the heater assembly housing 1886 are disposed and a groove for receiving the sealing ring of the heater assembly housing 1886).
- a sealing ring e.g., an O-ring
- FIG. 16A-16D are various views of a heater assembly 1950 that includes a wick assembly 1951 including a cylindrical porous layer and a set of heating elements provided as coils (e.g. heating coils 1952a and 1952b), and that can be used to aerosolize a liquid consumable, according to an embodiment.
- the wick assembly 1951 can include contact pins 1853 extending out of the wick assembly 1953 of the heater assembly 1950 as shown in FIG. 16A-16D, where the contact pins 1953 can apply heat to aerosolize the liquid consumable.
- FIG. 16B shows a top view of the wick assembly 1951 with a cap 1954 (e.g., a silicone cap) located at the top and center of the upper surface area of the wick assembly 1951.
- the contact pins 1953 can extend in the opposite direction and away from the wick assembly 1951. As shown in FIG. 16C, the contact pins 1953 can be located outside the wick assembly 1951, where the contact pins 1953 are equidistant from a longitudinal axis C of the heater assembly 1950.
- FIG. 16D shows a side cross-section view of the heating assembly 1950 showing the heating coils (e.g. heating coil 1952a / 1952b) located inside the wick assembly 1951, where the heating coils are in contact with a larger surface area inside the wick assembly 1951.
- the wick assembly 1951 and/or the heater assembly 1950 can include a chimney channel 1954, where the chimney channel 1954 can define an airpath flow for aerosol.
- FIG. 17 is a schematic flow diagram of a method 2000 for aerosolizing a consumable via a heater assembly that includes a set of heating elements (e.g., any of the heater assemblies described herein), according to an embodiment.
- the method 2000 includes coupling a cartridge assembly including a consumable to a vaporizer pen including the heater assembly, at 2002.
- the cartridge assembly can be consistent with any cartridge assembly as described in the entirety of this disclosure.
- the cartridge assembly can include a solid consumable such as a thin sheet including multiple consumable segments or a liquid pod.
- the heater assembly can be consistent with any heater assembly as described in the entirety of this disclosure.
- the heater assembly can include a set of heating elements, a wick assembly, a flat heater, a mesh, coils, or the like thereof.
- the cartridge assembly can couple to a cartridge holder of the vaporizer pen where the heater assembly of the vaporizer pen and the consumable of the cartridge assembly.
- the method 2000 includes receiving, via a draw sensor, a request for a vapor of the consumable.
- the draw sensor can include any draw sensor as described herein.
- the method 2000 can include requesting a specific type of consumable to be aerosolized, rate of aerosolization, dosage amount, and/or volume of aerosol produced.
- the method can include interacting with a controller and/or a control interface including visual and/or haptic feedbacks to send a signal representing the request to a processor in the vaporizer pen.
- the consumable can produce any aerosol and/or vapor.
- the method 2000 includes selectively activation, via the controller, a portion of a set of heating elements of the heater assembly.
- the heater assembly includes a set of heating elements that can be individually activated to intermittently aerosolize the consumable. In some implementations, the heater assembly can activate multiple heating elements concurrently.
- the method 2000 can include selectively activating one heating element to aerosolize about equal to or greater than 2.5 mg of the consumable. In some embodiments, at 2006, the method 2000 can include selectively activating two or more heating elements to aerosolize about equal to or greater than 5.0 mg of the consumable for an extended period of time. In some embodiments, at 2006, the method 2000 can include selectively activating two or more heating elements to aerosolize about equal to or greater than 7.0 mg of the consumable for an extended period of time.
- FIG. 18 is a schematic illustration of a system 2200 for manufacturing a consumable assembly 2230, according to an embodiment.
- the consumable assembly 2230 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 110.
- the consumable assembly 2230 can be formed as a hollow tube including a tubular heating element layer 2270, a tubular aerosolgenerating substance portion layer 2260 radially outward of and in contact with the heating element layer 2270, and a tubular membrane layer 2264 disposed radially outward of and in contact with the tubular aerosol-generating substance portion layer 2260.
- Each of the layers can start out and be fed simultaneously through the system 2300 as elongated sheets, with the exception of the tubular heating element 2370 layer which can be fed through the system as an elongated electrically conductive material such as a sheet or a plurality of elongated rods, threads, or wires.
- a first roller assembly 2200A of the system 2200 can draw a first aerosol-generating substance from a first aerosol-generating substance source 2260A in the form of a first elongated continuous thin film layer 2260B.
- the first aerosolgenerating substance source 2260 A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the first roller assembly 2200A as the roller is rotating such that a portion of the first continuous elongated thin film layer 2260B is disposed on the roller of the first roller assembly 2200A.
- the first roller assembly 2200A can draw a first elongated continuous membrane layer 2264B from a source of the first elongated continuous membrane layer and can dispose a portion of the elongated continuous membrane layer 2264B on a portion of an upper surface of the first thin film layer 2260B (e.g., so that contacting portions of the first thin film layer 2260B and the elongated continuous membrane layer 2264B are substantially co-planar), forming a first multi-layered assembly.
- a second roller assembly 2200C of the system 2200 can draw a continuous elongated heating element layer 2270B simultaneously with drawing the first multi-layered assembly (e.g., the layered first elongated continuous membrane layer 2264B and first elongated continuous thin film layer 2260B) from the first roller assembly 2200A.
- the first elongated continuous film layer 2260B can be disposed on an upper side of the continuous elongated heating element layer 2270B, forming a second multi-layered assembly.
- the first elongated continuous film layer 2260B is disposed between an associated portion of the elongated heating element layer 2270B and the first elongated continuous membrane layer 2264B.
- the aerosol-generating substance forming the first elongated continuous thin film layer 2260B can include and/or function as an adhesive to bond the first elongated continuous membrane layer 2264B to the elongated heating element layer 2270.
- the system 2200 can include a tube-forming assembly 2290 (also referred to as a rolling assembly).
- the system 2200 can include a third roller assembly 2200D that can be used to redirect the second multi-layered assembly toward the tube-forming assembly 2290.
- the tube-forming assembly 2290 can receive the second multi-layered assembly in planar form and can output the second multi-layered assembly in a tubular form.
- the tube-forming assembly 2290 can urge opposing ends or sides of the second multi-layered assembly toward each other to form a tube such that each of the first elongated continuous thin film layer 2260B, the first elongated continuous membrane layer 2264B, and the continuous elongated heating element layer 2270B are formed as a multi-layered continuous hollow tube exiting the tube-forming assembly 2290.
- the consumable assembly 2230 can be formed as a hollow tube (e.g., by the tube-forming assembly 2290) having a seam formed by overlapping edge portions.
- An adhesive can be applied to the overlapping edge portions such that the consumable assembly 2230 can maintain a hollow tubular shape (e.g., until the tubular aerosol-generating substance portion layer 2260 hardens).
- the adhesive can be, for example, a rapidly hardening adhesive that hardens to hold the consumable assembly 2230 in a hollow tubular shape more quickly than the first aerosol-generating substance layer 2260 hardens into a cylindrical shape.
- an adhesive portion can be applied to one or both elongated ends of an internalfacing or external-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) such that elongated end(s) can be adhered to the other of the elongated ends of the first membrane layer 2364 when the first membrane layer 2364 is rolled such that the edges overlap and contact each other.
- the multi-layered continuous hollow tube can be provided to a cutting assembly 2292.
- the cutting assembly 2292 can cut the multi-layered continuous hollow tube into individual consumable assemblies 2230 having substantially the same length.
- Each consumable assembly 2230 can be formed as a hollow tube including a tubular heating element 2270 having a tubular first aerosol-generating substance layer 2260 on an outer side thereof and a tubular first membrane layer 2264 as an outer layer thereof, each having substantially the same length from a first end to a second end of the consumable assembly 2230.
- Each consumable assembly 2230 can be included in a cartridge, such as any of the cartridges described herein (e.g., cartridge 110).
- each consumable assembly 2230 can be included in a cylindrical housing that is the same or similar in structure and/or function as the housing 114 described with respect to FIG. 1, along with any other suitable components for a functional user consumable product including the consumable assembly 2230.
- the cartridge including the consumable assembly 2230 can also include one or more of wrapping paper, filters (e.g., mono, multi-bore, and/or tube), cooling elements, perforations and venting features, foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
- filters e.g., mono, multi-bore, and/or tube
- cooling elements e.g., mono, multi-bore, and/or tube
- perforations and venting features foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
- each of the assemblies of the system 2200 can be configured to operate simultaneously on different portions of the materials used to produce each consumable assembly 2230.
- the first roller assembly 2200A e.g., in a first stage
- the second roller assembly 2200C e.g., in a second stage
- the tube-forming assembly 2290 e.g., in a third stage
- the cutting assembly 2292 e.g., in a fourth stage
- the tube-forming assembly 2290 can form the rolled tube with the tubular aerosol-generating substance portion layer 2260 disposed radially outward of the elongated heating element layer 2270. In some implementations, alternatively, the tube-forming assembly 2290 can form the rolled tube with the tubular aerosolgenerating substance portion layer 2260 disposed radially inward of the elongated heating element layer 2270.
- FIG. 19 is a schematic illustration of a system 2300 for manufacturing a consumable assembly 2330, according to an embodiment.
- the consumable assembly 2330 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 110.
- the consumable assembly 2330 can be the same or similar in structure and/or function to the consumable assembly 2130 shown and described with respect to FIG.
- 3K which is formed as a hollow tube including a first aerosolgenerating substance layer 2360 disposed on a first side of a tubular heating element 2370, a second aerosol generating substance layer 2362 disposed on a second side of the tubular heating element 2370, a first membrane layer 2364 disposed on an opposite side of the first aerosolgenerating substance layer 2360 than the tubular heating element 2370 and forming an outer surface of the consumable assembly 2330, and a second membrane layer 2366 disposed on opposite side of the second aerosol-generating substance layer 2370 from the tubular heating element 2370 and forming an inner surface of the consumable assembly 2230 defining an inner passageway.
- the system 2300 for manufacturing the consumable assembly 2330 can be substantially the same as or similar to the system 2200 shown and described with respect to FIG. 18, with the exception that the system 2300 includes an additional rolling assembly configured to couple the second aerosol-generating substance portion layer 2362 on a side of the elongated heating element layer 2370 opposite the side to which the first aerosol-generating substance portion layer 2360 is coupled. Additionally, the system 2300 is configured to couple a second membrane layer 2366 to the second aerosol generating substance layer 2362 on a side opposite the elongated heating element layer 2370. Similarly as described with respect to FIG.
- each of the layers can start out and be fed simultaneously through the system 2300 as elongated sheets, with the exception of the tubular heating element 2370 layer which can be fed through the system as an elongated electrically conductive material such as a sheet or a plurality of elongated rods, threads, or wires.
- a first roller assembly 2300 A of the system 2300 can draw a first aerosol-generating substance from a first aerosol-generating substance source 2360A in the form of a first elongated continuous thin film layer 2360B.
- the first aerosolgenerating substance source 2360 A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the first roller assembly 2300A as the roller is rotating such that a portion of the first continuous elongated thin film layer 2360B is disposed on the roller of the first roller assembly 2300A.
- the first roller assembly 2300 A can draw a first elongated continuous membrane layer 2364B from a source of the first elongated continuous membrane layer and can dispose a portion of the elongated continuous membrane layer 2364B on a portion of an upper surface of the first thin film layer 2360B (e.g., so that contacting portions of the first thin film layer 2360B and the elongated continuous membrane layer 2364B are substantially co-planar), forming a first multi-layered assembly.
- a second roller assembly 2300B can draw a second aerosol-generating substance from a second aerosol-generating substance source 2362A in the form of a second elongated continuous thin film layer 2362B.
- the second aerosol-generating substance source 2362A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the second roller assembly 2300B as the roller is rotating such that a portion of the second continuous elongated thin film layer 2362B is disposed on the roller of the second roller assembly 2300B.
- the second roller assembly 2300B can draw a second elongated continuous membrane layer 2366B from a source of the second elongated continuous membrane layer and can dispose a portion of the second elongated continuous membrane layer 2366B on a portion of a lower surface of the second thin film layer 2362B (e.g., so that contacting portions of the second thin film layer 2362B and the second elongated continuous membrane layer 2366B are substantially co-planar), forming a second multi-layered assembly.
- a third roller assembly 2300C of the system 2300 can draw a continuous elongated heating element layer 2370B simultaneously with drawing the first multi-layered assembly (e.g., the layered first elongated continuous membrane layer 2364B and first elongated continuous thin film layer 2360B) from the first roller assembly 2300 A and with drawing the second multi-layered assembly (e.g., the layered second elongated continuous membrane layer 2366B and second elongated continuous thin film layer 2362B) from the second roller assembly 2300B.
- first multi-layered assembly e.g., the layered first elongated continuous membrane layer 2364B and first elongated continuous thin film layer 2360B
- second multi-layered assembly e.g., the layered second elongated continuous membrane layer 2366B and second elongated continuous thin film layer 2362B
- the first elongated continuous film layer 2360B can be disposed on an upper side of the continuous elongated heating element layer 2370B and the second elongated continuous thin film layer 2362B can be disposed on a lower side of the continuous elongated heating element layer 2370B opposite the upper side, forming a third multi-layered assembly.
- the first elongated continuous film layer 2360B is disposed between an associated portion of the elongated heating element layer 2370B and the first elongated continuous membrane layer 2364B and the second elongated continuous thin film layer 2362B is disposed between the associated portion of the continuous elongated heating element layer 2370B and the second elongated continuous membrane layer 2364B.
- the aerosol-generating substance forming the first elongated continuous thin film layer 2360B and/or the second elongated continuous thin film layer 2362B can include and/or function as an adhesive to bond the first elongated continuous membrane layer 2364B and the second elongated continuous membrane layer 2366B to the elongated heating element layer 2370.
- the system 2300 can include a tube-forming assembly 2390 (also referred to as a rolling assembly).
- the system 2300 can include a fourth roller assembly 2300D that can be used to redirect the third multi-layered assembly toward the tube-forming assembly 2390.
- the tube-forming assembly 2390 can receive the third multi-layered assembly in planar form and can output the third multi-layered assembly in a tubular form. For example, as shown in portion 19A in FIG.
- the tube-forming assembly 2390 can urge opposing ends or sides of the third multi-layered assembly toward each other (e.g., along lines Z1 and Z2, respectively) to form a tube such that each of the first elongated continuous thin film layer 2360B, first elongated continuous membrane layer 2364B, the continuous elongated heating element layer 2370B, the second elongated continuous thin film layer 2362B, and the second elongated continuous membrane layer 2366B are formed as a multi-layered continuous hollow tube exiting the tube-forming assembly 2390.
- the consumable assembly 2330 can be formed as a hollow tube (e.g., by the tube-forming assembly 2390) having a seam formed by overlapping edge portions.
- An adhesive can be applied to the overlapping edge portions such that the consumable assembly 2330 can maintain a hollow tubular shape (e.g., until the tubular aerosol-generating substance portion layer 2360 and/or the second aerosol generating substance layer 2362 hardens).
- the adhesive can be, for example, a rapidly hardening adhesive that hardens to hold the consumable assembly 2330 in a hollow tubular shape more quickly than the first aerosolgenerating substance layer 2360 and the second aerosol generating substance layer 2362 harden into a cylindrical shape. For example, as shown in portion 19A in FIG.
- an adhesive portion 2369 can be applied to both opposing elongated ends of an internal-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) such that the ends of the first membrane layer 2364 can be adhered to each other and/or to the second membrane layer 2366.
- the adhesive portion 2369 can be applied to one elongated end of an internal-facing or external-facing surface of the first membrane layer 2364 (e.g., by the tubeforming assembly 2390) such that elongated end can be adhered to an opposite elongated end of the first membrane layer 2364 that the first membrane layer 2364 is rolled to overlap with.
- an adhesive portion 2369 can be applied to one or both opposing elongated ends of an internal-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) and/or one or both opposing elongated ends of an externalfacing surface of the second membrane layer 2366 such that the first membrane layer 2364 and/or the second membrane layer 2366 can be adhered to opposite elongated ends of themselves and/or each other.
- the first elongated continuous membrane layer 2364B and/or the second elongated continuous membrane layer 2366B can be wider than the first elongated continuous thin film layer 2360B and/or the second elongated continuous thin film layer 2362B such that the first membrane layer 2364 and/or the second membrane layer 2366 can have overlapping ends without the continuous elongated heating element layer 2370B, the first elongated continuous thin film layer 2360B, and/or the second elongated continuous thin film layer 2362B overlapping when the consumable assembly 2330 is formed as tube.
- the multi-layered continuous hollow tube can be provided to a cutting assembly 2392.
- the cutting assembly 2392 can cut the multi-layered continuous hollow tube into individual consumable assemblies 2330 having substantially the same length.
- Each consumable assembly 2330 can be formed as a hollow tube including a tubular heating element 2370 having a tubular first aerosol-generating substance layer 2360 on an outer side thereof and a tubular second aerosol generating substance layer 2362 on an inner side thereof and a tubular first membrane layer 2364 as an outer layer thereof and a tubular second membrane layer 2366 as an inner layer thereof, each having substantially the same length from a first end to a second end of the consumable assembly 2330.
- Each consumable assembly 2330 can be included in a cartridge, such as any of the cartridges described herein (e.g., cartridge 110).
- each consumable assembly 2330 can be included in a cylindrical housing that is the same or similar in structure and/or function as the housing 114 described with respect to FIG. 1, along with any other suitable components for a functional user consumable product including the consumable assembly 2330.
- the cartridge including the consumable assembly 2330 can also include one or more of wrapping paper, filters (e.g., mono, multi-bore, and/or tube), cooling elements, perforations and venting features, foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
- filters e.g., mono, multi-bore, and/or tube
- cooling elements e.g., mono, multi-bore, and/or tube
- perforations and venting features foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
- each of the assemblies of the system 2300 can be configured to operate simultaneously on different portions of the materials used to produce each consumable assembly 2330.
- the first roller assembly 2300A and the second roller assembly 2300B can operate simultaneously (e.g., in a first stage) on different portions of the materials used for a particular consumable assembly 2330, while the third roller assembly 2300B (e.g., in a second stage), the tube-forming assembly 2390 (e.g., in a third stage), and the cutting assembly 2392 (e.g., in a fourth stage) each operate simultaneously on respective different portions of materials used to produce respective additional consumable assemblies 2330.
- 21 is a schematic flow chart of a method 2400 of manufacturing a consumable assembly, such as any of the consumable assemblies described herein (e.g., the consumable assembly 130, the consumable assembly 2230, and/or the consumable assembly 2330).
- the method 2400 can be a method performed by a manufacturing system such as the system 2200 and/or the system 2300 described above.
- the method 2400 can include, at 2402, disposing a portion of a continuous elongated first aero sol -sub stance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly.
- the method 2400 can include, at 2404, disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly.
- the method 2400 can include, at 2406, transitioning the second planar layered assembly into a continuous tubular layered assembly.
- the method can include, at 2408, separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
- the method 2400 can optionally include: disposing a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly; and disposing the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosolsubstance generating layer and the portion of the continuous elongated second membrane layer.
- the continuous elongated electrically-conductive layer includes a metal sheet. In some embodiments, the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
- the method 2400 can optionally include coupling a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
- each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
- each of the first aerosol-substance generating layer and the second aerosolsubstance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosol-substance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
- the method 2400 can optionally include disposing a consumable assembly of the plurality of consumable assemblies within a cartridge having a housing, a filter, and defining an airflow channel from the consumable assembly through a proximal opening of the cartridge.
- any one or more of the aspects and embodiments described herein can be conveniently implemented using one or more machines (e.g., one or more compute devices that are utilized as a user compute device for an electronic document, one or more server devices, such as a document server, etc.) programmed according to the teachings of the present specification, as will be apparent to those of ordinary skill in the computer art.
- Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those of ordinary skill in the software art.
- Aspects and implementations discussed above employing software and/or software modules can also include appropriate hardware for assisting in the implementation of the machine executable instructions of the software and/or software module.
- Automatically is used herein to modify actions that occur without direct input or prompting by an external source such as a user. Automatically occurring actions can occur periodically, sporadically, in response to a detected event (e.g., a user logging in), or according to a predetermined schedule.
- a detected event e.g., a user logging in
- determining encompasses a wide variety of actions and, therefore, “determining” can include calculating, computing, processing, deriving, investigating, looking up (e.g., looking up in a table, a database or another data structure), ascertaining and the like. Also, “determining” can include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” can include resolving, selecting, choosing, establishing and the like.
- processor should be interpreted broadly to encompass a general-purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a controller, a microcontroller, a state machine and so forth. Under some circumstances, a “processor” can refer to an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable gate array (FPGA), etc.
- ASIC application specific integrated circuit
- PLD programmable logic device
- FPGA field programmable gate array
- processor can refer to a combination of processing devices, e.g., a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in conjunction with a DSP core or any other such configuration.
- instructions and “code” should be interpreted broadly to include any type of computer-readable statement(s).
- the terms “instructions” and “code” can refer to one or more programs, routines, sub-routines, functions, procedures, etc.
- “Instructions” and “code” can comprise a single computer-readable statement or many computer-readable statements.
- Hardware modules can include, for example, a general-purpose processor, a field programmable gate array (FPGA), and/or an application specific integrated circuit (ASIC).
- Software modules (executed on hardware) can be expressed in a variety of software languages (e.g., computer code), including C, C++, JavaTM, Ruby, Visual BasicTM, and/or other object-oriented, procedural, or other programming language and development tools.
- Examples of computer code include, but are not limited to, micro-code or micro-instructions, machine instructions, such as produced by a compiler, code used to produce a web service, and files containing higher-level instructions that are executed by a computer using an interpreter.
- embodiments can be implemented using imperative programming languages (e.g., C, Fortran, etc.), functional programming languages (Haskell, Erlang, etc.), logical programming languages (e.g., Prolog), object-oriented programming languages (e.g., Java, C++, etc.) or other suitable programming languages and/or development tools.
- Additional examples of computer code include, but are not limited to, control signals, encrypted code, and compressed code.
- Various concepts can be embodied as one or more methods, of which at least one example has been provided.
- the acts performed as part of the method can be ordered in any suitable way. Accordingly, embodiments can be constructed in which acts are performed in an order different than illustrated, which can include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.
- features can not necessarily be limited to a particular order of execution, but rather, any number of threads, processes, services, servers, and/or the like that can execute serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and/or the like in a manner consistent with the disclosure. As such, some of these features can be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.
- the disclosure can include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisionals, and/or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments.
- the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%.
- a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.
- the indefinite articles “a” and “an,” as used herein in the specification and in the embodiments, unless clearly indicated to the contrary, should be understood to mean “at least one.”
- a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.
- the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements.
- This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.
- “at least one of A and B” can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.
Landscapes
- Resistance Heating (AREA)
Abstract
A system (100) can include a heater assembly (150) configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element. The system can include a processor (125) operatively coupled to each heating element of the set of heating elements and a memory (123) operatively coupled to the processor. The memory can store instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable, deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
Description
SYSTEMS AND METHODS FOR OPTIMIZING HEATING IN AN AEROSOL
GENERATING SYSTEM
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/395,618, entitled “Systems and Methods for Optimizing Heating in an Aerosol Generating System,” filed August 5, 2022, the disclosure of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure generally relates to the field of aerosol generation. In particular, the present disclosure is directed to systems and methods for optimizing heating in an aerosol generating system.
BACKGROUND
[0003] Smoking and inhaling aerosolized substances is a commoditized activity for many users. Most methods of heating tobacco, cannabis, or the like using heat-not-burn devices are inefficient due to their use of insulating material optimized for combustion heating methods. While electronic aerosol generating systems can be integrated into electronic devices to enable inhalation-based delivery of cannabis components, nicotine, and other substances in more efficient and less wasteful manners, the complications of integrating electronics to stimulate smoking can pose risk in the aerosolization of certain substances and the safe inhalation of such substances.
SUMMARY
[0004] In some embodiments, an apparatus includes a heater assembly configured to be disposed proximate to a consumable. The heater assembly includes a set of heating elements, a processor operatively coupled to each heating element of the set of heating elements, and a memory operatively coupled to the processor. The memory stores instructions to cause the processor to receive a request for delivering an aerosol of the consumable, the request including at least one of a user preference and a desired amount of the aerosol of the consumable, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable so as to produce varying amounts of the aerosol based on the request.
[0005] In some embodiments, a system includes a consumable assembly and a heater assembly. The consumable assembly includes at least one segment, the at least one segment including a consumable material. The heater assembly includes at least one heating element, the at least one segment of the consumable assembly being in direct contact with the at least one heating element. The heater assembly further includes a controller operatively coupled to the at least one heating element. The controller is configured to receive a request for an aerosol of the consumable material, the request including at least one of a user preference and a desired amount of the aerosol of the consumable. The controller is also configured to activate the at least one heating element to heat the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
[0006] In some embodiments, a system includes a pen assembly and a cartridge assembly. The cartridge assembly is configured to be removably coupled to the pen assembly. The pen assembly includes a heater assembly, the heater assembly including a set of heating elements. The pen assembly further includes a controller operatively coupled to the heater assembly. The cartridge assembly includes a container defining an airflow path and a consumable assembly disposed in the container, the consumable assembly including a consumable material. The cartridge assembly is configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly. The controller of the pen assembly is configured to receive a pressure data from a draw sensor disposed in the pen assembly and receive a preference input from a control interface provided in the pen assembly. The controller is further configured to selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
[0007] In some embodiments, a system includes a cartridge assembly and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly. The cartridge assembly includes a consumable assembly including at least one segment, where the consumable assembly includes a consumable material. The cartridge assembly includes at least one heating element in direct contact with the at least one segment of the consumable assembly. The pen assembly includes a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly. The pen assembly further includes a controller operatively coupled to the heater assembly, the controller configured to receive a request for an aerosol of the consumable material, the request including
at least one of a user preference and a desired amount of the aerosol of the consumable. The controller is also configured to selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
[0008] In some embodiments, the techniques described herein relate to an apparatus, including: a heater assembly configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element; a processor operatively coupled to each heating element of the set of heating elements; and a memory operatively coupled to the processor, the memory storing instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
[0009] In some embodiments, the techniques described herein relate to a system, including: a consumable assembly including at least one segment, the at least one segment including a consumable material; and a heater assembly including: a first heating element and a second heating element, the first heating element and the second heating element being in thermal communication with the at least one segment including a consumable material, and a controller operatively coupled to the at least one heating element, the controller configured to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
[0010] In some embodiments, the techniques described herein relate to a system, including: a pen assembly, including: a heater assembly, the heater assembly including a set of heating elements, and a controller operatively coupled to the heater assembly; a cartridge assembly configured to be removably coupled to the heater assembly, the cartridge assembly including: a container defining an airflow path and a heater chamber, and a consumable assembly disposed in the container, the consumable assembly including a consumable material, the cartridge assembly configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly, and the controller being
configured to: receive a pressure data from a draw sensor disposed in the pen assembly, receive a preference input from a control interface provided in the pen assembly, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
[0011] In some embodiments, the techniques described herein relate to a system including: a cartridge assembly, including: a consumable assembly including at least one segment, the consumable assembly including a consumable material, and at least one heating element being in direct contact with the at least one segment of the consumable assembly; and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly, the pen assembly including: a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly, and a controller operatively coupled to the heater assembly, the controller configured to: receive a request for an aerosol of the consumable material, the request including a user preference or a desired amount of the aerosol of the consumable, and selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
[0012] In some embodiments, the techniques described herein relate to a system, including: an electrically-conductive layer having a first side and a second side opposite the first side; a first aerosol-substance generating layer having a first side and a second side opposite the first side, the first side of the first aerosol-substance generating layer disposed in contact with the first side of the electrically-conductive layer; a second aerosol-substance generating layer having a first side and a second side opposite the first side, the second side of the second aerosol-substance generating layer disposed in contact with the second side of the electrically- conductive layer; a first membrane layer disposed on the second side of the first aerosolsubstance generating layer; and a second membrane layer disposed on the first side of the second aerosol-substance generating layer.
[0013] In some embodiments, the techniques described herein relate to a system, including: a first rolling assembly configured to dispose a portion of a continuous elongated first aerosolsubstance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; a second rolling assembly configured to dispose a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; a tube-forming assembly configured to transition the second
planar layered assembly into a continuous tubular layered assembly; and a cutting assembly configured to separate the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
[0014] In some embodiments, the techniques described herein relate to a method, including: disposing a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; transitioning the second planar layered assembly into a continuous tubular layered assembly; and separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic block diagram of an aerosolization system, according to an embodiment.
[0016] FIG. 2 is a schematic illustration of a portion of a heater assembly including a set of heating elements disposed proximate to a portion of a consumable assembly, according to an embodiment.
[0017] FIG. 3A is a schematic illustration of a consumable assembly, according to an embodiment.
[0018] FIG. 3B is a side cross-section view of the consumable assembly of FIG. 3 A taken along the line A-A in FIG. 3 A.
[0019] FIG. 3C is a schematic illustration of a consumable assembly, according to an embodiment.
[0020] FIG. 3D is a side cross-section view of the consumable assembly of FIG. 3C taken along the line B-B in FIG. 3C.
[0021] FIG. 3E is a schematic illustration of a consumable assembly, according to an embodiment.
[0022] FIG. 3F is a schematic illustration of a consumable assembly, according to an embodiment.
[0023] FIG. 3G is a schematic illustration of a consumable assembly, according to an embodiment.
[0024] FIG. 3H is a schematic illustration of a consumable assembly, according to an embodiment.
[0025] FIG. 31 is a schematic illustration of a consumable assembly, according to an embodiment.
[0026] FIG. 3J is a schematic illustration of a consumable assembly, according to an embodiment.
[0027] FIG. 3K is a schematic illustration of a consumable assembly, according to an embodiment.
[0028] FIG. 4A is a schematic illustration of a portion of a vaporizer pen, where a heater assembly is contained in the vaporizer pen, according to an embodiment.
[0029] FIG. 4B is a schematic illustration of a cartridge assembly configured to be coupled to the vaporizer pen of FIG. 4A with a consumable assembly being disposed in a housing of the cartridge assembly, according to an embodiment.
[0030] FIG. 4C is a schematic illustration of a portion of a vaporizer pen assembly that can be used in the with the cartridge of the system of FIG. 4A-4B, according to an embodiment.
[0031] FIG. 4D is a schematic illustration of a portion of a vaporizer pen assembly that can be used in the with the cartridge of the system of FIG. 4A-4B, according to an embodiment.
[0032] FIG. 5 A is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly of FIG. 4A-4B coupled to the vaporizer pen assembly of FIG. 4C or 4D.
[0033] FIG. 5B is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly of FIG. 4B coupled to the vaporizer pen assembly of FIG. 4C, and indicating the direction of aerosol flow through the system, according to an embodiment.
[0034] FIG. 6A is a schematic illustration of a portion of a vaporizer pen assembly that can be used in an aerosolization system, according to an embodiment.
[0035] FIG. 6B is a side cross-section of a portion of a system that includes the vaporizer pen assembly of FIG. 6 A coupled to a cartridge assembly, according to an embodiment.
[0036] FIG. 7A and FIG. 7B are side cross-section views of portions of aerosolization systems including a cartridge assembly coupled to a vaporizer pen, according to various embodiments.
[0037] FIG. 8 is a schematic illustration of a consumable assembly including a consumable formed into a sheet having multiple segments, and a heating element including a susceptor sheet configured to be disposed on and contact the consumable sheet, according to an embodiment.
[0038] FIG. 9A is a schematic illustration of a consumable assembly that includes a sheet of a consumable that is in contact with a susceptor, and rolled or wound into a spool or coil, according to an embodiment.
[0039] FIG 9B is a top of view of the consumable assembly of FIG. 9A wound into a flat coil, according to an embodiment.
[0040] FIG. 9C is a top view of the consumable assembly of FIG. 9A wound into a circular coil, according to an embodiment
[0041] FIG. 9D is a schematic illustration of a cartridge assembly including the consumable assembly of FIG. 9A wound into a spool or coil, according to an embodiment.
[0042] FIG. 10A is a side cross-section view of a portion of an aerosolization system that includes a cartridge assembly that includes a consumable assembly with a consumable sheet and susceptor, coupled to a vaporizer pen assembly that includes multiple inductor coils, according to an embodiment.
[0043] FIG. 10B is a side cross-section view of a portion of an aerosolization system that includes a cartridge assembly that includes a consumable assembly with a consumable sheet and susceptor, coupled to a vaporizer pen assembly that includes an injector coil mounted on an actuator, according to an embodiment.
[0044] FIG. 11 A-l IB is an aerosolization system including a portion of vaporizer pen with a heater assembly including a susceptor with wicks on both sides of the susceptor, according to an embodiment.
[0045] FIG. 11C is a front view of an assembly including a susceptor with wicks on both sides of the susceptor formed into a tube, according to an embodiment.
[0046] FIG. 12A is a schematic illustration of an aerosolization system including a cartridge assembly coupled to a vaporizer pen assembly, according to an embodiment.
[0047] FIG. 12B is a schematic illustration of the cartridge assembly of FIG. 12A, according to an embodiment.
[0048] FIG. 12C a schematic illustration of the vaporizer pen assembly of FIG. 12 A, according to an embodiment.
[0049] FIG. 12D is a side cross-section view of the cartridge assembly of FIG. 12A-1 IB.
[0050] FIG. 12E is a side cross-section view of the vaporizer pen assembly of FIG. 12A and 12C.
[0051] FIG. 12F is a side cross-section view of the cartridge assembly of FIGS. 12A-1 IB, and 1 ID coupled to the vaporizer pen assembly of FIGS. 12A, 12C, and 12E.
[0052] FIG. 13 A is a plot showing power management of a set of heating elements included in a heater assembly of an aerosolization system, according to an embodiment.
[0053] FIG. 13B is a plot showing temperature profiles of three heating elements of a heater assembly that are sequentially activated, and associated temperature of a consumable that is located proximate to or in contact with each of the three heating elements of the heater assembly.
[0054] FIG. 14 is a schematic block diagram of a controller that can be configured to selectively activate each of a set of heating elements included in a heater assembly, according to an embodiment.
[0055] FIG. 15 A- 15E are various views of a heater assembly that includes a wick including a flat porous layer and a set of heating elements arranged in a flat configuration, and that can be used to aerosolize a liquid consumable, according to an embodiment.
[0056] FIG. 15F is an exploded view of the heater assembly of FIGS. 15A-14E, an associated heater assembly housing and a base, according to an embodiment.
[0057] FIG. 16A-16D are various views of a heater assembly that includes a wick including a cylindrical porous layer and a set of heating elements provided as coils, and that can be used to aerosolize a liquid consumable, according to an embodiment.
[0058] FIG. 17 is a schematic flow diagram of a method for aerosolizing a consumable via a heater assembly that includes a set of heating elements, according to an embodiment.
[0059] FIG. 18 is a schematic illustration of a system for manufacturing a consumable assembly, according to an embodiment.
[0060] FIG. 19 is a schematic illustration of a system for manufacturing a consumable assembly, according to an embodiment.
[0061] FIG. 20 is a schematic illustration of an implementation of the system of FIG. 1, according to an embodiment.
[0062] FIG. 21 is a schematic flow diagram of a method for manufacturing a consumable assembly, according to an embodiment.
DETAILED DESCRIPTION
[0063] Embodiments described herein relate to systems and methods for aerosolizing solid, liquid, gel, and other consumables. In particular, embodiments described herein relate to aerosol generating systems that include a vaporizer pen configured to heat a consumable assembly via a heater assembly included in the vaporizer pen or a cartridge coupled to the vaporizer pen to produce aerosol for inhalation.
[0064] In some embodiments, the techniques described herein relate to an apparatus, including: a heater assembly configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element; a processor operatively coupled to each heating element of the set of heating elements; and a memory operatively coupled to the processor, the memory storing instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
[0065] In some embodiments, the techniques described herein relate to an apparatus, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
[0066] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power and the second power are substantially equal.
[0067] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
[0068] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly further includes a third heating element, and the memory stores instructions to cause the processor to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
[0069] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power, the second power, and the third power are substantially equal.
[0070] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
[0071] In some embodiments, the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element are disposed in contact with the consumable during a heating operation.
[0072] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly extends axially along a longitudinal axis of the consumable.
[0073] In some embodiments, the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element extend parallel to a longitudinal axis of the consumable, the first heating element and the second heating element being separated from each other along a circumferential direction about the longitudinal axis.
[0074] In some embodiments, the techniques described herein relate to an apparatus, wherein the first heating element and the second heating element extend in a circumferential direction about a longitudinal axis of the consumable, the first heating element and the second heating element being axially separated from each other along the longitudinal axis.
[0075] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly defines an axial channel therethrough.
[0076] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly is configured to be disposed at least one of radially outward or radially inward of the consumable.
[0077] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly has at least one of a flat, a circular, a star, a cylindrical, a polygonal, a tubular, a coiled, or an asymmetric shape.
[0078] In some embodiments, the techniques described herein relate to an apparatus, wherein: the heater assembly includes one or more inductor coils, the consumable includes at least one susceptor and an aerosol-generating substance disposed proximate to or in contact with the at least one susceptor, and activating the first heating element includes activating at least a portion of the one or more inductor coils so as to heat an associated portion of the at least one susceptor and thereby, an associated portion of the aerosol-generating substance.
[0079] In some embodiments, the techniques described herein relate to an apparatus, wherein the at least one susceptor includes a porous sheet, the aerosol-generating substance includes a consumable sheet, and the at least one susceptor and the consumable sheet are coiled into a spool.
[0080] In some embodiments, the techniques described herein relate to an apparatus, wherein the at least one susceptor includes an electrically-conductive sheet and the aerosolgenerating substance includes one or more of a layer of a porous consumable sheet, a layer of an aerosol-producing gel, or a layer of an aerosol-producing paste.
[0081] In some embodiments, the techniques described herein relate to an apparatus, wherein the consumable includes the layer of a porous consumable sheet, and the aerosolgenerating substance includes one of a layer of an aerosol-producing gel or a layer of an aerosol-producing paste disposed between the layer of the porous consumable sheet and the electrically-conductive sheet.
[0082] In some embodiments, the techniques described herein relate to an apparatus, wherein: the consumable includes a liquid, and the heating element further includes a wick at least one of presoaked with the liquid or configured to draw the liquid from a reservoir.
[0083] In some embodiments, the techniques described herein relate to a system, including: a consumable assembly including at least one segment, the at least one segment including a consumable material; and a heater assembly including: a first heating element and a second heating element, the first heating element and the second heating element being in thermal communication with the at least one segment including a consumable material, and a controller operatively coupled to the at least one heating element, the controller configured to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request:
activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
[0084] In some embodiments, the techniques described herein relate to an apparatus, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
[0085] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power and the second power are substantially equal.
[0086] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
[0087] In some embodiments, the techniques described herein relate to an apparatus, wherein the heater assembly further includes a third heating element, and controller configured to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
[0088] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power, the second power, and the third power are substantially equal.
[0089] In some embodiments, the techniques described herein relate to an apparatus, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
[0090] In some embodiments, the techniques described herein relate to a system, wherein: the consumable assembly includes a plurality of segments, and each of the first heating element and the second heating element is associated with at least one segment of the plurality of segments.
[0091] In some embodiments, the techniques described herein relate to a system, wherein: the controller is configured to selectively activate one of the first heating element or the second
heating element to heat the at least one segment of the plurality of segments associated with the one of the first heating element or the second heating element.
[0092] In some embodiments, the techniques described herein relate to a system, wherein the controller is configured to activate each of the first heating element and the second heating element concurrently and intermittently so as to control a rate of the aerosol generated based on the request.
[0093] In some embodiments, the techniques described herein relate to a system, wherein the consumable assembly is aligned with and co-extensive with the set of heating elements of the heater assembly.
[0094] In some embodiments, the techniques described herein relate to a system, wherein the consumable assembly includes a sheet having a thickness in a range of about 0.05 mm to about 5 mm.
[0095] In some embodiments, the techniques described herein relate to a system, wherein the consumable assembly includes a sheet having a plurality of layers, each layer having a thickness in a range of about 0.05 mm to about 5 mm.
[0096] In some embodiments, the techniques described herein relate to a system, wherein each of the layers is formed as one of a solid or a gel.
[0097] In some embodiments, the techniques described herein relate to a system, wherein the consumable assembly and at least one of the first heating element and the second heating element are each assembled as a flat sheet, a tube, a spooled coil, or having complex shape such that the at least one segment of the consumable is in direct contact and aligned with the at least one heating element.
[0098] In some embodiments, the techniques described herein relate to a system, wherein the at least one heating element of the set of heating elements are disposed radially outward or radially inward of the at least one segment of the consumable assembly.
[0099] In some embodiments, the techniques described herein relate to a system, wherein: each of the first heating element and the second heating element includes at least one inductor coil, the consumable assembly includes at least one susceptor, activating the first heating element includes activating the at least one inductor coil of the first heating element to heat a first portion of the at least one susceptor, and activating the second heating element includes
activating the at least one inductor coil of the second heating element to heat a second portion of the at least one susceptor .
[0100] In some embodiments, the techniques described herein relate to a system, wherein: each of the first heating element and the second heating element includes at least one inductor coil, the consumable assembly includes at least one susceptor, the heater assembly includes an actuator, the at least one inductor coil of the first heating element being coupled to the actuator, the controller configured to actuate the actuator to cause the actuator to displace the inductor coil axially relative to the at least one susceptor so as to position the at least one inductor coil proximate to a portion of the susceptor such that activation of the at least one inductor coil causes heating of the portion of the susceptor.
[0101] In some embodiments, the techniques described herein relate to a system, wherein: the consumable material is a liquid, and the consumable assembly includes a porous material at least one of presoaked with the liquid or in fluid communication with a reservoir of the liquid.
[0102] In some embodiments, the techniques described herein relate to a system, including: a pen assembly, including: a heater assembly, the heater assembly including a set of heating elements, and a controller operatively coupled to the heater assembly; a cartridge assembly configured to be removably coupled to the heater assembly, the cartridge assembly including: a container defining an airflow path and a heater chamber, and a consumable assembly disposed in the container, the consumable assembly including a consumable material, the cartridge assembly configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly, and the controller being configured to: receive a pressure data from a draw sensor disposed in the pen assembly, receive a preference input from a control interface provided in the pen assembly, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
[0103] In some embodiments, the techniques described herein relate to a system, wherein each heating element of the set of heating elements includes a mesh configured to allow the aerosol to pass through each heating element of the set of heating elements and the airflow path.
[0104] In some embodiments, the techniques described herein relate to a system, wherein the container includes a porous material disposed therein such that the produced aerosol flows through the porous material.
[0105] In some embodiments, the techniques described herein relate to a system, wherein the heater assembly includes a heater matrix including each heating element of the set of heating elements, the heater matrix being configured as a sheet, and the consumable assembly includes a consumable sheet such that selective activation of the portion of the set of heating elements by the controller causes an associated portion of the consumable sheet to be aerosolized.
[0106] In some embodiments, the techniques described herein relate to a system including: a cartridge assembly, including: a consumable assembly including at least one segment, the consumable assembly including a consumable material, and at least one heating element being in direct contact with the at least one segment of the consumable assembly; and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly, the pen assembly including: a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly, and a controller operatively coupled to the heater assembly, the controller configured to: receive a request for an aerosol of the consumable material, the request including a user preference or a desired amount of the aerosol of the consumable, and selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
[0107] In some embodiments, the techniques described herein relate to a system, wherein: the heating element includes a susceptor, the susceptor being aligned with and co-extensive with the at least one segment of the consumable assembly, and selectively activating the at least one heating element includes selectively activating the at least one inductor coil so as to heat an associated portion of the susceptor.
[0108] In some embodiments, the techniques described herein relate to a system, including: an electrically-conductive layer having a first side and a second side opposite the first side; a first aerosol-substance generating layer having a first side and a second side opposite the first side, the first side of the first aerosol-substance generating layer disposed in contact with the first side of the electrically-conductive layer; a second aerosol-substance generating layer having a first side and a second side opposite the first side, the second side of the second
aerosol-substance generating layer disposed in contact with the second side of the electrically- conductive layer; a first membrane layer disposed on the second side of the first aerosolsubstance generating layer; and a second membrane layer disposed on the first side of the second aerosol-substance generating layer.
[0109] In some embodiments, the techniques described herein relate to a system, wherein the electrically-conductive layer is formed by a metal sheet.
[0110] In some embodiments, the techniques described herein relate to a system, wherein the electrically-conductive layer is formed by at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
[OHl] In some embodiments, the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length.
[0112] In some embodiments, the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length and width.
[0113] In some embodiments, the techniques described herein relate to a system, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have a circular cross-section and a tubular shape.
[0114] In some embodiments, the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
[0115] In some embodiments, the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
[0116] In some embodiments, the techniques described herein relate to a system, wherein at least one of the first membrane layer and the second membrane layer are at least one of permeable or perforated.
[0117] In some embodiments, the techniques described herein relate to a system, further including an elongated hollow tube defining an annular space between an outer surface of the second membrane layer and an inner surface of the elongated hollow tube.
[0118] In some embodiments, the techniques described herein relate to a system, including: a first rolling assembly configured to dispose a portion of a continuous elongated first aerosolsubstance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; a second rolling assembly configured to dispose a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; a tube-forming assembly configured to transition the second planar layered assembly into a continuous tubular layered assembly; and a cutting assembly configured to separate the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
[0119] In some embodiments, the techniques described herein relate to a system, further including a third rolling assembly configured to dispose a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly, the second rolling assembly configured to disposed the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosolsubstance generating layer and the portion of the continuous elongated second membrane layer.
[0120] In some embodiments, the techniques described herein relate to a system, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
[0121] In some embodiments, the techniques described herein relate to a system, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
[0122] In some embodiments, the techniques described herein relate to a system, wherein the tube-forming assembly is configured to couple a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
[0123] In some embodiments, the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
[0124] In some embodiments, the techniques described herein relate to a system, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
[0125] In some embodiments, the techniques described herein relate to a method, including: disposing a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; transitioning the second planar layered assembly into a continuous tubular layered assembly; and separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
[0126] In some embodiments, the techniques described herein relate to a method, further including: disposing a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly; and disposing the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosol-substance generating layer and the portion of the continuous elongated second membrane layer.
[0127] In some embodiments, the techniques described herein relate to a method, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
[0128] In some embodiments, the techniques described herein relate to a method, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
[0129] In some embodiments, the techniques described herein relate to a method, further including coupling a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
[0130] In some embodiments, the techniques described herein relate to a method, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
[0131] In some embodiments, the techniques described herein relate to a method, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosolsubstance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
[0132] In some embodiments, the techniques described herein relate to a method, further including disposing a consumable assembly of the plurality of consumable assemblies within a cartridge having a housing, a filter, and defining an airflow channel from the consumable assembly through a proximal opening of the cartridge.
[0133] In some implementations, the consumable assembly can include a thin dense sheet of a solid consumable material that can be formed into a flat sheet, formed into a cylindrical shape, wound into a spool or coil, or formed into any other polygonal or complex three dimensional surface shape and disposed in a cartridge assembly configured to be coupled to the vaporizer pen such that one or more heating elements of the heater assembly are disposed proximate to the consumable. In some implementations, the one or more heating elements can be in direct contact with the consumable assembly such that a surface of the thin dense sheet is mated with a surface area of the heating elements of the heater assembly. In some implementations, the consumable assembly can include a solid consumable, for example, a pressed plant-based material. The thin dense sheet of the consumable material can be mated with an equal size or larger heating element(s) to transfer heat through the mass of the consumable quickly and efficiently. The thin dense sheet can consist of one or more segments where one or more segments of the consumable are associated with one or more segments of a heating element, or one or more heating elements of the heater assembly so as to heat the thin dense sheet and/or its segments at the same time or separately, sequentially, intermittently, or in any desired order. The desired order of activating the set of heating elements can be based
on at least one of a user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and a desired amount of the aerosol of the consumable (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, amount of consumable material remaining, etc.).
[0134] In some embodiments, the consumable assembly can include a porous material, for example, a wick presoaked with a liquid consumable and/or in fluid communication with a reservoir of the liquid consumable. In some implementations, the vaporizer pen can be optimized to support multiple consumable materials. For example, the vaporizer pen can support multiple types of nicotine consumables such as e-juice, enabling safe and accurate aerosolization of substances other than burnable substances such as cannabis and traditional tobacco. In some implementations, the controller can be configured to heat the consumable at various rates for combustible and/or vaporizable consumable materials. In some implementations, the heater assembly can also support sublimation of solid consumables, such as glycerin / propylene glycol based gels/solids. The vaporizer pen can include a controller (e.g., the processor 125) configured to selectively activate one or more heating elements included in the heater assembly to allow for accurate dosing of aerosolized consumable and increase efficiency of aerosolization of the consumable. In some implementations, the controller can control the aerosolization rate and/or the volume of aerosol produced based on user inputs or preferences by increasing surface area of active heating, not increasing the temperature to which the consumable is heated. In some implementations, the heater assembly can be configured to aerosolize a consumable that does not include additives, thereby reducing and/or eliminating harmful by-products delivered to a user in the consumable aerosol. The cartridge assembly can be removably coupled to the vaporizer pen, allowing for a used cartridge assembly to be removed from the vaporizer pen and replaced with a new cartridge assembly containing the same or a different consumable to be used with the vaporizer pen.
[0135] The vaporizer pen can be implemented to support the consumable in a variety of shapes and forms such as, but not limited to, flat, circular, star, cylindrical, polygonal, tubular, coiled, asymmetric shapes, or complex three dimensional (“3D”) shapes. To support the consumable of variety of shapes and forms, the vaporizer pen can also be implemented to include a heater assembly with the same (or similar) shapes and forms as the consumable, where the heater assembly mates (directly or proximate to) with a consumable and/or
consumable assembly in the cartridge assembly when coupled to the heater assembly of the vaporizer pen.
[0136] For instance, the consumable can be sandwiched in between a surface of the heater assembly and a surface of the cartridge assembly to hold the consumable in place and in direct (or proximate) contact with the heater assembly. In some embodiments, the consumable can include a solid thin dense sheet between about 0.01 millimeters and about 2.5 millimeters thick, inclusive, mated with the heater assembly, and that can be about equal size, shape, or form with the heater assembly. The thin dense sheet mated to the heater assembly in equal size is beneficial because the heater assembly can transfer heat to the thin dense sheet quickly and efficiently, thereby resulting in quick and efficient aerosolization and inhalation.
[0137] In some implementations, the heating element can include one or more susceptors (e.g., solid sheets, porous sheets, meshes, etc.) that are configured to be energized to generate heat via electromagnetic energy provided by inductor(s). The inductor(s) can include any solid inductor such as, but not limited to, coils, flat plate inductors, etc. In such implementations, the susceptors can be mated with the consumable, i.e., provided in direct contact with the consumable sheet in the consumable assembly, and disposed in the cartridge assembly along with the consumable assembly.
[0138] The heater assembly can include one or more heating elements, which can form a heater matrix. In some implementations, the consumable can include a thin dense sheet, where the thin dense sheet includes one or more consumable segments, where the one or more heating elements corresponds to the surface area of the one or more consumable segments. The multiple consumable segments can be beneficial in dosing and volume control of aerosolization as each consumable segment can include a precise quantity of a desired consumable, where the one or more heating elements corresponding to the one or more consumable segments can deliver precise or predefined dose(s) and/or enable adjustability of the rate of aerosol delivery of a desired consumable in each consumable segment. The heater assembly with multiple heating elements significantly enhances the surface area of the consumable that is heated. The vaporizer pen can be implemented to include a power source that can conserve power consumption by intermittently powering each heating element such that fewer heating elements are on at any one time. In some implementations, the process of heating the consumable can focus higher energy on a smaller surface of the consumable, or one or more consumable segments, at a time. The power source of the vaporizer pen can be configured to cycle each heating element with peak power output, enabling a user to vary the volume of aerosol
produced. In some implementations, the power source of the vaporizer pen can be configured to cycle each heating element with or without uniform power output to enable the user to vary the volume of aerosol produced.
[0139] Embodiments of the systems and methods described herein for aerosolizing a consumable can provide one or more benefits including, for example: (1) providing a thin dense sheet of a solid consumable material that can be selectively heated and aerosolized to allow better aerosolization of the solid consumable material; (2) providing multiple heating elements in a heater assembly that can be selectively activated in any suitable configuration to optimize aerosolization of multiple consumable materials, thereby increasing heating surface area, increasing aerosolization rate, and providing aerosolization of greater than 50% of the consumable; (3) enabling accurate dosing via aerosolization of a thin dense sheet of the solid consumable material (4) reducing power consumption and extending power source life by allowing activation of less than all heating elements included in the heater assembly at a given time; (5) allowing generation of consumable aerosols at a rate of greater than 7 mg/sec that is greater than 2 times the maximum vapor generated by cigarettes including the same consumable material; (6) providing all electronics in a vaporizer pen allowing cartridges configured to be coupled to the vaporizer pen to be formed from exclusively biodegradable materials; and (7) allowing control of aerosol volume produced and/or aerosolization rate based on user preference or a desired amount of the aerosol of the consumable, thus allowing varying amounts of the aerosol to be delivered based on a request.
[0140] FIG. 1 is a schematic block diagram of an aerosolization system 100, according to an embodiment. The aerosolization system 100 can be referred to as an “electronic aerosol delivery system,” “aerosol generating system,” or “electronic vapor delivery system.” In some embodiments, the aerosolization system 100 can be a heat-not-bum system. The aerosolization system 100 includes a cartridge 110 and a vaporizer pen 140. The cartridge 110 can also be referred to and/or formed as a “cartridge assembly,” a “cartridge portion,” a “container,” a “capsule,” a “capsule assembly,” a “pack,” a “pod,” a “consumable,” a “stick,” or a “consumable portion.” The vaporizer pen 140 can also be referred to as a “pen assembly,” a “vape pen,” a “vaporizer pen assembly,” a “pen portion,” a “pen housing,” a “vaporizer body,” a “reusable,” a “reusable portion,” a “reusable device,” a “battery portion,” a “heating control assembly,” or a “heating control device.”
[0141] The cartridge 110 can be removably coupled to the vaporizer pen 140 such that the vaporizer pen 140 can control aerosolization of one or more aerosol-generating substances
included in the cartridge 110. For example, as shown in FIG. 1, the cartridge 110 can include at least one heating element 170 (also referred to as at least one “heat-emitting elements”) and at least one aerosol-generating substance (e.g., a first aerosol-generating substance portion 160), and the vaporizer pen 140 can include a heater assembly 150 operatively coupled to a power supply 124. As used herein, “aerosol-generating substance” can also be referred to as a “consumable substance” or a “consumable material,” and can refer to any substance that can be vaporized, combusted, and/or aerosolized for inhalation. The heater assembly 150 and the least one heating element 170 can be configured such that, when the cartridge 110 is engaged with the vaporizer pen 140, the heater assembly 150 can operate to initiate a temperature increase of the least one heating element 170 sufficient such that the at least a portion of the at least one aerosol-generating substance is heated by the least one heating element 170 and aerosolized for inhalation by a user of the aerosolization system 100.
[0142] The vaporizer pen 140 can include a housing 142 defining a cartridge receptacle 141 configured to receive the cartridge 110 such that aerosolization of at least one aerosolgenerating substance included in the cartridge 110 can be controlled by the heater assembly 150. For example, the cartridge 110 can include a proximal end (e.g., a mouth end) and a distal end. The cartridge receptacle 141 can be configured to receive at least a portion of the cartridge 110 such that the distal end of the cartridge 110 is disposed within the cartridge receptacle 141. In some embodiments, the cartridge receptacle 141 is configured to receive a portion of the cartridge 110 such that a proximal end of the cartridge 110 is accessible by a user (e.g., for engagement with a user’s mouth) when the cartridge 110 is operatively engaged with the vaporizer pen 140 for an aerosolization operation.
[0143] As shown in FIG. 1, in some implementations, the cartridge 110 can include a consumable assembly 130 including the first aerosol-generating substance portion 160 and the at least one heating element 170. In some implementations, the consumable assembly 130 can include a second aerosol -generating substance portion 162. In some implementations, the consumable assembly 130 can include a first membrane layer 164 and/or a second membrane layer 166. In some implementations, the first aerosol-generating substance portion 160 and the second aerosol -generating substance portion 162 can be formed as independent segments or portions that can be independently aerosolized by the heater assembly 150 (e.g., via an associated portion of heater element of the heater assembly 150). Each of the segments or portions of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162) can include the same
consumable material or different consumable materials in any suitable combination. In some implementations, the cartridge 110 can include three or more aerosol-generating substance portions having similar characteristics to first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162.
[0144] In some implementations, the at least one heating element 170 can be disposed between the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162. In some implementations, the at least one heating element 170 can include a plurality of heating elements disposed between the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162. In some implementations, the first aerosol -generating substance portion 160 can be disposed between the at least one heating element 170 and the first membrane layer 164. In some implementations, the second aerosol-generating substance portion 162 can be disposed between the at least one heating element 170 and the second membrane layer 166. In some implementations, the consumable assembly 130 can include the at least one heating element 170, the first aerosol-generating substance portion 160, the second aerosol-generating substance portion 162, and the first membrane layer 164. In some implementations, the consumable assembly 130 can include the at least one heating element 170, the first aerosolgenerating substance portion 160, the second aerosol -generating substance portion 162, the first membrane layer 164, and the second membrane layer 166. In some implementations, the at least one heating element 170 can include a first heating element and a second heating element. The first heating element can be disposed on a first side of the first aerosol-generating substance portion 160 and the second heating element can be disposed on a second side of the first aerosol-generating substance portion 160, and the second aerosol-generating substance portion 162 can or can not be included in the consumable assembly 130.
[0145] In some implementations, the first aerosol -generating substance portion 160 and/or the second aerosol -generating substance portion 162 is disposed in direct contact with the at least one heating element 170. In some implementations, the first membrane layer 164 is disposed in direct contact with the first aerosol -generating substance portion 160 and/or the second membrane layer 166 is disposed in direct contact with the second aerosol -generating substance portion 162. In some implementations, rather than the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162 being disposed in direct contact with the at least one heating element 170, a thin membrane layer (not shown in FIG. 1) can be disposed between the first aerosol-generating substance portion 160
and the at least one heating element 170 and/or between the second aerosol -generating substance portion 162 and the at least one heating element 170. In some implementations, the thin membrane layer can be formed as a thin, paper-like substrate. In some implementations, the thin membrane layer can be the same or similar in structure and/or function as the first membrane layer 164 and/or the second membrane layer 166.
[0146] In some implementations, the consumable assembly 130 can be formed as a hollow tube such that a channel 131 is defined by the consumable assembly 130 from a distal end to a proximal end of the consumable assembly 130 (e.g., along a central axis of the consumable assembly 130). In some implementations, aerosol produced by the first aerosol -generating substance portion 160 and/or the second aerosol -generating substance portion 162 can travel through the channel 131 toward the proximal end of the consumable assembly 130 and/or the mouth end of the cartridge 110.
[0147] In some implementations, the consumable assembly 130 can be formed as a flat, planar multi-layered sheet having a thickness significantly smaller than a length and width of the consumable assembly 130. For example, each of the components of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160, the at least one heating element 170, and the optional second aerosol-generating substance portion 162, the optional second aerosol-generating substance portion 162, the optional first membrane layer 164, and/or the optional second membrane layer 166) can be formed to have the same perimeter shape (e.g., a rectangular shape) and stacked to form a multi-layered sheet such that one of the components (e.g., the first membrane layer 164, the first aerosol-generating substance portion 160, or the at least one heating element 170) forms an outermost layer on a first side including a first surface and another of the components (e.g., at least one heating element 170, the second aerosolgenerating substance portion 162, or the second membrane layer 166) forms an outermost layer on a second side opposite the first side including a second surface. The first side and the first surface face an opposite direction as and are disposed in a parallel plane to the second side and the second surface.
[0148] In some implementations, rather than being formed as a tube or a planar multi-layer sheet, the consumable assembly 130 can have any suitable overall shape and/or cross-sectional shape. For example, the cross-sectional shape of the at least one heating element 170 and/or the consumable assembly consumable assembly 130 can be rectangular, circular, star-shaped, polygonal, spiraled, coiled, asymmetric, and/or a complex three dimensional (“3D”) shape. In
some implementations, the consumable assembly 130 can be flexible or malleable to form multiple distinct shapes or configurations further described in FIG. 3 A-K.
[0149] In some implementations, the one or more segments or portions of the consumable substance (e.g., first aerosol -generating substance portion 160 and/or the second aerosolgenerating substance portion 162) can be in direct contact or configured to be in direct contact with one or more heating elements of the heater assembly 150. In some implementations, the one or more heating elements of the heater assembly 150 can be aligned with and/or substantially corresponding in area (e.g., have about the same area or a slightly larger area than a surface area of the sheet of consumable assembly 130) with the consumable assembly 130 and/or the one or more segments or portions of the consumable substance therein (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162). Although FIG. 1 shows the consumable assembly 130 as including at least one heating element 170, in some implementations, the consumable assembly 130 and/or the cartridge 110 does not include the at least one heating element 170. In some implementations, the consumable assembly 130 can include, or be formed from a consumable material (e.g., a solid consumable material) that is configured (e.g., disposed, shaped, and/or sized) to be directly aerosolized by the heater assembly 150 (e.g., via direct and/or indirect contact with the heater assembly 150).
[0150] In some implementations, each of the components of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160, the at least one heating element 170, and the optional second aerosol -generating substance portion 162, the optional second aerosolgenerating substance portion 162, the optional first membrane layer 164, and/or the optional second membrane layer 166) can have the same length (e.g., taken along a line parallel to or coaxial with a central axis of the consumable assembly 130), the same width, and/or the same perimeter shape and/or size as adjacent components. In some implementations, the cross- sectional shape and size of each component of the consumable assembly 130 (e.g., the first aerosol -generating substance portion 160, the at least one heating element 170, and the optional second aerosol-generating substance portion 162, the optional second aerosol-generating substance portion 162, the optional first membrane layer 164, and/or the optional second membrane layer 166) can be the same (e.g., constant and continuous) from the distal end to the proximal end of the consumable assembly 130 (e.g., taken along a central axis of the consumable assembly).
[0151] In some implementations, each of the components of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160, the at least one heating element 170, and the optional second aerosol -generating substance portion 162, the optional second aerosolgenerating substance portion 162, the optional first membrane layer 164, and/or the optional second membrane layer 166) can have the same thickness. For example, the first aerosolgenerating substance portion 160, the at least one heating element 170, and the second aerosolgenerating substance portion 162 can have the same thickness. In some implementations, the first membrane layer 164 and the second membrane layer 166 can each have a thickness less than a thickness of the first aerosol-generating substance portion 160, the at least one heating element 170, and/or the second aerosol-generating substance portion 162.
[0152] In some implementations, surfaces of the at least one heating element 170, the first aerosol-generating substance portion 160, and the optional at least one heating element 170 that directly abut or face other surfaces of the at least one heating element 170, the first aerosolgenerating substance portion 160, and the optional at least one heating element 170 have substantially the same perimeter shape and size and substantially the same area as the surface that is abutted or faced. For example, the at least one heating element 170 can be formed as a planar sheet or hollow tube having a first surface and a second surface opposite the first surface. In implementations in which the at least one heating element 170 is formed as a hollow tube, the first surface can be an interior surface and the second surface can be an exterior surface. In some implementations, the first aerosol-generating substance portion 160 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the at least one heating element 170. The second surface of the first aerosolgenerating substance portion 160 and the first surface of the at least one heating element 170 can have the same length, the same or substantially (e.g., in the case of abutting non-planar surfaces) the same area, the same perimeter shape, and/or the same or substantially the same (e.g., in the case of abutting non-planar surfaces) perimeter size. In some implementations, the second aerosol -generating substance portion 162, which can be included in the consumable assembly 130 in addition to the first aerosol-generating substance portion 160 or in the alternative to the first aerosol -generating substance portion 160) can have a first surface in contact with and/or facing the second surface of the at least one heating element 170 and a second surface opposite the first surface. The first surface of the second aerosol-generating substance portion 162 and the second surface of the at least one heating element 170 can have
the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size.
[0153] Similarly, in some implementations, the first membrane layer 164 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the first aerosol-generating substance portion 160. The second surface of the first membrane layer 164 and the first aerosol-generating substance portion 160 can have the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size. The second membrane layer 166 can have a first surface and a second surface opposite the first surface and in contact with and/or facing the first surface of the second aerosol-generating substance portion 162. The second surface of the second membrane layer 166 and the second aerosol-generating substance portion 162 can have the same length, the same or substantially the same area, the same perimeter shape, and/or the same or substantially the same perimeter size.
[0154] In some implementations, the at least one heating element 170 can include a coil heating element, rod-shaped heating element, a pancake heating element, a chemical heating element, a ceramic heating element, a resistive heating element, a wick heating element (or wicks), a ceramic wick heating element, an electromagnetic heating element such as at least one susceptor configured to be heated by inductor coils, infrared light, a radiant heater such as an infrared heater, and/or any other heating element or combination thereof that is sized, dimensioned, and constituted of material suitable for heating the consumable substance in the consumable assembly 130. In some embodiments, the heating element(s) 170 can include a resistive element (e.g., coil or serpentine solid state heaters such as ceramic heaters) that can be solid or have a porosity of at least about 25% (e.g., at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%, inclusive). In some embodiments, the heating element(s) 170 can include one or more susceptor(s) in the form of a solid foil, or a perforated foil or a mesh with porosity of at least about 25% (e.g., at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%, inclusive). In some embodiments, the solid or porous heating element 170 can be in direct contact with a largest surface area of the consumable substance (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) of the consumable assembly 130. In
embodiments in which a porous heating element is included, the pores or openings through the heating element(s) 170 can allow air and, thus, aerosol, to flow through the pores or openings of the heating element(s) 170.
[0155] In some implementations, the at least one heating element 170 can be formed of one or more solid sheets, solid sheets with perforations, and/or porous sheets. In some implementations, the at least one heating element 170 can be formed of a single sheet-like heating element (e.g., foil). As described above, the single sheet-like heating element can be used in a planar multi-layer consumable assembly 130 or can be formed into a hollow tube for use in a tubular consumable assembly 130. In some implementations, the at least one heating element 170 can be formed of a mesh or a web that can optionally allow aerosol-generating substance or aerosol produced therefrom to flow therethrough. In some implementations, the at least one heating element 170 can include a plurality of thin rods, wires, strips, or other elements that are disposed adjacent to neighboring elements in series to form a layer (e.g., a tubular or flat, planar layer). For example, in some implementations, the at least one heating element 170 can include a plurality of heating elements, with each heating element arranged in contact with an adjacent heating element or spaced from an adjacent heating element a distance of less than a thickness of the individual heating elements. As described above, in some implementations, the at least one heating element 170 can have a constant cross-sectional shape and size along a central axis of the consumable assembly 130 and can extend from the distal end to the proximal end of the consumable assembly 130.
[0156] The at least one heating element 170 can include a thin heating layer (e.g., a sheet). For example, in some implementations, the at least one heating element 170 can have a thickness of less than 2 mm, less than 1 mm, and/or less than 0.2 mm. In some implementations, the thin heating layer can have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 0.3 mm, about 0.9 mm, about 1.2 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive). In some implementations, the thin heating layer can have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive. In some implementations, the thin heating layer can have a thickness less than 5 mm (e.g. less than 4.5 mm, less than 4.0 mm, less than 3.5 mm, less than 3.0 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm). In some implementations, the thin heating layer can have a thickness in range of about 0.2 mm to about 1 mm, inclusive. In some embodiments, the thin heating layer can have a thickness of about 0.3 mm.
[0157] In some implementations, the at least one heating element 170 can be formed to function as or include one or more susceptors that is energized by electromagnetic energy provided by an external inductor (e.g., included in the heater assembly 150 of the vaporizer pen 140) such that the at least one heating element 170 increases in temperature and generates heat that is transferred to the first aerosol -generating substance portion 160, the second aerosolgenerating substance portion 162, the first membrane layer 164, and/or the second membrane layer 166. For example, the at least one heating element 170 can be formed of an electrically- conductive material (e.g., metal). In some implementations, the at least one heating element 170 can include any material configured to be heated by a magnetic induction system. In some implementations, the at least one heating element 170 can be ferro-magnetic. In some implementations, the at least one heating element 170 can be formed of, for example, ceramic, graphite, and/or a composite. For example, the at least one heating element 170 can include a susceptor including solid sheet, perforated sheet, porous sheet, mesh sheet, or plurality of elongated wires that is formed to define a central passageway (e.g., formed as a tube) to allow aerosol to pass therethough and through fluidic channels defined in the cartridge 110 following an airflow path to and through a proximal end of the cartridge 110 for inhalation by a user. The at least one susceptor can be heated via induction by one or more inductor coils (e.g., included in the vaporizer pen 140) to cause aerosolization of consumable substance within the consumable assembly 130 and heating of air passing through a central portion of the cartridge 110 along a longitudinal axis of the vaporizer pen 140 and/or the cartridge 110. In some implementations, the susceptor(s) included in the at least one heating element 170 can include a porous sheet and the first aerosol-generating substance portion 160 and/or the second aerosolgenerating substance portion 162 can include a sheet including consumable substance (e.g., a sheet formed of a solid or gel consumable material or a porous sheet soaked with a liquid consumable). In some implementations, the porous sheet susceptor(s) and the consumable substance sheet(s) can be coiled together into a spool (e.g., as shown in FIGS. 9A-C). In some implementations, the cartridge 110 can include one or more susceptor(s) in addition to or as an alternative to the one or more susceptors that can be included in the at least one heating element 170 within the consumable assembly 130.
[0158] In some implementations, the at least one heating element 170 can include at least one resistive heating element including two or more electrical pads or contacts (e.g., forming or included in an input/output (I/O) module 136 of the cartridge 110) and one or more active heating sections. In some implementations, the resistive heating element can be formed as a
porous, perforated, or solid sheet. The at least one heating element 170 can be configured to be resistively heated under the control of the heater assembly 150 of the vaporizer pen 140 when the electrical contacts of the at least one heating element 170 are electrically coupled to the heater assembly 150. The electrical contacts can be disposed relative to the cartridge 110 such that the electrical contacts are accessible from an exterior of the cartridge 110 (e.g., disposed on or project from an outer surface thereof).
[0159] In some implementations, the first aerosol -generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can be formed as a thin layer. For example, in some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can each have a thickness of less than 2 mm, less than 1 mm, and/or less than 0.2 mm. In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 0.3 mm, about 0.9 mm, about 1.2 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive). In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can each have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive. In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosolgenerating substance portion 162 can each have a thickness less than 5 mm (e.g. less than 4.5 mm, less than 4.0 mm, less than 3.5 mm, less than 3.0 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm). In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness in range of about 0.2 mm to about 1 mm, inclusive. In some embodiments, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can each have a thickness of about 0.3 mm.
[0160] In some implementations, the consumable substance(s) included in the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162) can have a consistency of a liquid, a gel, a solid, a paste, a gel that functions as a paste, a gel that hardens at room temperature and functions as an adhesive, or a substance between a gel and a solid (e.g., a semi-solid) (e.g., at room temperature). In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can include a
consumable substance including a mixture of vegetable glycerin (VG) and propylene glycol (PG) in any suitable proportion, such as about 10% VG to about 90% PG, more than about 50% VG, more than about 60% VG, or more than about 65% VG. In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosolgenerating substance portion 162, in addition to the VG and PG, can include a consumable substance including about 0.5% to about 10% water.
[0161] In some implementations, the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can include a consumable substance including one or more gelling agents such as, for example, food-grade additives such as xanthate gum, xanthan gum, carboxymethyl-cellulose, microcrystalline cellulose, methyl cellulose, Arabic gum, guar gum, lambda carrageenan, chitosan, hydroxymethylcellulose, cellulose derivatives or starch in the range of about 0.1 to about 5.0 w/w% of the total mixture, of about 0.5 to about 3.5 w/w% of the total mixture, or of about 1 to about 2.0 w/w% of the total mixture. In some implementations, the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can optionally include a consumable substance including nicotine (e.g., freebase or salt), such as Nicotine Benzoate, Nicotine Lactate, Nicotine Levulinate, Nicotine Malate, Nicotine Pyruvate, Nicotine Salicylate, Nicotine Tartrate, or any other Nicotine derivative, cannabis, tetrahydrocannabinol (THC), any individual cannabinoids / terpenes, other pharmaceutical substances, one or more flavoring agents, one or more flavor modifying agents, aromatics, binders, solidifying agents, any other substance suitable for aerosol delivery, and/or water and/or any other suitable nontoxic solvents. In some implementations, the first aerosol-generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can optionally include a consumable substance including tobacco. In some implementations, the consumable substance can be a liquid that includes, for example, one more of a nicotine extract, a cannabis extract, glycerin, vegetable oil, flavorants, additives, and/or water.
[0162] In some implementations, the first aerosol -generating substance portion 160 and/or the optional second aerosol-generating substance portion 162 can be porous or can include or included in a porous material. For example, in some implementations, the first aerosolgenerating substance portion 160 and/or the optional second aerosol -generating substance portion 162 can include any of the mixtures and/or ingredients described above, be formed as a liquid or a gel, and can be suspended in one or more wick(s) 122 formed of an absorbent and/or wicking substrate. The wick(s) 122 can be or include, for example, silica, borosilicate,
foam, cotton, cellulose, and/or tobacco and be formed as a thin absorbent sheet. In some implementations, the wicking substrate can be or include, for example, any other thin wicking material (e.g., less than 2 mm, less than 1 mm, or less than 0.5 mm thick) with high heat resistance that remains non-reactive at temperatures of 250 C or higher. In some implementations, for example, the wick(s) 122 can have sufficient porosity while being sufficiently heat resistant so as to allow the liquid consumable imbued therein (e.g., PG/VG, nicotine, tobacco extract, cannabis extract, other plant extract, or any other substance that is appropriate for aerosolization) to be aerosolized without itself undergoing phase transformation or burning. In some implementations, the consumable assembly 130 can include wick(s) 122 that can be disposed in and/or have a surface facing and/or forming a boundary of an air flow path within the cartridge 110, and, in some implementations, the heater assembly 150 can include one, two, or more heating elements of the heater assembly 150 disposed or configured to be disposed in direct contact with the wick(s) 122. In some implementations, the wick(s) 122 can include a porous ceramic wick that is configured to be heated by at least one heating element 170 and/or at least one heating element of the heater assembly 150 (e.g., when the cartridge 110 is coupled to the vaporizer pen 140). In some implementations, the wick(s) 122 can be formed as a cylindrical stick analogous to a traditional cigarette stick intended to be heated through combustion. In some implementations, the wick(s) 122 can also be wrapped around foam and structured to be in contact with one or more heating elements of the heater assembly 150 (e.g., when the cartridge 110 is coupled to the vaporizer pen 140). The wick(s) 122 can include a porous material that is presoaked with a liquid or gel consumable substance or can be in fluid communication with a reservoir 138 including a liquid or gel consumable substance. Various configurations of cartridges 110 that include a liquid consumable are described in detail in U.S. Application No. PCT/CA2022/050455, filed March 25, 2022, and entitled “Methods and Systems for Variable Viscosity Carrier Vaporizers,” the entire disclosure of which is hereby incorporated by reference herein.
[0163] In some implementations, a drug component can be applied to the wick(s) 122 of the consumable assembly 130 or included in the liquid or gel consumable imbued or soaked therein (e.g., through nozzle application or dipping during manufacturing of the consumable assembly 130 or the cartridge 110). In some implementations, the consumable assembly 130 can include one or more segments or portions of a consumable substance, similar the one or more segments or portions of a consumable substance formed of a solid material described above. In some implementations, the consumable segment(s) of the consumable assembly 130
can be in direct contact with the heater assembly 150 (e.g., one or more heating elements of the heater assembly 130), where the heater assembly 150 can include the wick(s) 122 having wicking material pressed or divided into the consumable substance to delineate individual consumable segments. In some cases, each consumable segment can be separated by completely separating the wicking material, and disposing the wicking material in the consumable substance such that the wicking material is pressed or quilted therein, to prevent movement of the consumable assembly 130 and its materials between consumable segments. In some embodiments, a portion of the heater assembly 150 can be disposed in the cartridge 110. For example, one or more heating elements of the heater assembly 150 can be disposed in the cartridge 110 (e.g., as at least one heating element 170), and can be disposed proximate to or in contact with the consumable assembly 130 (e.g., a porous consumable assembly 130). In some implementations, one or more heating elements of the heater assembly 150 can be aligned with and/or corresponding in area to the consumable assembly 130 including the liquid consumable. In some implementations, each consumable segment can be physically separate. In some implementations, the consumable assembly 130 can be configured as a flat sheet, a tube, a spooled coil, or any complex shape equal to, substantially equal to, or slightly larger than the size and/or the surface area of the heater assembly 150 of the vaporizer pen 140.
[0164] In some implementations, as described above, the consumable substance(s) included in the consumable 130 (e.g., in the first aerosol-generating substance portion 160, second aerosol-generating substance portion 162, first membrane layer 164, and/or second membrane layer 166) can include solid consumable materials. The solid consumable materials can include a densely pressed plant or synthetic consumable material such as, for example, tobacco, or cannabis products and extracts made from plant material, such as crystal or solid extractions reconstituted into a sheet format. In some implementations, the sheet can be made using a dehydration processes, reconstitution processes, extraction processes, or the like, and can contain additives such as propylene glycol (PG) or vegetable glycerin (VG) to create desirable constitution and/or physical attributes. The processes used to form the consumable assembly 130 can also increase visible aerosol feedback and/or delivery of active components such as, but not limited to, nicotine, THC and other individual cannabinoids or terpenes for effect delivery, as well as flavoring agents. In some implementations, the solid consumable materials and/or sheets made therefrom can include any ingredients described with respect to any of the consumable substances described herein.
[0165] The optional first membrane layer 164 and/or the optional second membrane layer 166 can each be formed as a thin layer. For example, in some implementations, the first membrane layer 164 and/or the second membrane layer 166 can have a thickness of less than 1 mm, less than 0.5 mm, and/or less than 0.3 mm. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can be paper-like. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can be porous and/or perforated to allow aerosol to pass therethrough. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can form outermost layers of the consumable assembly 130 or an innermost layer and an outermost layer of the consumable assembly 130 (e.g., in the case of a tubular consumable assembly 130). In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can be configured to prevent aerosol-generating substance (e.g., gel) included in the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162 from flowing or migrating away from the at least one heating element 170 and/or through the first membrane layer 164 and/or second membrane layer 166 before aerosolization of the aerosol-generating substance.
[0166] In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a reconstituted tobacco sheet. In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a paper sheet. The paper sheet can be formed from natural and/or synthetic materials, such as silica or cotton, that are able to withstand temperatures greater than 160 C. The paper sheet can optionally include a coating that includes flavoring agents, flavor modifying agents, and/or one or more active ingredients (e.g., nicotine, cannabinoids, and/or any pharmaceutical-use active ingredient appropriate for heated aerosol delivery). In some implementations, the first membrane layer 164 and/or the second membrane layer 166 can each be formed of a sheet formed of a plant-based material including one or more active ingredients that can be delivered via inhalation, such as, for example, cannabis.
[0167] In some implementations, the first membrane layer 164 and/or the second membrane layer 166 (e.g., each formed of reconstituted tobacco sheet and/or a paper sheet) can each be perforated. The perforations can each have a diameter less than, for example, 1 mm or 0.3 mm. The number and size of the perforations can allow for increased airflow of aerosol through the reconstituted tobacco sheet, such as at least about 5% more airflow or at least about 15% more airflow.
[0168] The consumable assembly 130 can have a length that is shorter than the overall length of the cartridge 110. The distal end of the consumable assembly 130 can be disposed at, near, or adjacent to a distal end of the cartridge 110 and the proximal end of the consumable assembly 130 can be disposed closer to the proximal end of the cartridge 110 than the distal end of the consumable assembly 130 is disposed relative to the proximal end of the cartridge 110. In some embodiments, the consumable assembly 130 can be disposed within the consumable assembly 130 such that the consumable assembly 130 and the overall cartridge 110 are coaxial.
[0169] In some implementations, as shown in FIG. 1, the cartridge 110 includes a housing 114 (also referred to as a “membrane”) forming an outer surface of the cartridge 110. The housing 114 can define a container within which the consumable assembly 130 and any other components of the cartridge 110 can be disposed. For example, the cartridge 110 can include one or more structural elements, filters, ventilation features, dilution features, tipping papers, fluid channel(s) 135, tubes, and/or other elements configured to provide structure, airflow, ventilation, temperature management, flavoring, anti-sticking, tracking, anti-leaking, antibreakage, and/or any other features, each of which can be disposed within the housing 114. The cartridge 110 can include structures to facilitate positioning of the consumable assembly 130 within the housing 114 and to guide the flow of aerosol from the consumable assembly 130 to the proximal end of the cartridge 110 (e.g., to the opening of a mouthpiece 133 described below) for inhalation by a user. As an example, FIG. 20 is a schematic illustration of an implementation of the system 100 in which the consumable assembly 130 is disposed within the housing 114 of the cartridge 110. The cartridge 110 is partially disposed within a cartridge receptacle 141 of the pen assembly 140. The consumable assembly 130 is formed as a hollow tube and optionally has multiple tubular layers such as a tubular first aerosol-generating substance portion 160, a tubular at least one heating element 170, a tubular second aerosolgenerating substance portion 162, a tubular first membrane layer 164, and a tubular second membrane layer 166, as further described herein. Also as further described herein, each of the first aerosol-generating substance portion 160 and the second aerosol-generating substance portion 162 can be formed of an aerosol-generating gel or paste configured to be heated by the at least one heating element 170, and each of the first membrane layer 164 and the second membrane layer 166 can optionally be configured to be indirectly heated by the at least one heating element 170 via the first aerosol-generating substance portion 160 and the second
aerosol-generating substance portion 162, respectively, such that the first membrane layer 164 and second membrane layer 166 are heated at a lower temperature.
[0170] The housing 114 can have any suitable shape, such as a shape corresponding to an inner and/or outer shape of the consumable assembly 130. For example, the housing 114 can have a tubular shape and can be arranged coaxially with the consumable assembly 130 formed as a tube. The housing 114 can be open at both the proximal end and the distal end such that components disposed within the housing 114 at the proximal end and the distal end of the cartridge 110 are exposed. In some implementations, the housing 114 can have a tubular shape and the consumable assembly 130 can have a flat multi-layer planar shape. In some implementations, the housing 114 can be elongated and can have a rectangular, oblong, or any other suitable cross-section such that the housing 114 has a constant cross-sectional shape and size from the distal end to the proximal end of the housing 114. In some implementations, the housing 114 can be formed as a coating for the internal components (e.g., disposed on the outer surface of other components) of the cartridge 110. In some implementations, the housing 114 can be wrapped around the internal components (e.g., around the outer surface of other components) of the cartridge 110.
[0171] In some implementations, the housing 114 can include a thin sheet of material such as a paper sheet formed of natural and/or synthetic materials. In some implementations, the housing 114 can be configured and arranged to provide structure for the cartridge 110 such that the cartridge 110 is maintained in a particular overall shape and the components of the cartridge 110 are held together for transport and use. In some implementations, the housing 114 can be include material similar to the material forming an outer surface of a traditional cigarette stick intended to be heated through combustion. In some implementations, the housing 114 and the cartridge 110 can be shaped and/or configured to mimic the feel of a traditional cigarette stick intended to be heated through combustion (e.g., can be cylindrical). In some implementations, the housing 114 can be liquid impermeable to serve as a barrier to any liquids, gels, or semisolids disposed within the cartridge 110 (e.g., within the consumable assembly 130).
[0172] In some implementations, the cartridge 110 can include porous materials (e.g., foams and/or filters) disposed within the housing 114 such that any produced aerosols flow through the porous materials. In some implementations, an inner surface of the housing 114 can include, contain, or be formed from the porous materials. In some implementations, the housing 114 can function as filter or a liquid isolator (e.g., in the case of liquid aerosol-
generating material being included in the cartridge 110) to prevent liquid from leaking out of the cartridge 110.
[0173] In some implementations, the housing 114 can define an opening coated and/or covered by a membrane. For example, in some implementations, the aerosol-generating substance (e.g., the first aerosol-generating substance portion 160) can be a liquid aerosolgenerating substance (also referred to as a “liquid consumable”) (e.g., including an oil carrier), and the cartridge 110 can include one or more reservoirs 138 configured to contain the liquid aerosol-generating substance (also referred to as a precursor reservoir) which can be in fluid communication with the mouthpiece 133, one or more vapor chambers (e.g., vapor expansion chambers), and/or one or more fluidic channels, to facilitate the heating and drawing of aerosol and/or vapor from the cartridge 110. The at least one heating element 170 and the wick(s) 122 can be arranged and configured such that the wick(s) 122 can deliver the liquid aerosolgenerating substance from the one or more reservoirs 138 to the at least one heating element 170 and the at least one heating element 170 can heat and aerosolize the liquid aerosolgenerating substance. The wick(s) 122 and/or the at least one heating element 170 can include a porous ceramic and can be configured to be heated under control of the heater assembly 150. For example, the wick(s) 122 can include a porous ceramic material and the at least one heating element 170 can include coils directly coupled to the wick(s) 122 and configured to be operatively coupled to the heater assembly 150 for heating of the coils and the porous ceramic material to aerosol liquid consumable disposed in the porous ceramic. In some implementations, the at least one heating element 170 can include the wick(s) 122 (e.g., presoaked in liquid or gel consumable substance or configured to draw liquid or gel consumable substance from the reservoir 138). The opening and the membrane can be arranged such that a consumable substance, such as a liquid consumable, can be supplied to the reservoir(s) 138 of the cartridge 110 via the opening (e.g., via insertion of a needle through the membrane or via delivery through the opening before closing the opening with the membrane or while the membrane is temporarily removed). In some implementations, the membrane can include a valved impermeable or semi-permeable material, such as, for example, rubber, polyvinyl chloride (PVC), and/or silicone. In some implementations, the membrane can be resealable (e.g., automatically after removal of a needle).
[0174] In some implementations, the cartridge 110 can be formed from biodegradable material a to allow the cartridge 110 that can be disposable, to have minimal impact on the environment when disposed after being used.
[0175] The housing 114 can be disposed such that the housing 114 and an outer surface of the consumable assembly 130 define an annular space forming a fluid channel 135 through which aerosol produced by the consumable assembly 130 can flow to reach the proximal end of the cartridge 110.
[0176] In some implementations, the cartridge 110 can include a mouthpiece 133. In some implementations, the mouthpiece 133 of the cartridge 110 can include one or more of ceramic, heat-resistant plastic, anodized aluminum, and/or any other suitable material, and can define one or more mouthpiece openings through which a user can draw fluid (e.g., air) through the cartridge 110 and through the mouthpiece opening(s) and can draw aerosol produced within the cartridge 110 through the mouthpiece opening(s). In some implementations, the mouthpiece 133 can be coupled to a proximal end of the housing 114. In some implementations, the mouthpiece 133 can be spaced from a proximal end of the consumable assembly 130. In some implementations, rather than including a separate mouthpiece component coupled to the housing 114, the proximal end of the housing 114 can include a mouthpiece portion. The mouthpiece portion can, for example, be formed of a similar of the same material as the housing 114 (e.g., reconstituted tobacco or paper) and/or can have the same outer diameter as the remainder of the housing 114, similar to a traditional cigarette stick.
[0177] As shown in FIG. 1, the vaporizer pen 140 can include a processor 125 (which can also be referred to as a “controller” and/or included in a controller) and a memory 123 operatively coupled to the processor. The processor 125 can be operatively coupled to the heater assembly 150 and/or the power supply 124 such that the processor 125 can control heating operations of the heater assembly 150.
[0178] The heater assembly 150 is configured to be disposed proximate to (e.g., aligned with and/or coupled to) the consumable assembly 130 when the cartridge 110 is coupled to the vaporizer pen 140 (e.g., properly received within the cartridge receptacle 141). A “heater assembly,” as used herein, can refer to a combination of components and/or devices to initiate, provide, and/or enable heating. In some implementations, the heater assembly 150 can include a set of heating elements. In some implementations, the heater assembly 150 can form a heater matrix, such as is described, for example, with respect to FIG. 2. The set of heating elements can also be referred to as “heating elements” or “vaporizer device heating elements.” Each heating element of the set of heating elements of the heater assembly 150 can also be referred to as “heater segments,” “individual heaters,” or “heaters.” In some implementations, the heating elements are configured to be disposed proximate to (e.g., sufficiently aligned with or
coupled to such that the heating elements of the heater assembly 150 can heat the at least one heating element 170) the at least one heating element 170 of the consumable assembly 130, and spaced from (i.e., not in contact with) the consumable assembly 130, when the cartridge 110 is coupled to the vaporizer pen 140 (e.g., properly received within the cartridge receptacle 141). In some implementations, the processor 125 of the vaporizer pen 140 is operatively coupled to each heating element of the set of heating elements of the heater assembly 150 such that the processor 125 can individually control the operation (e.g., heating activation and deactivation) of each heating element of the set of heating elements of the heater assembly 150.
[0179] In some implementations, the heater assembly 150 and/or the set of heating elements thereof can extend axially along a longitudinal axis parallel to or coaxial with a central axis of the cartridge receptacle 141 and/or a central axis of the cartridge 110 when the cartridge 110 is engaged with the vaporizer pen 140. For example, in some implementations, the cartridge receptacle 141 of the vaporizer pen 140, the heater assembly 150 of the vaporizer pen 140, and the cartridge 110 can have a cylindrical shape, similar to the shape of a traditional cigarette stick heatable via combustion.
[0180] In some implementations, the heater assembly 150 can be configured to be disposed at least one of radially outward or radially inward of the consumable assembly 130 and/or at least one segment of the consumable assembly 130. For example, when the cartridge 110 is coupled to the vaporizer pen 140 and the heater assembly 150 is in direct contact with or proximate to the cartridge 110 and sufficient close to the at least one heating element 170 of the consumable assembly 130 to heat the at least one heating element 170, the heater assembly 150 can be disposed radially outward (e.g., around an outer circumferential surface of the consumable assembly 130 as shown in FIG. 5B) or radially inward (e.g., disposed within an inner circumferential surface of the consumable assembly 130 as shown in FIG. 5 A) relative to the cartridge 110 and/or the at least one heating element 170.
[0181] In some implementations, the set of heating elements of the heater assembly 150 can be arranged to form a cylindrical structure. For example, the heating elements can each be formed as an elongated member arranged circumferentially around a central axis (e.g., the central axis of the cartridge receptacle 141) (e.g., as shown in FIG. 4C) or can be formed as annular rings arranged along the central axis (e.g., as shown in FIG. 4D). In some implementations, each of the heating elements can be spaced from adjacent heating elements of the heater assembly 150 (e.g., separated from one another along a circumferential path around the central axis or along a longitudinal axis parallel to the central axis).
[0182] In some implementations, the heater assembly 150, or a portion thereof, is configured to be received within an interior portion of the cartridge 110 (e.g., within an interior portion of the consumable assembly 130), such as within the central channel 131, with the set of heating elements of the heater assembly 150 disposed within and aligned with the at least one heating element 170 of the cartridge 110. In some implementations, the set of heating elements of the heater assembly 150 can be arranged to define an axial channel therethrough, which can function as an airflow path that extends along the central axis, through the cartridge 110, and through the mouthpiece 133 for inhalation by a user.
[0183] In some implementations, the heater assembly 150, or a portion thereof, is disposed outside of and/or at least partially defines the cartridge receptacle 141 such that the heater elements of the heater assembly 150 are disposed radially outward of and/or surround the cartridge receptacle 141 and the at least one heating element 170 of the cartridge 110 when the cartridge 110 is received within the cartridge receptacle 141.
[0184] In some implementations, the heater assembly 150 and/or the heating elements of the heater assembly 150 can have at least one of a flat, circular, star, cylindrical, polygonal, tubular, coiled, complex three-dimensional surface, asymmetric shape, or any other suitable shape, and can be similar (e.g., about equal) in size and/or shape to the consumable assembly 130. In some implementations, the surface area of a side of the heater assembly 150 and/or heating elements facing the consumable assembly 130 can be substantially similar to or the same as the surface area of a portion of the consumable assembly 130 (e.g., of the at least one heating element 170) facing the side of the heater assembly 150 and/or heating elements (e.g., disposed radially inward or radially outward of the consumable assembly 130). In some implementations, the surface a side of the heater assembly 150 and/or heating elements facing the consumable assembly 130 can be in direct contact with or proximate to the surface of a portion of the cartridge 110 (e.g., of the consumable assembly 130 or of the at least one heating element 170) facing the side of the heater assembly 150 and/or heating elements (e.g., disposed radially inward or radially outward of the consumable assembly 130). In some implementations, the consumable assembly 130, which can be aligned with at least one heating element of the heater assembly 150, can be formed as or include a component formed to complement or mate with the heater assembly. For example, the consumable assembly 130 can be formed as or include a component formed as a flat sheet, a tube, a spooled coil, and/or a complex 3D shape such that at least one segment of the consumable assembly 130 remains in
direct contact and/or aligned with the at least one heating element of the set of heating elements of the heater assembly 150.
[0185] In some implementations, the heater assembly 150 includes one or more inductive heating elements (also referred to as inductors) configured to generate electromagnetic energy (e.g., radiofrequency and/or microwave radiation) in response to being activated by the processor 125. For example, the heater assembly 150 can include one or more solid inductors such as inductor coils or flat plate inductors. In some implementations, the inductor element(s) (e.g., coil(s)) are disposed within the housing 142 of the vaporizer pen 140 and surround the cartridge receptacle 141. In some implementations, the at least one heating element 170 of the consumable assembly 130 (functioning as a susceptor) can be disposed proximate to or in contact with aerosol-generating substances (e.g., first aerosol-generating substance portion 160 and/or second aerosol-generating substance portion 162) included in the consumable assembly 130 (e.g., as shown in FIGS. 7A-B). For example, the at least one heating element 170 can be located in direct contact with a sheet including an aerosol-generating substance, a segmented sheet including an aerosol-generating substance, a porous layer including an aerosol-generating substance, or a wick soaked with a liquid or gel including an aerosol-generating substance. In some implementations, as described above, the at least one heating element 170 can include, for example, a metallic solid foil, a metallic porous or perforated sheet, a metallic wire mesh, or elongated metallic rods, wires, or threads, and the at least one heating element 170 can generate heat when energized by the inductor elements (e.g., inductor coil(s)) of the heater assembly 150.
[0186] In some implementations, the vaporizer pen 140 can include an input/output (I/O) module 126. The I/O module can be configured to electrically engage with electrical contacts of the cartridge 110. For example, in implementation in which the at least one heating element 170 of the consumable assembly 130 is configured to be heated resistively via two or more pads or contacts (e.g., including in an I/O module 136 of the cartridge 110), the I/O module 126 of the vaporizer pen 140 can include, for example, contacts or connectors (e.g., pogo pins) operatively coupled to the processor 125 and/or the heater assembly and configured to engage with the contacts or pads of the cartridge assembly 110. Thus, in some implementations, the processor 125 can control the heater assembly 150 and/or the power supply 124 to provide current to the at least one heating element 170 via the I/O module 126 and the pads or contacts of the cartridge 110 to cause the at least one heating element 170 to increase in temperature
and aerosolize the first aerosol-generating substance portion 160 and/or the second aerosolgenerating substance portion 162.
[0187] In some implementations, the processor 125 can be configured to receive a request (e.g., via a draw sensor 121 of the vaporizer pen 140 and/or via a user actuator included in the I/O module 136) for delivery of an aerosol from the cartridge 110. In response, the processor 125 can send an instruction to the heater assembly 150 to activate. One or more heating elements and/or portions of heating elements of the heater assembly can activate to cause an increase in temperature of the at least one heating element 170 of the cartridge 110 and aerosolization of at least a portion of the consumable substance of the cartridge 110 based on the instructions.
[0188] In some implementations, the processor 125 can be configured to individually and/or selectively activate one or more heating elements of the heater assembly 150 and/or one or more portions of one or more heating elements of the heater assembly 150. For example, in some implementations, each heating element of a set of heating elements of the heater assembly 150 can be individually and/or selectively activated and/or controlled by the processor 125. Additionally, in some implementations, each heating element of the set of heating elements of the heater assembly 150 can be individually and/or selectively caused to change in temperature to a temperature different from a temperature of one or more other heating elements of the set of heating elements. The processor 125 can individually control the heating elements based on various inputs and/or pre-set heating instructions, such as, for example, based on type of consumable substance included in the consumable assembly 130, one or more predetermined temperatures or heating profiles (e.g., associated with a heating element, the heater assembly 150, and/or the consumable substance(s) disposed in the cartridge 110), an amount of consumable substance (e.g., portion of the first aerosol-generating substance portion 160 and/or second aerosol -generating substance portion 162 of the cartridge 110) previously aerosolized and/or remaining, a draw pressure, and/or a user setting (e.g., as inputted via the I/O module 136 and/or via interaction with a compute device (e.g., a mobile device) in communication with the vaporizer pen 140. In some implementations, individual portions of a heating element of the heater assembly 150 can be individually and/or selectively activated and/or controlled by the processor 125. In some implementations, a controller separate from the processor 125 (e.g., included in or coupled to the heater assembly 150) or a controller including the processor 125 can be used to control the operations of the heater assembly 150 and/or the heating element(s)
of the heater assembly 150. An example controller that can be used to control the operations of the heater assembly 150 is described with respect to FIG. 14.
[0189] In some implementations, for example, the set of heating elements of the heater assembly 150 can include at least a first heating element, a second heating element, and a third heating element. In such embodiments, the processor 125 (or a controller separate from or including the processor 125) can be configured to selectively activate the first heating element at a first time and/or for a first time period. The processor 125 (or a controller separate from or including the processor 125) is further configured to selectively activate the second heating element at a second time and/or for a second time period. The first time can optionally be different from the second time and the first time period can optionally have a different duration than the second time period. The first time, first time period, second time, and/or second time period can be selected based on, for example, a user input, a desired amount or rate of aerosol desired by the user, or a portion of consumable substance (e.g., a portion of the first aerosolgenerating substance portion 160 and/or second aerosol-generating substance portion 162) known to be remaining in the cartridge 110 (e.g., based on known characteristics and/or previous usage of the cartridge 110). In some embodiments, the processor 125 (or a controller separate from or including the processor 125) can be further configured to selectively activate the third heating element at a third time and/or for a third time period (e.g., based on similar inputs as described above). The third time can optionally be different from the first time and/or second time and the third time period can optionally have a different duration than the first time period and/or the second time period.
[0190] The first time period, the second time period, and/or the third time period can be in a range of about 0.1 seconds to about 3 seconds (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, or 3 seconds, inclusive). The second time period can be immediately subsequent to the first time period, or commence after a first gap period between the first time period and the second time period. Similarly, the third time period can be immediately subsequent to the second time period, or commence after a second gap period between the second time period and the third time period. In some embodiments, the second heating element can be located adjacent to the first heating element or one or more heating elements can be located between the first heating element and the second heating element. Similarly, the third heating element can be located adjacent to the second heating element or one or more heating elements can be located between the second heating element and the third heating element.
[0191] In some implementations, the processor 125 (or a controller separate from or including the processor 125) can be configured to cycle through multiple heating elements (e.g. the first heating element, the second heating element, and/or the third heating element) of the heater assembly 150 to cause the consumable substance of the consumable assembly 130 (e.g., the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) and/or the at least one heating element 170 to increase in temperature. In some implementations, the processor 125 (or a controller separate from or including the processor 125) can be configured to control the heater assembly 150 such that the heating of one or more portions of the at least one heating element 170 is cycled. For example, a user can prefer activating a smaller number or portions of heating elements to generate a smaller volume aerosol or to generate aerosol at a lower rate, or can prefer activating a larger number or portions of heating elements to generate a larger volume aerosol or to generate aerosol at a higher rate. In some implementations, for example, a user can set the aerosolization system 100 to activate only one heating element in a set of three heating elements included in the heater assembly 150 to produce aerosol at a rate of 2.5 mg/s. In some implementations, for example, a user can set the aerosolization system 100 to activate two heating elements to produce aerosol at a rate of 5 mg/s. In some implementations, for example, a user can set the aerosolization system 100 to activate all three heating elements to produce aerosol at a rate of equal to or greater that than 7 mg/s.
[0192] If the partial heating of the consumable substance of the consumable assembly 130 is not managed properly, consumable substance disposed in contact with or near a heating element (e.g., of the at least one heating element 170 and/or of the heater assembly 150) (e.g., consumable substance disposed in or near a wick such as a ceramic wick thermally coupled to a heating coil) that is inactive or lower in temperature than other (e.g., adjacent) heating elements can solidify (e.g., transition from a liquid state to a solid state), increase in thickness, and/or obstruct an aerosol flow path within the aerosolization system 100. To prevent such an issue, in some implementations, the flow of liquid consumable substance in the consumable assembly 130 can be managed via cycling the activation and/or heating profiles of multiple heating elements of the heater assembly 150 to cause the cycling of heating of the consumable substance (e.g., via the at least one heating element 170). In some implementations, the flow of liquid consumable substance in the consumable assembly 130 can be managed via cycling the activation and/or heating profiles of the at least one heating element 170 and/or portions thereof under control by the heater assembly 150. Thus, the heating elements of the heater
assembly 150 or portions thereof and/or portions of the at least one heating element 170 can function as wicks for managing the flow of liquid consumable substance in one or more inactive sections or areas of the consumable assembly 130. For example, if a user sets the aerosolization system 100 to activate only one heating element in a set of three heating elements included in the heater assembly 150 (or to generate aerosol in a volume or rate associated with the activation of only one heating element), the processor 125 can cycle or activate the three heating elements one at a time to remove built up flow of consumable substance (e.g., liquid) at the surface of the three heating elements (e.g., when a liquid consumable is used). If the user sets the aerosolization system 100 to activate two heating elements (or to generate aerosol in a volume or rate associated with the activation of two heating elements), the processor 125 can cycle or activate the three heating elements so that two are activated at a time. If the user sets the aerosolization system 100 to activate all three heating elements (or to generate aerosol in a volume or rate associated with the activation of three heating elements), the processor can cycle all three heaters at the same time and/or intermittently. The processor 125 can also cycle the heating elements and/or more than three heating elements in multiple different variations. Thus, the processor 125 (or the controller including the processor 125) can be configured to activate any one of the first, second, or third heating elements, or any number of heating elements included in the heater assembly 150 in any suitable order or combination so as to generate a desired amount of aerosol at a desired rate. Using a set of heating elements that can be independently activated and controlled can allow for a larger surface area of the heating surface compared to a system in which the heating elements are not independently controllable, thereby increasing vapor volume and allow more efficient consumption of the entire mass or volume of the consumable material included in the consumable assembly 130.
[0193] In some embodiments, the processor 125 can selectively activate each heating element of the heater assembly 150 sequentially, intermittently, and/or more than one at a time, and/or can activate a subset of the set of heating elements with each heating element being activated at a different heating power to control aerosolization rate, volume, and/or ensure substantially complete consumption of the consumable substance included in the cartridge 110 over the life of the cartridge 110. The selective activation can be based on at least one of a user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and a desired amount of the aerosol of the consumable (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, type of consumable material, and/or amount of consumable material remaining). Example
configurations of activating the heating elements based on the request can include: i) subsequent activation of heating elements located adjacent to each other with each being activated for a given time period with each being activated one at a time; ii) subsequent activation of heating elements that are not located adjacent to each other with each being activated for a given time period and being activated one at a time; iii) activating two heating elements of the set of heating elements at any given time in any suitable sequence or order; iv) activating more than one but less than all heating elements at different power levels (e.g., some in a range of about 10% to about 50% power, and others in a range about 60% to about 100% power); or v) activating all heating elements with each heating element being activated at a different power level (e.g., in a range of about 0% to about 100% power). For example, in some implementations, a first heating element can be activated at 80% power, and a second heating element can be activated at 20% power at a first time point for a first time period, and optionally, the activation of power level of the first heating element and the second heating element can be alternated during the first time period (e.g., selectively switched such that the second heating element is operated at 80% power and the first heating element is operated at 20% power. It should be appreciated that these configurations are only examples and the each of the set of heating elements can be activated in any suitable sequence, at any suitable time, and any suitable power based on the request.
[0194] In some implementations, the cartridge 110 can define one or more airflow paths from the distal end to the proximal end of the cartridge 110. In some implementations, the airflow path(s) can include the channel 131 through the consumable assembly 130, which can also be referred to and function as a heater chamber. As described above, in some implementations, the cartridge 110 can also define an airflow path including an annular space defined between an inner surface of the housing 114 and an outer surface of the consumable assembly 130 (e.g., a fluid channel 135) such that aerosol can be drawn toward and through the proximal end of the cartridge 110 from both a first side of the consumable assembly 130 (e.g., an interior when the consumable assembly 130 is formed as a hollow tube) and a second side of the consumable assembly 130 (e.g., an exterior when the consumable assembly 130 is formed as a hollow tube).
[0195] In some implementations, as described above, the vaporizer pen 140 can include a draw sensor 121 operably coupled to the processor 125 such that the processor 125 can activate the heater assembly 150 (e.g., to heat the at least one heating element 170 of the cartridge 110) in response to the draw sensor 121 sensing a decrease in pressure (e.g., within the cartridge
receptacle). Thus, heating of the at least one heating element 170 to generate aerosol from the consumable assembly 130 can be triggered in response to a user sucking or drawing on the proximal end of the cartridge 110 (e.g., on an opening of the mouthpiece 133) and causing a drop in pressure at the draw sensor 121. In response to the draw sensor 121 sensing a drop in pressure beyond a threshold pressure or change in pressure beyond a threshold change within the cartridge receptacle 141 and/or within the cartridge 110 (e.g., within the channel 131), the draw sensor 121 can send a signal to the processor 125 indicating the sensed pressure change. In response to receiving the signal from the draw sensor 121, the processor 125 can activate the heater assembly 150.
[0196] In some embodiments, the draw sensor 121 can be configured to be used periodically by the user as a spirometer. For example, the user can blow into an opening of the vaporizer pen 140 (e.g., an opening of the cartridge receptacle 141) without the cartridge 110 being coupled to the vaporizer pen 140. The draw sensor 121 can sense an increase in pressure within the vaporizer pen 140 (e.g., within the cartridge receptacle), and send one or more signals to the processor 125 indicating the amount of change in pressure (e.g., relative to particular pre-set thresholds or ranges). The processor 125 can then send an instruction including the sensed pressure data to another device (e.g., a mobile device or server) for processing and/or can determine an exhalation pressure associated with the lungs of a user based on the signal(s) received from the draw sensor 121 as an indicator of the user’s lung function or capacity.
[0197] In some implementations, the processor 125 can adjust the volume of aerosol produced based on the air pressure or change in air pressure detected by an inhalation from the user. For example, the processor 125 can selectively activate more heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a larger drop in pressure and can selectively activate fewer heating elements of the heater assembly 150 in response to the draw sensor 121 detecting a relatively smaller drop in pressure. The activation of more heating elements can cause a larger portion of the at least one heating element 170 to be heated, causing a larger portion or volume of the aerosol-generating substance in the cartridge 110 (e.g., in the first aerosol-generating substance portion 160 and/or the second aerosol-generating substance portion 162) to be aerosolized. In some embodiments, the processor 125 can be configured to selectively activate one or more of the heating elements based on at least one of a pre-set or indicated user preference (e.g., low pressure draw, high pressure draw, smaller or larger quantity of aerosol desired, etc.) and/or based on a predetermined target amount or volume of
aerosol to be generated per draw or per a time period (e.g., based on system parameters, a stored user preference, a determined user preference based on a user draw force, a type of consumable material, and/or an amount of consumable material remaining).
[0198] In some implementations, as described above, the vaporizer pen 140 can include a volume control feature based on a threshold change in pressure and/or a threshold pressure that is associated with higher or lower volumes of aerosol produced. In some implementations, the volume control can include an engagement features, such as a pressure-sensitive button or toggle included in the vaporizer pen 140. For example, a user can actuate a pressure-sensitive button by applying a higher force (e.g., with a finger) to the button to indicate that a higher aerosol volume output is desired and by applying a relatively lower force to the button to indicate that a lower aerosol volume output is desired. A pressure sensor associated with the button can send a signal to the processor 125 indicative of the pressure or force applied, and the processor 125 can control the heater assembly 150 to apply an amount and/or duration of heat to the cartridge 110 associated with the amount of pressure or force and associated aerosol volume. In some implementations, the volume control can include multiple buttons associated with higher or lower volumes of aerosol production (e.g., per drag). For example, the buttons can include pressure or volume control buttons (also referred to herein as “+/- buttons”), where activation of the + button causes a signal to be sent to the processor 125 indicating an increase in pressure and/or volume of aerosol to be produced and activation of the - button causes a signal to be sent to the processor 125 indicated a decrease in pressure and/or volume of aerosol to be produced. The aerosol produced can vary in volume and/or rate of aerosolization.
[0199] In some implementations, additionally, or alternatively, to the +/- buttons, the processor 125 can be configured to enable easier and/or more difficult aerosolization of the consumable assembly 130 based on the air pressure detected from the inhalation of the user by the draw sensor 121. For instance, if the user wants more aerosolization of the consumable assembly 130 using less air pressure for inhalation, the user can press the + button to trigger aerosolization based on a lower threshold pressure. In other embodiments, the processor 125 can be configured to deliver a higher or lower volume and/or pressure of the aerosol of the consumable material in response to the draw sensor 121 detecting a higher or lower draw pressure, respectively, based on a higher or lower draw pressure exerted on the mouthpiece 133 by the user. In some implementations, the vaporizer pen 140 can control the volume of aerosol produced by cycling the heater assembly 150 including one or more heating elements. In some implementations, an interface used to control and/or vary the volume of aerosol produced can
be integrated on a web application (e.g., accessible via a remote compute device). The buttons, the volume control, and/or the interface used to control the volume of aerosol produced can be used to control the aerosolization of any consumable including solid consumables, liquid consumables, and/or the like.
[0200] The cartridge 110 can be manufactured, shipped and/or sold separately from the vaporizer pen 140, and assembled by a user to form the aerosolization system 100. The consumable assembly 130 can be manufactured, shipped, and/or sold separately from the cartridge 110 and, for example, a manufacturer can assembly the cartridge 110 including the consumable assembly 130 before commercial sale of the cartridge 110 to a user. To assemble the aerosolization system 100, a user can, prior to use (e.g., upon purchase of a new cartridge 110), couple the cartridge 110 to the vaporizer pen 140. For example, in some implementations, as described herein, the cartridge 110 can be configured to be received within a cartridge receptacle 141 of the vaporizer pen 140. In some implementations, the cartridge 110 and the vaporizer pen 140 can be configured to be mechanically connected, for example by one or more of screw attachment, press-fit attachment, snap-fit attachment, magnetic attachment, or any other suitable connection means. In some implementations, the cartridge 110 can be received loosely within the cartridge receptacle 141. In some implementations, the vaporizer pen 140 can be considered the reusable portion of the vaporizer system 100, and the cartridge 110 can be considered a disposable or “replaceable” portion of the vaporizer system 100. Thus, the vaporizer pen 140 can be configured to be used with a plurality of cartridges 110, with each cartridge 110 being replaceable with a new cartridge after use.
[0201] In some implementations, the cartridge 110 can optionally include a processor 132 and a memory 137 operatively coupled to the processor 132, where the memory 137 stores instructions configured to be executed by the processor 132. In some implementations, when the vaporizer pen 140 is coupled to the cartridge 110, the processor 132 of the cartridge 110 can be configured to receive information from the processor 125 of the vaporizer pen 140, provide information to the processor 125 of the vaporizer pen 140, and/or receive operational power from the power supply 124 of the vaporizer pen 140. In some implementations, the cartridge 110 can draw operational power from the power supply 124 of the vaporizer pen 140 (e.g., to power a heater included in the cartridge 110) via, for example, a control interface 128 of the vaporizer pen 140 (e.g., under control of the processor 132 of the cartridge 110). In some implementations, the processor 132 can be configured to receive the signal from the draw
sensor 121 (e.g., via the processor 125 of the vaporizer pen 140) and communicate an activation signal to the heater assembly 150 via the control interface 128.
[0202] In some implementations, the cartridge 110 can include one or more optional sensors 134 (e.g., operatively coupled to the optional processor 132). The one or more optional sensors 134 can include, for example, a pressure sensor, a temperature sensor, a position sensor, a light sensor, a magnetic sensor (e.g., a hall or strip), an orientation sensor, or the like. In some embodiments, the one or more optional sensors 134 can additionally, or alternatively, be disposed in the vaporizer pen 140 and operatively coupled to the processor 125.
[0203] The processor 125 and/or the processor 132 can each include one or more of: a general purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a controller, a microcontroller, a state machine and so forth. In some implementations, a “processor” can include an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable gate array (FPGA), etc. The term “processor” can refer to a combination of processing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core or any other such configuration. The processor 125 of the vaporizer pen 140 can be in electronic communication with the memory 123 of the vaporizer pen 140 and can be configured to read information from and/or write information to the memory 123. In some embodiments, the processor 125 and the memory 123 can be included on a common tracking component or in a control assembly of the vaporizer pen. The tracking component or control assembly can be, for example, an integrated circuit (e.g., Application-Specific Integrated Circuits (ASICs)).
[0204] The memory 123 and/or the memory 137 can each include any electronic component capable of storing electronic information. The term memory can refer to various types of processor-readable media such as random access memory (RAM), read-only memory (ROM), non-volatile random access memory (NVRAM), programmable read-only memory (PROM), erasable programmable read only memory (EPROM), electrically erasable PROM (EEPROM), flash memory, magnetic or optical data storage, registers, etc. Memory is said to be in electronic communication with a processor if the processor can read information from and/or write information to the memory. Memory that is integral to a processor is in electronic communication with the processor. The memory 123 of the vaporizer pen 140 is operational to store instructions (e.g., code, algorithm, data, etc.) configured to cause the processor 125 to perform the functions of the vaporizer pen 140 described herein.
[0205] The power supply 124 of the vaporizer pen 140 can include any suitable battery or fuel cell configured to provide operational power to the vaporizer pen 140 components. For example, the power supply 14 can have high-drain characteristics. In some implementations, the vaporizer pen 140 can include a mechanical interface (e.g., a button) as part of the I/O module 126 that the user can actuate (e.g., engage) to trigger the heating and vaporization of the consumable assembly 130. The I/O module 126 can include one or more of: a push-button control for causing vapor generation (as an alternative, or in addition to, activating the heater assembly 150 based on a signal received from the draw sensor 121), a battery status indicator, an electromechanical connector for charging and/or data communication, a light source (e.g., one or more light-emitting diodes), etc. In some implementations, the vaporizer pen 140 can include indicator(s) such as, but not limited to, an illumination source (e.g., one or more lightemitting diodes), a speaker, a display screen, a haptic feedback (e.g., vibration) component (e.g., a vibration motor or a piezoelectric vibrating element), etc. In some embodiments, one or more of the indicator(s) can be included in or controlled by a component of the I/O module 126. In various embodiments, the processor 125, the memory 123, the I/O module 126, the power supply 124, and/or other electronic components of the vaporizer pen 140 can be included in, be part of, or associated with a controller or a control unit.
[0206] In some embodiments, the vaporizer pen 140 can include one or more of a GPS receiver, one or more antennae, and/or a transmitter or transceiver for wireless (e.g., Bluetooth, WI-FI®, ZigBee, NFC, or WAN/LTE) communication with a command center (e.g., a cloudbased server, a centralized server and/or the like) and/or with one or more other remote compute devices (e.g., a mobile device, such as a smartphone or tablet, or a smart connected accessory, such as a base or hub device such as a connected charger/dock or a home connected unit which can also be configured for direct contact with the vaporizer pen 140 for data exchange and/or charging). In some implementations, the vaporizer pen 140 can communicate with the command center and/or other remote compute devices as part of a cartridge 110 identification process and/or a cartridge 110 and/or vaporizer pen 140 activation process (e.g., as an additional or alternative method of communicating with a command center regarding identifiers and activation as described herein). In some implementations, the vaporizer pen 140 can communicate various statuses of the cartridge 110, the vaporizer pen 140, or of a user action via any of the communication methods disclosed herein (e.g., consumable supply level, draw frequency, draw duration, draw volume, draw pressure level, and/or blow pressure level).
[0207] In some implementations, the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to selectively activate a portion of the heater assembly 150 (e.g., a portion of the heating elements) to selectively heat the consumable assembly 130. For example, for aerosolization systems 100 implementing inductive heating, the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to selectively activate a portion of the inductor coil(s) of the heater assembly 150 to heat the susceptor(s) of the at least one heating element 170 and, thereby, the consumable substance (e.g., the first aerosolgenerating substance portion 160 and/or second aerosol-generating substance portion 162) of the consumable assembly 130. For example, the processor 125 can be configured to selectively activate at least a portion of the one or more inductor coils so as to heat an associated portion of the at least one susceptor and thereby, the consumable substance included in the consumable assembly 130 and associated with (e.g., directly coupled to) the portion of the at least one susceptor.
[0208] In some implementations, the processor 125 can control a set of induction coils so that a first induction coil heats a first portion of a susceptor to cause aerosolization of a first portion of the consumable substance in contact with or adjacent to the first portion of the susceptor for a first time period and a second induction coil heats a second portion of the susceptor to cause aerosolization of a second portion of the consumable substance in contact with or adjacent to the second portion of the susceptor for a second time period. In some implementations, a third induction coil can be controlled by the processor 125 to heat a third portion of the susceptor to cause aerosolization of a third portion of the consumable substance in contact with or adjacent to the susceptor for a third time period, etc. In some implementations, when each portion of the susceptor is heated, no other portions of the susceptor are heated (e.g., no other induction coils are activated). Thus, the system 100 can direct more energy to a smaller aerosolization area, and the quantity of aerosol produced during one heating session (e.g., one draw or series of draws in a session) can be controlled. In some implementations, one portion of the consumable substance can be aerosolized at a time such that consistent quantities of aerosol can be generated per session (e.g., per draw or series of draws in a session). Such a feature can be used for consistent dosing of the aerosol material generated. In some implementations, each induction coil can be heated for the period of time associated with aerosolization of the portion of the consumable substance associated with the portion of the susceptor heated by the induction coil. In some implementations, the portions of the consumable material are aerosolized in linear, serial order (e.g., starting with the distal-
most portion), so the induction coils are activated by the processor 125 serially starting with the distalmost induction coil. In some implementations, the processor 125 can activate each induction coil for a pre-set number of draws or a pre-set volume of air drawn through the system 100 (e.g., determined based on data from the draw sensor 121) associated with the cartridge 110 before no longer activating that induction coil and activating the next induction coil.
[0209] In some implementations, the heater assembly 150 can include an actuator (not shown) such as, for example, a lead screw and associated nut or any other suitable actuator. In such embodiments, the at least one inductor coil can be coupled to the actuator and the processor 125 can be configured to selectively actuate the actuator to displace the inductor coil axially relative to the at least one susceptor of the at least one heating element 170 of the cartridge 110 so as to position the at least one inductor coil proximate to a particular portion of the at least one susceptor such that selective activation of the at least one inductor coil causes heating of the associated portion of the susceptor. For example, in some implementations, initial aerosolization and draws from the cartridge 110 can be associated with a consumable substance portion disposed distally of subsequent draws. Thus, as the user continues using the cartridge 110, the at least one inductor coil can be moved proximally by the actuator under the control of the processor 125 to aerosolize the consumable substance of the cartridge 110 linearly (e.g., serially, section by section in a linear direction toward the proximal end of the consumable assembly 130.
[0210] In some implementations, the heating element of the heater assembly 150 can include a radiant heater. For example, the heating element can include one or more infrared (IR) heater (e.g., an IR light emitting diode (LED)) configured to deliver radiant heat to the consumable assembly 130. In such implementations, the heating element(s) can be located proximate to the consumable assembly 130 but with a gap (e.g., an annular space) defined therebetween. In such implementations, the at least one heating element 170 can optionally not be included in the cartridge 110.
[0211] In some embodiments, the consumable assembly 130 can include a plurality of segments, and the at least one heating element of the heater assembly 150 can be configured to selectively direct heat to or on the at least one segment of the plurality of segments. In some embodiments, the heater assembly 150 can include a set of heating elements, each of which is contact with at least one associated segment of the plurality of segments of the consumable assembly 130. In such embodiments, the processor 125 (or a controller including the processor 125) can be configured to selectively activate a portion of the set of heating elements to heat
the at least one associated segment of the plurality of segments of the consumable assembly 130. Moreover, the processor 125 (or a controller including the processor 125) can be configured to activate each element of the set of heating elements concurrently or intermittently in any suitable order so as to control a rate of the aerosol generated based on the request received from the user or the draw sensor 121.
[0212] In some embodiments, the processor 125 (or a controller including the processor 125) can receive pressure data from the draw sensor 121 included in the vaporizer pen 140, and can receive a preference input from a control interface (e.g., the I/O module 126) provided in the vaporizer pen 140 (e.g., provided by a user) associated with a volume of aero. In some cases, the processor 125 (or a controller including the processor 125) can selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable based on the pressure data and a volume preference input to produce aerosol based on a preference of the user, for example, based on a draw pressure exerted by the user on the mouthpiece and measured by the draw sensor 121, and/or based on a user setting entered by the user via the +/- buttons.
[0213] In some embodiments, each element of the set of heating elements can include a mesh configured to allow the aerosol to pass through each heating element of the set of heating elements and the airflow path. In some embodiments, the housing 114 of the cartridge 110 can include or be formed from a porous material or include a porous material disposed therein such that the produce aerosol produced aerosol flows through the porous material. In some embodiments, the heater assembly 150 can include a heater matrix including each heating element of the set of heating elements. The heater matrix can be configured, shaped, or formed a sheet and the consumable can include a consumable sheet such that selective activation of the portion of the set of heating elements by the processor 125 (or a controller including the processor 125) such that selective activation of the portion of the set of heating elements by the controller causes an associated portion of the consumable sheet to be aerosolized. In some embodiments, the heating element(s) can include a susceptor that is aligned with and coextensive with at least one segment of the consumable assembly. In such embodiments, the heater assembly 150 can include at least one inductor coil and the processor 125 (or a controller including the processor 125) can be configured to selectively activate the at least one inductor coil so as to heat an associated portion of the susceptor(s) and thereby, the associated segment(s) of the consumable assembly 130.
[0214] The memory 123 of the vaporizer pen 140 can store instructions for the processor 125 to receive a request for delivering an aerosol of the consumable material (e.g., a signal from the draw sensor 121), and interpret the request to deliver a suitable or desired amount of aerosol of the consumable material to the user. In some embodiments, the vaporizer pen 140 can include an interface, input devices, or the like, to transmit a signal representing the request for aerosol delivery to the processor 125. The request can include a request by the user to inhale a specific dose or volume of aerosol, specific type of consumable material, or the like. The memory 123 can further stores instructions to cause the processor 125 to selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable assembly 130 based on the request. For example, at least a portion consumable segment of the consumable assembly 130 can include a predetermined amount of the consumable material (e.g., tobacco, cannabis, PG/VG, a flavored drug, etc.), for example, in a range of about 2 mg to about 30 mg, inclusive, (e.g., about 5 mg, 10 mg, 15 mg, 20 mg, 25 mg, or 30 mg, inclusive of the consumable material in each segment of the consumable material 130). In some embodiments, the heating element(s) of the heater assembly 150 can be configured to heat the consumable assembly so as to generate in a range of about 1 mg/sec to about 10 mg/sec of the consumable material to the user (e.g., about 2.5 mg/sec, about 5.0 mg/sec, about 6.0 mg/sec, about 6.5 mg/sec, about 7.0 mg/sec, about 7.5 mg/sec, about 8.0 mg/sec, about 8.5 mg/sec, about 9.0 mg/sec, about 9.5 mg/sec, or about 10.0 mg/sec, inclusive of the aerosol of the consumable material).
[0215] The user can interact with the I/O module 126 and/or interface any other interface of the vaporizer pen 140 to select an amount of aerosol that is desired by the user. The user can also select the type of consumable, drug, flavor, and/or the like, to be aerosolized for inhalation. In some embodiments, the vaporizer pen 140 including the power source 124 can be implemented to conserve power consumption by intermittently and/or concurrently powering each heating element such that fewer heating elements are on at any one time so as to control the rate of the aerosol generated based on the request provided by the user. In some implementations, the process of heating the consumable assembly 130 can focus higher energy on a smaller surface of the consumable assembly 130, or one or more consumable segments, at a time to reduce or eliminate latency of heating. The power source 124 of the vaporizer pen 140 can be configured to cycle each heating element with uniform peak power output, enabling the user to vary the volume of aerosol produced.
[0216] The memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 to receive pressure data from the draw sensor 121 disposed in the vaporizer pen 140. The processor 125 can receive a signal including a measured pressure or force, and can send an instruction to cause the heater assembly 150 to heat the consumable assembly 130 based on the signal. The processor 125 can send instructions to cause the heater assembly 150 to produce more aerosol volume and/or produce aerosol at a faster rate in response to receiving a signal including a higher measured pressure or force. The processor 125 can send instructions to cause the heater assembly 150 to produce less aerosol volume and/or produce aerosol at a slower rate in response to receiving a signal including a relatively lower measured pressure or force. The memory 123 can also store instructions to cause the processor 125 to receive a preference input from the draw sensor 121 and/or the other sensor(s) 134 and send an instruction to the heater assembly 150 based on the received input. In some implementations, the processor 125 can be configured to selectively activate the portion of the set of heating elements to aerosolize the at least a portion of the consumable assembly 130 based on the pressure data and the preference input so as to produce aerosol and/or produce aerosol of the consumable material.
[0217] In some implementations, the cartridge 110 will not operate when coupled to the vaporizer pen 140 unless the cartridge 110 has first been validated and/or activated. In use, a user can use a mobile device (not shown) to communicate with a command center to retrieve information associated with the cartridge 110 by sending data such as cartridge identifying information, the pressure data from the draw sensor 121 and/or a preference input from the processor 125 to the command center. In response to receiving the information associated with the cartridge 110, the mobile device can present a presentation (e.g., a webpage or an application) on a display of the mobile device (e.g., automatically) including at least some of the information associated with the cartridge 110. Thus, the user can view information associated with the cartridge 110, such as a source of the contents of the consumable assembly 130, reservoir 138, concentration, dosage, or the like thereof.
[0218] In some embodiments, the vaporizer pen 140 can include a display that shows fill and/or usage data associated with the cartridge 110 (e.g., the type of consumable disposed in the cartridge 110, amount of consumable remaining, aerosol delivery rate, etc.). In some implementations, the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 of the vaporizer pen 140 to transmit the fill and/or usage data to the mobile device. For instance, the fill and/or usage data can include, for example, one or more of
consumable materials and/or ingredients, consumable formulation, nicotine concentration, nicotine plant genetics, nicotine provenance data (e.g., the tobacco plant(s) from which the nicotine was derived, the grow location of the nicotine plant(s), the grow and/or harvesting date of the nicotine plant(s), etc.) cannabinoid concentration(s), cannabinoid provenance data (e.g., the cannabis plant(s) from which the cannabinoid(s) were derived, the grow location of the cannabis plant(s), seed information associated with the cannabis plant(s), the date on which the cannabis seeds were planted, the grow and/or harvesting date of the cannabis plant(s), the dispensary from which the cannabinoid(s) were obtained, etc.), active ingredient (e.g., drug) concentration, extraction method(s) (and details thereof) used when converting the cannabis plant(s) into carrier material, inactive ingredient concentration, functionality of the vaporizer (e.g., physics of vapor generation, sequence of steps performed by the vaporizer when activated, etc.), details regarding effects within/on the user when the vapor is inhaled, and/or the like.
[0219] In some embodiments, the memory 123 of the vaporizer pen 140 can store instructions to cause the processor 125 of the vaporizer pen 140 to communicate the fill and/or usage data to the processor 132 of the cartridge 110. The processor 132 can transition the cartridge 110 from a deactivated status to an activated status (e.g., activate the cartridge 110) (e.g., in response to receiving an activation signal from the vaporizer pen 140). Upon activation, the cartridge 110 can be used by the user for aerosolization of the contents of the consumable assembly 130 (e.g., a solid or gel consumable substance included in the consumable assembly 130 and/or a liquid consumable substance soaked in the consumable assembly 130 or stored in the reservoir 138).
[0220] In some embodiments, the processor 132 of the cartridge 110 or the processor 125 of the vaporizer pen 140 can include a fraud mitigation feature to avoid a brute force activation in which the user can attempt to activate the cartridge 110 by aligning a light sensor (not shown) on the vaporizer pen 140 with the display displaying or flashing a color or series of colors (e.g., button(s), a button code, a randomized display, etc.). For instance, a combination of button presses can enable and/or disable the fraud mitigation control. The fraud mitigation feature can include a lock-out feature such that, in the event of a certain number of failed activation attempts (e.g., one, two, three). In some implementations, the memory 137 / 121 can store instructions to cause the processor 132 / 125 to pause or lock the cartridge 110 and the vaporizer pen 140 for a predetermined period of time (e.g., thirty seconds, two minutes, three minutes) before another activation attempt can be initiated. In some embodiments, the predetermined
period of time can progressively increase with each failed activation attempt, such that the first pause of lock period is shorter than the duration of the second, which is shorter than the duration of the third, etc. For example, the first pause period can be thirty seconds, the second can be two minutes, the third can be ten minutes, the fourth can be an hour, the fifth can be six hours, etc. In some embodiments, such as in severe abuse cases, the lockout period can be permanent.
[0221] In some embodiments, the sensor(s) 134 of the cartridge 110 and/or the light sensor of the vaporizer pen 140 can be configured to read an indication generated by the remote compute device (e.g., a mobile device or a remote server). For example, the remote compute device can include an indication generator configured to present the indication. In some embodiments, the indication generator of the remote compute device can include a display (e.g., liquid-crystal display (LCD)), organic light-emitting diode (OLED), active-matrix organic light emitting diodes (AMOLED), Super AMOLED, a thin film transistor technology (TFT) LCD, an in-place switching (IPS) LCD, a resistive touchscreen LCD, a capacitive touchscreen LCD display) configured to generate a visual or optical indication. In some embodiments, the indication generator can be a speaker configured to generate an auditory indication. In some embodiments, the indication generator can be a vibration component (e.g., a vibration motor or a piezoelectric vibrating element) configured to generate a vibratory indication. Thus, the indication can be at least one of a visual indication, an auditory indication, or a vibratory indication.
[0222] In some embodiments, the vaporizer pen 140 can include a lock, for example, a mechanical or electronic lock. The operation of the vaporizer pen 140 and the cartridge 110 together can be a locking or unlocking operation. The lock can optionally be a mechanical lock. The lock status of the vaporizer pen 140 can be a lock status of the mechanical lock and the mechanical lock can be in a locked configuration when the lock status is locked, and the mechanical lock can be in an unlocked configuration when the lock status is unlocked. In some embodiments, the interior space of a housing of the vaporizer pen 140 can be inaccessible when the mechanical lock is in the locked configuration and can be accessible when the mechanical lock is in the unlocked configuration.
[0223] In some embodiments, the vaporizer pen 140 will not unlock, operate, or perform one or more particular operations unless the aerosolization system 100 has first been activated, validated and/or instructed (e.g., via data or instructions provided via the indication generated by the indication generator of the remote compute device). In some embodiments, a calibration sequence can be presented in conjunction with the indication. For example, the calibration
sequence and the indication can both be presented as part of the remote compute device presentation presented by the indication generator. In some implementations, the calibration sequence can be used to ensure that the indication sensed by the sensor(s) 134 is accurately understood by the processor 125 or 132 regardless of the variation or distortion in the indication generator compared to other indication generators. For example, the calibration sequence can include a predetermined sequence of colors (e.g., including each color used in the indication (e.g., in the portion of the compute device presentation associated with the key indicator)) displayed on the display of the cartridge 110. The processor 125 or 132 can be configured to recognize the colors in the calibration sequence based on the predetermined sequence. The processor 125 or 132 can be configured to understand the indication (e.g., to identify the key indicator in the portion of the compute device presentation associated with the key indicator) based on the colors in the calibration sequence.
[0224] The processor 125 of the cartridge 110 can then actuate the heater assembly 150 to pass a current through one or more of heating element(s) that is in contact with, or in sufficiently close proximity to, the carrier material or a wick material containing at least a portion of the carrier material, so as to cause the aerosolization of the portion of the consumable assembly 130. One or more characteristics of the current or affecting the delivery of the current passed through the heating element(s) (e.g., voltage, wattage) can be controlled by the processor 125 based on, for example, an ambient temperature measured by a temperature sensor of the sensor(s) 134, a resistance of the heating element, and/or a heating profile or target temperature range associated with the consumable material (e.g., as determined by the processor 125 and/or provided to the processor 125 and/or stored in the memory 123 prior to use).
[0225] In some embodiments, the volatilized consumable material, aerosol, and/or vapor, travels toward the mouthpiece 133 of the cartridge 110 via one or more of the expansion chamber(s), the heater chamber 131, or one or more of the fluidic channels until it exits a mouthpiece opening for inhalation by the user. In some embodiments, the cartridge 110 and/or the vaporizer pen 140 can be coupled to the mobile device (e.g., a mobile phone, tablet, external connected hub, smart charger or dock, or computer) via, for example, Bluetooth or Wi-Fi, such that the mobile device can control one or more operations of the cartridge and/or the vaporizer pen 140. For example, the mobile device can lock and/or unlock the cartridge 110 such that the processor 125 does not actuate the heater assembly 150 when locked and the processor 125 can actuate the heater assembly 150 when unlocked.
[0226] In some embodiments in which the cartridge 110 includes the memory 137, the memory 137 can include or store a second identifier of the cartridge 110. A command center can include a database in a memory of the command center associating the first identifier, the second identifier, and consumable material data (e.g., mass data, volume data, or fill data) associated with the cartridge 110. In some embodiments, the second identifier is unique to only one cartridge 110. In some embodiments, the second identifier can be used in more than one cartridge 110. In some embodiments, the second identifier can be used in more than one cartridge 110, but used in only a small portion of manufactured cartridges 110 (e.g., less than 5%, less than 1%). The consumable data can include, for example, one or more of carrier ingredients, carrier formulation, nicotine concentration, nicotine plant genetics, nicotine provenance data (e.g., the tobacco plant(s) from which the nicotine was derived, the grow location of the nicotine plant(s), the grow and/or harvesting date of the nicotine plant(s), etc.) cannabinoid concentration(s), cannabinoid provenance data (e.g., the cannabis plant(s) from which the cannabinoid(s) were derived, the grow location of the cannabis plant(s), seed information associated with the cannabis plant(s), the date on which the cannabis seeds were planted, the grow and/or harvesting date of the cannabis plant(s), the dispensary from which the cannabinoid(s) were obtained, etc.), active ingredient (e.g., drug) concentration, extraction method(s) (and details thereof) used when converting the cannabis plant(s) into carrier material, inactive ingredient concentration, functionality of the vaporizer (e.g., physics of vapor generation, sequence of steps performed by the vaporizer when activated, etc.), details regarding effects within/on the user when the aerosol and/or vapor is inhaled, and/or the like.
[0227] FIG. 2 is a schematic illustration of a portion of a heater assembly 250 including a set of heating elements disposed proximate to a portion of a consumable assembly 230, according to an embodiment. The heater assembly 250 can be the same or similar in structure and/or function to the heater assembly 150 and/or the at least one heating element 170 described with respect to FIG. 1. The heater assembly 250 can include a matrix of heating elements (e.g., heating element 252a / 252b) collectively forming the heater assembly 250. In some implementations, the heating elements (e.g., 252a / 252b) can be configured in a geometrically uniform shape or form. The heater assembly 250 and/or the heating elements (e.g., 252a / 252b) can mate with the consumable assembly 230. In some implementations, the heater assembly 250 can directly contact the consumable assembly 230 and/or be densely pressed onto the consumable assembly 230.
[0228] The consumable assembly 230 includes a solid, semi-solid, or gel consumable substance. The consumable assembly 230 can also be referred to as a “consumable.” The consumable assembly 230 can be the same or similar in structure and/or function to the consumable assembly 130 described with respect to FIG. 1. The consumable assembly 230 can be configured as a sheet. In such implementations, the sheet can have a thickness in a range of about 0.05 millimeters to about 5 millimeters, inclusive (e.g., about 0.05 mm, about 0.1 mm, about 0.15 mm, about 2.0 mm, about 2.5 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, or about, 5.0 mm, inclusive). In some implementations, consumable assembly 230 can have a thickness in a range of about 0.05 mm to about 2.5 mm, inclusive. In some implementations, the consumable 230 can have a thickness less than 5 mm (e.g. less than 4.5 mm, less than 4.0 mm, less than 3.5 mm, less than 3.0 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm) In some implementations, the consumable assembly 230 can have a thickness in range of about 0.2 mm to about 1 mm, inclusive. The consumable assembly 230 can also be flexible or malleable to form multiple distinct shapes or configurations further described in FIG. 3A-K. In some implementations, the consumable assembly 230 can include, or be formed from a solid, semi-solid, or gel consumable material configured to be directly aerosolized by the heater assembly 250 and/or the heating elements (e.g. 252a / 252b).
[0229] The consumable assembly 230 can have several different configurations and include various materials. For example, solid consumable materials used in the consumable assembly 230 can be a densely pressed plant or synthetic consumable material such as, for example, tobacco, or cannabis products and extracts made from plant material, such as crystal or solid extractions reconstituted into a sheet format. In some implementations, the sheet can be made using a dehydration processes, reconstitution processes, extraction processes, or the like, and can contain additives such as propylene glycol (PG) or vegetable glycerin (VG) to create desirable constitution and/or physical attributes of the consumable assembly 230.
[0230] As shown in FIG. 2, the consumable assembly 230 can include a sheet having multiple segments. Each of the segments (e.g. consumable segment 260 / 262) of the consumable assembly 230 can include the same consumable material or different consumable materials in any suitable combination. The one or more segments of the consumable assembly 230 can be in direct contact and/or proximate with the one or more heating elements of the heater assembly 250. For example, when the heater assembly 250 directly contacts the consumable assembly 230, each corresponding heating element (e.g. heating element 252a /
252b) directly contacts with a corresponding segment (e.g. segment 260 / 262) of the consumable segment 230. As shown in FIG. 2, the heating element 252a directly contacts the segment 260 and the heating element 252b directly contacts the segment 262. Each heating element of the heater assembly 250 directly contacts an associated segment of the consumable segment 230. In such an implementation, the heater assembly 250 (and the heating elements) share a similar configuration as the consumable assembly 230 (and the segments), for example, have about the same size and shape (e.g., have about the same surface area and/or axial extents), and can be aligned with the consumable assembly 230. In some embodiments, the heater assembly 250 can be in direct contact with the consumable assembly 230, as described herein.
[0231] FIG. 3A is a schematic illustration of a consumable assembly 330, according to an embodiment. The consumable assembly 330 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 330 includes a heater assembly 350 disposed proximate to and radially outward of an aerosol-generating substance portion 360 having a circular cross-sectional shape. The heater assembly 350 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. In some implementations, the heater assembly 350 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 330). In some implementations, the heater assembly 350 can include a single heating element, such as a solid metal sheet.
[0232] As shown in FIG. 3A, the aerosol-generating substance portion 360 and the heater assembly 350 are formed as (e.g., rolled into) a hollow tube shape having a circular crosssection. An outer surface area of the heater assembly 350 is in direct contact with an inner surface area of the aerosol-generating substance portion 360. As such, an inner diameter of the aerosol-generating substance portion 360 is about equal to or slightly larger than an outer diameter of the heater assembly 350. The aerosolization of the aerosol-generating substance portion 360 can occur on the side that is directly interfacing with the heater assembly 350. For instance, the heater assembly 350 can aerosolize the aerosol-generating substance portion 360 by applying heat to the inner surface of the aerosol-generating substance portion 360, thereby aerosolizing the aerosol-generating substance portion 360 from an inner surface thereof.
[0233] In some embodiments, aerosolization can occur on either side of the aerosolgenerating substance portion 360 via the side that is directly interfacing with the heater
assembly 350. For example, the aerosol-generating substance portion 360 and/or the heater assembly 350 can include features that allow for air to flow through the consumable assembly 330. For instance, the aerosol-generating substance portion 360 and/or the heater assembly 350 can include a surface pattern for perforations, be porous, or define apertures therethrough.
[0234] FIG. 3B is a side cross-section view of the consumable assembly 330 taken along the line A-A in FIG. 3 A. The heater assembly 350 and the aerosol-generating substance portion 360 can be directly in contact, forming a thin configuration, where the aerosol -generating substance portion 360 is on top of and/or in direct contact with the outer surface of the heater assembly 350 as shown in FIG. 3B.
[0235] FIG. 3C is a schematic illustration of a consumable assembly 430, according to an embodiment. The consumable assembly 430 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 430 includes a heater assembly 450 disposed proximate to and radially inward of an aerosol-generating substance portion 460 having a circular cross-sectional shape. The heater assembly 450 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. In some implementations, the heater assembly 450 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 430). In some implementations, the heater assembly 450 can include a single heating element, such as a solid metal sheet.
[0236] As shown in FIG. 3C, the aerosol-generating substance portion 460 and the heater assembly 450 are formed as (e.g., rolled into) a hollow tube shape having a circular crosssection. An inner surface area of the heater assembly 450 is in direct contact with an outer surface area of the aerosol-generating substance portion 460. As such, an inner diameter of the heater assembly 450 is about equal to or slightly larger than an outer diameter of the aerosolgenerating substance portion 460. The aerosolization of the aerosol-generating substance portion 460 can occur on the side that is directly interfacing with the heater assembly 450. For instance, the heater assembly 450 can aerosolize the aerosol-generating substance portion 360 by applying heat to the outer surface of the aerosol-generating substance portion 460, thereby aerosolizing the aerosol-generating substance portion 460 from an outer surface thereof.
[0237] FIG. 3D is a side cross-section view of the consumable assembly 430 taken along the line B-B in FIG. 3C. The heater assembly 450 and the aerosol-generating substance portion 460 can be directly in contact, forming a thin configuration, where the heater assembly heater assembly 450 is on top of and/or in direct contact with the outer surface area of aerosolgenerating substance portion 460 as shown in FIG. 3C.
[0238] FIG. 3E is a schematic illustration of a consumable assembly 530. The consumable assembly 530 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 530 includes a heater assembly 550 including a first heating element 552a and a second heating element 552b. The first heating element 552a is disposed proximate to and radially outward of an aerosol-generating substance portion 560 having a circular cross-sectional shape, and the second heating element 552b is disposed proximate to and radially inward of the aerosol-generating substance portion 560. The heater assembly 550 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. In some implementations, each of the first heating element 552a and the second heating element 552b can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 530). In some implementations, each of the first heating element 552a and the second heating element 552b can include a single heating element, such as a solid metal sheet.
[0239] As shown in FIG. 3E, the aerosol-generating substance portion 560, the first heating element 552a, and the second heating element 552b are formed as (e.g., rolled into) a hollow tube shape having a circular cross-section. An inner surface area of the first heating element 552a is in direct contact with an outer surface area of the aerosol-generating substance portion 560. An outer surface area of the second heating element 552b is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
[0240] FIG. 3F is a schematic illustration of a consumable assembly 630, according to an embodiment. The consumable assembly 630 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 630 includes a heater assembly 650 disposed proximate to (e.g., in contact with) and outward of an aerosolgenerating substance portion 660. Each of the heater assembly 650 and the aerosol-generating
substance portion 660 have a star cross-sectional shape. The heater assembly 650 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. In some implementations, the heater assembly 650 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 630). In some implementations, the heater assembly 650 can include a single heating element, such as a solid metal sheet. In some implementations, the configuration (e.g., cross-sectional shape and elongated shape) of the heater assembly 650 and the aerosol-generating substance portion 660 can be in any radially symmetrical shape or form.
[0241] FIG. 3G is a schematic illustration of a portion of a consumable assembly 730, according to an embodiment. The consumable assembly 730 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 730 includes a heater assembly 750 disposed proximate to (e.g., contacting) and having a cross- sectional shape corresponding to an aerosol-generating substance portion 760. The heater assembly 750 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. As shown in FIG. 3G, the heater assembly 750 and the aerosol-generating substance portion 760 can be formed to define an asymmetric curve and the aerosol-generating substance portion 760 can be disposed on an outer or upper surface of the heater assembly 750. In some implementations, the heater assembly 750 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 730). In some implementations, the heater assembly 750 can include a single heating element, such as a solid metal sheet.
[0242] FIG. 3H is a schematic illustration of a portion of a consumable assembly 830, according to an embodiment. The consumable assembly 830 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 830 includes a heater assembly 850 disposed proximate to (e.g., contacting) and having a cross- sectional shape corresponding to an aerosol-generating substance portion 860. The heater assembly 850 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170
and/or heater assembly 150 described with respect to FIG. 1. As shown in FIG. 3G, the heater assembly 850 and the aerosol-generating substance portion 860 can be formed to define an asymmetric curve and the aerosol-generating substance portion 860 can be disposed on an inner or lower surface of the heater assembly 850. In some implementations, the heater assembly 850 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 830). In some implementations, the heater assembly 850 can include a single heating element, such as a solid metal sheet.
[0243] The heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include any suitable heating element(s). In some implementations, for example, the heating element(s) and/or heating assemblies described with respect to FIGS. 3A-3H can include a direct resistive heater such as the metallic coil, a printed coil circuit, or the like. In some implementations, the heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include an embedded indirect heater such as a ceramic diffuser and a coil, a printed sheet heater, and/or any conductive foil/mesh in contact with any of the aerosolgenerating substance portions described with respect to FIGS. 3A-3H. In some implementations, the heating element(s) and/or heating assemblies described with respect to FIGS. 3 A-3H can include or be formed as susceptors.
[0244] FIG. 31 is a schematic illustration of a portion of a consumable assembly 930 including a heater assembly 950 including one or more heating elements 952 disposed in contact with an aerosol-generating substance portion 960. The heating assembly 950 includes a susceptor 956 radially spaced apart from the one or more heating elements 952 and the aerosol-generating substance portion 960. The one or more heating elements 952 can include a metallic sheet or foil in contact with the aerosol-generating substance portion 960. In some implementations, the susceptor 956 is configured to be energized by an inductor coil (not shown) located proximate thereto and to generate heat so as to heat an associated portion of the metallic foil 952 and, thereby, the aerosol-generating substance portion 960. The configuration shown in FIG. 31 includes the susceptor 956 located proximate to the one or more heating elements 952, but, in some implementations, the susceptor 956 can be in direct contact with the 960 such that the metallic foil 952 can be excluded. The susceptor 956 can include any material that absorbs electromagnetic energy (via the associated portion of the metallic foil) and converts the electromagnet energy into heat, where the susceptor 956 then applies heat to the metallic foil in contact with the consumable assembly aerosol-generating substance portion
[0245] FIG. 3J is a schematic illustration of a portion of a consumable assembly 1030 including an aerosol -generating substance portion 1060 disposed proximate to a set of heating elements 1052 of a heater assembly 1050, each of which is configured to provide radiant heat to an associated portion of the aerosol -generating substance portion 1060. Each of the heating elements 1052 can include a radiant heater and/or an infrared (IR) heater that is not in direct contact with the consumable assembly 1030, but is in proximity to the consumable assembly 1030. Each heating element 1052 can radiate heat on a surface of aerosol-generating substance portion 1060 facing the heating element 1052. In some implementations, the heating elements 1052 and/or the heater assembly 1050 can apply heat to the aerosol-generating substance portion 1060 using a laser, a magnetron, a heated air jet, or the like.
[0246] FIG. 3K is a schematic illustration of a consumable assembly 2130. The consumable assembly 2130 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 130 described above with respect to FIG. 1. The consumable assembly 2130 includes heater element(s) 2170, a first aerosol-generating substance portion 2160, and a second aerosol-generating substance portion 2162. The second aerosol -generating substance portion 2162 is disposed proximate to (e.g., contacting) and radially outward of the heater element(s) 2170 and the first aerosolgenerating substance portion 2160 is disposed proximate to (e.g., contacting) and radially inward of the heater element(s) 2170. The heater element(s) 2170 can be the same or similar in structure and/or function to any of the heater assemblies or heating elements described herein, such as the at least one heating element 170 and/or heater assembly 150 described with respect to FIG. 1. In some implementations, the heater element(s) 2170 can include a plurality of heating elements (e.g., longitudinally extending rods extending parallel to the central axis of the consumable assembly 2130). In some implementations, the heater element 2170 can include a single heating element, such as a solid metal sheet. As shown in FIG. 3K, the heater element(s) 2170, the first aerosol -generating substance portion 2160, and the second aerosolgenerating substance portion 2162 are each formed as hollow tubes having a constant circular cross-section along the length of the consumable assembly 2130. Optionally, the consumable assembly 2130 includes a first membrane layer 2164 (e.g., disposed on an interior surface of the first aerosol-generating substance portion 2160) and a second membrane layer 2164 (e.g., disposed on an exterior surface of the second aerosol -generating substance portion 2162) that can be the same or similar to the first membrane layer 164 and/or the second membrane layer 166 described with respect to FIG. 1.
[0247] As shown in FIG. 3E, the aerosol-generating substance portion 560, the first heating element 552a, and the second heating element 552b are formed as (e.g., rolled into) a hollow tube shape having a circular cross-section. An inner surface area of the first heating element 552a is in direct contact with an outer surface area of the aerosol-generating substance portion 560. An outer surface area of the second heating element 552b is in direct contact with an outer surface area of the aerosol-generating substance portion 560.
[0248] FIG. 4A-5B are schematic illustrations of various configurations of an aerosolization system 1100 that includes a cartridge 1110 and a vaporizer pen 1140 configured to be coupled to the cartridge 1110, according to an embodiment. Specifically, FIG. 4A is a schematic illustration of a portion of a vaporizer pen 1140, according to an embodiment. The vaporizer pen 1140 can be the same or similar in structure and/or function to any of the vaporizer pens described herein, such as the vaporizer pen 140. For example, the vaporizer pen 1140 includes a heater assembly 1150 that can be the same or similar in structure and/or function to any of the heater assemblies described herein, such as the heater assembly 150. In some implementations, the heater assembly 1150 can be inserted or positioned in a cartridge holder 1141 located at one end of the vaporizer pen 1140. As shown in FIG. 4A, the vaporizer pen 1140 and the heater assembly 1150 includes a radially symmetrical shape such as a tube, cylinder, stick, or the like. The heater assembly 1150 can include on one end a housing and/or opening defining a receptacle shaped and sized to receive the cartridge 1110.
[0249] FIG. 4B is a schematic illustration of the cartridge assembly 1110 configured to be coupled to the vaporizer pen 1140 shown in FIG. 4 A. The cartridge assembly 1110 can be the same or similar in structure and/or function to any of the cartridges described herein, such as the cartridge 110. For example, the cartridge assembly 1110 includes a consumable assembly 1130 disposed within a housing 1114 of the cartridge assembly 1110. The housing 1114 can also be referred to as a “container.” The housing 1114 can provide structure for holding or securing the consumable assembly 1130. In some implementations, the housing 1114 can be used as a filter or liquid isolator to prevent liquid or gel from leaking out of the housing 1114, such as in implementations in which the consumable assembly 1130 includes a liquid and/or a high concentration of glycerin or similar contained in a wick. The housing 1114 can include a single container or multiple parts forming the container. The housing 1114 can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like. In some implementations, an outer surface area of the housing 1114 can be coated with a membrane such as any of the coatings or membranes described with respect to the housing 114 described
in FIG. 1. In some implementations, the housing 1114 can also function as a heating chamber consistent with the heating chamber described with respect to the cartridge 100 shown in FIG. 1.
[0250] The housing 1114 of the cartridge assembly 1110 includes a hollow housing that defines an airflow path towards a mouthpiece opening (not shown) at a top end of an airflow path 1115. As such, in an implementation, the consumable assembly 1130 can also include a channel 1132 extending through one or both ends of the consumable assembly 1130 such that aerosol produced by the consumable assembly 1130 can travel upwards through the channel 1132 and into the mouthpiece opening for inhalation. The channel 1132 can act as a heater chamber to facilitate and/or draw aerosol through the housing 1114 of the cartridge assembly 1110, along the airflow path 1115, and into the mouthpiece opening for inhalation. In some implementations, the housing 1114 can define a heater chamber located radially inwards of the consumable assembly 1130.
[0251] FIG. 4C is a schematic illustration of a portion of a vaporizer pen assembly 1140a that can be used in conjunction with the cartridge assembly 1110 of the system 1100 of FIG. 4A-4B, according to an embodiment. The cartridge assembly 1130 can be coupled to the vaporizer pen assembly 1140a, where the vaporizer pen assembly 1140a includes the cartridge holder 1141 to hold and/or house the cartridge assembly 1130. The cartridge holder 1141 can include a heater assembly 1150a that can be coupled to the consumable assembly 1130 of the cartridge assembly 1130 of the system of FIG. 4B. The heater assembly 1150a extends axially along a longitudinal axis AL. The heater assembly 1150a includes a set of heating elements such as heating element 1152al and heating element 1152a2. The heater assembly 1150a having a cylindrical body can include of multiple heating elements (e.g. heating element 1152al / 1152a2) where each heating element extends axially parallel to the longitudinal axis AL of the heater assembly 1150a, with the set of heating elements being separated from each other along a circumferential direction about the longitudinal axis AL. The configuration of the heater assembly 1150a can form an axial channel 1154a therethrough as shown in FIG. 4C. The axial channel 1154a can also be referred to as an “inner axial channel,” which can be configured to allow passage of air or aerosol therethrough. The heater assembly 1150a can also be disposed in between the inner axial channel 1154a located radially inward of the heater assembly 1150a and an outer axial channel 1143a located radially outward of the heater assembly 1150a.
[0252] FIG. 4D is a schematic illustration of a portion of a vaporizer pen assembly 1140b that can be used in the with the cartridge assembly 1110 of the system 1100 of FIG. 4A-4B, according to an embodiment. The cartridge assembly 1130 can be coupled to the vaporizer pen assembly 1140b, where the vaporizer pen assembly 1140b includes the cartridge holder 1141 to hold and/or house the cartridge assembly 1130. The cartridge holder 1141 can include a heater assembly 1150b that can be coupled to the consumable assembly 1130 of the cartridge assembly 1130 of the system of FIG. 4B. The heater assembly 1150b extends in a circumferential direction about the longitudinal axis AL, where the heating elements of the set of heating elements are axially separated from each other along the longitudinal axis AL. The heater assembly 1150b having a cylindrical body can include multiple heating elements (e.g. heating element 1152b 1 / 1152b2) where each heating element (e.g. heating element 1152b 1 / 1152b2) of the set of heating elements extends in a circumferential direction about the longitudinal axis AL AL, with the heating elements being axially separated from each other along the longitudinal axis AL. The configuration of the heater assembly 1150b can form an axial channel 1154b therethrough as shown in FIG. 4D. The axial channel 1154b can also be referred to as an “inner axial channel,” which can be configured to allow passage of air or aerosol therethrough. The heater assembly 1150b can also be formed in between the inner axial channel 1154b located radially inward of the heater assembly 1150b and an outer axial channel 1143b located radially outward of the heater assembly 1150b.
[0253] In some implementations, the inner axial channel 1154a / 1154b and/or the outer axial channel 1143a / 1143b can act as a holder for the consumable assembly 1130, where either side of the consumable assembly 1130 is in direct contact with and/or proximate to the heater assembly 1150a / 1150b as shown in the configurations 350 and 450 in FIG. 3A and FIG. 3C, respectively. In some implementations, the heater assembly 1150a / 1150b can also be disposed at least one of radially outward or radially inward of the consumable assembly 1130. For instance, the cartridge assembly 1110 can couple to the vaporizer pen assembly 1140a / 1140b by inserting the cartridge assembly 1110 into the outer axial channel 1143a / 1143b, where the consumable assembly 1130 in the cartridge assembly 1110 is subsequently inserted in the inner axial channel 1154a / 1154b. The consumable assembly 1130 can be in direct contact with and/or proximate to the inner surface area of the heater assembly 1150a / 1150b, where the heater assembly 1150a / 1150b and/or at least one of the heating elements (e.g. heating element 1152al / 1152bl) can apply heat to the consumable assembly 1130, to
produce aerosol. The produced aerosol can travel upwards along the longitudinal axis AL through an airflow path defined by the inner axial channel 1154a / 1154b.
[0254] FIG. 5 A is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly 1110 of FIG. 4A-4B coupled to the vaporizer pen assembly 1140a / 1140b of FIG. 4C or 4D, respectively. The cartridge assembly 1110 including the consumable assembly 1130 can be coupled to the vaporizer pen assembly 1140a / 1140b of FIG. 4C or 4D, respectively where the consumable assembly 1130 and the cartridge assembly 1110 is placed in the outer axial channel 1143a / 1143 b of FIG. 4C or 4D. As such, the heater assembly 1150a / 1150b can apply heat to the consumable assembly 1130 through the inner surface area of the consumable assembly 1130 to produce aerosol. The produced aerosol can then travel upwards along an airflow path 1115 and through the mouthpiece opening for inhalation. The cartridge assembly 1110 can also include the housing 1114 previously described in FIG. 4B.
[0255] The housing 1114 and/or the cartridge assembly 1110 can also be wrapped with a membrane 1111 on the outer surface area of the housing 1114 and/or the cartridge assembly 1110. The housing 1114 can be consistent with the housing or membrane 114 described in FIG. 1. In some implementations, the membrane 1111 can include a thin sheet such as paper or a synthetic form sheet to provide further structure for the housing 1114 and/or the cartridge assembly 1110. The membrane 1111 can also include paper to imitate the texture and feel of a cigarette stick. In some implementations, the membrane 1111 cannot include any water and/or liquid permeable material as to serve as a barrier for any liquid that can be contained inside the consumable assembly 1130. The cartridge assembly 1110 can also include a consumable holder 1157 that serves to hold the consumable assembly 1130 in place and stably. The consumable holder 1157 can also include a continuous cleaning mechanism to clean the heater assembly 1150a / 1150b for each use of the consumable assembly 1130, such as replacing the cartridge assembly 1110 with a new cartridge assembly and/or each time the heater assembly 1150a / 1150b applies heat to the consumable assembly 1130.
[0256] FIG. 5B is a side cross-section view of a portion of the system of FIGS. 4A-4D with the cartridge assembly 1110 of FIG. 4B coupled to the vaporizer pen assembly 1140a of FIG. 4C, and indicating the direction of aerosol flow F through the system, according to an embodiment. The consumable assembly 1130 can directly contact and/or be proximate to the heater assembly 1150a, where the heater assembly 1150a includes the set of heating elements (e.g., heating element 1152al / 1152a2) extending axially along the longitudinal axis of the heater assembly 1150a. In this embodiment, the heater assembly 1150a can include material
that allows for aerosol flow F to pass through the heater assembly 1150a (e.g., perforation) and along the airflow path 1115 towards the mouthpiece opening. The heater assembly 1150a can include a mesh heater, a set of mesh heaters, printed filament with porous substrate, and/or any other heating element that allows for aerosol to pass through it.
[0257] FIG. 6A is a schematic illustration of a portion of a vaporizer pen assembly 1240 that can be used in an aerosolization system 1200, according to an embodiment. The vaporizer pen assembly 1240 includes a cartridge holder 1241 at one end of the vaporizer pen assembly 1240. The portion of the vaporizer pen assembly 1240 is consistent with or substantially similar to the portion of the vaporizer pen assembly 1140b of FIG. 4D. The vaporizer pend assembly 1240 includes a heater assembly 125 that extends in a circumferential direction about the longitudinal axis AL, where the heating elements (e.g., heating elements 1252a / 1252b) of the set of heating elements are axially separated from each other along the longitudinal axis AL. The heater assembly 1250 having a cylindrical body can include multiple heating elements (e.g. heating element 1252a / 1252b) where each heating element (e.g. heating element 1252a / 1252b) of the set of heating elements extends in a circumferential direction about the longitudinal axis AL, where the heating elements are axially separated from each other along the longitudinal axis AL, The configuration of the heater assembly 1250 can form an outer axial channel 1243 located radially outward of the heater assembly 1250 as shown in FIG. 6A. In some implementations, the set of heating elements (e.g. heating element 1252a / 1252b) extending in the circumferential direction about the longitudinal axis AL can include a set of mesh heaters as further described in FIG. 6B.
[0258] FIG. 6B is a side cross-section of a portion of the aerosolization system 1200 that includes the vaporizer pen assembly 1240 of FIG. 6A couped to a cartridge assembly 1210, according to an embodiment. In this embodiment, the cartridge assembly 1210 and a consumable assembly 1230 included in the cartridge assembly 1210 can be inserted into the outer axial channel 1243, where the consumable assembly 1230 is in direct contact with and/or proximate to the heater assembly 1250 and/or the set of heating elements (e.g. heating element 1252a / 1252b) as shown in FIG. 6B. The set of heating elements and/or the heater assembly 1250 can include a mesh heater, at least one or more segments of a mesh, printed filament, embedded ceramic element, filament embedded into ceramic substrate or any other heating element that can be constructed as a rod (e.g. round, square, etc.), or the like. The housing 1214 can include a porous material such as cellulose or cotton that allows aerosol to pass directly
through the housing 1214 as directed by the airflow path F, where aerosolization of the consumable assembly 1230 occurs on all sides of the consumable assembly 1230.
[0259] The cartridge assembly 1210 can also include a housing 1214 that allows for an aerosol flow F out of the consumable assembly 1230 and through the housing 1214. In some implementations, the heater assembly 1250 can include a portion 1253 at one end of the heater assembly 1250. The portion 1253 can be inserted into a heater chamber 1215 defined by the cartridge assembly 1210. The heater chamber 1215 can include an opening and/or space for the heater assembly 1250 to occupy while applying heat to the consumable assembly 1230. The cartridge assembly 1210 also includes a membrane 1211 wrapped around the outer surface of the housing 1214 and/or the cartridge assembly 1210, where the membrane is consistent with any membrane as described in the entirety of this disclosure. As shown in FIG. 6B, the heater chamber 1215 can be closed at an end distal from heater assembly 1250. The housing 1214 can be formed from a porous material such that aerosol produced due to heating of the consumable assembly 1230 flows through the porous material of the housing 1214 towards a user.
[0260] FIG. 7 A is side cross-section view of a portion of an aerosolization system 1300a including a cartridge assembly 1310a coupled to a housing 1341a of a vaporizer pen 1340a, according to various embodiments. The cartridge assembly 1310a includes an assembly 1329a including a consumable assembly 1330a and heating element(s) 1339a that include a susceptor disposed on a radially outer surface of the consumable assembly 1330a. The aerosolization system 1300a produces aerosol by using at least one susceptor. The at least a susceptor can also be referred to as a “susceptor,” a “susceptor material,” or “susceptor(s) .” The heater assembly 1350a can include at least one induction segment or inductor coils (e.g. induction segment 1352al / 1352a2 / 1352a3). The at least one induction segment can also be referred to as “induction segment.” In some implementations, multiple induction segments 1352al / 1352a2 / 1352a3 can include at least a coil. The heater assembly 1350a and/or the set of heating elements 1339a can include a susceptor 1339a that can include perforated metallic foil or mesh that is contact with a consumable assembly 1330a of the cartridge 1310a, and is configured to be heated by the induction segments (e.g., the induction segments 1352al / 1352a2 / 1352a3), where the at least a induction segments can be wrapped around the heater assembly 1350a and/or the set of heating elements 1339a. The inductor segments 1352al / 1352a2 / 1352a3 can be configured to selectively apply electromagnetic energy to an associated segment of the susceptor 1339a to heat the susceptor 1339a to aerosolize the consumable assembly 1330a. In
some implementations, the heater assembly 1350a can be configured to include pairs of induction segments. For instance, a pair of coils can be placed through and around the cartridge 1310a when the cartridge 1310a is coupled to the vaporizer pen assembly 1340a.
[0261] The inductor segments 1352al / 1352a2 / 1352a3 can be powered by a power source in the vaporizer pen 1340a (not shown) to heat the heater assembly 1350a, where the heater assembly 1350a can apply the heat via the heating elements 1339a (e.g., susceptor(s)) to the consumable assembly 1330a. In such an implementation, a set of heating elements 1339a of the heater assembly 1350a can be located radially outward of the consumable assembly 1330a, aerosolizing the consumable assembly 1330a from the outside, where the produced aerosol follows the aerosol flow F through the airflow path 1315a.
[0262] The cartridge assembly 1310 can also include a housing 1313a, where the housing 1313a is consistent with any housing as described in the entirety of this disclosure. The housing 1311a and/or the cartridge assembly 1310 can also be wrapped around by a membrane 1313a, where the membrane 1313a is consistent with any membrane as described in the entirety of this disclosure.
[0263] FIG. 7B is a side cross-section views of portions of aerosolization system 1300b including a cartridge assembly 1310b coupled to a housing 1341b of a vaporizer pen 1340b, according to embodiments. The cartridge assembly 1310b includes an assembly 1329b that includes a consumable assembly 1330b and heating element(s) 1339b that include a susceptor disposed on a radially inner surface of the consumable assembly 1330b. The aerosolization system 1300b produces aerosol by using at least one susceptor, similar to the at least one susceptor of FIG. 7A. The heater assembly 1350b can include at least an induction segment or inductor section (e.g. induction segment 1352b 1 / 1352b2 / 1352b3). The at least an induction segment can also be referred to as “induction segment.” In some implementations, multiple induction segments 1352b 1 / 1352b2 / 1352b3 can include inductor coils, elements or “coils”. The heater assembly 1350b and/or the set of heating elements 1339b can include a susceptor (e.g., solid sheet, perforated metallic foil or mesh) configured to be heated by the induction segment including the at least a coil (e.g., in response to receiving electromagnetic radiation from the induction segment), where the at least a coil can be disposed around the heater the set of heating elements 1339b and thus, the cartridge 1310b when the cartridge 1310b is coupled to the vaporizer pen assembly 1340b. The inductor segments 1352b 1 / 1352b2 / 1352b3 can apply electromagnetic radiation to the set of heating elements 1339b (e.g., susceptors) to cause at least an associated portion of the set of heating elements 1339b to generate heat to aerosolize
the consumable assembly 1330b or at least an associated portion of the consumable assembly 1330b (e.g., associated segments of the consumable assembly 1330b). In some implementations, the heater assembly 1350b can be configured to include sections of induction segments. For instance, a section of induction segments can include one, two, or three segments of coils and/or any solid inductors placed through and around the heater assembly 1350b and/or the set of heating elements 1339b.
[0264] The set of heating elements 1339b of the heater assembly 1350b can be located radially inward 1329b of the consumable assembly 1330b, and configured to aerosolize the consumable assembly 1330b or segments thereof from the inner surface area of the consumable assembly 1330a closer to the center of the cartridge assembly 1310, where the produced aerosol follows the aerosol flow F through the airflow path 1315b. As shown in FIG. 7B, the radially inward set of heating elements 1339b can apply heat to the inner surface area of the consumable assembly 1330b, where the set of heating elements 1339b can include or define perforations via the heat to allow produced aerosol to pass through the set of heating elements 1339b for the aerosol flow F to travel along the airflow channel 1315b.
[0265] The cartridge assembly 1310 can also include a housing 1313b, where the housing 1313b is consistent with any housing as described in the entirety of this disclosure. The housing 1313b and/or the cartridge assembly 1310 can also be wrapped around by a membrane 1313b, where the membrane 1313b is consistent with any membrane as described in the entirety of this disclosure.
[0266] FIG. 8 is a schematic illustration of an assembly 1429 that includes consumable assembly 1430 including a consumable formed into a sheet having multiple segments, and a heating element 1439 including a susceptor sheet configured to be disposed on and contact the consumable sheet, according to an embodiment. The heating element 1439 includes any heating element and/or a set of heating elements as described in the entirety of this disclosure. In some implementations, the heating element 1439 includes a perforated metallic foil and/or mesh acting as a susceptor, heated by at least one induction segment (e.g., at least one of the induction segment 1352al / 1352b 1 , 1352a2 / 1352b2, and/or 1352a3 / 1352b3 as described in FIGS. 7A or 7B). The heating element 1439 can be applied directly to the consumable assembly 1430 formed into a sheet having multiple consumable segments, where the consumable segments are consistent with the consumable segments described in FIG. 2. The heating element 1439 can be directly applied to the consumable sheet 1430, where the heating element 1439 and the consumable sheet 1430 are in direct contact with and/or proximate to each other.
[0267] The heating element 1439 including the susceptor sheet can include a thin sheet formed from any ferromagnetic material and/or any material excitable by an electromagnetic radiation. Such materials can include, but are not limited to, Nichrome, Series 400 Stainless Steel, or the like. In some embodiments, the heating element 1439 can include a thickness between about 0.005 mm and about 0.2 mm, inclusive. In some embodiments, the heating element 1439 can have a porosity of at least 30% (e.g., at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90%, inclusive).
[0268] In some embodiments, the heating element 1439 or any other heating element described herein can be coupled to or placed in contact with the consumable sheet 1430 or any other consumable sheet described herein to form an assembly that is spooled into a cylindrical coil. For example, FIG. 9A is a schematic illustration of a spooled assembly 1429 that includes a consumable assembly that includes a sheet of a consumable that can be in contact with a susceptor, and rolled or wound into a spool or coil, according to an embodiment. The spooled assembly 1429 can include an empty spiral channel located in the gap between the successive layers of the spool assembly 1429 that allow for aerosol flow F through and/or between the successive layers of the spool assembly 1429. In some implementations, the spool is wound with at least minimal airflow between the surfaces of each layer of the spool. The spooled assembly 1429 can include the consumable assembly and/or the susceptor (e.g. heating element) disposed onto the consumable assembly. In some embodiments, the consumable assembly can include a quilt like feature to allow for aerosol flow F through one end of the spooled assembly and out the other end. In some implementations, the susceptor and/or the heating element disposed on the consumable assembly can include a mesh with three- dimensional features that create the aerosol flow F to travel in an X or Y dimension.
[0269] In some implementations, the susceptor and/or the heating element can be incorporated into a heater assembly in a vaporizer pen assembly, where the susceptor is spooled or coiled to form a cylindrical shape. A cartridge assembly can be configured to house a spooled consumable assembly including a thin sheet, where the spooled consumable assembly can be inserted into an empty spiral channel located in the gap between the successive layers of spool. The cartridge assembly and the spooled consumable assembly can be coupled to the heater assembly and the vaporizer pen.
[0270] FIG 9B is a top of view of the assembly 1429 of FIG. 9A wound into a flat coil, according to an embodiment. The spooled assembly 1429 comprising the consumable assembly
and the susceptor disposed onto the consumable assembly can be foldable as shown in FIG. 9B. In some implementations, the spooled assembly 1429 can form any shape that is foldable.
[0271] FIG. 9C is a top view of the assembly 1429 of FIG. 9A wound into a circular coil, according to an embodiment. The spooled assembly 1429 comprising the consumable assembly and the susceptor disposed onto the consumable assembly can be spooled to form a coil having circular cross section (e.g., as shown in FIG. 4C).
[0272] FIG. 9D is a schematic illustration of a cartridge assembly 1410 including the spooled assembly 1429 of FIG. 9A disposed in a housing or a membrane 1411 according to an embodiment. The spooled assembly 1429 includes a spooled thin consumable sheet and can optionally, include a susceptor coupled to the consumable sheet. The spooled assembly 1429 and/or the spooled consumable assembly can be coupled to a heating element, where the heating element includes a spooled/coiled thin perforated metallic foil or mesh acting as a susceptor. The spooled assembly 1429 is disposed inside the cartridge assembly 1410, where the cartridge assembly 1410 includes a housing 1411 that can be surrounded and/or wrapped in a membrane. The housing 1411 and/or the membrane can be consistent with any membrane as described in the entirety of this disclosure.
[0273] The spooled assembly 1429 can include an empty spiral channel located in the gap between the successive layers of the spool that allow for aerosol flow F through and/or between the successive layers of the spool, where the aerosol flow F travels through an airflow path 1415 upwards and towards a mouthpiece opening (not shown). In some embodiments, the consumable assembly can include a quilt like feature to allow for aerosol flow F through one end of the spooled assembly 1429 and out the other end. In some implementations, the susceptor and/or the heating element disposed on the consumable assembly can include a mesh with three-dimensional features that create the aerosol flow F to travel in an X or Y dimension.
[0274] FIG. 10A is a side cross-section view of a portion of an aerosolization system 1400a that includes a cartridge assembly 1410a that includes a spooled assembly 1429a that includes consumable assembly 1430a (e.g., a consumable sheet) and a heating element 1439a, coupled to a housing 1441a of vaporizer pen assembly 1440a that includes multiple induction segments 1452al / 1452a2 / 1452a3, such as inductor coils, according to an embodiment. The multiple induction segments 1452al / 1452a2 / 1452a3 can be consistent with the multiple induction segments as described in FIG. 7 A or 7B. The consumable assembly 1430a can be spooled or coiled to form a spooled consumable assembly 1429a as described in FIG. 9A-D. the heating
element 1439a can be disposed in contact with the consumable assembly 1430a, where the heating element 1439a is also spooled so as to form the spooled assembly 1429. In some implementations, the spooled heating element can include a thin metallic foil that can form perforations when heat is applied. The consumable assembly 1430a and the heating element 1439a disposed on the consumable assembly 1430a can form a spooled assembly 1429a, where the spooled assembly 1429 can be consistent with any spooled assembly as described in the entirety of this disclosure.
[0275] In some implementations, the heater assembly 1450a and/or the set of heating elements 1439a can include a perforated metallic foil or mesh and heated by the induction segment 1452al / 1452a2 / 1452a3 including the at least a coil (e.g., an inductor coil), where the at least a coil can be disposed around the set of heating elements 1439a or otherwise, the cartridge assembly 1410a when it is coupled to the vaporizer pen assembly 1440. The inductor segments 1452al / 1452a2 / 1452a3 can apply heat to the at least a susceptor of the heater assembly 1450a and/or the set of heating elements 1439a to aerosolize the consumable assembly 1430a. The produced aerosol can pass through perforations formed in the set of heating elements 1439a along an airflow path 1415a.
[0276] The cartridge assembly 1410a can include a housing 1413a that provides structure for the consumable assembly 1430a. The housing 1413a can be consistent with any housing of a cartridge assembly as described in the entirety of this disclosure. In some embodiments, the housing 1413a can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like. The housing 1413a can define an airflow path 1415a for aerosol flow F. In some implementations, an outer surface area of the housing 1413a can be coated with a membrane 1411a, where the membrane 1411a can be consistent with any membrane as described herein.
[0277] FIG. 10B is another side cross-section view of a portion of an aerosolization system 1400b that includes a cartridge assembly 1410b that includes a spooled assembly including a consumable assembly 1430b (e.g., a consumable sheet) that is in contact with and spooled with a heating element 1439b (e.g., a susceptor). The cartridge assembly 1410b is configured to be coupled to a vaporizer pen assembly that includes a heater assembly 1450b. the heater assembly 1450b includes an inductor coil 1452b mounted on a mounting arm 1453b (e.g., a lead screw) that is coupled to an actuator 1455b, according to an embodiment. The actuator 1455b can include a linear motor, stepper motor, or the like. The inductor coil 1452b is disposed parallel to a longitudinal axis of the vaporizer pen assembly.
[0278] The inductor coil 1452b included is configured to provide electromagnetic radiation to a corresponding or associated portion of the heating element 1439 so as to heat the corresponding or associated portion, and thereby, aerosolize a corresponding or associated portion of the consumable assembly 1430. The actuator 1455b is configured to be selectively actuated to linear displace the inductor coil 1452b along the mounting arm 1453b so as to heat different associated portions of the heating element 1439b, and thereby the consumable assembly 1430b. In this manner, more efficient aerosolization of the consumable assembly 1430b can be achieved such that substantially all of the consumable assembly 1430 can be aerosolized over an operational life of the cartridge assembly 1410b.
[0279] FIG. 11A-11B is a side cross-section view of an aerosolization system 1500 including a portion of vaporizer pen 1540 with a heater assembly 1550 including a susceptor 1553 with wicks 1551 on both sides of the susceptor 1553. The susceptor 1553 can include a single sheet susceptor. The vaporizer pen 1540 can include induction segments 1552a / 1552b / 1552c which can be powered by a power source in the vaporizer pen 1540 (not shown) to heat the heater assembly 1550, where the heater assembly 1550 can apply the heat via the susceptor 1553 which then heats the wicks 1551 located on both sides of the susceptor 1553. The wicks 1551 can include ceramic wicks, any other any wicks as described herein. In some implementations, the susceptor 1553 and the wicks 1551 can form a single flat shape or have a flat profile, where the wicks 1551 are disposed on both sides of the single flat shape. In some embodiments, the susceptor 1553 can be a flat sheet with a first layer of the wick 1551 assembly disposed on a first side thereof, and a second layer of the wick 1551 or any other consumable assembly disposed on a second side thereof, with the wicks 1551 having a flat shape. The vaporizer pen 1540 can be coupled to a cartridge assembly 1510 containing a consumable assembly (not shown), where the consumable assembly can be configured to have any structure that directly contacts with and/or is proximate with the wicks 1551, where the wicks 1551 can aerosolize the consumable assembly.
[0280] FIG. 11C is a top view of an assembly 1529a that can be included in a cartridge assembly (e.g., the cartridge assembly 1510) including a susceptor 1553a with wicks 1551a disposed on both sides of the susceptor 1553a, where the susceptor 1553a and the wicks 1551a are formed into a tube. In some implementations, the cartridge assembly (e.g., the cartridge assembly 1510) including the assembly 1529a can be configured to couple to the vaporizer pen 1540, where the consumable assembly is disposed radially outwards of an outer wick (e.g., as shown in FIG. 3A). In some implementations, the cartridge assembly (e.g., the cartridge
assembly 1510) including the assembly 1529a can be configured to be coupled to the vaporizer pen 1540, where the consumable assembly is disposed radially inward of an inner wick (e.g., as shown in FIG. 3C).
[0281] The cartridge assembly 1410b can include a housing that provides structure for the consumable assembly 1430b. The housing can be consistent with any housing of a cartridge assembly as described in the entirety of this disclosure. The housing can be constructed out of cellulose fiber, silica, an open or closed cell polymer, or the like. The housing can define an airflow path 1415b for aerosol flow F. In some implementations, an outer surface area of the housing can be coated with a membrane 1411b, where the membrane 1411b can be consistent with any membrane as described herein.
[0282] FIG. 12A is a schematic illustration of an aerosolization system 1600 including a cartridge assembly 1610 coupled to a housing 1641 of vaporizer pen assembly 1640, according to an embodiment. The aerosolization system 1600 can include a configuration where the shape of the vaporizer pen assembly 1641 and/or the cartridge assembly 1610 is flat and/or stretched as shown in FIG. 12A-11C. The configuration of the cartridge assembly 1610 can be referred to as a “pack” or “pod.” FIG. 12A also shows the cartridge assembly 1610, where the cartridge assembly 1610 can be inserted into the vaporizer pen assembly 1640. The cartridge assembly
1610 can include an airflow path 1615 defined by the cartridge assembly 1610 for aerosol to travel along. The cartridge assembly 1610 can be consistent with material and quality as any cartridge assembly as described in the entirety of this disclosure. The configuration of the aerosolization system 1600 can support a consumable assembly comprising a large thin sheet and a heater assembly comprising a set of heating elements.
[0283] FIG. 12B is a schematic illustration of the cartridge assembly 1610 of a FIG. 12A, according to an embodiment. The cartridge assembly 1610 can include a housing 1611 configured to house a consumable assembly 1630, where the housing can define the airflow path 1615 for aerosol produced from the consumable assembly 1630. The housing of the cartridge assembly 1610 can be consistent with any housing as described in the entirety of this disclosure. The housing 1611, including a hollow area, can house the consumable assembly 1630, where the consumable assembly 1630 includes two large thin sheets such as a first consumable sheet 1630a and a second consumable sheet 1630b. In some implementations, the housing 1611 can be formed from plastic or folded paper. In some embodiments, the housing
1611 can be surrounded by the membrane, where the membrane includes at least a layer of
impermeable material to separate the membrane from the first consumable sheet 1630a and/or the second consumable sheet 1630b.
[0284] In some implementation, both the first consumable sheet 1630a and the second consumable sheet 1630b can be applied to the two longer sides of the housing as shown in FIG. 12B. A heater assembly 1650 of the vaporizer pen assembly 1640 can be coupled to the cartridge assembly 1610 and/or the consumable assembly 1630, where the heater assembly sits in between the first consumable sheet 1630a and the second consumable sheet 1630b, where the heater assembly 1650 comes into contact with and/or proximate to the first consumable sheet 1630a and the second consumable sheet 1630b (e.g., as shown in FIG. 12F).
[0285] FIG. 12C is a schematic illustration of the vaporizer pen assembly 1640 of FIG. 12 A, according to an embodiment. The vaporizer pen assembly 1640 can include a hollow housing configured to receive at least a portion of the cartridge assembly 1630 of FIG. 12B. The heater assembly 1650 is disposed in the housing and configured to be disposed onto the consumable assembly 1630, for example, between the first consumable sheet 1630a and the second consumable sheet 1630b, when the cartridge assembly 1610 is inserted in the housing 1641 as shown in FIG. 12A. For example, the heater assembly 1650 can include a flat sheet including one or more heating elements, which is configured to be disposed between the first consumable sheet 1630a and the second consumable sheet 1630b so that the heating assembly 1650 can establish contact with the first consumable sheet 1630a on one side of the heater assembly 1650 and establish contact with the second consumable sheet 1630b on a second side of the heater assembly 1650 opposite the first side. In some implementations the heater assembly 1650 can include or be connected to a battery. The heater assembly 1650 can be include porous elements, define pores or apertures therethrough, or be generally porous, to allow for aerosolization of the consumable assembly 1630 to occur through the heater assembly 1650 and through the center of the consumable assembly 1630.
[0286] FIG. 12D is a side cross-section view of the cartridge assembly 1610 of FIG. 12A- 12B. The cartridge assembly 1610 and/or the housing 1611 can define an airflow path such as a tortuous path 1618 to filter the aerosol produced by the aerosolization of the first consumable sheet 1630a and the second consumable sheet 1630b prior to inhalation. In some implementations, the tortuous path 1618 can include a zigzagged structure disposed or formed in the housing 1611. In some implementations, the housing 1611 can include a filter that defines the tortuous path 1618.
[0287] FIG. 12E is a side cross-section view of the vaporizer pen assembly 1640 of FIG. 12A and 12C. The vaporizer pen 1640 of the aerosolization system 1600 includes the housing 1641. The vaporizer pen 1640 includes the heater assembly 1650 of FIG. 12C. The heater assembly 1650 can be operatively connected to a power source (not shown) of the vaporizer pen assembly 1640, where at least a portion of the heater assembly 1650 is configured to disposed inside the cartridge assembly 1610. The housing 1641 can also provide housing and/or protection for the heater assembly 1650. The housing 1641 includes a cartridge channel 1643, where the cartridge channel 1643 can include an exposed area between the inner surface area of the cartridge holder 1641 and the outer surface area of the heater assembly 1650. The cartridge assembly 1610 of FIG. 12B or 11D can be coupled to the vaporizer pen assembly 1640 such that the cartridge assembly 1610 is inserted in the cartridge channel 1643 of the housing 1641 and/or the vaporizer pen assembly 1640.
[0288] FIG. 12F is a side cross-section view of the aerosolization system 1600 including the cartridge assembly 1610 of FIGS. 12A-12B, and 12D coupled to the vaporizer pen assembly 1640 of FIGS. 12A, 12C, and 12E. The aerosolization system 1600 includes the cartridge assembly 1610 located in the cartridge holder 1641 of the vaporizer pen assembly 1640. The cartridge assembly 1610 is coupled to the vaporizer pen assembly 1640 and/or the housing 1641 where the heater assembly 1650 is in contact with and/or proximate to the consumable assembly 1630 housed inside the cartridge assembly 1610. The cartridge assembly 1610 can include a membrane coated or disposed around the housing 1611 of the cartridge assembly 1610 where the membrane can allow for smooth coupling of the cartridge assembly 1610 to housing 1641 of the vaporizer pen assembly 1640.
[0289] In some implementations, the heater assembly 1650 can be located outward of the consumable assembly 1630, aerosolizing the consumable assembly 1630 from the outside, where the produced aerosol follows upwards and through the tortuous path 1618. In some implementations, the heater assembly 1650 can include multiple heating elements and/or a set of heating elements (e.g. the heating elements 1652a / 1652b). In some embodiments, the consumable assembly 1630 can also include multiple consumable segments, where the heater assembly 1650 and/or the set of heating elements (e.g., the heating elements 1652a / 1652b) can apply heat to associated consumable segments to produce aerosol.
[0290] In some implementations, the configuration of the aerosolization system 1600, which includes the consumable assembly 1650 including larger sheets (e.g. first consumable sheet 1652a and/or second consumable sheet 1652b), can be used instead of a liquid pod. The
aerosolization system 1600 and/or the consumable assembly 1600 can remove the need for an embedded heater and resolves the issues of liquid material leaking and/or clogging of a liquid pod. The configuration of the consumable assembly 1630 can also be cheaper and/or simpler to manufacture than the liquid pod. In some implementations, the aerosolization system 1600 can provide finite control of aerosol flow, rate of aerosolization, and/or volume of aerosol produced from the consumable assembly 1630 containing multiple consumable segments such as the first consumable sheet 1652a and/or the second consumable sheet 1652b.
[0291] FIG. 13 A is a plot showing power management of a set of heating elements included in a heater assembly of an aerosolization system, according to an embodiment. The aerosolization system can be consistent with any aerosolization system as described herein. Current multi heater designs can multiple the surface area being heated, but also increase power consumption. The heater assembly as described herein can include multiple heating elements that can be powered intermittently, such that fewer heater elements (in some cases only one) are on at any one time. When the heater assembly and its heating elements reaches or exceeds a ramp up power to achieve a desired aerosolization temperature rapidly, the heater assembly reduces or stops the supply of power to the heater assembly (including three heating elements Hl / H2 / H3) to a plateau power to maintain the desired aerosolization temperature for multiple consumable segments (a larger area of aerosolization) at a time as shown in the plot of FIG. 13 A. As shown in the plot of FIG. 13 A, the heater assembly including multiple heating elements can each be powered to reach a desired aerosolization temperature. In some cases, some heating elements can be powered to reach different temperatures than that of other heating elements. The aerosolization system can also include smaller and more powerful heating elements making up the heater assembly to apply heat to a variable size surface area of the consumable assembly more efficiently. For instance, smaller heating elements can be powered and apply heat over a large surface area of the consumable assembly multiple times to allow for faster powering and/or heating time and reduced latency to aerosolization.
[0292] FIG. 13B is a plot showing temperature profiles of three heating elements (e.g. heating element Hl / H2 / H3) of a heater assembly for an aerosolization system that are sequentially activated, and associated temperature of a consumable assembly that is located proximate to or in contact with each of the three heating elements of the heater assembly. The surface of the consumable assembly can create multiple consumable segments, where some consumable segments have a less viscous liquid at the surface of the consumable assembly as a result of intermittent heating of the consumable assembly by the heater assembly. In some
implementations, consumable segments that have viscous liquid at the surface of the consumable segment can experience leaking and/or dripping, where the heater assembly can be configured to mitigate the leaking and/or dripping by optimizing the timing of powering on/off the intermittent heating of heating elements Hl, H2, and/or H3, individually or concurrently.
[0293] In some embodiments, the aerosolization system can include a cartridge assembly that can support a liquid consumable assembly such as a liquid pod. The cartridge assembly can include a wick with a large surface area and in contact with a liquid consumable in the liquid consumable assembly. The wick can be included in a wick assembly containing multiple heating coils that can apply heat to the liquid consumable drawn by the wick. The heating coils can include ceramic coils. The heating coils and/or the wick can also be powered on/off to optimize the timing of the intermittent heating of the liquid consumable assembly to mitigate leaking and/or dripping of liquids. This is so, at least in part, to control the volume of aerosol produced, the rate of delivery, the optimization of power consumption, and/or the wick management.
[0294] FIG. 14 is a schematic block diagram of a controller 1770 of a vaporizer pen assembly 1770 that can be configured to selectively activate each of a set of heating elements or heaters 1752a, 1752b, 1752c, 1752d, 1752e (together referred to herein as “heaters 1752”). included in a heater assembly 1750, according to an embodiment. In some embodiments, the controller 1770 can be part of the heating assembly 1750. In other embodiments, the controller 1770 can be operatively coupled to the heating assembly 1750 but physically separate therefrom. The controller 177- include a power supply 1774, a processor 1775, and a set of transistors 1776a, 1776b, 1776c, 1776d, 1776e (together referred to herein as “transistors 1776”), operatively coupled to the heaters 1752a, 1752b, 1752c, 1752d, 1752e, respectively. The controller 1770 can include any controller as described herein. In some implementations, the transistors 1776 can include a field effect transistor (FET). The processor 1775 can be consistent with any processor as described in the entirety of this disclosure. The power supply 1774 can include a rechargeable battery (e.g., a Li-ion battery, a Li-sulfur battery, a Li-air battery, or any other suitable rechargeable power source), or a disposable battery that is configured to provide electrical power to the processor 1775, the transistors 1776, and/or the heaters 1752.
[0295] The controller 1770 can allow for aerosol volume control. In some embodiments, the controller 1770 can include a memory (not shown) that includes instructions to cause the
processor 1775 to power the heaters 1752a, 1752b, 1752c, 1752d, and/or 1752e intermittently or selectively provide electrical energy thereto. For instance, a user can control the volume of aerosol produced based on the user’s preference. The user can interact with the controller 177- and/or the control interface of the vaporizer pen assembly 1770 including a physical digital toggle to select the aerosol production from a consumable assembly to a desired level. Based on the desired level and/or the user preference, fewer or more heaters 1752a, 1752b, 1752c, 1752d, and/or 1752e can be powered concurrently by activating a corresponding one of the transistors 1776.
[0296] Alternatively or additionally, a flow or pressure sensor (not shown) can be used to intuitively provide a larger or smaller volume of aerosol by inhaling more or less powerfully by the user. The flow or pressure sensor can be used to trigger the activation of the heater assembly and can also measure the strength of inhalation. The memory can store instructions to cause the processor 1775 to adjust the number of heaters 1752 (e.g. heater 1752a / 1752b / 1752c / 1752d / 1752e) being activated, and in turn adjust the number of heaters 1752 acting in unison to increase or decrease the power in applying heat to the consumable assembly and/or the volume of aerosol produced. The controller 1770 can also be configured to communicate with features included in the vaporizer pen assembly that support haptic and/or visual feedback to indicate the cadence and/or rate of flow of aerosol being produced. The haptic and/or visual feedback can also indicate increasing and decreasing frequency in the rate of aerosol production. For instance, the haptic and/or visual feedback can include an LED light that can buzz and/or blink for every 2 mg of aerosol produced. The user can set a low or high setting for the haptic and/or visual feedback, where the blinking and/or buzzing can occur every second at the low setting or every 1/3 of a second at the high setting.
[0297] In some embodiments, a heater assembly can be configured to aerosolize liquid consumables. For example, FIG. 15A-15E are various views of a heater assembly 1850 such as a wick assembly 1851 including a flat porous layer and a set of heating elements arranged in a flat configuration, and that can be used to aerosolize a liquid consumable, according to an embodiment. The wick assembly 1850 includes heating coils (e.g. heating coil 1852a / 1852b / 1852c) located on an inner cup portion and/or surface area of the wick assembly 1851 as shown in FIG. 15B or 15E. The heating coils are configured in a geometrically snake-like pattern to cover a larger surface area of the wick assembly 1851. The wick assembly 1851 can be consistent with any wick assembly and/or wick as described in the entirety of this disclosure.
[0298] In some implementations, the heater assembly 1850 can include a flat heater operatively connected to the wick assembly 1851, where the wick assembly 1853 includes the heating coils 1852a, 1852b, and/or 1852c and wicks 1853 protruding and/or extending away from the inner surface area of the wick assembly 1851 as shown in FIG. 15 A, 15B, or 15D. Heater assembly 1850 and the wick assembly 1851 can be coupled to a liquid cartridge assembly (not shown) such as a liquid pod, where a liquid consumable is in contact with the wicks 1853.
[0299] In some implementations, the wick assembly 1851 can include multiple heating coils 1852a, 1852b, and/or 1852c (together referred to herein as “heating coils 1852c”), where the heating coils 1852 are disposed within (e.g. partially or fully embedded within) the wick assembly 1851 of the heater assembly 1850. In some implementations, the wick assembly 1851 can include a cup portion where the cup portion includes a sidewall (e.g., cylindrical or tubular) and can have a porous bottom. In some implementations, the wick assembly 1851 can be formed of ceramic, stainless steel, and/or cotton. For example, the cup portion can be formed of ceramic, the contact pins 1853 can be formed of cotton, and the heating coils can be formed of stainless steel. The liquid consumable is configured to be vaporized and removed from the bottom surface of the cup portion and to travel laterally away from the bottom surface of the cup portion of the wick assembly 1851.
[0300] The wick assembly 1851 can include three separate heating coils 1852a, 1852b, and 1852c as shown in FIG. 15B and 15E disposed proximate to different portions of a top surface of the wick assembly 1851. Thus selective activation of one or more of the heating coils 1852 aerosolizes a liquid consumable absorbed in an associated portion or segment of the top surface of the wick assembly 1851.
[0301] The individual heating coils 1852a, 1852b, and/or 1852c allow for two or three times the volume of aerosol produced relative to convention heaters that heat an entire surface of an associated therewith, without compromising ideal heating temperature. Thus, the heater assembly 1850 can cause the heating coils 1852a, 1852b, and/or 1852c to apply heat to the liquid consumable absorbed in associated portions of the wick assembly 1851 individually and/or concurrently to optimize heating and power consumption. The heater assembly 1850 and the wick assembly 1851 can fit into a pod configuration. In some implementations, the heater assembly 1850 can use cylindrical heater, coil heaters, and/or wicks, such as silica wick and coil, cotton wick and coil, wick and mesh, or the like.
[0302] In some embodiments, the heater assembly 1850 can include the wick assembly 1851 and a chimney component (not shown). The chimney component can be formed of a metal such as, for example, brass. The wick assembly 1851 can include the wicks 1853 component and the heating coils 1852a, 1852b, and 1852c coupled to and/or disposed within (e.g., partially or fully embedded within) the wick assembly. In some implementations, the wick assembly 1851 can include a flexible wick and a cylindrical portion defining a central passageway (not shown). The chimney component can define a number of openings (e.g., two, three, or four openings) such that a reservoir defined by the mouthpiece and/or the cartridge assembly (e.g., the cartridge assembly 110 of FIG. 1) and the housing of the cartridge assembly is in fluid communication with an outer surface area of the wick assembly via the openings when the wick assembly is disposed within an interior of the chimney component. Thus, liquid consumable can travel from the reservoir, through the openings, through the flexible wick portion, and into the ceramic portion of the wick assembly 1851. When the heating coils 1852a, 1852b, and/or 1852, the temperature of the ceramic portion rises and the liquid consumable within the ceramic portion can heat and transition to vapor or aerosol. Air can be drawn through the central passageway of the wick assembly 1851, combine with heated vapor inside the wick assembly, and travel to the mouthpiece opening of the cartridge assembly via the chimney component. In some implementations, the wick assembly 1851 and/or the cartridge assembly can include at least one filter for the aerosol prior to exiting out of the mouthpiece of the cartridge assembly.
[0303] FIG. 15F is an exploded view of the heater assembly 1850 of FIGS. 15A-15E, an associated heater assembly housing 1886 and a base 1885 according to an embodiment. In some embodiments, the heater assembly 1850 and/or the wick assembly 1851 can be part of a cartridge assembly (not shown). The heater assembly housing 1886 is configured to receive the heater assembly 1850 within a recess of the heater assembly housing 1886 such that a bottom surface of an interior of the flat heating elements 1852 included in the wick assembly 1851 can be accessed through an opening of the heater assembly housing 1886. The heater assembly housing 1886 and/or the heater assembly 1850 can couple to the base 1884 via the heating subassembly 1885.
[0304] As shown in FIG. 15F, the sidewalls of the cup portion of the wick assembly 1851 can be disposed in the recess of the heater assembly housing 1886. The heater assembly housing 1886 can include at least one opening 1887, where the at least one opening 1887 that can be sized and/or shaped to control the rate at which the liquid consumable travels from the reservoir
of the cartridge assembly into the wick assembly 1851 of the heater assembly 1850. For example, the at least one opening 1887 can be about 2 mm long by about 1 mm wide. The heater assembly housing 1887 can include three openings as shown in FIG. 15F, where each opening is identical in size, but in some embodiments, can be different in size or shape. The heater assembly housing 1886 can be formed of any suitable material, such as a food grade elastomeric membrane material such as silicone. The heater assembly housing 1886 can include a flange portion disposed around the perimeter of the heater assembly housing 1886 and configured to function as a sealing ring (e.g., an O-ring) to seal the heater assembly housing 1886 relative to the base 1885 (e.g., an inner surface of the base 1885 defining the space within which the wick assembly 1851 and/or the heater assembly 1850 and the heater assembly housing 1886 are disposed and a groove for receiving the sealing ring of the heater assembly housing 1886).
[0305] .FIG. 16A-16D are various views of a heater assembly 1950 that includes a wick assembly 1951 including a cylindrical porous layer and a set of heating elements provided as coils (e.g. heating coils 1952a and 1952b), and that can be used to aerosolize a liquid consumable, according to an embodiment. The wick assembly 1951 can include contact pins 1853 extending out of the wick assembly 1953 of the heater assembly 1950 as shown in FIG. 16A-16D, where the contact pins 1953 can apply heat to aerosolize the liquid consumable.
[0306] FIG. 16B shows a top view of the wick assembly 1951 with a cap 1954 (e.g., a silicone cap) located at the top and center of the upper surface area of the wick assembly 1951. The contact pins 1953 can extend in the opposite direction and away from the wick assembly 1951. As shown in FIG. 16C, the contact pins 1953 can be located outside the wick assembly 1951, where the contact pins 1953 are equidistant from a longitudinal axis C of the heater assembly 1950. FIG. 16D shows a side cross-section view of the heating assembly 1950 showing the heating coils (e.g. heating coil 1952a / 1952b) located inside the wick assembly 1951, where the heating coils are in contact with a larger surface area inside the wick assembly 1951. The wick assembly 1951 and/or the heater assembly 1950 can include a chimney channel 1954, where the chimney channel 1954 can define an airpath flow for aerosol.
[0307] FIG. 17 is a schematic flow diagram of a method 2000 for aerosolizing a consumable via a heater assembly that includes a set of heating elements (e.g., any of the heater assemblies described herein), according to an embodiment. The method 2000 includes coupling a cartridge assembly including a consumable to a vaporizer pen including the heater assembly, at 2002. The cartridge assembly can be consistent with any cartridge assembly as described in
the entirety of this disclosure. In some implementations, the cartridge assembly can include a solid consumable such as a thin sheet including multiple consumable segments or a liquid pod. The heater assembly can be consistent with any heater assembly as described in the entirety of this disclosure. In some implementations, the heater assembly can include a set of heating elements, a wick assembly, a flat heater, a mesh, coils, or the like thereof. The cartridge assembly can couple to a cartridge holder of the vaporizer pen where the heater assembly of the vaporizer pen and the consumable of the cartridge assembly.
[0308] At 2004, the method 2000 includes receiving, via a draw sensor, a request for a vapor of the consumable. The draw sensor can include any draw sensor as described herein. In some implementations, the method 2000 can include requesting a specific type of consumable to be aerosolized, rate of aerosolization, dosage amount, and/or volume of aerosol produced. The method can include interacting with a controller and/or a control interface including visual and/or haptic feedbacks to send a signal representing the request to a processor in the vaporizer pen. The consumable can produce any aerosol and/or vapor.
[0309] At 2006, the method 2000 includes selectively activation, via the controller, a portion of a set of heating elements of the heater assembly. The heater assembly includes a set of heating elements that can be individually activated to intermittently aerosolize the consumable. In some implementations, the heater assembly can activate multiple heating elements concurrently. In some embodiments, based on the request, at 2006, the method 2000 can include selectively activating one heating element to aerosolize about equal to or greater than 2.5 mg of the consumable. In some embodiments, at 2006, the method 2000 can include selectively activating two or more heating elements to aerosolize about equal to or greater than 5.0 mg of the consumable for an extended period of time. In some embodiments, at 2006, the method 2000 can include selectively activating two or more heating elements to aerosolize about equal to or greater than 7.0 mg of the consumable for an extended period of time.
[0310] FIG. 18 is a schematic illustration of a system 2200 for manufacturing a consumable assembly 2230, according to an embodiment. The consumable assembly 2230 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 110. For example, the consumable assembly 2230 can be formed as a hollow tube including a tubular heating element layer 2270, a tubular aerosolgenerating substance portion layer 2260 radially outward of and in contact with the heating element layer 2270, and a tubular membrane layer 2264 disposed radially outward of and in contact with the tubular aerosol-generating substance portion layer 2260. Each of the layers
can start out and be fed simultaneously through the system 2300 as elongated sheets, with the exception of the tubular heating element 2370 layer which can be fed through the system as an elongated electrically conductive material such as a sheet or a plurality of elongated rods, threads, or wires.
[0311] As shown in FIG. 18, a first roller assembly 2200A of the system 2200 can draw a first aerosol-generating substance from a first aerosol-generating substance source 2260A in the form of a first elongated continuous thin film layer 2260B. For example, the first aerosolgenerating substance source 2260 A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the first roller assembly 2200A as the roller is rotating such that a portion of the first continuous elongated thin film layer 2260B is disposed on the roller of the first roller assembly 2200A.
[0312] Simultaneously, the first roller assembly 2200A can draw a first elongated continuous membrane layer 2264B from a source of the first elongated continuous membrane layer and can dispose a portion of the elongated continuous membrane layer 2264B on a portion of an upper surface of the first thin film layer 2260B (e.g., so that contacting portions of the first thin film layer 2260B and the elongated continuous membrane layer 2264B are substantially co-planar), forming a first multi-layered assembly.
[0313] A second roller assembly 2200C of the system 2200 can draw a continuous elongated heating element layer 2270B simultaneously with drawing the first multi-layered assembly (e.g., the layered first elongated continuous membrane layer 2264B and first elongated continuous thin film layer 2260B) from the first roller assembly 2200A. At the second roller assembly 2200C, the first elongated continuous film layer 2260B can be disposed on an upper side of the continuous elongated heating element layer 2270B, forming a second multi-layered assembly. Thus, at or after being processed by the second roller assembly 2200C, the first elongated continuous film layer 2260B is disposed between an associated portion of the elongated heating element layer 2270B and the first elongated continuous membrane layer 2264B.
[0314] In some implementations, the aerosol-generating substance forming the first elongated continuous thin film layer 2260B can include and/or function as an adhesive to bond the first elongated continuous membrane layer 2264B to the elongated heating element layer 2270.
[0315] The system 2200 can include a tube-forming assembly 2290 (also referred to as a rolling assembly). Optionally, the system 2200 can include a third roller assembly 2200D that can be used to redirect the second multi-layered assembly toward the tube-forming assembly 2290. The tube-forming assembly 2290 can receive the second multi-layered assembly in planar form and can output the second multi-layered assembly in a tubular form. For example, the tube-forming assembly 2290 can urge opposing ends or sides of the second multi-layered assembly toward each other to form a tube such that each of the first elongated continuous thin film layer 2260B, the first elongated continuous membrane layer 2264B, and the continuous elongated heating element layer 2270B are formed as a multi-layered continuous hollow tube exiting the tube-forming assembly 2290.
[0316] In some implementations, the consumable assembly 2230 can be formed as a hollow tube (e.g., by the tube-forming assembly 2290) having a seam formed by overlapping edge portions. An adhesive can be applied to the overlapping edge portions such that the consumable assembly 2230 can maintain a hollow tubular shape (e.g., until the tubular aerosol-generating substance portion layer 2260 hardens). The adhesive can be, for example, a rapidly hardening adhesive that hardens to hold the consumable assembly 2230 in a hollow tubular shape more quickly than the first aerosol-generating substance layer 2260 hardens into a cylindrical shape. For example, an adhesive portion can be applied to one or both elongated ends of an internalfacing or external-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) such that elongated end(s) can be adhered to the other of the elongated ends of the first membrane layer 2364 when the first membrane layer 2364 is rolled such that the edges overlap and contact each other.
[0317] After being formed as a multi-layered continuous hollow tube by the tube-forming assembly 2290, the multi-layered continuous hollow tube can be provided to a cutting assembly 2292. The cutting assembly 2292 can cut the multi-layered continuous hollow tube into individual consumable assemblies 2230 having substantially the same length. Each consumable assembly 2230 can be formed as a hollow tube including a tubular heating element 2270 having a tubular first aerosol-generating substance layer 2260 on an outer side thereof and a tubular first membrane layer 2264 as an outer layer thereof, each having substantially the same length from a first end to a second end of the consumable assembly 2230.
[0318] Each consumable assembly 2230 can be included in a cartridge, such as any of the cartridges described herein (e.g., cartridge 110). For example, each consumable assembly 2230 can be included in a cylindrical housing that is the same or similar in structure and/or function
as the housing 114 described with respect to FIG. 1, along with any other suitable components for a functional user consumable product including the consumable assembly 2230. For example, the cartridge including the consumable assembly 2230 can also include one or more of wrapping paper, filters (e.g., mono, multi-bore, and/or tube), cooling elements, perforations and venting features, foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
[0319] As described herein, each of the assemblies of the system 2200 can be configured to operate simultaneously on different portions of the materials used to produce each consumable assembly 2230. For example, the first roller assembly 2200A (e.g., in a first stage), the second roller assembly 2200C (e.g., in a second stage), the tube-forming assembly 2290 (e.g., in a third stage), and the cutting assembly 2292 (e.g., in a fourth stage) each operate simultaneously on respective different portions of materials used to produce respective additional consumable assemblies 2330.
[0320] In some implementations, as described above, the tube-forming assembly 2290 can form the rolled tube with the tubular aerosol-generating substance portion layer 2260 disposed radially outward of the elongated heating element layer 2270. In some implementations, alternatively, the tube-forming assembly 2290 can form the rolled tube with the tubular aerosolgenerating substance portion layer 2260 disposed radially inward of the elongated heating element layer 2270.
[0321] FIG. 19 is a schematic illustration of a system 2300 for manufacturing a consumable assembly 2330, according to an embodiment. The consumable assembly 2330 can be the same or similar in structure and/or function to any of the consumable assemblies described herein, such as the consumable assembly 110. For example, the consumable assembly 2330 can be the same or similar in structure and/or function to the consumable assembly 2130 shown and described with respect to FIG. 3K, which is formed as a hollow tube including a first aerosolgenerating substance layer 2360 disposed on a first side of a tubular heating element 2370, a second aerosol generating substance layer 2362 disposed on a second side of the tubular heating element 2370, a first membrane layer 2364 disposed on an opposite side of the first aerosolgenerating substance layer 2360 than the tubular heating element 2370 and forming an outer surface of the consumable assembly 2330, and a second membrane layer 2366 disposed on opposite side of the second aerosol-generating substance layer 2370 from the tubular heating element 2370 and forming an inner surface of the consumable assembly 2230 defining an inner
passageway. The system 2300 for manufacturing the consumable assembly 2330 can be substantially the same as or similar to the system 2200 shown and described with respect to FIG. 18, with the exception that the system 2300 includes an additional rolling assembly configured to couple the second aerosol-generating substance portion layer 2362 on a side of the elongated heating element layer 2370 opposite the side to which the first aerosol-generating substance portion layer 2360 is coupled. Additionally, the system 2300 is configured to couple a second membrane layer 2366 to the second aerosol generating substance layer 2362 on a side opposite the elongated heating element layer 2370. Similarly as described with respect to FIG. 18, each of the layers can start out and be fed simultaneously through the system 2300 as elongated sheets, with the exception of the tubular heating element 2370 layer which can be fed through the system as an elongated electrically conductive material such as a sheet or a plurality of elongated rods, threads, or wires.
[0322] As shown in FIG. 19, a first roller assembly 2300 A of the system 2300 can draw a first aerosol-generating substance from a first aerosol-generating substance source 2360A in the form of a first elongated continuous thin film layer 2360B. For example, the first aerosolgenerating substance source 2360 A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the first roller assembly 2300A as the roller is rotating such that a portion of the first continuous elongated thin film layer 2360B is disposed on the roller of the first roller assembly 2300A.
[0323] Simultaneously, the first roller assembly 2300 A can draw a first elongated continuous membrane layer 2364B from a source of the first elongated continuous membrane layer and can dispose a portion of the elongated continuous membrane layer 2364B on a portion of an upper surface of the first thin film layer 2360B (e.g., so that contacting portions of the first thin film layer 2360B and the elongated continuous membrane layer 2364B are substantially co-planar), forming a first multi-layered assembly.
[0324] A second roller assembly 2300B can draw a second aerosol-generating substance from a second aerosol-generating substance source 2362A in the form of a second elongated continuous thin film layer 2362B. For example, the second aerosol-generating substance source 2362A can deposit a continuous and constant amount of the first aerosol-generating substance (e.g., having a constant cross-section) onto a roller of the second roller assembly 2300B as the roller is rotating such that a portion of the second continuous elongated thin film layer 2362B is disposed on the roller of the second roller assembly 2300B.
[0325] Simultaneously, the second roller assembly 2300B can draw a second elongated continuous membrane layer 2366B from a source of the second elongated continuous membrane layer and can dispose a portion of the second elongated continuous membrane layer 2366B on a portion of a lower surface of the second thin film layer 2362B (e.g., so that contacting portions of the second thin film layer 2362B and the second elongated continuous membrane layer 2366B are substantially co-planar), forming a second multi-layered assembly.
[0326] A third roller assembly 2300C of the system 2300 can draw a continuous elongated heating element layer 2370B simultaneously with drawing the first multi-layered assembly (e.g., the layered first elongated continuous membrane layer 2364B and first elongated continuous thin film layer 2360B) from the first roller assembly 2300 A and with drawing the second multi-layered assembly (e.g., the layered second elongated continuous membrane layer 2366B and second elongated continuous thin film layer 2362B) from the second roller assembly 2300B. At the third roller assembly 2300C, the first elongated continuous film layer 2360B can be disposed on an upper side of the continuous elongated heating element layer 2370B and the second elongated continuous thin film layer 2362B can be disposed on a lower side of the continuous elongated heating element layer 2370B opposite the upper side, forming a third multi-layered assembly. Thus, at or after being processed by the third roller assembly 2300C, the first elongated continuous film layer 2360B is disposed between an associated portion of the elongated heating element layer 2370B and the first elongated continuous membrane layer 2364B and the second elongated continuous thin film layer 2362B is disposed between the associated portion of the continuous elongated heating element layer 2370B and the second elongated continuous membrane layer 2364B.
[0327] In some implementations, the aerosol-generating substance forming the first elongated continuous thin film layer 2360B and/or the second elongated continuous thin film layer 2362B can include and/or function as an adhesive to bond the first elongated continuous membrane layer 2364B and the second elongated continuous membrane layer 2366B to the elongated heating element layer 2370.
[0328] The system 2300 can include a tube-forming assembly 2390 (also referred to as a rolling assembly). Optionally, the system 2300 can include a fourth roller assembly 2300D that can be used to redirect the third multi-layered assembly toward the tube-forming assembly 2390. The tube-forming assembly 2390 can receive the third multi-layered assembly in planar form and can output the third multi-layered assembly in a tubular form. For example, as shown in portion 19A in FIG. 19, the tube-forming assembly 2390 can urge opposing ends or sides of
the third multi-layered assembly toward each other (e.g., along lines Z1 and Z2, respectively) to form a tube such that each of the first elongated continuous thin film layer 2360B, first elongated continuous membrane layer 2364B, the continuous elongated heating element layer 2370B, the second elongated continuous thin film layer 2362B, and the second elongated continuous membrane layer 2366B are formed as a multi-layered continuous hollow tube exiting the tube-forming assembly 2390.
[0329] In some implementations, the consumable assembly 2330 can be formed as a hollow tube (e.g., by the tube-forming assembly 2390) having a seam formed by overlapping edge portions. An adhesive can be applied to the overlapping edge portions such that the consumable assembly 2330 can maintain a hollow tubular shape (e.g., until the tubular aerosol-generating substance portion layer 2360 and/or the second aerosol generating substance layer 2362 hardens). The adhesive can be, for example, a rapidly hardening adhesive that hardens to hold the consumable assembly 2330 in a hollow tubular shape more quickly than the first aerosolgenerating substance layer 2360 and the second aerosol generating substance layer 2362 harden into a cylindrical shape. For example, as shown in portion 19A in FIG. 19, an adhesive portion 2369 can be applied to both opposing elongated ends of an internal-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) such that the ends of the first membrane layer 2364 can be adhered to each other and/or to the second membrane layer 2366. In some implementations, the adhesive portion 2369 can be applied to one elongated end of an internal-facing or external-facing surface of the first membrane layer 2364 (e.g., by the tubeforming assembly 2390) such that elongated end can be adhered to an opposite elongated end of the first membrane layer 2364 that the first membrane layer 2364 is rolled to overlap with.
[0330] In some implementations, an adhesive portion 2369 can be applied to one or both opposing elongated ends of an internal-facing surface of the first membrane layer 2364 (e.g., by the tube-forming assembly 2390) and/or one or both opposing elongated ends of an externalfacing surface of the second membrane layer 2366 such that the first membrane layer 2364 and/or the second membrane layer 2366 can be adhered to opposite elongated ends of themselves and/or each other. In some implementations, the first elongated continuous membrane layer 2364B and/or the second elongated continuous membrane layer 2366B can be wider than the first elongated continuous thin film layer 2360B and/or the second elongated continuous thin film layer 2362B such that the first membrane layer 2364 and/or the second membrane layer 2366 can have overlapping ends without the continuous elongated heating element layer 2370B, the first elongated continuous thin film layer 2360B, and/or the second
elongated continuous thin film layer 2362B overlapping when the consumable assembly 2330 is formed as tube.
[0331] After being formed as a multi-layered continuous hollow tube by the tube-forming assembly 2390, the multi-layered continuous hollow tube can be provided to a cutting assembly 2392. The cutting assembly 2392 can cut the multi-layered continuous hollow tube into individual consumable assemblies 2330 having substantially the same length. Each consumable assembly 2330 can be formed as a hollow tube including a tubular heating element 2370 having a tubular first aerosol-generating substance layer 2360 on an outer side thereof and a tubular second aerosol generating substance layer 2362 on an inner side thereof and a tubular first membrane layer 2364 as an outer layer thereof and a tubular second membrane layer 2366 as an inner layer thereof, each having substantially the same length from a first end to a second end of the consumable assembly 2330.
[0332] Each consumable assembly 2330 can be included in a cartridge, such as any of the cartridges described herein (e.g., cartridge 110). For example, each consumable assembly 2330 can be included in a cylindrical housing that is the same or similar in structure and/or function as the housing 114 described with respect to FIG. 1, along with any other suitable components for a functional user consumable product including the consumable assembly 2330. For example, the cartridge including the consumable assembly 2330 can also include one or more of wrapping paper, filters (e.g., mono, multi-bore, and/or tube), cooling elements, perforations and venting features, foil, flavoring and flavor producing elements, coatings, spacers, glue, additional tobacco components, additional cannabis components and/or additional plant-based active ingredient materials, identifying features, and/or tipping paper.
[0333] As described herein, each of the assemblies of the system 2300 can be configured to operate simultaneously on different portions of the materials used to produce each consumable assembly 2330. For example, the first roller assembly 2300A and the second roller assembly 2300B can operate simultaneously (e.g., in a first stage) on different portions of the materials used for a particular consumable assembly 2330, while the third roller assembly 2300B (e.g., in a second stage), the tube-forming assembly 2390 (e.g., in a third stage), and the cutting assembly 2392 (e.g., in a fourth stage) each operate simultaneously on respective different portions of materials used to produce respective additional consumable assemblies 2330.
[0334] FIG. 21 is a schematic flow chart of a method 2400 of manufacturing a consumable assembly, such as any of the consumable assemblies described herein (e.g., the consumable assembly 130, the consumable assembly 2230, and/or the consumable assembly 2330). For example, the method 2400 can be a method performed by a manufacturing system such as the system 2200 and/or the system 2300 described above. The method 2400 can include, at 2402, disposing a portion of a continuous elongated first aero sol -sub stance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly. The method 2400 can include, at 2404, disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly. The method 2400 can include, at 2406, transitioning the second planar layered assembly into a continuous tubular layered assembly. The method can include, at 2408, separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
[0335] In some implementations, the method 2400 can optionally include: disposing a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly; and disposing the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosolsubstance generating layer and the portion of the continuous elongated second membrane layer.
[0336] In some implementations, the continuous elongated electrically-conductive layer includes a metal sheet. In some embodiments, the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
[0337] In some implementations, the method 2400 can optionally include coupling a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
[0338] In some implementations, each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel. In some embodiments, each of the first aerosol-substance generating layer and the second aerosolsubstance generating layer includes an aerosol-generating paste forming a binder such that the
first membrane layer is adhesively coupled to the electrically-conductive layer via the first aerosol-substance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosol-substance generating layer.
[0339] In some implementations, the method 2400 can optionally include disposing a consumable assembly of the plurality of consumable assemblies within a cartridge having a housing, a filter, and defining an airflow channel from the consumable assembly through a proximal opening of the cartridge.
[0340] It is to be noted that any one or more of the aspects and embodiments described herein can be conveniently implemented using one or more machines (e.g., one or more compute devices that are utilized as a user compute device for an electronic document, one or more server devices, such as a document server, etc.) programmed according to the teachings of the present specification, as will be apparent to those of ordinary skill in the computer art. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those of ordinary skill in the software art. Aspects and implementations discussed above employing software and/or software modules can also include appropriate hardware for assisting in the implementation of the machine executable instructions of the software and/or software module.
[0341] All combinations of the foregoing concepts and additional concepts discussed herewithin (provided such concepts are not mutually inconsistent) are contemplated as being part of the subject matter disclosed herein. The terminology explicitly employed herein that also can appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.
[0342] The drawings are primarily for illustrative purposes, and are not intended to limit the scope of the subject matter described herein. The drawings are not necessarily to scale; in some instances, various aspects of the subject matter disclosed herein can be shown exaggerated or enlarged in the drawings to facilitate an understanding of different features. In the drawings, like reference characters generally refer to like features (e.g., functionally similar and/or structurally similar elements).
[0343] The entirety of this application (including the Cover Page, Title, Headings, Background, Summary, Brief Description of the Drawings, Detailed Description, Embodiments, Abstract, Figures, Appendices, and otherwise) shows, by way of illustration, various embodiments in which the embodiments can be practiced. The advantages and features
of the application are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. Rather, they are presented to assist in understanding and teach the embodiments, and are not representative of all embodiments. As such, certain aspects of the disclosure have not been discussed herein. That alternate embodiments cannot have been presented for a specific portion of the innovations or that further undescribed alternate embodiments can be available for a portion is not to be considered to exclude such alternate embodiments from the scope of the disclosure. It will be appreciated that many of those undescribed embodiments incorporate the same principles of the innovations and others are equivalent. Thus, it is to be understood that other embodiments can be utilized and functional, logical, operational, organizational, structural and/or topological modifications can be made without departing from the scope and/or spirit of the disclosure. As such, all examples and/or embodiments are deemed to be non-limiting throughout this disclosure.
[0344] Also, no inference should be drawn regarding those embodiments discussed herein relative to those not discussed herein other than it is as such for purposes of reducing space and repetition. For example, it is to be understood that the logical and/or topological structure of any combination of any program components (a component collection), other components and/or any present feature sets as described in the figures and/or throughout are not limited to a fixed operating order and/or arrangement, but rather, any disclosed order is exemplary and all equivalents, regardless of order, are contemplated by the disclosure.
[0345] The term “automatically” is used herein to modify actions that occur without direct input or prompting by an external source such as a user. Automatically occurring actions can occur periodically, sporadically, in response to a detected event (e.g., a user logging in), or according to a predetermined schedule.
[0346] The term “determining” encompasses a wide variety of actions and, therefore, “determining” can include calculating, computing, processing, deriving, investigating, looking up (e.g., looking up in a table, a database or another data structure), ascertaining and the like. Also, “determining” can include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” can include resolving, selecting, choosing, establishing and the like.
[0347] The phrase “based on” does not mean “based only on,” unless expressly specified otherwise. In other words, the phrase “based on” describes both “based only on” and “based at least on.”
[0348] The term “processor” should be interpreted broadly to encompass a general-purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a controller, a microcontroller, a state machine and so forth. Under some circumstances, a “processor” can refer to an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable gate array (FPGA), etc. The term “processor” can refer to a combination of processing devices, e.g., a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in conjunction with a DSP core or any other such configuration.
[0349] The terms “instructions” and “code” should be interpreted broadly to include any type of computer-readable statement(s). For example, the terms “instructions” and “code” can refer to one or more programs, routines, sub-routines, functions, procedures, etc. “Instructions” and “code” can comprise a single computer-readable statement or many computer-readable statements.
[0350] Some embodiments and/or methods described herein can be performed by software (executed on hardware), hardware, or a combination thereof. Hardware modules can include, for example, a general-purpose processor, a field programmable gate array (FPGA), and/or an application specific integrated circuit (ASIC). Software modules (executed on hardware) can be expressed in a variety of software languages (e.g., computer code), including C, C++, Java™, Ruby, Visual Basic™, and/or other object-oriented, procedural, or other programming language and development tools. Examples of computer code include, but are not limited to, micro-code or micro-instructions, machine instructions, such as produced by a compiler, code used to produce a web service, and files containing higher-level instructions that are executed by a computer using an interpreter. For example, embodiments can be implemented using imperative programming languages (e.g., C, Fortran, etc.), functional programming languages (Haskell, Erlang, etc.), logical programming languages (e.g., Prolog), object-oriented programming languages (e.g., Java, C++, etc.) or other suitable programming languages and/or development tools. Additional examples of computer code include, but are not limited to, control signals, encrypted code, and compressed code.
[0351] Various concepts can be embodied as one or more methods, of which at least one example has been provided. The acts performed as part of the method can be ordered in any suitable way. Accordingly, embodiments can be constructed in which acts are performed in an order different than illustrated, which can include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Put differently, it is to be
understood that such features can not necessarily be limited to a particular order of execution, but rather, any number of threads, processes, services, servers, and/or the like that can execute serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and/or the like in a manner consistent with the disclosure. As such, some of these features can be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.
[0352] In addition, the disclosure can include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisionals, and/or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and/or characteristics of an individual and/or enterprise user, database configuration and/or relational model, data type, data transmission and/or network framework, syntax structure, and/or the like, various embodiments of the technology disclosed herein can be implemented in a manner that enables a great deal of flexibility and customization as described herein.
[0353] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.
[0354] As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.
[0355] The indefinite articles “a” and “an,” as used herein in the specification and in the embodiments, unless clearly indicated to the contrary, should be understood to mean “at least one.”
[0356] The phrase “and/or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.
[0357] As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.
[0358] As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting
example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.
[0359] In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.
Claims
1. An apparatus, comprising: a heater assembly configured to be disposed proximate to a consumable, the heater assembly including a first heating element and a second heating element; a processor operatively coupled to each heating element of the set of heating elements; and a memory operatively coupled to the processor, the memory storing instructions to cause the processor to: receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
2. The apparatus of claim 1, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
3. The apparatus of claim 1, wherein the first power and the second power are substantially equal.
4. The apparatus of claim 1, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
5. The apparatus of claim 1, wherein the heater assembly further comprises a third heating element, and the memory stores instructions to cause the processor to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
6. The apparatus of claim 5, wherein the first power, the second power, and the third power are substantially equal.
7. The apparatus of claim 5, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
8. The apparatus of claim 1, wherein the first heating element and the second heating element are disposed in contact with the consumable during a heating operation.
9. The apparatus of claim 1, wherein the heater assembly extends axially along a longitudinal axis of the consumable.
10. The apparatus of claim 1, wherein the first heating element and the second heating element extend parallel to a longitudinal axis of the consumable, the first heating element and the second heating element being separated from each other along a circumferential direction about the longitudinal axis.
11. The apparatus of claim 1, wherein the first heating element and the second heating element extend in a circumferential direction about a longitudinal axis of the consumable, the first heating element and the second heating element being axially separated from each other along the longitudinal axis.
12. The apparatus of claim 1, wherein the heater assembly defines an axial channel therethrough.
13. The apparatus of claim 1, wherein the heater assembly is configured to be disposed at least one of radially outward or radially inward of the consumable.
14. The apparatus of claim 1, wherein the heater assembly has at least one of a flat, a circular, a star, a cylindrical, a polygonal, a tubular, a coiled, or an asymmetric shape.
15. The apparatus of claim 1, wherein: the heater assembly includes one or more inductor coils,
the consumable includes at least one susceptor and an aerosol-generating substance disposed proximate to or in contact with the at least one susceptor, and activating the first heating element includes activating at least a portion of the one or more inductor coils so as to heat an associated portion of the at least one susceptor and thereby, an associated portion of the aerosol-generating substance.
16. The apparatus of claim 15, wherein the at least one susceptor includes a porous sheet, the aerosol-generating substance includes a consumable sheet, and the at least one susceptor and the consumable sheet are coiled into a spool.
17. The apparatus of claim 15, wherein the at least one susceptor includes an electrically- conductive sheet and the aerosol-generating substance includes one or more of a layer of a porous consumable sheet, a layer of an aerosol-producing gel, or a layer of an aerosolproducing paste.
18. The apparatus of claim 17, wherein the consumable includes the layer of a porous consumable sheet, and the aerosol-generating substance includes one of a layer of an aerosolproducing gel or a layer of an aerosol-producing paste disposed between the layer of the porous consumable sheet and the electrically-conductive sheet.
19. The apparatus of claim 1, wherein: the consumable includes a liquid, and the heating element further includes a wick at least one of presoaked with the liquid or configured to draw the liquid from a reservoir.
20. A system, comprising: a consumable assembly including at least one segment, the at least one segment including a consumable material; and a heater assembly including: a first heating element and a second heating element, the first heating element and the second heating element being in thermal communication with the at least one segment including a consumable material, and a controller operatively coupled to the at least one heating element, the controller configured to:
receive a request for delivering an aerosol of the consumable, and, in response to receiving the request: activate the first heating element for a first period of time at a first power to cause aerosolization of a first portion of the consumable; deactivate the first heating element after the first period of time; and activate the second heating element for second period of time at a second power to cause aerosolization of a second portion of the consumable.
21. The apparatus of claim 20, wherein the request includes at least one of a user preference or a desired amount of the aerosol of the consumable, and the activating the first heating element, deactivating the first heating element, and activating the second heating element is based at least in part on the at least one of a user preference or a desired amount of the aerosol of the consumable.
22. The apparatus of claim 20, wherein the first power and the second power are substantially equal.
23. The apparatus of claim 20, wherein the first power is a maximum power of the first heating element and the second power is a maximum power of the second heating element.
24. The apparatus of claim 20, wherein the heater assembly further comprises a third heating element, and controller configured to: deactivate the second heating element after the second period of time; and activate the third heating element for a third period of time at a third power to cause aerosolization of the consumable.
25. The apparatus of claim 24, wherein the first power, the second power, and the third power are substantially equal.
26. The apparatus of claim 24, wherein the first power is a maximum power of the first heating element, the second power is a maximum power of the second heating element, and the third power is a maximum power of the third heating element.
27. The system of claim 20, wherein: the consumable assembly includes a plurality of segments, and each of the first heating element and the second heating element is associated with at least one segment of the plurality of segments.
28. The system of claim 27, wherein: the controller is configured to selectively activate one of the first heating element or the second heating element to heat the at least one segment of the plurality of segments associated with the one of the first heating element or the second heating element.
29. The system of claim 28, wherein the controller is configured to activate each of the first heating element and the second heating element concurrently and intermittently so as to control a rate of the aerosol generated based on the request.
30. The system of claim 20, wherein the consumable assembly is aligned with and coextensive with the set of heating elements of the heater assembly.
31. The system of claim 20, wherein the consumable assembly includes a sheet having a thickness in a range of about 0.05 mm to about 5 mm.
32. The system of claim 20, wherein the consumable assembly includes a sheet having a plurality of layers, each layer having a thickness in a range of about 0.05 mm to about 5 mm.
33. The system of claim 32, wherein each of the layers is formed as one of a solid or a gel.
34. The system of claim 31, wherein the consumable assembly and at least one of the first heating element and the second heating element are each assembled as a flat sheet, a tube, a spooled coil, or having complex shape such that the at least one segment of the consumable is in direct contact and aligned with the at least one heating element.
35. The system of claim 34, wherein the at least one heating element of the set of heating elements are disposed radially outward or radially inward of the at least one segment of the consumable assembly.
36. The system of claim 20, wherein: each of the first heating element and the second heating element includes at least one inductor coil, the consumable assembly includes at least one susceptor, activating the first heating element includes activating the at least one inductor coil of the first heating element to heat a first portion of the at least one susceptor, and activating the second heating element includes activating the at least one inductor coil of the second heating element to heat a second portion of the at least one susceptor.
37. The system of claim 20, wherein: each of the first heating element and the second heating element includes at least one inductor coil, the consumable assembly includes at least one susceptor, the heater assembly includes an actuator, the at least one inductor coil of the first heating element being coupled to the actuator, the controller configured to actuate the actuator to cause the actuator to displace the inductor coil axially relative to the at least one susceptor so as to position the at least one inductor coil proximate to a portion of the susceptor such that activation of the at least one inductor coil causes heating of the portion of the susceptor.
38. The system of claim 20, wherein: the consumable material is a liquid, and the consumable assembly includes a porous material at least one of presoaked with the liquid or in fluid communication with a reservoir of the liquid.
39. A system, comprising: a pen assembly, including: a heater assembly, the heater assembly including a set of heating elements, and a controller operatively coupled to the heater assembly; a cartridge assembly configured to be removably coupled to the heater assembly, the cartridge assembly including: a container defining an airflow path and a heater chamber, and a consumable assembly disposed in the container, the consumable assembly including a consumable material,
the cartridge assembly configured to be coupled to the pen assembly to cause the consumable assembly to be disposed proximate to or in direct contact with the heater assembly, and the controller being configured to: receive a pressure data from a draw sensor disposed in the pen assembly, receive a preference input from a control interface provided in the pen assembly, and selectively activate a portion of the set of heating elements to aerosolize at least a portion of the consumable material of the consumable assembly based on the pressure data and the preference input so as to produce varying amounts of aerosol.
40. The system of claim 39, wherein each heating element of the set of heating elements includes a mesh configured to allow the aerosol to pass through each heating element of the set of heating elements and the airflow path.
41. The system of claim 39, wherein the container includes a porous material disposed therein such that the produced aerosol flows through the porous material.
42. The system of claim 39, wherein the heater assembly includes a heater matrix including each heating element of the set of heating elements, the heater matrix being configured as a sheet, and the consumable assembly includes a consumable sheet such that selective activation of the portion of the set of heating elements by the controller causes an associated portion of the consumable sheet to be aerosolized.
43. A system comprising: a cartridge assembly, including: a consumable assembly including at least one segment, the consumable assembly including a consumable material, and at least one heating element being in direct contact with the at least one segment of the consumable assembly; and a pen assembly, the cartridge assembly configured to be removably coupled to the pen assembly, the pen assembly including:
I l l
a heater assembly configured to be operatively coupled to the cartridge assembly when the cartridge assembly is coupled to the pen assembly, and a controller operatively coupled to the heater assembly, the controller configured to: receive a request for an aerosol of the consumable material, the request including a user preference or a desired amount of the aerosol of the consumable, and selectively activate the heater assembly to cause heating of at least a portion of the at least one segment of the consumable assembly to generate varying amounts of the aerosol of the consumable material based on the request.
44. The system of claim 43, wherein: the heating element includes a susceptor, the susceptor being aligned with and coextensive with the at least one segment of the consumable assembly, and selectively activating the at least one heating element includes selectively activating the at least one inductor coil so as to heat an associated portion of the susceptor.
45. A system, comprising: an electrically-conductive layer having a first side and a second side opposite the first side; a first aerosol-substance generating layer having a first side and a second side opposite the first side, the first side of the first aerosol-substance generating layer disposed in contact with the first side of the electrically-conductive layer; a second aerosol-substance generating layer having a first side and a second side opposite the first side, the second side of the second aerosol-substance generating layer disposed in contact with the second side of the electrically-conductive layer; a first membrane layer disposed on the second side of the first aerosol-substance generating layer; and a second membrane layer disposed on the first side of the second aerosol-substance generating layer.
46. The system of claim 45, wherein the electrically-conductive layer is formed by a metal sheet.
47. The system of claim 45, wherein the electrically-conductive layer is formed by at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
48. The system of claim 45, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length.
49. The system of claim 45, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have the same overall length and width.
50. The system of claim 45, wherein each of the electrically-conductive layer, the first aerosol-substance generating layer, the second aerosol-substance generating layer, the first membrane layer, and the second membrane layer have a circular cross-section and a tubular shape.
51. The system of claim 45, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
52. The system of claim 45, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically- conductive layer via the first aerosol-substance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosolsubstance generating layer.
53. The system of claim 45, wherein at least one of the first membrane layer and the second membrane layer are at least one of permeable or perforated.
54. The system of claim 45, further comprising an elongated hollow tube defining an annular space between an outer surface of the second membrane layer and an inner surface of the elongated hollow tube.
55. A system, comprising: a first rolling assembly configured to dispose a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; a second rolling assembly configured to dispose a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; a tube-forming assembly configured to transition the second planar layered assembly into a continuous tubular layered assembly; and a cutting assembly configured to separate the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
56. The system of claim 55, further comprising a third rolling assembly configured to dispose a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly, the second rolling assembly configured to disposed the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosol-substance generating layer and the portion of the continuous elongated second membrane layer.
57. The system of claim 55, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
58. The system of claim 55, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
59. The system of claim 55, wherein the tube-forming assembly is configured to couple a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
60. The system of claim 56, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
61. The system of claim 56, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically- conductive layer via the first aerosol-substance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosolsubstance generating layer.
62. A method, comprising: disposing a portion of a continuous elongated first aerosol-substance generating layer on a portion of a continuous elongated first membrane layer to form a first planar layered assembly; disposing a portion of a continuous elongated electrically-conductive layer on the first planar layered assembly to form a second planar layered assembly; transitioning the second planar layered assembly into a continuous tubular layered assembly; and separating the continuous tubular layered assembly into a plurality of consumable assemblies of equal length.
63. The method of claim 62, further comprising: disposing a portion of a continuous elongated second aerosol-substance generating layer on a portion of a continuous elongated second membrane layer to form a third planar layered assembly; and disposing the third planar layered assembly on the portion of the continuous elongated electrically conductive layer on a side of the portion of the continuous elongated electrically conductive layer opposite the side contacting the first planar layered assembly, the second planar layer assembly including the portion of the continuous elongated second aerosolsubstance generating layer and the portion of the continuous elongated second membrane layer.
64. The method of claim 62, wherein the continuous elongated electrically-conductive layer includes a metal sheet.
65. The method of claim 62, wherein the continuous elongated electrically-conductive layer includes at least one of a plurality of elongated metal rods or a plurality of elongated metal strings.
66. The method of claim 62, further comprising coupling a first edge of the first membrane layer to a second opposite edge of the first membrane layer via an edge adhesive.
67. The method of claim 63, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating gel.
68. The method of claim 63, wherein each of the first aerosol-substance generating layer and the second aerosol-substance generating layer includes an aerosol-generating paste forming a binder such that the first membrane layer is adhesively coupled to the electrically- conductive layer via the first aerosol-substance generating layer and the second membrane layer is adhesively coupled to the electrically-conductive layer via the second aerosolsubstance generating layer.
69. The method of claim 62, further comprising disposing a consumable assembly of the plurality of consumable assemblies within a cartridge having a housing, a filter, and defining an airflow channel from the consumable assembly through a proximal opening of the cartridge.
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US20200245684A1 (en) * | 2017-08-09 | 2020-08-06 | Philip Morris Products S.A. | Aerosol generating system with multiple inductor coils |
US11241032B2 (en) * | 2017-12-29 | 2022-02-08 | Jt International S.A. | Aerosol generating articles and methods for manufacturing the same |
US20210161201A1 (en) * | 2018-07-31 | 2021-06-03 | Nicoventures Trading Limited | Consumable |
US20210307383A1 (en) * | 2018-07-31 | 2021-10-07 | Nicoventures Trading Limited | Consumable for use with apparatus for heating aerosolisable material |
US20220225682A1 (en) * | 2019-06-28 | 2022-07-21 | Nicoventures Trading Limited | Aerosol provision device |
WO2021037826A1 (en) * | 2019-08-28 | 2021-03-04 | Philip Morris Products S.A. | Aerosol-generating device with axially movable induction heater |
US20220183366A1 (en) * | 2019-09-06 | 2022-06-16 | Juul Labs, Inc. | Cartridge-based heat not burn vaporizer |
WO2022118009A1 (en) * | 2020-12-01 | 2022-06-09 | Nicoventures Trading Limited | Aerosol-generating component |
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