Cartridge for vaporizer device
A cartridge may include a cartridge, a reservoir, a heating element, and a wicking element. The housing may include a first housing segment coupled with a second housing segment. A portion of the cartridge housing may form a wick housing. The reservoir may include a collector having an overflow channel with microfluidic features configured to provide a constriction point at which a meniscus forms to prevent air entering the reservoir from passing the vaporizable material in the overflow channel. The heating element may include a heating portion disposed inside the wick housing and a contact portion extending outside of the wick housing. The wicking element may be disposed inside the wick housing and proximate to the heating portion of the heating element. The wicking element may be in fluid communication with the reservoir and configured to draw the vaporizable material from the reservoir for vaporization by the heating element.
1 . A cartridge for a vaporizer device, the cartridge comprising:
a cartridge housing having a first housing segment coupled with a second housing segment, at least a portion of the cartridge housing forming a wick housing;
a reservoir disposed within the cartridge housing, the reservoir including a storage chamber and a collector, the collector including an overflow channel configured to retain a volume of a vaporizable material in fluid contact with the storage chamber, the overflow channel including one or more microfluidic features configured to provide a constriction point at which a meniscus forms to create a pressure differential between the reservoir and ambient pressure, the meniscus further regulating an exchange of air and the vaporizable material into and out of the reservoir;
a heating element, the heating element including a heating portion disposed at least partially inside the wick housing and a contact portion extending at least partially outside of the wick housing, the contact portion including one or more cartridge contacts configured to form an electric coupling with one or more contacts in the vaporizer device; and
a wicking element disposed at least partially inside the wick housing and proximate to the heating portion of the heating element, the wicking element being in fluid communication with the reservoir, and the wicking element configured to draw the vaporizable material from the reservoir for vaporization by the heating element.
2 . The cartridge of claim 1 , wherein the collector is disposed between the first housing segment and the second housing segment.
3 . The cartridge of claim 1 , wherein the first housing segment includes a first portion of the collector, and wherein the second housing segments includes a second portion of the collector.
4 . The cartridge of claim 1 , wherein the first housing segment and the second housing segment are joined by one or more of an adhesive, ultrasonic welding, electron beam welding, and laser beam welding.
5 . The cartridge of claim 1 , wherein the first housing segment and the second housing segment are joined by a laser beam forming a laser weld between the first housing segment and the second housing segment.
6 . The cartridge of claim 5 , wherein the first housing segment is formed from a first material that is transparent to the laser beam, wherein the second housing segment is formed from a second material that is opaque to the laser beam, and wherein the laser beam penetrates the first housing segment to form the laser weld by melting the second housing segment.
7 . The cartridge of claim 5 , wherein the first housing segment and the second housing segment are formed from a first material that is transparent to the laser beam, wherein a film of a second material that is opaque to the laser beam is disposed between the first housing segment and the second housing segment, and wherein the laser beam penetrates the first housing segment or the second housing segment to form the laser weld by melting the film disposed between the first housing segment and the second housing segment.
8 . The cartridge of claim 1 , wherein a portion of the cartridge comprises a male connector including at least a portion of the wick housing and configured to be disposed at least partially inside a receptacle in a body of the vaporizer device.
9 . The cartridge of claim 8 , wherein the cartridge includes a sleeve extending at least partially over and/or around the male connector, wherein the sleeve extends below an open top of the receptacle to at least partially enclose the receptacle when the cartridge is coupled with the body of the vaporizer device, wherein a recessed area is formed between the sleeve and the body of the vaporizer device when the cartridge is coupled with the body of the vaporizer device, wherein the receptacle includes one or more air inlets configured to provide airflow to the cartridge coupled with the body of the vaporizer device, and wherein the one or more air inlets in the receptacle are disposed within the recessed area when the cartridge is coupled with the body of the vaporizer device.
10 . The cartridge of claim 1 , wherein a portion of the cartridge comprises a female connector configured to couple with a protrusion in a body of the vaporizer device.
11 . The cartridge of claim 1 , wherein the contact portion is further configured to form a mechanical coupling with a receptacle of the vaporizer device, and wherein the mechanical coupling secures the cartridge to the receptacle of the vaporizer device.
12 . The cartridge of claim 1 , wherein the wick housing includes one or more vents configured to provide airflow to the wicking element.
13 . The cartridge of claim 1 , further comprising:
an airflow passageway connecting the wick housing to an orifice in the cartridge that provides an outlet for an aerosol that is formed by the heating element vaporizing the vaporizable material, the airflow passageway having an interior surface including one or more features configured to collect a condensate formed by the aerosol and direct at least a portion of the collected condensate towards the wicking element.
14 . The cartridge of claim 13 , wherein the airflow passageway includes one or more impact plates configured to collect a condensate formed by the aerosol, wherein the airflow passageway further includes a fluid return formed from a porous material, and wherein the fluid return is configured to absorb the condensate collected by the one or more impact plates and direct the condensate to the reservoir.
15 . The cartridge of claim 13 , further comprising:
a sponge disposed proximate to an interface between the airflow passageway and the orifice, the sponge configured to filter a condensate formed by the aerosol.
16 . The cartridge of claim 13 , further comprising:
an intake slot through which air enters the airflow passageway in response to air being drawn into the cartridge; and
an air intake flap configured to admit the air into the airflow passageway while preventing an egress of the vaporizable material from the intake slot, the air intake flap in an undeflected state covering the intake slot to prevent the egress of the vaporizable material from the intake slot, the air intake flap being configured to deflect in response to the air being drawn into the cartridge through the intake slot, and the intake slot being at least partially uncovered while the air intake flap is in a deflected state to admit air into the airflow passageway.
17 . The cartridge of claim 1 , wherein the one or more microfluidic features include one or more bumps, raised edges, and/or protrusions extending from an interior surface of the overflow channel.
18 . The cartridge of claim 1 , wherein the one or more microfluidic features include one or more spirals, curves, bends, tapers, slopes, and/or turns along a length of the overflow channel.
19 . The cartridge of claim 1 , wherein the heating element comprises a substrate material that is cut and folded to form the heating portion of the heating element and the contact portion of the heating element, and wherein the heating portion of the heating element is configured to receive at least a portion of the wicking element.
20 . The cartridge of claim 1 , wherein an interior surface of the wicking housing includes at least one channel extending from the storage chamber to the wick housing, and wherein the at least one channel is configured to route the vaporizable material in the storage chamber to one or more portions of the wicking element disposed proximate to the heating portion of the heating element.
21 . The cartridge of claim 1 , wherein the vaporizable material enters the overflow channel through a first opening at a first end of the overflow channel, wherein the first opening is disposed proximate to the wick element to at least minimize a hydrostatic head between the wicking element and the storage chamber, and wherein air enters the overflow channel through a second opening at a second end of the overflow channel.
22 . The cartridge of claim 1 , wherein a lip is disposed at least partially around perimeter of the wick housing, and wherein the lip provides a capillary break preventing a contact between the vaporizable material and a body of the vaporizer device by at least forming a gap between the wick housing and the body of the vaporizer device when the cartridge is coupled with the body of the vaporizer device.