WO2014144678A2

WO2014144678A2 - Electronic smoking device systems and methods

Info

Publication number: WO2014144678A2
Application number: PCT/US2014/029193
Authority: WO
Inventors: Michael W. Lewis
Original assignee: Lewis Michael W
Priority date: 2013-03-15
Filing date: 2014-03-14
Publication date: 2014-09-18
Also published as: WO2014144678A3

Abstract

Provided are systems and methods for implementing an electronic smoking device. One embodiment of the present disclosure is directed to the implementation of an electronic smoking device including various artwork, structure, inhale response circuitry and/or sensors, variable visible feedback components, and/or other components adapted to reproduce the burning ember end of various conventional cigarettes and/or cigars. One embodiment of the present disclosure is directed to the implementation of a process to form an electronic smoking device and/or assembly utilizing various stiffness thermoplastic polyurethane compounds and/or an adhesive process adapted to provide a reliable, sealed, and at least partially flexible interface between various structures of an electronic smoking device. One embodiment of the present disclosure is directed to the implementation of an electronic smoking device including a sealed flue assembly adapted to substantially reduce a risk of a user coming in contact with fluid in the electronic smoking device.

Description

ELECTRONIC SMOKING DEVICE SYSTEMS AND METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to and the benefit of U.S. Provisional Application 61/802,204, filed on March 15, 2013 and entitled "Electronic Smoking Device Systems and Methods," the entire contents of which are hereby expressly incorporated by reference.

BACKGROUND

Field of the Invention

[0002] The present disclosure generally relates to electronic smoking devices and more particularly to systems and methods for manufacturing electronic smoking devices.

Related Art

[0003] Conventional cigarette smoking has been on the decline for a number of years. Many jurisdictions have enacted laws banning conventional cigarettes and cigars in almost every public venue, and smoking in general has subsequently become more and more of a solitary endeavor. In addition, smoke from conventional cigarettes and cigars typically includes a number of substances generally detrimental to the health of the smoking individual.

[0004] Various electronic smoking devices have been developed to provide a substitute method for the mechanical and/or chemical physical interactions associated with smoking, both to provide an avenue for social interaction and to provide a healthier alternative for the smoker and those around him or her. However, many such devices are expensive to manufacture and are relative fragile and prone to mechanical damage. Chemical leaks and mechanical damage related to unreliable inner construction can cause harm to a user. Thus, there is a need in the art for electronic smoking devices that are more reliable, safer to use, and easier to manufacture.

SUMMARY

[0005] Techniques are disclosed for systems and methods to provide safe and reliable electronic smoking devices. An electronic smoking device may include a number of modular elements including a multi-piece flue assembly, a tube for housing the active compound (e.g., the e-liquid), and an inhalation tip that, with the multi-piece flue assembly, helps to seal the active compound within the tube and away from undesirable contact with a user. The multi-piece flue assembly may be configured to support a heating filament and to passively meter the active compound to the heating element during operation of the electronic smoking device. The device may additionally include a patterned lens cap, one or more coatings, labeling, compounds, and materials, and/or other features configured to simulate the look and feel of a lit cigarette, cigar, and/or other smoking implement. The resulting device may be held and used by a user to replicate similar operation of a tobacco-based smoking implement.

[0006] In various embodiments, an electronic smoking device may include a single or multi-piece tube, a multi-piece flue assembly, an inhalation tip, a heating filament, a battery, one or more flexible gas permeable membranes, an air pressure sensor, a flexible circuit, a light emitting diode (LED), a matrix to physically stabilize the active compound, and/or one or more other modular elements mounted to or in proximity to the tube housing of the electronic smoking device. One or more elements of the device (e.g., the air pressure sensor, LED, battery, and/or flexible circuit) may be implemented with an electronic switch, charge storage device, and/or logic device configured to selectively electrically couple the battery to the heating element and/or LED when a user inhales through the inhalation tip.

[0007] One embodiment of the present disclosure is directed to the implementation of an electronic smoking device including various artwork, structure, inhale response circuitry and/or sensors, variable visible feedback components (e.g., variable brightness LEDs, and/or other feedback components), and or other features adapted to reproduce the burning ember end of various conventional cigarettes and/or cigars.

[0008] One embodiment of the present disclosure is directed to the implementation of a process to form an electronic smoking device and/or assembly utilizing various stiffness thermoplastic polyurethane (TPU) compounds and/or a glue process adapted to provide a reliable, sealed, and at least partially flexible interface between various structures of an electronic smoking device.

[0009] One embodiment of the present disclosure is directed to the implementation of an electronic smoking device including a sealed multi-piece flue assembly configured to substantially reduce a risk of a user coming in contact with the bulk of an active compound (e.g., e-liquid, and/or other types of nicotine, flavoring, and/or other stimulants and/or pharmaceutical containing substances, for example) in the electronic smoking device.

[0010] One embodiment of the present disclosure is directed to the implementation of an alternative to a liquid based active compound in an electronic smoking device, such as a paste and/or gel based active compound. In some embodiments, the flue assembly may be adapted to be permeable to the active substance in an aerosol form. In various embodiments, the multi-piece flue assembly and/or electronic smoking device may be reusable.

[0011] One embodiment of the present disclosure is directed to the implementation of a system for assembling a plurality of electronic smoking devices, implemented according to various embodiments described herein, in an automated fashion, and/or including various sensors, actuators, logic devices, controllers, memory devices, hoppers, manipulators, stations, and/or other devices and/or systems.

[0012] In one embodiment, an electronic smoking device includes a tube configured to house an active compound; an inhalation tip coupled to a first end of the tube; and a multi-piece flue assembly disposed within the tube, wherein the multi-piece flue assembly is configured to seal a bulk of the active compound from a second end of the tube and from exiting the inhalation tip .

[0013] In another embodiment, a method for assembling an electronic smoking device mcludes providing an inhalation tip, a multi-piece flue assembly, and a tube configured to house an active compound; inserting at least a portion of the multi-piece flue assembly into the tube; adding a bulk of the active compound to an interior of the tube defined, at least in part, by the portion of the multi-piece flue assembly; and coupling the inhalation tip to the tube and/or the multi-piece flue assembly to seal the bulk of the active compound within the tube.

[0014] In a further embodiment, a method for assembling an electronic smoking device includes providing a tube, wherein the tube is adapted to house an active compound and comprises polycarbonate, polyester terephthalate, acrylic, and/or one or more other flexible tube materials; providing an inhalation tip comprising silicon, thermoplastic polyurethane, and/or one or more other flexible tip materials; and binding the inhalation tip to the tube using an ultra-violet (UV) cured flexible glue.

[0015] The scope of the invention is defined by the claims, which are incorporated into this section by reference. These and other features and advantages of the present disclosure will be more readily apparent from the detailed description of the embodiments set forth below taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

[0016] The various figures and text attached herein illustrate various processes, devices, and systems for implementing one or more electronic smoking devices and/or assemblies, processes to make, sell and/or use such devices and/or assemblies, and/or systems embodying such processes, devices, and/or assemblies, for example, in accordance with embodiments of the disclosure.

[0017] Figs. 1 A-D illustrate various diagrams and views of an electronic smoking device in accordance with embodiments of the disclosure.

[0018] Figs. 2A-E illustrate various diagrams and views of an electronic smoking device in accordance with embodiments of the disclosure.

[0019] Figs. 3A-D illustrate various diagrams and views of an electronic smoking device in accordance with embodiments of the disclosure.

[0020] Figs. 4A-C illustrate various diagrams and views of an electronic smoking device in accordance with embodiments of the disclosure.

[0021] Fig. 5A illustrates various diagrams and views of a lens cap for an electronic smoking device in accordance with embodiments of the disclosure.

[0022] Fig. 5B illustrates progressive views of the formation of a lens cap for an electronic smoking device in accordance with embodiments of the disclosure.

[0023] Fig. 6 illustrates an electronic smoking device assembly system in accordance with an embodiment of the disclosure.

[0024] Fig. 7 illustrates various label designs for an electronic smoking device in accordance with an embodiment of the disclosure.

[0025] Fig. 8 illustrates silicon caps for use with an electronic smoking device assembly system in accordance with an embodiment of the disclosure.

[0026] Fig. 9 illustrates a flow diagram of various operations to assemble an electronic smoking device in accordance with an embodiment of the disclosure.

[0027] Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same. DETAILED DESCRIPTION

[0028] In accordance with various embodiments of the present disclosure, safe and reliable electronic smoking devices, systems, and methods may advantageously include a number of modular elements including a multi-piece flue assembly, a tube for housing an active compound (e.g., e-liquid, and/or other types of nicotine, flavoring, and/or other stimulants and/or pharmaceutical containing substances, for example), and an inhalation tip that, with the multi-piece flue assembly, helps to seal the active compound within the tube and away from undesirable contact with a user. For example, the multi-piece flue assembly may be configured to support a heating filament and to passively meter the active compound to the heating element during operation of the electronic smoking device. The device may additionally include a patterned lens cap, one or more coatings, labeling, compounds, and materials, and/or other features configured to simulate the look and feel of a lit cigarette, cigar, and/or other smoking implement. The resulting device may be held and used to simulate operation of a tobacco-based smoking implement without requiring the actual burning of tobacco.

[0029] In one embodiment, an electronic smoking device includes a multi-piece flue assembly including a breathable and/or flexible membrane (e.g., is gas permeable but not fluid permeable) that is secured to the multi-piece flue assembly on one end to an inhalation tip on the other end, with a long slot on the sides of a portion of the multi-piece flue assembly to slip over the heating element leads and wicking fibers to form a small flue inlet for the active compound. This embodiment virtually eliminates the potential for active compound leakage, and its modular implementation is beneficial for automated assembly.

[0030] In another embodiment, an electronic smoking device includes an inhalation tip with multiple (e.g., five) vapor orifices and a breathable flexible membrane disc glued in place to the inhalation tip. In one embodiment, an electronic smoking device may include a breathable flexible membrane disc integrated with the multi-piece flue assembly that allows air into the flue and active compound housing area but prevents the bulk active compound from leaking into the battery compartment. In some embodiments, an electronic smoking device may include a modular, press-fit, and/or crimp based design configured to eliminate a need for soldered electrical connections. In various embodiments, an electronic smoking device may include an IC sensor, a specialized sealed and/or rechargeable battery, and/or a flat flexible wiring harness or circuit. [0031] Fig. 1A illustrates an exploded view of electronic smoking device 100A in accordance with an embodiment of the disclosure. In various embodiments, device 100A may be configured to vaporize a metered portion of an active compound housed within device 100A when a user inhales through device 100A. In some embodiments, device 100 A may be implemented in modular form and assembled by an automated process that minimizes human interaction.

[0032] In the embodiment shown in Fig. 1 , device 100A may be implemented as a monolithic assembly that is entirely disposable after its supply of active compound and/or its power source is exhausted, for example, and that can be adapted to simulate operation of a conventional smoking implement. In one embodiment, device 100A may include a tube 1 10 configured to house an active compound (e.g., physically stabilized by fiber matrix 138), a multi-piece flue assembly (e.g., including at least a plug 132, an inner flue 134, and an outer flue 136) configured to facilitate safe and metered vaporization of the active compound, an inhalation tip 140 that may be coupled to one end of tube 1 10, and one or more other elements described herein. As shown in Fig. 1A, air may be drawn through tube 1 10 (e.g., by a user inhaling through inhalation tip 140 and/or orifice 142), and the pressure differential caused by the inhalation may be sensed by air pressure sensor 1 14. Air pressure sensor 1 14 and/or other electronic elements (e.g., one or more logic devices, timers, switches, charge storage devices, and/or other electronic devices) integrated with air pressure sensor 1 14 and/or flexible circuit 1 18 may couple sealed battery/power source 1 16 to contact pins 122, leads 124, and/or heating filament 126 to vaporize a metered portion of the active compound wicked into heating filament 126 by wicking fibers 128.

[0033] In some embodiments, heating filament 126 may be energized while air pressure sensor 1 14 is detecting an inhalation. In other embodiments, heating filament 126 may be energized for a predetermined duration once inhalation is detected and/or for a maximum aggregate duration over multiple detected inhalations. In further embodiments, air pressure sensor 1 14 and/or other electronic elements of device 100A may be configured to detect when heating filament 126 is at risk of damage and/or no longer in contact with active compound (e.g., if the active compound is exhausted, wicking fibers 128 are malfunctioning, and/or other elements of device 100A are malfunctioning) and de- energize heating filament 126. For example, such electronic elements may be configured to monitor a voltage across heating filament 126, a power output and/or charge level of sealed battery 1 16, and/or other operational characteristics of device 100A and determine whether heating filament 125 is in contact with active compound (e.g., and thereby thermally stabilized) and/or is otherwise at risk of damage. In addition to controlling operation of heating filament 126, air pressure sensor 114 and/or other electronic elements of device 100A may be configured to energize and/or de-energize an LED (e.g., LED 115 in Fig. IB) under lens cap 112 upon detection of an inhalation, for example, to simulate a burning ember.

[0034] Tube 110 may be implemented as a cylinder, an n-sided prism, and/or other shapes to ease automated mechanical assembly, for example, and in some embodiments may be made of a rigid material (e.g., stainless steel) for durability, may be made of a flexible material (e.g., medical grade polycarbonate, polyester terephthalate, acrylic, and/or other flexible polymers or materials) to simulate the feel of a conventional smoking implement, or may be made of a combination of rigid and flexible materials. In embodiments where tube 110 is implemented from polycarbonate or other materials that are substantially transparent to ultraviolet (UV) light, assembly of device 100A may benefit from use of a UV-cured adhesive, such as within sealed portions of device 100A. In similar embodiments, transparency to various spectra, including infrared and UV, may benefit assembly of device 100A by providing for automated camera/imaging inspection of bonded, press fit, and/or otherwise sealed portions of device 100A for quality control. In some embodiments, tube 1 10 may be implemented from extruded and/or visibly clear or colored material, for example, and/or a material selected to be substantially inert with respect to a particular active compound. Tube 1 10 may be sized to simulate a conventional cigarette or cigar, for example, and/or implemented with a diameter and/or wall thickness that are sufficient to allow for press-fit and/or adhesive bonding of lens cap 1 12, air pressure sensor 114, adapter 120, plug 132, fiber matrix 138, and/or inhalation tip 140.

[0035] Inhalation tip 140 may be implemented from food or medical grade thermoplastic urethane (TPU), silicone, and/or other thennoplastic elastomers (TPEs) such as styrenic or olefinic TPEs, for example, or may be implemented from one or more rigid materials, such as stainless steel. In embodiments where inhalation tip 140 is made from TPU or other TPEs, inhalation tip 140 may be configured to form a reliable and flexible bond with a polycarbonate embodiment of tube 1 10, using a flexible adhesive for example, and inhalation tip 140 may be injection moulded to speed and lower the cost of manufacture as compared to compression moulding and/or the use of silicone. In various

embodiments, inhalation tip 140 may be implemented according to a pliability (e.g., 60A, 70A, 80A, 90A, and/or other hardness on the durometer scale) selected to simulate a conventional smoking implement, to match a flexibility of tube 1 10 (e.g., to lower a risk of rupturing a seal with tube 1 10 during operation of device 100A), and/or to adjust durability and/or ease of assembly. As shown in Fig. 1 A, inhalation tip 140 may in some embodiments include a single orifice 142 configured to mate with a corresponding inner diameter of outer flue 136, as described herein.

[0036] When assembled as shown in view 101C of Fig. 1C, plug 132, inner flue 134, and outer flue 136 form multi-piece flue assembly 130. Plug 132 may be implemented from a relatively soft or pliable elastomer polymer and/or may be configured to form an air-tight or liquid tight seal with an interior surface of tube 110. Plug 132 may include a central through hole that is sealed by an integrated breathable membrane (e.g., membrane 133 of Fig. IB), and the membrane (flexible or rigid) and the seal with tube 1 10 may be configured to prevent bulk active compound from passing through plug 120 and/or into contact with adapter 120, flexible circuit 118, and/or sealed battery 116. Inner flue 134 and outer flue 136 may be made from the same material as plug 132, for example, or may be made from a material selected to be resistant to degradation caused by high temperatures (e.g., produced by heating filament 126), such as polycarbonate, polyester terephthalate, various TPEs, acrylics, ceramics, metals, and/or other materials. Inner flue 134 and outer flue 136 may each include a center through hole, substantially aligned with the through hole of plug 132, such that air traveling through multi-piece flue assembly 130 travels through each of plug 132, inner flue 134, and outer flue 136.

[0037] As shown in Fig. 1A, inner flue 134 may be press fit and/or bonded to plug 132 to form a stable structure upon which to mount heating filament 126. As is also shown in Fig. 1A, plug 132 may be configured to physically support one or more conductive contact pins 122, for example, that are press fit and/or adhesively bonded to plug 132. Conductive pins 122 may be configured to electrically couple leads 124 to sealed battery 1 16 without requiring solder and without risk of damaging the liquid-tight seal provided by plug 132. For example, each of conductive pins 122 may include blind hollow portions and/or blunt portions that may be crimped to leads 124 and/or pressed against or crimped to positive and negative contact pads of flexible circuit 1 18 and/or sealed battery 1 16. Leads 124 may in turn be crimped to opposing sides of heating filament 126, thereby completing the electrical circuit from flexible circuit 1 18 to heating filament 126.

[0038] Heating filament 126 may be implemented as a conductive cylinder or coil of wire that is configured to vaporize active compound in contact with heating filament 126 when energized by sealed battery 116. As shown in Fig. 1A, heating filament 126 may be supported by notch 135 of inner flue 134 such that heating filament 126 is positioned substantially within or across the central through hole of inner flue 134. Outer flue 136 may be implemented with slot 137 allowing outer flue 136 to be fitted over and mated with inner flue 134 without disturbing heating filament 126, leads 124, and/or contact pins 122, for example, and/or to secure heating filament 126 in notch 135. In some embodiments, notch 135 and slot 137 may be configured to form a flue inlet (e.g., flue inlet 130c of Fig. 1C) that allows the bulk of the active compound (e.g., bound to fiber matrix 138) to enter and/or contact the heating filament at a predetermined rate related to the shape and/or diameter of the flue inlet. In various embodiments, wicking fibers 128, which may be glass or another type of heat resistant material, may be press fit within heating filament 126 and configured to wick active compound into heating filament 126 (e.g., from fiber matrix 138) and/or help stabilize the predetermined rate or metering of active compound provided by the flue inlet.

[0039] In some embodiments, device 100A may include fiber matrix 138, for example, which may be configured to physically stabilize an active compound housed by tube 1 10. Fiber matrix 138 may be implemented as a cloth or other relatively inexpensive fibrous material, for example, and may include slot 139 allowing fiber matrix 138 to be fitted over or mated with outer flue 136 without disturbing heating filament 126, leads 124, and/or contact pins 122. In embodiments where the active compound is liquid, fiber matrix 138 may be configured to prevent formation of bubbles and to help provide/wick the active compound to wicking fibers 128. In other embodiments, fiber matrix 138 may be configured to provide a wicking surface area for a liquid, paste, or gel based active compound. In still further embodiments, device 100A may omit fiber matrix 138.

[0040] As shown in Fig. 1A, adapter 120 and air pressure sensor 1 14 may be press fit and/or bonded to tube 1 10 and be configured to mechanically press contact pads of flexible circuit 118 against corresponding terminals of sealed battery 1 16. Flexible circuit 1 18 may be implemented as one or more flexible insulated conductors, conductive traces, printed circuit boards, conductive ribbons, and/or other circuitry, for example, that may be configured to electrically couple terminals of sealed battery 1 16 to various other components of device 100A, including air pressure sensor 1 14. For example, flexible circuit 1 18 may be implemented as a flexible insulated conductive ribbon with a number of isolated conductive traces and corresponding exposed contact pads configured to electrically couple to terminals of sealed battery 116, contact pins 122, and/or air pressure sensor 1 14.

[0041] Air pressure sensor 1 14, which may be formed within a polymer housing similar to the material used to form plug 132, may be implemented as one or more logic devices, switches, charge storage devices (e.g., capacitors), and/or other analog or digital electronic components configured to detect inhalation through inhalation tip 140 and energize heating filament 126 and/or other elements of device 100A. For example, air pressure sensor 1 14 may be configured to detect an air pressure differential within tube 1 10 caused by inhalation through inhalation tip 140 mechanically by sensing actuation of a spring loaded airflow switch within air pressure sensor 114. In other embodiments, air pressure sensor 114 may be configured to detect inhalation electromechanically using an air wheel and a hall effect sensor, for example, or a piezoelectric film configured to distend in the presence of airflow. In general, air pressure sensor 1 14 may be configured to detect inhalation using mechanical, electrical, or electromechanical flow and/or pressure sensors. In various embodiments, air pressure sensor 1 14 and/or flexible circuit 1 18 may be integrated with one or more logic devices, switches, charge storage devices (e.g., capacitors), and/or other analog or digital electronic components that may be arranged, adapted, and/or configured to implement any of the methods described herein, including providing a voltage of sealed battery 1 16, and/or a modulated and/or attenuated form of that voltage, across an element of device 100A.

[0042] Sealed battery 1 16 may be used to power each of the elements of device 100 A, including air pressure sensor 1 14 and heating filament 126. Advantageously, sealed battery 116 may be implemented so as to stay sealed against leakage of electrolyte when subjected to prolonged periods of discharge, multiple recharging cycles, contact with active compound vapor and/or moisture, and/or other detrimental environmental conditions, thereby increasing user safety. In some embodiments, sealed battery 116 may be sized to slide freely within tube 110, for example, and electrical contact with flexible circuit 1 18 may be maintained by press fit and/or adhesive bonding of air pressure sensor 1 14, plug 132, and/or adapter 120 at positions within tube 110 configured to provide contact pressure between contact pads of flexible circuit 1 18 and terminals of sealed battery 1 1 6. Such arrangement eliminates a need to solder sealed battery 116 to other elements of device 100A, which would slow assembly and risk damage to sealed battery 1 16 and other elements of device 100A. Adapter 120 may be implemented from the same materials used to form plug 132 and/or a housing for air pressure sensor 1 14, for example, and may be implemented with one or more notches, slots, through holes, and/or other features configured to allow contact pins 122 and air to pass through adapter 120.

[0043] Also shown in Fig. 1 A is lens cap 1 12. Lens cap 112 may be implemented from an at least partially optically transparent material, including any of the materials used to form tube 1 10, adapter 120, multi-piece flue assembly 130, and/or inhalation tip 140. In some embodiments, lens cap 1 12 may include one or more air inlets (e.g., inlets 586 in Fig. 5A) and/or legs (e.g., legs 584 in Fig. 5A) configured to allow air to pass through lens cap 112 into tube 110 and/or to facilitate press fit mounting and/or adhesive bonding of lens cap 1 12 to an end of tube 110. In various embodiments, air pressure sensor 114 may include one or more LEDs of various colors (e.g., red) configured to illuminate lens cap 1 12 to simulate a burning ember in response to a detected inhalation, In such embodiments, lens cap 1 12 may be partially optically opaque to simulate the glow effect of a burning ember. In further embodiments, lens cap 112 may include a raised pattern (e.g., raised pattern 582 in Fig. 5A) configured to simulate the shape of a burning ember of a conventional smoking implement.

[0044] Fig. IB illustrates a different exploded view 100B of electronic smoking device 100A of Fig. 1A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. IB, and described above with reference to elements of Fig. 1A, device 100A may include one or more LEDs/light sources 115 physically and/or electrically coupled to air pressure sensor 1 14 and adjacent lens cap 1 12, and plug 132 may include breathable membrane 133. In some embodiments, LEDs 115 may be configured to emit one or more illuminated colors, such as varying shades of red, orange, and/or yellow, to simulate a burning ember in the presence of varying airflow. For example, in embodiments where air pressure sensor 1 14 is configured to detect an airflow velocity of a detected inhalation, the airflow velocity may be used to vary the intensity and/or shade of an illuminated color emitted by LED 115. Breathable membrane 133 may be integrated with and/or configured to seal a central through hole through plug 132, for example, and may be selected to be flexible or rigid to more closely match a flexibility of plug 132 and/or tube 110 to reduce a risk of damage to tube 110, plug 132, and/or membrane 133 in the presence of physical stress, such as clamping and/or bending.

[0045] Fig. 1C illustrates a side exploded view l OOC and an assembled side view 101C of electronic smoking device 100A of Fig. 1A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in view 101 C, and described above with reference to elements of Figs. 1A-B, plug 132, inner flue 134, and outer flue 136 may be assembled into multi-piece flue assembly 130 including flue inlet 130c. Also shown in view 101C, air pressure sensor 1 13 and adapter 120 may be fitted within tube 110 to press contact pads 118a, 1 18b of flexible circuit 1 18 against terminals of sealed battery 1 16. Furthermore, views lOOC and l Ol C shows plug 132 of multi-piece flue assembly 130 fitted within tube 110 to press contact pins 122 against contact pads 1 18b of flexible circuit 118.

[0046] Fig. ID illustrates a side detailed view 100D of multi-piece flue assembly 130 and inhalation tip 140 of electronic smoking device 100A of Fig. 1A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in view 100D, and described above with reference to elements of Figs. 1A-C, plug 132 may include first and second plug portions 132a, 132b disposed on either side of breathable membrane 133. In some embodiments, first and second plug portions 132a, 132b may be held and/or bonded together by contact pins 122, which may in turn be supported by the resulting plug 132. For example, contact pins 122 may be press fit and/or otherwise inserted into first and second plug portions 132a, 132b to form the displaced assembly shown in view 100D, membrane 133 may be placed between first and second plug portions 132a, 132b, and first and second plug portions 132a, 132b may be pressed together and/or adhesively bonded to form plug 132. As shown, first plug portion 132a may be coupled to inner flue 134 (e.g., by press fit and/or adhesive coupling), and plug 132 including membrane 133 may be configured to allow air through plug 132 and block bulk active compound from passing through plug 132, as described herein.

[0047] Also shown in view 100D, in some embodiments, inhalation tip 140 may include an internal riser/nipple 144 that is aligned with orifice 148 and/or a central through hole of multi-piece flue assembly 130, for example, and that is configured to couple to multi- piece flue assembly 130, at an end of outer flue 136, such as by press fit and/or adhesive bonding. In such embodiments, internal riser 144 is configured to form a seal 146 with the multi-piece flue assembly to allow active compound vapor (e.g., produced by heating filament 126) to pass through orifice 142 of inhalation tip 140. In some embodiments, orifice 142 and/or a central through hole of multi-piece flue assembly 130 may be partially or completely filled with filter material 148, for example, to help ensure bulk active compound and/or other fluids and/or particles do not reach the mouth of a user. In one embodiment, filter material 148 may be formed of the same material used to form membrane 133. Although internal riser 144 is shown in Fig. ID as being disposed about an external surface of outer flue 136, in other embodiments, internal riser 144 may be inserted into an inner surface/central through hole of outer flue 136.

[0048] By providing a modular assembly of an electronic smoking device, including the various features configured to remove a need for soldering elements of the electronic smoking device to one another for electrical connection, embodiments of the present disclosure facilitate high volume automated machine assembly of reliable and safe electronic smoking products across a varied product line, as described herein.

[0049] Fig. 2A illustrates an exploded view of electronic smoking device 200A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 2A, device 200A includes many of the same features of device 100A of Fig. 1A, except inhalation tip 140 of device 100A is replaced with inhalation tip 250, and device 200A includes flexible tip membrane 254. In some embodiments, flexible tip membrane 254 may be formed from the same material used to form membrane 133, for example, and may be configured to be gas or vapor permeable, but liquid impermeable. In related embodiments, the degree of flexibility of flexible tip membrane 254 and/or inhalation tip 2 0 may be selected to substantially match each other, to substantially match that of tube ] 10, and/or to simulate the feel of a conventional smoking implement. In various embodiments, flexible tip membrane 254 may be bonded to an interior surface of inhalation tip 250, for example, and configured to form a seal with inhalation tip 250 to allow active compound vapor through orifices 252 of inhalation tip 250 and to block bulk active compound from exiting inhalation tip 250 through orifices 252. In such embodiments, inhalation tip 250 may not couple to multi-piece flue assembly 130, for example, and device 200A may be configured for higher vapor flow than capable with device 100A.

[0050] Fig. 2B illustrates a different exploded view 200B of electronic smoking device 200A of Fig. 2A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 2B, inhalation tip 250 lacks an internal riser such as internal riser 144 of inhalation tip 140, and instead relies on the seal provided by flexible tip membrane 254. This is illustrated more clearly in Fig. 2C, which includes a side exploded view 200C and an assembled side view 201C of electronic smoking device

200A of Fig. 2A in accordance with an embodiment of the disclosure. As shown by the embodiments presented in views 200C and 201C, and described above with reference to elements of Figs. 2A-B, inhalation tip 250 includes multiple orifices 252, lacks an internal riser, and flexible tip membrane 254 may be disposed within inhalation tip 250 to cover all orifices 252. Also, in some embodiments, such as the one illustrated in view 201C, multi-piece flue assembly 130 may not extend far enough into inhalation tip 250 to seal against a surface of inhalation tip 250. In such embodiments, bulk active compound wicked to heating filament 126 but not vaporized (e.g., due to high volume flow rate, for example) may be reintroduced to the remaining bulk active compound (e.g., in fiber matrix 138). In other embodiments, multi-piece flue assembly 130 and/or inhalation tip 250 may be configured to contact each other and form a relatively wide bore seal (e.g., as compared to device 100A) to allow a high volume vapor flow of the active compound through orifices 252 of inhalation tip 250, where excess bulk active compound is not allowed to recombine in fiber matrix 138.

[0051] Fig. 2D illustrates perspective detailed views 200D, 20 ID of multi-piece flue assembly 130 and inhalation tip 250 of electronic smoking device 200A of Fig. 2A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in views 200D, 201D, and described above with reference to elements of Figs. 2A-C, plug 132 may include first and second plug portions 132a, 132b disposed on either side of breathable membrane 133, and first plug portion 132a may include internal riser/nipple 232c that is configured to couple to inner flue 134. In some embodiments, first plug portion 132a and inner flue 134 may be press fit and/or adhesively bonded together prior to or after forming plug 133 (e.g., using contact pins 122 as described herein).

[0052] Also shown in view 200D, in some embodiments, inhalation tip 250 may be bonded to flexible tip membrane 254 using adhesive/glue bead 256 to form a flexible seal. In some embodiments, adhesive bead 256 may be formed by a flexible adhesive configured to retain flexibility after curing, as described herein. This is illustrated more clearly in Fig. 2E, which includes an exploded view 200E and an assembled view 20 IE of inhalation tip 250 and flexible tip membrane 254 in accordance with an embodiment of the disclosure. As shown by the embodiments presented in views 200E and 201E, and described above with reference to elements of Figs. 2A-D, in some embodiments, flexible tip membrane 254 may include a washer edge 255 configured to accept adhesive bead 256 and form a flexible seal with inhalation tip 250 without damaging or obstructing the membrane portion of flexible tip membrane 254. The final assembly shown in view 20 IE is configured to provide a high volume vapor flow through orifices 252.

[0053] By providing a modular assembly of an electronic smoking device, including the various features configured to increase vapor flow rate without risking active compound leakage to a user, embodiments of the present disclosure facilitate automated machine assembly of reliable and safe electronic smoking products across product lines that can be easily tailored to customer desires, as described herein.

[0054] Fig. 3A illustrates an exploded view of electronic smoking device 300A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 3A, device 300A includes many of the same features of devices 100A of Fig. 1 A and 200A of Fig. 2A, except tube 1 10/device 300A is split into battery tube portion 310 and cartridge (also referred to as "cartomizer") tube portion 360, which may be physically and electrically coupled together to form tube 1 10/device 300A without soldering using threaded bushings 362, 364 and terminals 366, 368. For example, multi- piece flue assembly 130 and/or the bulk active compound may be disposed substantially within cartridge tube portion 360, and sealed battery 116 may be disposed substantially within battery tube portion 310. Also, contact pins 322, plug 332, and/or various other elements of device 300A are modified versions of similar elements of device 100A configured to facilitate the physical and electrical coupling and recharging of sealed battery 116. For example, in the embodiment shown in Fig. 3A, air pressure sensor 1 14, flexible circuit 1 18, and/or other electronic components of device 300A may be configured to detect a low charge state of sealed battery 1 16 and indicate the low charge state to a user using one or more pulses of light (e.g., provided by LED 1 15, for example) that are not coincident with a detected inhalation.

[0055] As shown in Fig. 3A, threaded bushings 362, 364 may be press fit and/or adhesively bonded within respective tubes 360, 310. Threaded bushings 362, 364 may be electrically conductive and configured to couple one terminal of sealed battery 316 to heating filament 126, as described herein. Terminals 366, 368 may also be electrically conductive and configured to couple the other terminal of sealed battery 316 to heating filament 126, as described herein. In some embodiments, terminals 366, 368 may be disposed within respective threaded bushings 362, 364 and/or within an insulating coating or housing configured to press fit and/or adhesively bond to respective threaded bushings 362, 364 without shorting the terminals of sealed battery 316. In various embodiments, terminals 366, 368 and threaded bushings 362, 364 may be configured and/or arranged to provide contact pressure between contact pads of flexible circuit 118 and terminals of sealed battery 116 while threaded bushings 362, 364 are securely coupled together. This is illustrated more clearly in Figs. 3B-D. [0056] Fig. 3B illustrates a different exploded view 300Bof electronic smoking device 300A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 3B, device 300A includes modified plug 332 and integrated membrane 333, both of which are configured to allow air through plug 332 and to block bulk active compound from passing through plug 332, similar to plug 132 and membrane 133, but adapted to facilitate the physical and electrical coupling provided by threaded bushings 362, 364 and terminals 366, 368. Fig. 3C illustrates side exploded view 300C of battery tube portion 310, side exploded view and 301 C of cartridge tube portion 360, and assembled side view 302C of electronic smoking device 300A in accordance with embodiments of the disclosure. As shown by the embodiments presented in Fig. 3C, plug 332 supports offset contact pins 322a, 322b, which in final assembly (shown in view 302C) are electrically coupled to the terminals of sealed battery 1 16 over flexible circuit 1 18, threaded bushings 362, 364, and terminals 366, 368. Also, as shown, air pressure sensor 1 14 and terminal 368 may be configured to supply contact pressure (e.g., when assembled) between contact pads of flexible circuit 218 and terminals of sealed battery 1 14.

[0057] Fig. 3D illustrates a side cross section detail 300D of electronic smoking device 300A with assembled battery tube portion 310 separated from assembled cartridge tube portion 360, in accordance with embodiments of the disclosure. As shown by the embodiments presented in Fig. 3D, plug 332 supports offset contact pins 322a, 322b so that contact pin 322a is electrically coupled to threaded bushing 362 and contact pin 322b may be electrically coupled to terminal 366 (e.g., depending on the positions of threaded bushing 362 and terminal 366 and/or whether sufficient contact pressure is supplied to terminal 366 by threaded bushings 362, 364 and terminal 368). Also shown in Fig. 3D, terminal 368 may be electrically coupled to contact pad 370 of flexible circuit 1 18 (e.g., which is in turn coupled to a positive terminal of sealed battery 1 16), and threaded bushing 364 is electrically coupled to contact pad 371 of flexible circuit 118 and/or a negative terminal of sealed battery 1 16. Each terminal 366, 368 is disposed within but electrically isolated from its respective threaded bushing 362, 364 by respective insulating portions (e.g., coatings, washers, housings) 367, 369. Thus, when threaded bushings 362, 364 are securely coupled to each other, heating filament 126 may be electrically coupled to sealed battery 116, at least in part, through threaded bushings 362, 364 and terminals 366, 368, without resorting to soldering, as shown. [0058] Fig. 4A illustrates an exploded view of electronic smoking device 400A in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 4A, device 400A includes many of the same features of devices 100A of Fig. 1A, 200A of Fig. 2A, and 300A of Fig. 3A, arranged as a modification of device 300A according to elements (e.g., inhalation tip 250 and flexible tip membrane 254) of device 200A.

[0059] Fig. 4B illustrates a different exploded view 400B of electronic smoking device 300A in accordance with an embodiment of the disclosure. Fig. 4C illustrates side exploded view 400C of battery tube portion 310, side exploded view 401C of cartridge tube portion 360, and assembled side view 402C of electronic smoking device 400A in accordance with embodiments of the disclosure. As shown by the embodiments presented in Fig. 3C, multi-piece flue assembly 130 may be configured, in some embodiments, to not extend into any portion of inhalation tip 250. Fig. 4D illustrates an assembled view of battery tube portion 310 physically and electrically coupled to recharging power source 416d using threaded bushings 362, 364 and terminals 366, 368. In one embodiment, air pressure sensor 1 14, flexible circuit 1 18, and/or or one or more logic devices integrated with various elements of device 400A may be configured to detect when recharging power source 41 6d is attached to battery tube portion 310 (e.g., as opposed to a cartridge tube portion) and couple sealed battery 116 to recharging power source 416d during a charge cycle. In other embodiments, battery tube portion 310 may be configured to enter a charge cycle whenever a sufficient charge voltage is supplied across threaded bushings 362, 364 and terminals 366, 368. In various embodiments, recharging power source 416d may be implemented as one or more rechargeable batteries, voltage regulators, voltage and/or current sensors, AC to DC converters, transfonners, mains interfaces, photovoltaic panels, logic devices, and/or other analog or digital power supply components.

[0060] Fig. 5A illustrates a top view 500A, perspective views 501 A, and plan views 502A of lens cap 580 in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 5 A, lens cap 580 may be implemented with a raised pattern 582 configured to simulate a burning ember when lit from within, such as by LED 1 15 of device 1 10A. Lens cap 580 may also be implemented with one or more air inlets 586 that are configured to allow air to be drawn within tube 110 when a user inhales through an inhalation tip. In some embodiments, air inlets 586 and/or lens cap 580 may be configured to meter the air allowed into tube 110, using a number, shape, and/or size of air inlets 586 and/or lens cap 580 for example, to set a particular vapor flow rate, such as a maximum vapor flow rate for an electronic smoking device. In other embodiments, air inlets 586 and/or lens cap 580 may be configured to direct a flow of air to air pressure sensor 1 14 to facilitate more accurate detection of inhalation and/or an airflow velocity of an inhalation. In one embodiment, lens cap 580 may include one or more legs 584 configured to facilitate press fit and/or adhesive bonding with tube 1 10 without risking obstruction to the air flow metered by air inlets 586.

[0061] Fig. 5A illustrates a top view 500A, perspective views 501A, and plan views 502A of lens cap 580 in accordance with an embodiment of the disclosure. As shown by the embodiment presented in Fig. 5 A, lens cap 580 may be implemented with a raised pattern 582 configured to simulate a burning ember when lit from within, such as by LED 1 15 of device 1 10A. Lens cap 580 may also be implemented with one or more air inlets 586 that are configured to allow air to be drawn within tube 1 10 when a user inhales through an inhalation tip. In some embodiments, air inlets 586 and/or lens cap 580 may be configured to meter the air allowed into tube 110, using a number, shape, and/or size of air inlets 586 and/or lens cap 580 for example, to set a particular vapor flow rate, such as a maximum vapor flow rate for an electronic smoking device. In other embodiments, air inlets 586 and/or lens cap 580 may be configured to direct a flow of air to air pressure sensor 1 14 to faci litate more accurate detection of inhalation and/or an airflow velocity of an inhalation. In one embodiment, lens cap 580 may include one or more legs 584 configured to facilitate press fit and/or adhesive bonding with tube 1 10 without risking obstruction to the air flow metered by air inlets 586.

[0062] Fig. 5B illustrates a flowchart for and progressive views of the formation of lens cap 580 for an electronic smoking device in accordance with embodiments of the disclosure. For example, to form raised pattern 582 shown in Fig. 5A, an assembly apparatus may be configured to provide a blank lens cap insert 580a, press an indent pattern onto a top surface of blank lens cap insert 580a to form a relief pattern 582b in the top surface and produce lens cap insert 580b, paint (e.g., by roller, stamp, and/or other surface painting method) a raised portion of the relief pattern of lens cap insert 580b to produce raised pattern 582c of lens cap insert 580c, and then illuminate an interior of lens cap insert 580c to produce a simulated ember pattern 582d of lens cap insert 80d.

[0063] Fig. 6 illustrates a block diagram of an assembly system 600 in accordance with an embodiment of the disclosure. In various embodiments, system 600 may be configured to assemble electronic smoking devices (e.g., electronic smoking devices 100A, 200A, 300 A, and/or 400A, for example) according to an automated process, as disclosed herein. As shown in Fig. 6, system 600 may include a variety of hoppers, material supply drums, stations, substations, and controllers, where assembly lines 601 represent one or two way conduits for materials and/or data, and where data line 602 represents a two way data conduit to controller 608.

[0064] Controller 608 may be implemented as any appropriate logic device (e.g., processing device, microcontroller, processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), memory storage device, memory reader, network interface, or other device or combinations of devices) that may be adapted to execute, store, and/or receive appropriate instructions, such as software instructions implementing a control loop for controlling various operations of system 600, as described herein. Such software instructions may also implement methods for processing sensor signals, determining sensor information, providing user feedback (e.g., through a user interface), querying devices for operational parameters, selecting operational parameters for devices, or performing any of the various operations described herein. For example, in an initialization state, controller 608 may be configured to poll various stations to determine if any materials are low or expect to be required to complete an assembly run.

[0065] Dial machine may be implemented as a central feed through and control node for assembly system 600 that is configured to facilitate continuous operation of system 600. For example, dial machine 610 may include a number of tube grippers, arms, actuators, and/or other mechanical devices adapted to exchange tubes across assembly lines 601 with any of the coupled stations substantially simultaneously.

[0066] Tube hopper 612 may be configured to receive and/or store a number of partially assembled electronic smoking device tubes, such as tube 1 10 and/or cartridge tube portion 360. In one embodiment, each of the partially assembled tubes may lack active compound, an inhalation tip, an outer coating or label, and/or various packaging covers, such as silicone caps used to limit evaporation of the active compound. Tube hopper 612 may be configured to serve tubes to discriminator station 614, which may be configured to select only a particular type of tube for a particular assembly run and serve the particular type of tube to dial machine 610. In some embodiments, tube hopper 612 and/or discriminator station 614 may also be configured to orient tubes consistently before serving them to dial machine 610. In other embodiments, dial machine 610 may be configured to orient supplied tubes consistently. [0067] Filling station 620 may be configured to accept tubes from dial machine 610 and dispense a predetermined amount of active compound (e.g., liquid, past, or gel) from drum 622 into the tubes using positive displacement pump 624. After filling and/or partially filling the tubes with active compound, filling station 620 may be configured to serve the filled tubes back to dial machine 610 for delivery to tip assembly station 630. In alterantive embodiments, filling station 620 and tip assembly station 630 may be physically linked by an assembly line 601 so as to bypass dial machine 610.

[0068] Tip assembly station 630 may be configured to accept filled tubes from dial machine 610 and/or filling station 620 and press fit and/or adhesively bond an inhalation tip to an end of each tube. In some embodiments, the inhalation tips may be formed from hard/rigid plastic and may be press fit only. In such embodiments, tip assembly station 630 may be configured to receive tips from tip hopper 632 (e.g., which may be configured to orient them properly), place them in the appropriate end of corresponding tubes, and press fit them into the tubes. In other embodiments, the inhalation tips may be formed from relatively flexible material, for example, and/or may be adhesively bonded only or both press fit and adhesively bonded. In such embodiments, tip assembly station 630 may be configured to serve tips from tip hopper 632 and tubes from dial machine 610 to adhesive station 634. Alternatively, adhesive station 634 may be physically linked by an assembly line 601 to adhesive station 634 and the tips may be served directly.

[0069] Adhesive station 634 may be configured to receive tips and tubes and adhesive (e.g., from adhesive drum 636) and use the adhesive to glue the tips to the ends of the tubes. For example, in one embodiment, adhesive station 634 may be configured to apply adhesive to an outer diameter of a tip and/or an inner diameter of a tube, spin the tip and/or tube to distribute the adhesive evenly, press the tip into the tube, and/or process the assembled tip and tube according to a particular curing procedure. For example, where the adhesive may be cured by UV light, adhesive station 634 may be configured to pass the tip/tube assembly through a UV light tunnel and/or spinning the assembly within a UV light source configured to cure the adhesive. In such embodiments, the tube may be made of polycarbonate, for example, which is substantially transparent to UV light and allows the UV light to thoroughly cure the adhesive across the full width of the adhering surface. In some embodiments, the adhesive may be selected/configured to form a flexible bond between the tip and tube, for example, that is cured by UV light. In additional embodiments, adhesive station 634 may be configured to apply adhesive around a perimeter of a tip and/or tube using positioning sensors, actuators (e.g., a robotic arm and/or a tip/tube rotator), and a dispensing needle, for example. In various embodiments, the adhesive may be implemented as a cyanoacrylate, and epoxy, and/or other adhesives, for example, and the same or similar adhesives may be used throughout assembly of an electronic smoking device.

[0070] In some embodiments, system 600 may include one or more inspection stations, such as inspection station 680 linked to tip assembly station 630 in Fig. 6. In such embodiments, each inspection station may be configured to inspect a tip, tube, and/or tip/tube assembly at any stage of the assembly process, using any one of a variety of spectra and/or other sensing mechanisms, and to accept or reject the inspected element based on predetermined quality control criteria. For example, in the embodiment shown in Fig. 6, tip assembly station 630 may be configured to serve filled and cured tip/tube assemblies to inspection station 680, and inspection station 680 may be configured to receive the assemblies and inspect their fill levels and/or an adhesive bond between the tip and tube, using a high speed camera sensitive to visible and/or UV light, for example. In some embodiments, inspection station 680 may be configured accept or reject each tube based on whether the fill level is within a predetermined range and/or whether the adhesive bond traverses the circumference of the tip/tube assembly. In related embodiments, inspection station 680 may be configured to serve rejected assemblies to rejection hopper 682 for later manual inspection and/or to notify controller 608 of the circumstances of the rejection. For example, inspection station 680 may be configured to halt system 600 and notify controller 608 when a predetermined number of consecutive rejections and/or percentage of rejections (e.g., 5, or 5%) is detected.

[0071] In various embodiments, tip assembly station 630 may be configured to serve filled tip/tube assemblies (e.g., accepted and/or uninspected) to dial machine 610, which may be configured to serve the filled tip/tube assemblies to labeling/coating station 640. As shown in Fig. 6, labeling/coating station 640 may be configured to receive coating material (e.g., powder coating material, paint, inking, and/or other coating material) from coating drum 644 and/or labels (e.g., adhesive labels) from label hopper 642 and apply either or both to an outer surface of received filled tip/tube assemblies. In some embodiments, the outer coating and/or label may be configured to simulate, at least in part, a cigarette, a cigar, and/or a burning ash end. Examples of such outer coatings and/or labels are provided in views 700-703 of Fig. 7. For example, view 700 illustrates a full label for tube 110, including portion 710 corresponding to battery tube portion 310, portion 760 corresponding to cartridge tube portion 360, and burning ash end 711. View 701 illustrates a similar design, but with two separate labels corresponding to portions 710 and 760. View 702 illustrates a different design, but still with two separate labels corresponding to portions 710 and 760. View 703 illustrates a close up view of burning ash end 71 1 and corresponding burning ember lens cap 780.

[0072] After each filled tip/tube assembly is labeled, labeling/coating station 640 may be configured to serve the labeled assemblies to dial machine 610, which may then pass the labeled assemblies to cap station 650. As shown, cap station 650 may be configured to receive caps (e.g., silicone and/or other sealing caps, such as caps 805 shown in Fig. 8 with tube 1 10, inhalation tips 240, and cartridge tube portion 860) from cap hopper 652, place the caps on corresponding tip ends of the labeled assemblies, and then press the caps onto the tip ends. In some embodiments, such as when the labeled assemblies correspond to cartridge tube portions for example, cap station 650 may be configured to reposition the labeled assemblies after the first caps are pressed onto the tip ends, place second caps on the opposing ends of the labeled assemblies, and/or press the second caps onto the opposing ends to seal both ends of the labeled assemblies. After capping is completed, cap station 650 may serve the capped assemblies to dial machine 610, which may then pass the capped assemblies to discharge station 660, Discharge station 660 may be implemented as an inspection station, a discharge hopper, a wrapping station, and/or a discriminator and/or tally station, for example, and be configured to update controller 608 with an ongoing status of the productivity of system 600.

[0073] Also shown in Fig. 6 is other stations 690. Other stations 690 may be

implemented as one or more pre-assembly stations, for example, and/or one or more post assembly stations, such as a mailing station configured to package discharged assemblies and ready the packages for mailing according to addresses and/or delivery methods supplied by controller 608. In some embodiments, other stations 609 may be

implemented as a pre-assembly station configured to provide an inhalation tip (e.g., by injection and/or compression moulding), to provide tube 110 (e.g., by extrusion, moulding, and/or machining), to assemble multi-piece flue assembly 130 and/or insert multi-piece flue assembly 130 into tube 1 10 and/or tube portion 360, to cut tube 1 10 into tube portions 310 and 360, to press fit and/or adhesively bond threaded bushings to appropriate ends of tube portions 310 and 360, to insert sealed battery 116 into tube 110 and/or tube portion 310, to print one or more labels for application to tube 1 10 and/or tube portion 360, to provide a lens cap and press fit and/or adhesively couple the lens cap to tube 1 10 and/or tube portion 310, and/or to provide any of the elements of an electronic smoking device, as described herein. Such pre-assembly stations may be configured to provide pre-assembled tubes to tube hopper 612.

[0074] Fig. 9 illustrates a flow diagram of process 900 to assemble an electronic smoking device in accordance with an embodiment of the disclosure. In some embodiments, the operations of Fig. 9 may be implemented as software instructions executed by one or more logic devices associated with corresponding electronic devices, sensors, and/or structures depicted in Fig. 6. More generally, the operations of Fig. 9 may be

implemented with any combination of software instructions and/or electronic hardware (e.g., inductors, capacitors, amplifiers, actuators, assembly lines, or other analog and/or digital components).

[0075] It should be appreciated that any step, sub-step, sub-process, or block of process 900 may be performed in an order or arrangement different from the embodiment illustrated by Fig. 9. For example, in other embodiments, one or more blocks may be omitted, and other blocks may be included. Furthermore, block inputs, block outputs, and/or other operational parameters may be stored to one or more memories (e.g., of system 600) prior to moving to a following portion of process 900. Although process 900 is described with reference to devices 100A, 200A, 300A, and/r 400A, and system 600, process 900 may be performed by other systems different from system 900 and including a different selection of electronic devices, sensors, assemblies, stations, and/or system attributes.

[0076] Process 900 represents a method for assembling an electronic smoking device using system 600 in accordance with embodiments of the disclosure. At the initiation of process 900, various system parameters and/or pre-assembled materials may be populated by prior execution of a process similar to process 900, for example.

[0077] In block 902, an assembly system provides an inhalation tip, a multi-piece flue assembly, and a tube configured to house an active compound. For example controller 608 of system 600 may be configured to control one or more hoppers, stations, and or dial machine 610 to provide inhalation tip 240, multi-piece flue assembly 130. and tube 1 10 to an assembly station (e.g., other stations 690) and/or other devices of system 1 10.

[0078] In block 904, an assembly system inserts a portion of the multi-piece flue assembly into the tube. For example controller 608 may be configured to control the assembly station that received the various elements in block 902 to insert at least a portion of multi-piece flue assembly 130 into tube 1 10. For example, an assembly station similar to tip assembly station 630 may be adapted to receive plug 132 and inner flue 134 of multi-piece flue assembly 130 from a corresponding hopper, and tube 110 from dial machine 610, and insert plug 132 and inner flue 134 and/or multi-piece flue assembly 130 into tube 1 10.

[0079] In block 906, an assembly system dispenses a bulk of the active compound into the tube. For example controller 608 may be configured to control filling station 620 to receive partially assembled tube 110 provided in block 904 and dispense a predetermined bulk amount of active compound (e.g., from drum 622) into partially assembled tube 1 10.

[0080] In block 908, an assembly system couples the inhalation tip to the tube to seal the bulk of the active compound within the tube. For example controller 608 may be configured to control tip assembly station 630 to couple inhalation tip 240, provided in block 902, to filled and partially assembled tube 1 10 provided in block 906.

[0081] Embodiments of the present disclosure can thus provide inexpensive, feature- filled, reliable, and accurate sonar systems, data and/or imagery. Such embodiments may be used to provide sonar data to assist in navigation and/or mapping for a mobile structure and/or to assist in the operation of other systems, devices, and/or sensors coupled to the mobile structure.

[0082] One or more processors, logic devices, and other components of the various systems described herein perform specific operations by executing sequences of instructions contained in one or more memories. Logic may be encoded in a computer readable medium, which may refer to any medium that participates in providing instructions to processors for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. In various implementations, non-volatile media includes optical or magnetic disks, volatile media includes dynamic memory, and transmission media includes coaxial cables, copper wire, and fiber optics. In one embodiment, logic may be encoded in non-transitory computer readable medium. In one example, transmission media may take the form of acoustic or light waves, such as those generated during radio wave, optical, and infrared data communications.

[0083] Some common forms of computer readable media includes, for example, floppy disk, flexible disk, hard disk, magnetic tape, any other magnetic medium, CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, RAM, PROM, EEPROM, FLASH-EEPROM, any other memory chip or cartridge, or any other medium from which a computer is adapted to read. [0084] In various embodiments of the present disclosure, execution of instruction sequences to practice the present disclosure may be performed by one or more elements of any of the systems described herein. In various other embodiments of the present disclosure, a plurality of systems coupled to a network (e.g., such as a LAN, WLAN, PTSN, and/or various other wired or wireless networks, including telecommunications, mobile, and cellular phone networks) may perform instruction sequences to practice the present disclosure in coordination with one another.

[0085] Where applicable, various embodiments provided by the present disclosure may be implemented using hardware, software, or combinations of hardware and software. Also, where applicable, the various hardware components and/or software components set forth herein may be combined into composite components comprising software, hardware, and/or both without departing from the spirit of the present disclosure. Where applicable, the various hardware components and/or software components set forth herein may be separated into sub-components comprising software, hardware, or both without departing from the scope of the present disclosure. In addition, where applicable, it is contemplated that software components may be implemented as hardware components and vice-versa.

[0086] Software, in accordance with the present disclosure, such as program code and/or data, may be stored on one or more computer readable mediums. It is also contemplated that software identified herein may be implemented using one or more general purpose or specific purpose computers and/or computer systems, networked and/or otherwise.

Where applicable, the ordering of various steps described herein may be changed, combined into composite steps, and/or separated into sub-steps to provide features described herein.

[0087] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, persons of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.

Claims

WHAT IS CLAIMED IS:

1. A device comprising:

a tube configured to house an active compound;

an inhalation tip coupled to a first end of the tube; and

a multi-piece flue assembly disposed within the tube, wherein the multi-piece flue assembly is configured to seal a bulk of the active compound from a second end of the tube and from exiting the inhalation tip.

2. The device of claim 1, wherein the multi-piece flue assembly comprises: an inner flue comprising a notch configured to support a heating filament;

an outer flue comprising a slot, wherein the outer flue and the slot are configured to mate with the inner flue and the notch to form a flue inlet, and wherein the flue inlet is configured allow the bulk of the active compound to contact the heating filament at a predeter ined rate; and

a plug comprising first and second plug portions and a flexible plug membrane disposed therebetween, wherein the first portion is coupled to the inner flue, and wherein the plug and/or the flexible plug membrane are configured to allow air through the plug and to block the bulk of the active compound from passing through the plug.

3. The device of claim 2, wherein:

the first and second plug portions are configured to support one or more contact pins; and

the one or more contact pins are configured to provide electrical coupling to the heating filament through the plug.

4. The device of claim 1 , wherein the inhalation tip comprises an internal riser coupled to the multi-piece flue assembly, and wherein the internal riser is configured to form a seal with the multi-piece flue assembly to allow a vapor of the active compound through an orifice of the inhalation tip.

5. The device of claim 1 , further comprising a flexible tip membrane bonded to an interior surface of the inhalation tip, wherein the flexible tip membrane is configured to form a seal with the inhalation tip to allow a vapor of the active compound through the inhalation tip and to block the bulk of the active compound from exiting the inhalation tip.

6. The device of claim 1, wherein:

the tube is substantially cylindrical and comprises polycarbonate, polyester terephthalate, acrylic, and/or one or more other flexible tube materials, and;

the inhalation tip comprises silicon, thermoplastic polyurethane, and/or one or more other flexible tip materials; and

the inhalation tip is bonded to the tube using a flexible adhesive.

7. The device of claim 1, further comprising:

a sealed battery disposed within the tube;

a heating filament disposed substantially within the multi-part flue assembly; and an air pressure sensor disposed within the tube and electrically coupled to the sealed battery and the heating filament, at least in part, by a flexible circuit, wherein the air pressure sensor and/or the flexible circuit are configured to detect an inhalation through the inhalation tip and energize the heating filament in response to a detected inhalation.

8. The device of claim 7, further comprising a lens cap disposed opposite the inhalation tip with respect to the tube, wherein the air pressure sensor and/or the flexible circuit are configured to energize a light source adjacent the lens cap in response to the detected inhalation.

9. The device of claim 8, wherein:

the lens cap comprises a raised pattern configured to simulate a burning ember; and

the tube comprises an outer coating and/or label configured to simulate, at least in part, a cigarette, a cigar, and/or a burning ash end.

10. The device of claim 1, wherein:

the tube comprises first and second tube portions coupled to each other using corresponding first and second bushings and/or first and second insulated terminals; the multi -piece flue assembly and/or the bulk of the active compound are disposed substantially within the first tube portion; and

a sealed battery is disposed substantially within the second tube portion and is electrically coupled to a heating filament disposed substantially within the multi-part flue assembly, at least in part, by the first and second bushings and/or the first and second insulated terminals.

1 1. A method comprising:

providing an inhalation tip, a multi-piece flue assembly, and a tube configured to house an active compound;

inserting at least a portion of the multi-piece flue assembly into the tube;

dispensing a bulk of the active compound into an interior of the tube defined, at least in part, by the portion of the multi-piece flue assembly; and

coupling the inhalation tip to the tube and/or the multi-piece flue assembly to seal the bulk of the active compound within the tube.

12. The method of claim 1 1, wherein the multi-piece flue assembly comprises: an inner flue comprising a notch configured to support a heating filament;

an outer flue comprising a slot, wherein the outer flue and the slot are configured to mate with the inner flue and the notch to form a flue inlet, and wherein the flue inlet is configured allow the bulk of the active compound to contact the heating filament at a predetermined rate; and

a plug comprising first and second plug portions and a flexible plug membrane disposed therebetween, wherein the first portion is coupled to the inner flue, the first and second plug portions are configured to support one or more contact pins, and the one or more contact pins are configured to provide electrical coupling to the heating filament through the plug.

13. The method of claim 11, further comprising coupling an internal riser of the inhalation tip to the multi-piece flue assembly, wherein the internal riser is configured to form a seal with the multi-piece flue assembly to allow a vapor of the active compound through an orifice of the inhalation tip.

14. The method of claim 11, further comprising bonding a flexible tip membrane to an interior surface of the inhalation tip, wherein the flexible tip membrane is configured to form a seal with the inhalation tip to allow a vapor of the active compound through the inhalation tip and to block the bulk of the active compound from exiting the inhalation tip.

15. The method of claim 1 1, further comprising:

providing a sealed battery disposed within the tube;

providing a heating filament disposed substantially within the multi-part flue assembly;

providing an air pressure sensor disposed within the tube; and

electrically coupling the air pressure sensor to the sealed battery and the heating filament, at least in part, using a flexible circuit, wherein the air pressure sensor and/or the flexible circuit are configured to detect an inhalation through the inhalation tip and energize the heating filament in response to a detected inhalation.

16. The method of claim 15, further comprising providing a lens cap disposed opposite the inhalation tip with respect to the tube, wherein the air pressure sensor and/or the flexible circuit are configured to energize a light source adjacent the lens cap in response to the detected inhalation.

17. The method of claim 16, further comprising:

providing, to the lens cap, a raised pattern configured to simulate a burning ember; and

providing, to the tube, an outer coating and/or label configured to simulate, at least in part, a cigarette, a cigar, and/or a burning ash end.

18. The method of claim 1 1, wherein:

the tube comprises first and second tube portions coupled to each other using corresponding first and second bushings and/or first and second insulated terminals; the multi-piece flue assembly and/or the bulk of the active compound are disposed substantially within the first tube portion; and

19. A method comprising:

providing a tube, wherein the tube is adapted to house an active compound and comprises polycarbonate, polyester terephthalate, acrylic, and/or one or more other flexible tube materials;

dispensing a predetermined amount of the active compound into the tube;

providing an inhalation tip comprising silicon, thermoplastic polyurethane, and/or one or more other flexible tip materials; and

bonding the inhalation tip to the tube using an ultra-violet (UV) cured flexible adhesive.

20. The method of claim 19, further comprising:

providing a lens cap, wherein the lens cap comprises a raised pattern configured to simulate a burning ember;

coupling the lens cap to the tube; and

applying an outer coating and/or label to the tube, wherein the coating and/or labeling is configured to simulate, at least in part, a cigarette, a cigar, and/or a burning ash end.