It also seems to me that using extra dry -dry to the gland- material in a small or reasonable quantity will maintain that particle size to a minimum. Notice how harsh it gets when you have over-packed or when you're pulling with all your lungs on a not so dry load to finish it.
The harshness in overpacked or damp loads results from the intense hot-spotting that occurs under such conditions (either from the uneven flow when overpacked or the localised cooling occuring in still-wet areas as higher-flow zones dry out). Pyrolysis (an exothermic process of chemical degradation which differs from full combustion in that oxygen is not consumed) occurs at these hot spots, and being exothermic, can lead to localised thermal runaway, and thus tiny points of plant material (or, more likely, the graphitic matrix left by local pyrolysis) can be raised very close to, or even over, combustion point. Under these conditions and a hard pull (and thus a lot of negative pressure) these spots will actually start to liberate tiny
smoke particles, which are the source of the harshness. Such a session, even through water, can give you a dry cough for days even if you're a regular vaper.
Oh yeah, this is also how cherries can form in vape bowls even when the hot air stream itself never actually reaches combustion temps. The oxidation that is producing smoke particles is also an exothermic process (but much more so), so the tiny pieces of plant substrate giving up smoke particles can actually heat up to higher temperatures than the air passing over them. If this continues long enough, enough extra energy will have been dumped into the local environment to bring that tiny hot spot up to ignition point, at which point the superheated, pyrolysed, ragged shreds of plant cellulose sitting in a super hot, continually refreshed oxygen supply are only too eager to burst into cherry and start spreading into the cooler areas of the bowl. :c
Cotton in the vapor path seems to smooth the hits out for me. I'd like to think the smaller particles can flow freely through the cotton while the bigger particles stick to the cotton. I'd also like to think I know what I'm actually talking about... but I'm pretty high right now.
Yeah, this works really well. A properly set up cotton (or hemp, but cotton is just as good) filter will catch all the larger particles, some of the smaller ones, and all the the particulate, while having neglible effect on draw resistance. Plus you can take out the filter and vape it when it gets saturated enough to noticably affect flow (which can take months), and that shit is going to give you the biggest clouds you've ever seen, in that the resulting sodden cotton is basically a perfect substrate for holding oil with maximal surface area (and thus rapid vaping potential), but at this point contains
many times more oil than the same volume of even the best herb you ever had.
There will be some "sticking" as you say, but it's mainly rejecting larger particles mechanically, that is by packing the fibres tight enough that there's no complete paths through the wad that have minimal openings large enough to allow the larger particles to pass, so they are trapped and the smaller ones pulled through by gas flow. Essentially you want to pack the wad as tight as you can without noticing any significant draw resistance, and it'll do the rest for the next several months.
Another thing cotton will do is stop that the ugly brown hydrated-oil gunge patterns that form up the walls of a piece, often after just a few good hits. The walls will still collect resin, but
much more slowly, and in a more even "haze" pattern without any water droplet patterns. Seriously, they can look "clean" for tens upon tens of good hits. Most of the shit that was getting stuck on the walls is now stuck in the filter instead.
One final note: Once you have a few loads through it the filter will become quite sticky to the touch. Do not touch or mess with it unless you really have to at this point, because squashing or compressing it even slightly will close up pathways through the filter, and now that the fibres are sticky they will
stay closed, increasing draw resistance noticably. If you nudge a sticky filter accidentally you might find draw difficulty increases enough that you'll need to replace it, and ideally you don't want to replace it until it becomes sodden on its own as that shit is just mind-erasingly good when you finally get to enjoy it. If you don't interfere with the filter the resin will hold all the fibres in place just fine, and it will last a surprisingly long time.
It makes me wonder if it has to do w/ Brutish extraction temps that make large particles out of any cannabinoids??
Particle size is determined by the conditions under which condensation occurs, not the conditions under which the original evapouration occured. A slower cool will result in smaller, more evenly-sized, more spherical particles, while flash condensation (such as in expansion chambers) produces a broad mix of sizes and shapes.
Also, resin is much stickier the warmer it is, so collects more readily on surfaces while the vapour/air stream is hot (or the surfaces are hot, but still below the evapouration point of oil). This why the Sub atomiser is more effective when warm. There are a bunch of reasons why it's more likely to pick up larger particles than smaller ones, but this post is turning into too much of a science lesson as is.