EP4338619A1 - Consumable cartridge for an aerosol generation device - Google Patents
Consumable cartridge for an aerosol generation device Download PDFInfo
- Publication number
- EP4338619A1 EP4338619A1 EP22195653.5A EP22195653A EP4338619A1 EP 4338619 A1 EP4338619 A1 EP 4338619A1 EP 22195653 A EP22195653 A EP 22195653A EP 4338619 A1 EP4338619 A1 EP 4338619A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- aluminium
- wick
- nozzle
- consumable cartridge
- end cover
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000443 aerosol Substances 0.000 title claims abstract description 82
- 239000004411 aluminium Substances 0.000 claims abstract description 96
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 96
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 96
- 239000007788 liquid Substances 0.000 claims abstract description 77
- 238000004519 manufacturing process Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 12
- 238000009833 condensation Methods 0.000 claims description 6
- 230000005494 condensation Effects 0.000 claims description 6
- 238000004080 punching Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 description 12
- 238000010438 heat treatment Methods 0.000 description 8
- 239000012528 membrane Substances 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 5
- 239000006260 foam Substances 0.000 description 5
- 230000009102 absorption Effects 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 239000000565 sealant Substances 0.000 description 4
- 238000009826 distribution Methods 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 238000012387 aerosolization Methods 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000003571 electronic cigarette Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 208000025371 Taste disease Diseases 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000037237 body shape Effects 0.000 description 1
- 238000010273 cold forging Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 239000008263 liquid aerosol Substances 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 235000019656 metallic taste Nutrition 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 239000010847 non-recyclable waste Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920005597 polymer membrane Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000009103 reabsorption Effects 0.000 description 1
- 239000004590 silicone sealant Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
- A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
- A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
- A24F40/42—Cartridges or containers for inhalable precursors
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
- A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
- A24F40/10—Devices using liquid inhalable precursors
Definitions
- the present invention relates to a consumable cartridge for an aerosol generation device and a method of manufacture thereof.
- the disclosure is particularly applicable to a portable aerosol generation device.
- Consumable cartridges also known as pods, are used in aerosol generation devices such as electronic cigarettes and vaping devices to provide an aerosol generating medium or liquid that is heated to generate an aerosol or vapour for inhalation by a user.
- An object of the invention is to improve the manufacturability and recyclability of consumable cartridges for aerosol generating devices.
- a consumable cartridge for an aerosol generation device comprising: an aluminium body having a nozzle arranged along a longitudinal axis inside of the aluminium body, the nozzle configured to deliver generated aerosol to a user; a liquid reservoir comprising an aerosol generating liquid, the liquid reservoir positioned radially outwardly with respect to the nozzle within the aluminium body; a wick assembly comprising a wick and an opening, the wick configured to draw the aerosol generating liquid from the liquid reservoir through the opening; and an aluminium end cover connected to the aluminium body so as to encase the liquid reservoir and the wick assembly.
- the use of aluminium in consumable cartridges can be increased, which consequently allows for improved recyclability and reduces the impact on the environment.
- many of the parts in known cartridges typically use plastic materials which are easily formed to shape but can be more difficult to recycle or reuse.
- the outer casing of the present cartridges (that is the body and the end cover) is made of aluminium and would readily prompt a consumer to recycle a spent cartridge after use.
- the aluminium body may be cup-shaped.
- the wick may be a porous ceramic wick which is configured to store the aerosol generating liquid within the wick until the aerosol generating liquid is heated to a temperature that causes it to aerosolize, i.e. generate an aerosol.
- the porosity of the wick may be defined with respect to the viscosity of the aerosol generating liquid.
- the wick assembly comprises a seal arranged between the wick assembly and the liquid reservoir.
- the seal prevents the aerosol generating liquid from leaking out of the reservoir outside of the opening of the wicking assembly.
- the seal ensures that aerosol generating liquid only passes from the reservoir to the wick through the opening in the wick assembly.
- the wick assembly comprises an airflow path from outside of the consumable cartridge to the nozzle.
- air is directed to flow through the wick assembly and to carry generated aerosol from the wick to the nozzle, where the generated aerosol can be inhaled by the user.
- the airflow path may comprise an airflow channel that is formed in the wick assembly.
- the airflow path may comprise an inlet hole for outside air to reach the wick and an outlet hole for the air to continue flowing from the wick to the nozzle.
- the airflow path may be T-shaped, where two air channels in the wick assembly direct air in a horizontal direction from outside the consumable cartridge to the wick in a central area in the wick assembly, and where the air along with aerosol generated in the wick is directed in a vertical direction up the nozzle in the aluminium body.
- the wick assembly may comprise more than two air channels.
- the consumable cartridge comprises one or more air inlet holes in the aluminium body and/or the aluminium end cover.
- the air inlet holes allow air from outside the consumable cartridge to be drawn into the cartridge and the wick assembly.
- the air inlet holes may be provided in the aluminium body or the aluminium end cover, or both, according to design requirements.
- the wick assembly comprises one or more liquid traps along the airflow path.
- any undesirable moisture or condensation that forms in the airflow path which can obstruct or impede airflow, can be directed or drawn out of the airflow path.
- the moisture may due to the humidity of the outside air or from the aerosol generating liquid in the wick.
- the liquid trap may comprise one or more side channels in the airflow path that draw away any moisture in the airflow path by capillary action.
- the side channel(s) may lead the moisture to a foam or sponge material that absorbs and retains the moisture.
- the wick assembly further comprises a condensation trap arranged between the wick and the nozzle.
- a condensation trap arranged between the wick and the nozzle.
- the wick assembly further comprises a thermal interface layer arranged between the wick and one or more holes in the aluminium end cover.
- a thermal interface layer arranged between the wick and one or more holes in the aluminium end cover.
- the one or more holes in the aluminium end cover ensure that the heat from the heater is not conducted across the aluminium material away from the wick.
- a thermally insulating seal may be provided between the thermal interface layer and the aluminium end cover to minimise any undesirable thermal conduction into the end cover.
- the thermal interface layer may comprise a thermal interface material or membrane comprising stainless steel, titanium foil, or polyetheretherketone (PEEK).
- PEEK polyetheretherketone
- the thermal interface layer may have a thickness of 15 to 25 microns.
- the wick assembly is arranged radially inwardly with respect to the aluminium end cover.
- the aluminium end cover may be cup-shaped to hold the wick assembly within.
- the aluminium end cover may be punched and deep drawn to shape.
- the aluminium end cover may be pressured, or cold-forged depending on the speed and cost of the operation and manufacturer capability.
- a nozzle may be punched or otherwise formed in the aluminium end cover and cupshape of the outer wall may be drawn or otherwise shaped around the nozzle.
- the opening of the nozzle in the end cover may be plugged to prevent airflow through the opening, according to airflow design requirements of the cartridge.
- the nozzle and opening in the end cover may be used as the socket connection that is plugged by a plug provided in the aerosol generation device such that the plug-socket connection fixes or attaches the consumable cartridge to the device.
- wick assembly Holding the wick assembly in a cup-shaped aluminium end cover allows the outer wall of the aluminium end cover to provide a structural support to the wick assembly.
- the cup shape of the aluminium end cover and wick assembly provided within also ensures that the aerosol generating liquid in the cartridge is effectively used since the wick can be arranged at the lowest point of the cartridge.
- one or more holes may be drilled or otherwise provided in a bottom surface of the cartridge (adjacent to the heater or heater element of the aerosol generation device), such that the thermal interface layer acts as the interfacing layer between wick assembly and a heater.
- the wick comprises one or more air channels.
- the air channels may be provided toward the lower end of the wick, adjacent to the thermal interface layer.
- the air channels allow improved airflow through the wick, which in turn improves the distribution of heat and vaporisation of the aerosol generating liquid into generated aerosol.
- the air channels may also allow enhanced delivery to the nozzle of the cartridge for inhalation by the user, and thus minimise condensation of generated aerosol. As such, the air channels can ensure optimal vape generation and prevent vape accumulation below the wick.
- a cross-sectional area of the nozzle increases along the longitudinal axis in a direction to the user.
- the shape of the nozzle is configured to deliver an optimum airflow and draw resistance for a user.
- the vape of air and generated aerosol is thus delivered to the user as a homogeneous, laminar vape outflow.
- the airflow path widens across its cross-sectional profile which slows down the flow of air and generated aerosol in the nozzle, thereby cooling the vape before inhalation.
- the aluminium body or aluminium end cover is shaped to fasten into the aerosol generation device by a push-fit mechanism.
- the consumable cartridge can be readily attached to the aerosol generation device.
- the aluminium body and/or aluminium end cover may also comprise punched notches, or hard stops, to allow a press-fit or push-fit connection of the wick assembly into the body and/or end cover. This advantageously allows the assembly of the cartridge to be faster and more efficient.
- the aluminium end cover is connected to the aluminium body by a seamed edge connection.
- a seamed-edge connection can also advantageously speed up the manufacturing process of a consumable cartridge.
- the connection may further comprise sealant, such as silicone, on the respective seamed edges of the end cover and body.
- the aluminium end cover may be connected to the aluminium body by a press-fit connection. Sealant may also be used to ensure a leak-proof connection.
- an inner surface of the aluminium body is coated.
- the surface of the liquid reservoir in contact with the aerosol generating liquid is coated, which prevents any metallic contamination of the aerosol generating liquid (which may cause an undesirable metallic taste to the vape).
- a ceramic or polymer coating may be applied to the inner surface of the aluminium body, preferably after the body is formed in the aluminium, and before filling the reservoir or further assembly of the cartridge.
- the coating may be a Teflon coating.
- the inner surface of the aluminium end cover may also be coated.
- each of the aluminium body and the aluminium end cover is made of a single piece of aluminium.
- the consumable cartridge can be efficiently manufactured and assembled.
- the use of two single pieces of aluminium to form a cartridge can effectively reduce or eliminate any joints that may potentially be a source of liquid leakage.
- a method of manufacturing a consumable cartridge comprising the steps of: providing a first aluminium disc; punching through the first aluminium disc to form a nozzle; drawing the first aluminium disc around the nozzle to form a body around the nozzle, defining a liquid reservoir around the nozzle in the body; filling the liquid reservoir with an aerosol generating liquid; enclosing the liquid reservoir with a wick assembly comprising a wick and an opening; and connecting a second aluminium disc to the body of the first aluminium disc so as to encase the liquid reservoir and the wick assembly.
- a punch tool may be used to form the nozzle in an aluminium disc and another punch tool may be used to form the outer body shape.
- the nozzle may be punched several times or drawn to extend the length of the nozzle such that the outer surface of the nozzle and the inner surface of the body together form the liquid reservoir.
- the aluminium consumable cartridge of the present disclosure considers a production amount that would be envisaged for consumable cartridges for electronic cigarettes (a mass production of more than 10 million pieces per year), and realises that standard milling processes (such as CNC, machining or turning) cannot be realistically applied due to the high costs and long production time of such processes.
- the manufacturing method of the present invention therefore uses deep-drawing techniques for aluminium on all outer surfaces. It should be appreciated that, due to the manufacturing limitations of the deep drawing process, it may be possible that relatively large draft angles would need to be applied on the vertical faces. Cold forging or pressing may also be considered as alternative manufacturing methods.
- vapour is generally understood to refer to a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas.
- aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas.
- FIGS 1A and 1B illustrate outer views of a consumable cartridge 2 or pod according to a first embodiment of the invention.
- the consumable cartridge 2 has an aluminium outer shell which is made of an upper body 4, which is cup-shaped, and a lower end cover 6.
- the upper body 4 has an air outlet 8 from which generated aerosol can be delivered and inhaled by a user.
- the air outlet 8 is the open end of a nozzle provided inside of the upper cup-shaped body 4.
- the end cover 6 has a hole 10, which may be drilled, water jet cut or otherwise formed in the end cover 6, which reveals a thermal interface layer inside of the pod 2 against which a heating element 12 of an aerosol generation device (not shown) can press against and heat.
- the thermal interface layer is part of a wick assembly in the consumable cartridge 2 in which a wick holding an aerosol generating liquid, or e-liquid, is arranged.
- the consumable cartridge 2 also has air inlet holes 14 that are drilled into the side of the upper body 4, and notches 16 in the body 4 that are used as hard stops for the wick assembly during the manufacturing process of the pod.
- Figure 2 shows a cross-sectional view of the consumable cartridge 2 having the upper cup-shaped body part 4 and the lower end cover part 6.
- the upper body 4 is formed from a single piece of aluminium that is shaped to form a central nozzle 20 and an outer shell 22, and the upper body 4 has a seamed edge that is interconnected with a respective seamed edge of the end cover 6 to form a seamed-edge connection 24.
- the wall of the central nozzle 20 is tapered such that the cross-sectional profile of the nozzle 20 increases from an aerosolreceiving end 26 of the nozzle 20 to the air outlet 8 (i.e. the open end of the nozzle).
- the consumable cartridge 2 includes a wick assembly 28 arranged inside the upper body 4 and end cover 6.
- the outer surface of the central nozzle 20, the inner surface of the outer shell 22 (which may be a coated surface) and the top surface of the wick assembly 28 together form a liquid reservoir 30 in which an aerosol generating liquid can be stored inside the consumable cartridge 2.
- the reservoir 30 is able to accommodate up to 2 millilitres (ml) of liquid.
- the wick assembly 28 is a support structure that may be made of two plastic parts for ease of construction, and contains within a chamber 32 of the assembly and a porous ceramic wick 34 that draws the aerosol generating liquid out of the liquid reservoir 30 through at least one opening (not shown) in the wick assembly 28. It should be appreciated that, when constructed, the aerosol generating liquid can only flow out of the liquid reservoir 30 through the opening in the wick assembly 28 into the wick 34.
- the wick assembly 28 further includes air channels 36 which are aligned with the air inlet holes 14 in the upper body 4 to provide airflow paths from outside of the consumable cartridge 2 to the wick 34 in the chamber 32 of the wick assembly 28.
- the airflow paths along the air channels 36 direct air in a horizontal direction, and combine in the chamber 32 such that air is further directed up the central nozzle 20 in a single airflow path having a vertical direction.
- the combined airflow path through the air channels 36 and the central nozzle 20 is thus T-shaped.
- the air channels 36 each further comprise a side channel 38 that acts as a leakage path for any moisture that may collect or condense within a respective air channel 36.
- the side channels 38 can draw the moisture away from airflow path of the air channels 36 into an absorption foam 40 provided beneath the wick assembly 28, between the wick assembly 28 and the end cover 6.
- the absorption foam 40 can be arranged as part of the wick assembly 28, as will be obvious to the skilled person.
- the chamber 32 of the wick assembly 28 is arranged over the hole 10 in the end cover 6, and the wick assembly 28 includes a layer of thermal interface material 42 that covers the hole 10.
- the outer surface of the thermal interface material 42 is in contact with a heating element of an aerosol generation device in use and transmits heat from the heating element to the wick 34 that sits on the inner surface of the thermal interface material 42 in the chamber 32.
- a thermally insulating seal 44 is provided at the edge of the thermal interface material layer 42 such that the insulation seal 44 prevents heat from being conducted into the aluminium end cover 6 or the rest of the wick assembly 28.
- the thermal insulation seal 44 ensures that heat received from the heating element / heater is optimally transmitted through the thermal interface layer 42 to the wick 34, and heat loss to the surrounding material (of the end cover 6 or the wick assembly 28) is minimised.
- the wick assembly 28 is attached to the receiving end 26 of the nozzle 20 such that aerosol generated from the liquid in the wick 34 (on heating) can travel up through to nozzle 20 to a user.
- the wick assembly 28 includes a seal 46 provided at the attachment between the assembly 28 and the nozzle 20 to prevent any leakage from the liquid reservoir 30 into the chamber 32 or nozzle 20.
- the seal 46 may be made of silicone or another suitable material in the art, such as rubber.
- the wick assembly 28 further includes a core seal 48 or a chamber seal which is used to hold the wick 34 in place inside the chamber 32.
- the core seal 48 is heat resistant to prevent any deformation or heat transmission from the wick 34 to the remainder of the wick assembly 28.
- the core seal 48 is shaped to include a condensation trap 50 such that any aerosol that did not travel up the nozzle 20 or was not inhaled by the user is able to condense into droplets in the condensation trap 50 and return to the wick 34 for absorption and be re-heated for aerosolization.
- the core seal 48 may also be made of silicone.
- FIGs 3A and 3B show additional views of a constructed and exploded wick assembly 28.
- the air channels 36 are moulded into the plastic material of the wick assembly 28 between an air inlet of the wick assembly (which is aligned with a corresponding air inlet hole 14 of the upper body 4) and the central chamber 32.
- the top surface of the wick assembly 28 is used to enclose the liquid reservoir 30 between the nozzle 20 and the inner surface of the outer shell of the upper body 4, and aerosol generating liquid in the liquid reservoir 30 can enter the chamber 32 through the opening 52 in the wick assembly 28.
- the top channel 54 of the wick assembly 28 attaches to the receiving end 26 of the nozzle 20 and the seal 46 arranged around the inner surface of the top channel 54 interfaces with the outer surface of the receiving end 26 of the nozzle 20 to prevent any leakage.
- FIG. 3B The exploded view of the wick assembly 28 in Figure 3B shows how the wick assembly may be constructed.
- Figure 3B further illustrates the core seal 48 that fixes the position of the wick 34 inside the chamber 32 of the wick assembly 28 on top of the thermal interface layer 42.
- the outer edge of the thermal interface layer 42 is encased in a thermal insulation seal 44 to control the direction of heat transmission from the heater to the wick 34.
- the absorption foam layer 40 is provided below the main body of the wick assembly 28 such that the side channels 38 can direct any moisture in the air channels 36 to the foam layer 40.
- Figure 4 shows the wick 34 of the first embodiment of the invention, where the wick 34 includes a number of air channels 56 at the lower surface of the wick 34 where the wick 34 interfaces with the thermal interface layer 42.
- the air channels 56 in the wick allow air from the air channels 36 of the wick assembly 28 to readily flow into the wick 34 for improved aerosol delivery.
- the reduced surface area of the wick 34 against the thermal interface layer 42 effectively reduces the volume of the wick 34 (and aerosol generating liquid stored within) nearer the heater, which in turn reduces the heat-up time of the wick 34 and the generation of aerosol.
- Figure 5 illustrates a cross-sectional view of the consumable cartridge 2 without the wick assembly 28, and only shows the upper body 4 connected to the end cover 6.
- the upper body 4 has notches 16, which may be formed by a punching process, below the receiving end 26 of the nozzle 20.
- the notches 16 act as a stop or a push-fit mechanism for the main body of the wick assembly 28 during construction.
- the outer wall of the wick assembly 28 may be configured accordingly to match the shape of the notches 16.
- the seamed edge connection 24 between the upper body 4 and the end cover 6 is filled with a sealant to further enhance the leak-proof quality of the connection 24.
- FIGS 6A and 6B illustrate outer view of another consumable cartridge 102 or pod according to a second embodiment of the invention.
- the consumable cartridge has an aluminium outer shell that includes an upper body 104 and a lower end cover 106 or end part.
- the upper body 104 and the end cover 106 are both cup-shaped.
- the upper body 104 has an air outlet 108, which is the opening at the end of a nozzle provided inside of the upper body 104.
- the end cover 106 has two holes 110 cut out in its bottom surface, which reveal a thermal interface layer in the consumable cartridge 102.
- the thermal interface layer is configured to come into contact with a heater 112 of an aerosol generation device and conduct heat into the consumable cartridge 102.
- the thermal interface layer is part of a wick assembly in the consumable cartridge 102 in which a wick storing an aerosol generating liquid is provided.
- connection joint 114 may be filled with a sealant to ensure a leak-proof connection.
- Figure 6C shows a cross-sectional view of a first example, where the connection joint 114 is a seamed edge connection 114A, where the respective edges of both the upper body 104 and the end cover 106 are seamed.
- Figure 6D show a cross-sectional view of a second example, where the respective edges and the aluminium metal toward the edges of the upper body 104 and the end cover 106 are pressed or otherwise shaped respectively to provide a press-fit connection 114B between the upper body 104 and end cover 106.
- the consumable cartridge 102 also has air inlet holes 116 that are drilled or formed in the side of the end cover 106.
- the size of the air inlet holes 116 define a draw resistance of the cartridge 102.
- Figure 7 shows a cross-sectional view of the aluminium outer shell.
- the upper body 104 has a central nozzle 118 and an outer wall 120 formed radially around the outer surface of the central nozzle 118.
- the central nozzle 118 has an aerosol receiving end 122 and an opening which is the air outlet 108 of the cartridge 102.
- the wall of the central nozzle 118 is tapered, where the cross-sectional area of the nozzle 118 increases from the receiving end 122 to the air outlet 108.
- the outer wall 120 has a thickness of around 0.2 millimetres.
- the upper body 104 is made from a single piece or disc of aluminium that is punched and drawn in a multistage process, as will be described further below.
- the receiving end 122 of the central nozzle 118 and the edge of the outer wall 120 is shaped to a press-fit edge 124 for connection with the end cover 106.
- the end cover 106 also has a nozzle 126, which may be plugged and/or used for another purpose such as a push-fit or alignment connection with an aerosol generation device.
- the end cover 106 has an outer wall 128 radially around the nozzle 126, and the air inlet holes 116 described above are drilled into the end cover outer wall 128.
- the end cover nozzle 126 is also tapered such that the cross-sectional area of the nozzle 126 decreases from the bottom surface of the end cover 106 to the top end 130 of the end cover nozzle 126, which connects to the receiving end 122 of the central nozzle 118 of the upper body 104.
- the smaller cross-sectional area where the central nozzle 118 connects with the end cover nozzle 126 allows for a higher speed of delivery of aerosol into the central nozzle 118, and the widening cross-sectional area of the central nozzle 118 retards the speed of delivery of aerosol as it travels through the central nozzle 118 to a user, which allows the aerosol to cool.
- the end cover 106 in the second embodiment is also made from a single piece or disc of aluminium that is punched and drawn in a multistage process.
- the top end 130 of the end cover nozzle 126 and the edge of the outer wall 128 is shaped to a press-fit edge 132 for connection with the upper body 104.
- Aerosol delivery holes 134 are provided in the end cover nozzle 126 so as to provide an airflow path from the air inlet holes 116 to the aerosol delivery holes 134. It should therefore be understood that, in use, outside air enters the cartridge 102 through the air inlet holes 116, picks up generated aerosol as it passes through the wick, and the air and aerosol is delivered through the aerosol delivery holes 134 to the receiving end 122 of the central nozzle 118 of the upper body 104 for further delivery to the air outlet 108 and user inhalation.
- the bottom surface of the end cover 106 has holes 110 that are cut out in a shape to correspond with the interfacing heater of an aerosol generation device. This is to allow the heater or heating element to pass through the bottom surface of the end cover 106 and press against the thermal interface layer of the wick assembly of the cartridge 102.
- Figures 8 and 9 shows a cross-sectional views of the consumable cartridge 102 having the upper body 104 and the lower end cover 106 connected using a push-fit or press-fit connection.
- the press-fit edge 124 of the upper body 104 interlocks with the press-fit edge 132 of the end cover 106, and the top end 130 of the end cover nozzle 126 is pushed into and fitted within the receiving end 122 of the upper body central nozzle 118.
- the receiving end 122 of the central nozzle 118 also flares outwardly, which along with the press-fit edge 124 of the upper body 104 act as a stop for a wick assembly 136 of the consumable cartridge 102.
- the wick assembly 136 is positioned in the end cover 106 in the space radially around the end cover nozzle 126, between the outer surface of the end cover nozzle 126 and the inner surface of the outer wall 128 of the end cover 106.
- the outer surface of the central nozzle 118, the inner surface of the outer wall 120 of the upper body 104 and the top surface of the wick assembly 136 together form a liquid reservoir 138 in which an aerosol generating liquid can be stored inside the consumable cartridge 102.
- the internal surfaces of the upper body 104 and end cover 106 are coated with a ceramic or polymer coating.
- the wick assembly 136 includes a porous ceramic wick 140 that is surrounded by an upper seal cap 142 over its top surface, a membrane 144 around its side walls and a thermal interface layer 146 on its lower surface.
- the upper seal cap 142 is made of silicone and has openings 148 to allow aerosol generating liquid to flow out of the liquid reservoir 138 into the wick 140. It should be appreciated that, when constructed, the aerosol generating liquid can only flow out of the liquid reservoir 138 through the openings 148 in the upper seal cap 142 into the wick 140.
- the upper seal cap 142 extends over the top surface of the wick 140 to the upper end of the sides of the wick 140 (which include the surfaces of the wick 140 adjacent to both the end cover outer wall 128 and the end cover nozzle 126) to ensure any leakage of aerosol generating liquid away from the openings 148 is prevented.
- the interfacing surfaces of the upper seal cap 142 and the wick 140 along the sides of the wick 140 are ridged respectively to provide a secure fit of the upper seal cap 142 over the wick 140.
- the membrane 144 of the wick assembly 136 provided around the side surfaces of the wick 140 is a polymer membrane such as polytetrafluoroethylene (Teflon).
- the membrane 144 is air-permeable, and optionally may further include additional holes to improve the distribution air through the wick 140.
- the wick 140 and the membrane 144 is also shaped to allow a gap between the membrane and the outer wall 128 of the end cover 106 and/or the end cover nozzle 126 for improved airflow through the wick 140.
- the thermal interface layer 146 is an impermeable layer that covers the bottom surface of the wick 140 to prevent liquid from leaking out of the wick 140 through the holes 110 in the end cover 106.
- the thermal interface layer 146 extends across the bottom surface of the wick 140 to the lower end of the sides of the wick 140 (which include the surfaces of the wick 140 adjacent to both the end cover outer wall 128 and the end cover nozzle 126) to prevent leakage.
- the outer surface (i.e. the lower surface) of the thermal interface layer 146 is in contact with a heating element of an aerosol generation device in use and transmits heat from the heating element to the wick 140 that sits on the inner surface of the thermal interface layer 146 in the wick assembly 136.
- a thermally insulating seal (not shown), such as a silicone sealant, is used to glue the thermal interface layer 146 to the bottom surface of the end cover 106, which prevents or minimises heat from being conducted into the aluminium end cover 106.
- the wick 140 may include a number of air channels (not shown) at the lower surface of the wick 140 where the wick 140 interfaces with the thermal interface layer 146 to improve air and heat distribution through the wick 140.
- a plug 150 is optionally provided to block the opening of the end cover nozzle 126 at its bottom surface, or alternatively the plug 150 may be part of the aerosol generation device in which the consumable cartridge 102 is inserted.
- Figure 10 illustrates in schematic form a process 200 to form an aluminium body, such as the upper bodies 4, 104 of the consumable cartridges of the first and second embodiments and the end cover 106 of the second embodiment.
- an aluminium disc 250 is cut out from a sheet roll of aluminium metal.
- the size of the disc 250 is equal to the surface area of the upper part of a consumable cartridge 2, 102.
- the disc 250 may be cut out from the roll of aluminium using a stamp process.
- a punch tool 252 is used to strike the centre of the disc 250 to form a nozzle 254 in the disc 250.
- Multiple punches may be required to draw the nozzle 254 to a desired length shown at step 206.
- Lubrication such as oil or grease, may be applied to prevent any tearing of the disc 250.
- several punch tools of decreasing diameter may be used as the nozzle 254 is drawn out of the disc 250. It will be understood that the disc 250 is placed on a suitable holder during step 204 to prevent the material around the nozzle 254 from deforming during the punching process.
- a different punch tool 256 having a socket-style or tube-shaped form is used to form the outer wall 258 of the body.
- multiple punches may be required to draw the disc 250 around the nozzle 254 to a desired length, and multiple punch tools of different internal diameters may be used, as shown at step 210, to draw out the outer wall 258 and ensure a smooth outer profile.
- the outer wall 258 is drawn to a length greater than the length of the nozzle 254 to form the body.
Landscapes
- Containers And Packaging Bodies Having A Special Means To Remove Contents (AREA)
Abstract
A consumable cartridge (2, 102) for an aerosol generation device is disclosed, comprising: an aluminium body (4, 104) having a nozzle (8, 108) arranged along a longitudinal axis inside of the aluminium body, the nozzle configured to deliver generated aerosol to a user; a liquid reservoir (30, 138) comprising an aerosol generating liquid, the liquid reservoir positioned radially outwardly with respect to the nozzle within the aluminium body; a wick assembly (28, 136) comprising a wick (34, 140) and an opening (52, 148), the wick configured to draw the aerosol generating liquid from the liquid reservoir through the opening; and an aluminium end cover (6, 106) connected to the aluminium body so as to encase the liquid reservoir and the wick assembly.
Description
- The present invention relates to a consumable cartridge for an aerosol generation device and a method of manufacture thereof. The disclosure is particularly applicable to a portable aerosol generation device.
- Consumable cartridges, also known as pods, are used in aerosol generation devices such as electronic cigarettes and vaping devices to provide an aerosol generating medium or liquid that is heated to generate an aerosol or vapour for inhalation by a user.
- After a period of use, the consumable cartridge becomes depleted and is removed and discarded by the user. It has been found that consumable cartridges in the art are difficult to recycle or reuse, and are often thrown away as non-recyclable waste.
- An object of the invention is to improve the manufacturability and recyclability of consumable cartridges for aerosol generating devices.
- According to an aspect of the invention, there is provided a consumable cartridge for an aerosol generation device, comprising: an aluminium body having a nozzle arranged along a longitudinal axis inside of the aluminium body, the nozzle configured to deliver generated aerosol to a user; a liquid reservoir comprising an aerosol generating liquid, the liquid reservoir positioned radially outwardly with respect to the nozzle within the aluminium body; a wick assembly comprising a wick and an opening, the wick configured to draw the aerosol generating liquid from the liquid reservoir through the opening; and an aluminium end cover connected to the aluminium body so as to encase the liquid reservoir and the wick assembly.
- In this way the use of aluminium in consumable cartridges can be increased, which consequently allows for improved recyclability and reduces the impact on the environment. Due to the complexity of designs and the relatively small sizes of consumable cartridges, many of the parts in known cartridges typically use plastic materials which are easily formed to shape but can be more difficult to recycle or reuse. Advantageously, the outer casing of the present cartridges (that is the body and the end cover) is made of aluminium and would readily prompt a consumer to recycle a spent cartridge after use. The aluminium body may be cup-shaped.
- The wick may be a porous ceramic wick which is configured to store the aerosol generating liquid within the wick until the aerosol generating liquid is heated to a temperature that causes it to aerosolize, i.e. generate an aerosol. As will be understood, the porosity of the wick may be defined with respect to the viscosity of the aerosol generating liquid.
- Preferably, the wick assembly comprises a seal arranged between the wick assembly and the liquid reservoir. In this way, the seal prevents the aerosol generating liquid from leaking out of the reservoir outside of the opening of the wicking assembly. In other words the seal ensures that aerosol generating liquid only passes from the reservoir to the wick through the opening in the wick assembly.
- Preferably, the wick assembly comprises an airflow path from outside of the consumable cartridge to the nozzle. In this way, air is directed to flow through the wick assembly and to carry generated aerosol from the wick to the nozzle, where the generated aerosol can be inhaled by the user. The airflow path may comprise an airflow channel that is formed in the wick assembly. Alternatively the airflow path may comprise an inlet hole for outside air to reach the wick and an outlet hole for the air to continue flowing from the wick to the nozzle.
- The airflow path may be T-shaped, where two air channels in the wick assembly direct air in a horizontal direction from outside the consumable cartridge to the wick in a central area in the wick assembly, and where the air along with aerosol generated in the wick is directed in a vertical direction up the nozzle in the aluminium body. As will be apparent to the skilled person, the wick assembly may comprise more than two air channels.
- Preferably, the consumable cartridge comprises one or more air inlet holes in the aluminium body and/or the aluminium end cover. The air inlet holes allow air from outside the consumable cartridge to be drawn into the cartridge and the wick assembly. The air inlet holes may be provided in the aluminium body or the aluminium end cover, or both, according to design requirements.
- Preferably, the wick assembly comprises one or more liquid traps along the airflow path. In this way, any undesirable moisture or condensation that forms in the airflow path, which can obstruct or impede airflow, can be directed or drawn out of the airflow path. The moisture may due to the humidity of the outside air or from the aerosol generating liquid in the wick. As an example, the liquid trap may comprise one or more side channels in the airflow path that draw away any moisture in the airflow path by capillary action. The side channel(s) may lead the moisture to a foam or sponge material that absorbs and retains the moisture.
- Preferably, the wick assembly further comprises a condensation trap arranged between the wick and the nozzle. In this way, any condensed aerosol that has not been directed up the nozzle (and to a user) can be returned to the wick for reabsorption and re-aerosolization, thereby reducing wastage of unused aerosol generating liquid. This can also help to reduce contact between a user and any liquid aerosol forming substrate.
- Preferably, the wick assembly further comprises a thermal interface layer arranged between the wick and one or more holes in the aluminium end cover. In this way, heat transfer from a heater in the aerosol generation device to the wick can be improved. The one or more holes in the aluminium end cover ensure that the heat from the heater is not conducted across the aluminium material away from the wick. A thermally insulating seal may be provided between the thermal interface layer and the aluminium end cover to minimise any undesirable thermal conduction into the end cover. The thermal interface layer may comprise a thermal interface material or membrane comprising stainless steel, titanium foil, or polyetheretherketone (PEEK). The thermal interface layer may have a thickness of 15 to 25 microns.
- Preferably, the wick assembly is arranged radially inwardly with respect to the aluminium end cover. The aluminium end cover may be cup-shaped to hold the wick assembly within. The aluminium end cover may be punched and deep drawn to shape. Alternatively, the aluminium end cover may be pressured, or cold-forged depending on the speed and cost of the operation and manufacturer capability. A nozzle may be punched or otherwise formed in the aluminium end cover and cupshape of the outer wall may be drawn or otherwise shaped around the nozzle. The opening of the nozzle in the end cover may be plugged to prevent airflow through the opening, according to airflow design requirements of the cartridge. For example, the nozzle and opening in the end cover may be used as the socket connection that is plugged by a plug provided in the aerosol generation device such that the plug-socket connection fixes or attaches the consumable cartridge to the device.
- Holding the wick assembly in a cup-shaped aluminium end cover allows the outer wall of the aluminium end cover to provide a structural support to the wick assembly. The cup shape of the aluminium end cover and wick assembly provided within also ensures that the aerosol generating liquid in the cartridge is effectively used since the wick can be arranged at the lowest point of the cartridge. As indicated above, one or more holes may be drilled or otherwise provided in a bottom surface of the cartridge (adjacent to the heater or heater element of the aerosol generation device), such that the thermal interface layer acts as the interfacing layer between wick assembly and a heater.
- Preferably, the wick comprises one or more air channels. The air channels may be provided toward the lower end of the wick, adjacent to the thermal interface layer. In this way, the air channels allow improved airflow through the wick, which in turn improves the distribution of heat and vaporisation of the aerosol generating liquid into generated aerosol. The air channels may also allow enhanced delivery to the nozzle of the cartridge for inhalation by the user, and thus minimise condensation of generated aerosol. As such, the air channels can ensure optimal vape generation and prevent vape accumulation below the wick.
- Preferably, a cross-sectional area of the nozzle increases along the longitudinal axis in a direction to the user. In this way, the shape of the nozzle is configured to deliver an optimum airflow and draw resistance for a user. The vape of air and generated aerosol is thus delivered to the user as a homogeneous, laminar vape outflow. The airflow path widens across its cross-sectional profile which slows down the flow of air and generated aerosol in the nozzle, thereby cooling the vape before inhalation.
- Preferably, the aluminium body or aluminium end cover is shaped to fasten into the aerosol generation device by a push-fit mechanism. In this way, the consumable cartridge can be readily attached to the aerosol generation device. The aluminium body and/or aluminium end cover may also comprise punched notches, or hard stops, to allow a press-fit or push-fit connection of the wick assembly into the body and/or end cover. This advantageously allows the assembly of the cartridge to be faster and more efficient.
- Preferably, the aluminium end cover is connected to the aluminium body by a seamed edge connection. In this way a leak-proof connection is provided between the aluminium body and the aluminium end cover so that the aerosol generating liquid in the liquid reservoir cannot leak out of the cartridge in liquid form. A seamed-edge connection can also advantageously speed up the manufacturing process of a consumable cartridge. The connection may further comprise sealant, such as silicone, on the respective seamed edges of the end cover and body. Alternatively, the aluminium end cover may be connected to the aluminium body by a press-fit connection. Sealant may also be used to ensure a leak-proof connection.
- Preferably, an inner surface of the aluminium body is coated. In this way, the surface of the liquid reservoir in contact with the aerosol generating liquid is coated, which prevents any metallic contamination of the aerosol generating liquid (which may cause an undesirable metallic taste to the vape). A ceramic or polymer coating may be applied to the inner surface of the aluminium body, preferably after the body is formed in the aluminium, and before filling the reservoir or further assembly of the cartridge. For example, the coating may be a Teflon coating. The inner surface of the aluminium end cover may also be coated.
- Preferably, each of the aluminium body and the aluminium end cover is made of a single piece of aluminium. In this way, the consumable cartridge can be efficiently manufactured and assembled. In addition the use of two single pieces of aluminium to form a cartridge can effectively reduce or eliminate any joints that may potentially be a source of liquid leakage.
- In another aspect of the invention there is provided a method of manufacturing a consumable cartridge according to the first aspect of the invention, the method comprising the steps of: providing a first aluminium disc; punching through the first aluminium disc to form a nozzle; drawing the first aluminium disc around the nozzle to form a body around the nozzle, defining a liquid reservoir around the nozzle in the body; filling the liquid reservoir with an aerosol generating liquid; enclosing the liquid reservoir with a wick assembly comprising a wick and an opening; and connecting a second aluminium disc to the body of the first aluminium disc so as to encase the liquid reservoir and the wick assembly.
- In this way, a faster and more efficient manufacturing process is provided. Multiple steps of punching and drawing may be applied to form the aluminium body, and optionally the aluminium end cover. A punch tool may be used to form the nozzle in an aluminium disc and another punch tool may be used to form the outer body shape. The nozzle may be punched several times or drawn to extend the length of the nozzle such that the outer surface of the nozzle and the inner surface of the body together form the liquid reservoir.
- The aluminium consumable cartridge of the present disclosure considers a production amount that would be envisaged for consumable cartridges for electronic cigarettes (a mass production of more than 10 million pieces per year), and realises that standard milling processes (such as CNC, machining or turning) cannot be realistically applied due to the high costs and long production time of such processes.
- The manufacturing method of the present invention therefore uses deep-drawing techniques for aluminium on all outer surfaces. It should be appreciated that, due to the manufacturing limitations of the deep drawing process, it may be possible that relatively large draft angles would need to be applied on the vertical faces. Cold forging or pressing may also be considered as alternative manufacturing methods.
- Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:
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Figures 1A and 1B are perspective views of a consumable cartridge according to a first embodiment of the invention; -
Figure 2 is a cross-sectional view of the consumable cartridge according to the first embodiment of the invention; -
Figures 3A and 3B are schematic views of a wick assembly according to the first embodiment of the invention; -
Figure 4 is a schematic view of a wick according to the first embodiment of the invention; -
Figure 5 is another cross-sectional view of an aluminium consumable cartridge according to the first embodiment of the invention; -
Figures 6A and 6B are perspective views of a consumable cartridge according to a second embodiment of the invention; -
Figures 6C and 6D are cross-sectional views of connection joints according to the second embodiment of the invention; -
Figure 7 is a cross-sectional view of the consumable cartridge according to the second embodiment of the invention; -
Figure 8 is another cross-sectional view of an aluminium consumable cartridge according to the second embodiment of the invention; -
Figure 9 is an exploded cross-sectional view of the consumable cartridge according to the second embodiment of the invention; and -
Figure 10 is a schematic view of forming an aluminium body according to the invention. - As described herein, a vapour is generally understood to refer to a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms 'aerosol' and 'vapour' may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.
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Figures 1A and 1B illustrate outer views of aconsumable cartridge 2 or pod according to a first embodiment of the invention. Theconsumable cartridge 2 has an aluminium outer shell which is made of anupper body 4, which is cup-shaped, and alower end cover 6. Theupper body 4 has an air outlet 8 from which generated aerosol can be delivered and inhaled by a user. The air outlet 8 is the open end of a nozzle provided inside of the upper cup-shapedbody 4. - The
end cover 6 has ahole 10, which may be drilled, water jet cut or otherwise formed in theend cover 6, which reveals a thermal interface layer inside of thepod 2 against which aheating element 12 of an aerosol generation device (not shown) can press against and heat. As will be explained below, the thermal interface layer is part of a wick assembly in theconsumable cartridge 2 in which a wick holding an aerosol generating liquid, or e-liquid, is arranged. - The
consumable cartridge 2 also has air inlet holes 14 that are drilled into the side of theupper body 4, andnotches 16 in thebody 4 that are used as hard stops for the wick assembly during the manufacturing process of the pod. -
Figure 2 shows a cross-sectional view of theconsumable cartridge 2 having the upper cup-shapedbody part 4 and the lowerend cover part 6. Theupper body 4 is formed from a single piece of aluminium that is shaped to form acentral nozzle 20 and anouter shell 22, and theupper body 4 has a seamed edge that is interconnected with a respective seamed edge of theend cover 6 to form a seamed-edge connection 24. The wall of thecentral nozzle 20 is tapered such that the cross-sectional profile of thenozzle 20 increases from anaerosolreceiving end 26 of thenozzle 20 to the air outlet 8 (i.e. the open end of the nozzle). - The
consumable cartridge 2 includes awick assembly 28 arranged inside theupper body 4 and endcover 6. The outer surface of thecentral nozzle 20, the inner surface of the outer shell 22 (which may be a coated surface) and the top surface of thewick assembly 28 together form aliquid reservoir 30 in which an aerosol generating liquid can be stored inside theconsumable cartridge 2. Thereservoir 30 is able to accommodate up to 2 millilitres (ml) of liquid. - The
wick assembly 28 is a support structure that may be made of two plastic parts for ease of construction, and contains within achamber 32 of the assembly and a porousceramic wick 34 that draws the aerosol generating liquid out of theliquid reservoir 30 through at least one opening (not shown) in thewick assembly 28. It should be appreciated that, when constructed, the aerosol generating liquid can only flow out of theliquid reservoir 30 through the opening in thewick assembly 28 into thewick 34. - The
wick assembly 28 further includesair channels 36 which are aligned with the air inlet holes 14 in theupper body 4 to provide airflow paths from outside of theconsumable cartridge 2 to thewick 34 in thechamber 32 of thewick assembly 28. The airflow paths along theair channels 36 direct air in a horizontal direction, and combine in thechamber 32 such that air is further directed up thecentral nozzle 20 in a single airflow path having a vertical direction. The combined airflow path through theair channels 36 and thecentral nozzle 20 is thus T-shaped. - The
air channels 36 each further comprise aside channel 38 that acts as a leakage path for any moisture that may collect or condense within arespective air channel 36. Theside channels 38 can draw the moisture away from airflow path of theair channels 36 into anabsorption foam 40 provided beneath thewick assembly 28, between thewick assembly 28 and theend cover 6. Alternatively, theabsorption foam 40 can be arranged as part of thewick assembly 28, as will be obvious to the skilled person. - The
chamber 32 of thewick assembly 28 is arranged over thehole 10 in theend cover 6, and thewick assembly 28 includes a layer ofthermal interface material 42 that covers thehole 10. As explained above in reference toFigure 1B , the outer surface of thethermal interface material 42 is in contact with a heating element of an aerosol generation device in use and transmits heat from the heating element to thewick 34 that sits on the inner surface of thethermal interface material 42 in thechamber 32. A thermally insulatingseal 44 is provided at the edge of the thermalinterface material layer 42 such that theinsulation seal 44 prevents heat from being conducted into thealuminium end cover 6 or the rest of thewick assembly 28. In other words, thethermal insulation seal 44 ensures that heat received from the heating element / heater is optimally transmitted through thethermal interface layer 42 to thewick 34, and heat loss to the surrounding material (of theend cover 6 or the wick assembly 28) is minimised. - The
wick assembly 28 is attached to the receivingend 26 of thenozzle 20 such that aerosol generated from the liquid in the wick 34 (on heating) can travel up through tonozzle 20 to a user. Thewick assembly 28 includes aseal 46 provided at the attachment between theassembly 28 and thenozzle 20 to prevent any leakage from theliquid reservoir 30 into thechamber 32 ornozzle 20. Theseal 46 may be made of silicone or another suitable material in the art, such as rubber. - The
wick assembly 28 further includes acore seal 48 or a chamber seal which is used to hold thewick 34 in place inside thechamber 32. Thecore seal 48 is heat resistant to prevent any deformation or heat transmission from thewick 34 to the remainder of thewick assembly 28. In addition thecore seal 48 is shaped to include acondensation trap 50 such that any aerosol that did not travel up thenozzle 20 or was not inhaled by the user is able to condense into droplets in thecondensation trap 50 and return to thewick 34 for absorption and be re-heated for aerosolization. Thecore seal 48 may also be made of silicone. -
Figures 3A and 3B show additional views of a constructed and explodedwick assembly 28. As can be seen inFigure 3A , theair channels 36 are moulded into the plastic material of thewick assembly 28 between an air inlet of the wick assembly (which is aligned with a correspondingair inlet hole 14 of the upper body 4) and thecentral chamber 32. The top surface of thewick assembly 28 is used to enclose theliquid reservoir 30 between thenozzle 20 and the inner surface of the outer shell of theupper body 4, and aerosol generating liquid in theliquid reservoir 30 can enter thechamber 32 through theopening 52 in thewick assembly 28. Thetop channel 54 of thewick assembly 28 attaches to the receivingend 26 of thenozzle 20 and theseal 46 arranged around the inner surface of thetop channel 54 interfaces with the outer surface of the receivingend 26 of thenozzle 20 to prevent any leakage. - The exploded view of the
wick assembly 28 inFigure 3B shows how the wick assembly may be constructed.Figure 3B further illustrates thecore seal 48 that fixes the position of thewick 34 inside thechamber 32 of thewick assembly 28 on top of thethermal interface layer 42. The outer edge of thethermal interface layer 42 is encased in athermal insulation seal 44 to control the direction of heat transmission from the heater to thewick 34. Theabsorption foam layer 40 is provided below the main body of thewick assembly 28 such that theside channels 38 can direct any moisture in theair channels 36 to thefoam layer 40. -
Figure 4 shows thewick 34 of the first embodiment of the invention, where thewick 34 includes a number ofair channels 56 at the lower surface of thewick 34 where thewick 34 interfaces with thethermal interface layer 42. Theair channels 56 in the wick allow air from theair channels 36 of thewick assembly 28 to readily flow into thewick 34 for improved aerosol delivery. The reduced surface area of thewick 34 against thethermal interface layer 42 effectively reduces the volume of the wick 34 (and aerosol generating liquid stored within) nearer the heater, which in turn reduces the heat-up time of thewick 34 and the generation of aerosol. -
Figure 5 illustrates a cross-sectional view of theconsumable cartridge 2 without thewick assembly 28, and only shows theupper body 4 connected to theend cover 6. Theupper body 4 hasnotches 16, which may be formed by a punching process, below the receivingend 26 of thenozzle 20. Thenotches 16 act as a stop or a push-fit mechanism for the main body of thewick assembly 28 during construction. The outer wall of thewick assembly 28 may be configured accordingly to match the shape of thenotches 16. Theseamed edge connection 24 between theupper body 4 and theend cover 6 is filled with a sealant to further enhance the leak-proof quality of theconnection 24. -
Figures 6A and 6B illustrate outer view of anotherconsumable cartridge 102 or pod according to a second embodiment of the invention. The consumable cartridge has an aluminium outer shell that includes anupper body 104 and alower end cover 106 or end part. Theupper body 104 and theend cover 106 are both cup-shaped. Theupper body 104 has anair outlet 108, which is the opening at the end of a nozzle provided inside of theupper body 104. - The
end cover 106 has twoholes 110 cut out in its bottom surface, which reveal a thermal interface layer in theconsumable cartridge 102. The thermal interface layer is configured to come into contact with aheater 112 of an aerosol generation device and conduct heat into theconsumable cartridge 102. As will be explained below, the thermal interface layer is part of a wick assembly in theconsumable cartridge 102 in which a wick storing an aerosol generating liquid is provided. - The
upper body 104 and theend cover 106 are connected together at their respective edges at a connection joint 114. The connection joint 114 may be filled with a sealant to ensure a leak-proof connection. -
Figure 6C shows a cross-sectional view of a first example, where the connection joint 114 is aseamed edge connection 114A, where the respective edges of both theupper body 104 and theend cover 106 are seamed.Figure 6D show a cross-sectional view of a second example, where the respective edges and the aluminium metal toward the edges of theupper body 104 and theend cover 106 are pressed or otherwise shaped respectively to provide a press-fit connection 114B between theupper body 104 andend cover 106. - The
consumable cartridge 102 also has air inlet holes 116 that are drilled or formed in the side of theend cover 106. The size of the air inlet holes 116 define a draw resistance of thecartridge 102. -
Figure 7 shows a cross-sectional view of the aluminium outer shell. Theupper body 104 has acentral nozzle 118 and anouter wall 120 formed radially around the outer surface of thecentral nozzle 118. Thecentral nozzle 118 has anaerosol receiving end 122 and an opening which is theair outlet 108 of thecartridge 102. The wall of thecentral nozzle 118 is tapered, where the cross-sectional area of thenozzle 118 increases from the receivingend 122 to theair outlet 108. - The
outer wall 120 has a thickness of around 0.2 millimetres. Theupper body 104 is made from a single piece or disc of aluminium that is punched and drawn in a multistage process, as will be described further below. The receivingend 122 of thecentral nozzle 118 and the edge of theouter wall 120 is shaped to a press-fit edge 124 for connection with theend cover 106. - The
end cover 106 also has anozzle 126, which may be plugged and/or used for another purpose such as a push-fit or alignment connection with an aerosol generation device. Theend cover 106 has anouter wall 128 radially around thenozzle 126, and the air inlet holes 116 described above are drilled into the end coverouter wall 128. Theend cover nozzle 126 is also tapered such that the cross-sectional area of thenozzle 126 decreases from the bottom surface of theend cover 106 to thetop end 130 of theend cover nozzle 126, which connects to the receivingend 122 of thecentral nozzle 118 of theupper body 104. The smaller cross-sectional area where thecentral nozzle 118 connects with theend cover nozzle 126 allows for a higher speed of delivery of aerosol into thecentral nozzle 118, and the widening cross-sectional area of thecentral nozzle 118 retards the speed of delivery of aerosol as it travels through thecentral nozzle 118 to a user, which allows the aerosol to cool. - Similar to the
upper body 104, theend cover 106 in the second embodiment is also made from a single piece or disc of aluminium that is punched and drawn in a multistage process. Thetop end 130 of theend cover nozzle 126 and the edge of theouter wall 128 is shaped to a press-fit edge 132 for connection with theupper body 104. - Aerosol delivery holes 134 are provided in the
end cover nozzle 126 so as to provide an airflow path from the air inlet holes 116 to the aerosol delivery holes 134. It should therefore be understood that, in use, outside air enters thecartridge 102 through the air inlet holes 116, picks up generated aerosol as it passes through the wick, and the air and aerosol is delivered through the aerosol delivery holes 134 to the receivingend 122 of thecentral nozzle 118 of theupper body 104 for further delivery to theair outlet 108 and user inhalation. - The bottom surface of the
end cover 106 hasholes 110 that are cut out in a shape to correspond with the interfacing heater of an aerosol generation device. This is to allow the heater or heating element to pass through the bottom surface of theend cover 106 and press against the thermal interface layer of the wick assembly of thecartridge 102. -
Figures 8 and9 shows a cross-sectional views of theconsumable cartridge 102 having theupper body 104 and thelower end cover 106 connected using a push-fit or press-fit connection. The press-fit edge 124 of theupper body 104 interlocks with the press-fit edge 132 of theend cover 106, and thetop end 130 of theend cover nozzle 126 is pushed into and fitted within the receivingend 122 of the upper bodycentral nozzle 118. The receivingend 122 of thecentral nozzle 118 also flares outwardly, which along with the press-fit edge 124 of theupper body 104 act as a stop for awick assembly 136 of theconsumable cartridge 102. - The
wick assembly 136 is positioned in theend cover 106 in the space radially around theend cover nozzle 126, between the outer surface of theend cover nozzle 126 and the inner surface of theouter wall 128 of theend cover 106. The outer surface of thecentral nozzle 118, the inner surface of theouter wall 120 of theupper body 104 and the top surface of thewick assembly 136 together form aliquid reservoir 138 in which an aerosol generating liquid can be stored inside theconsumable cartridge 102. The internal surfaces of theupper body 104 andend cover 106 are coated with a ceramic or polymer coating. - As seen more clearly in the exploded view of
Figure 9 , thewick assembly 136 includes a porousceramic wick 140 that is surrounded by anupper seal cap 142 over its top surface, amembrane 144 around its side walls and athermal interface layer 146 on its lower surface. Theupper seal cap 142 is made of silicone and hasopenings 148 to allow aerosol generating liquid to flow out of theliquid reservoir 138 into thewick 140. It should be appreciated that, when constructed, the aerosol generating liquid can only flow out of theliquid reservoir 138 through theopenings 148 in theupper seal cap 142 into thewick 140. Theupper seal cap 142 extends over the top surface of thewick 140 to the upper end of the sides of the wick 140 (which include the surfaces of thewick 140 adjacent to both the end coverouter wall 128 and the end cover nozzle 126) to ensure any leakage of aerosol generating liquid away from theopenings 148 is prevented. The interfacing surfaces of theupper seal cap 142 and thewick 140 along the sides of thewick 140 are ridged respectively to provide a secure fit of theupper seal cap 142 over thewick 140. - The
membrane 144 of thewick assembly 136 provided around the side surfaces of the wick 140 (which include the surfaces of thewick 140 adjacent to both the end coverouter wall 128 and the end cover nozzle 126) is a polymer membrane such as polytetrafluoroethylene (Teflon). Themembrane 144 is air-permeable, and optionally may further include additional holes to improve the distribution air through thewick 140. Thewick 140 and themembrane 144 is also shaped to allow a gap between the membrane and theouter wall 128 of theend cover 106 and/or theend cover nozzle 126 for improved airflow through thewick 140. - The
thermal interface layer 146 is an impermeable layer that covers the bottom surface of thewick 140 to prevent liquid from leaking out of thewick 140 through theholes 110 in theend cover 106. Thethermal interface layer 146 extends across the bottom surface of thewick 140 to the lower end of the sides of the wick 140 (which include the surfaces of thewick 140 adjacent to both the end coverouter wall 128 and the end cover nozzle 126) to prevent leakage. - The outer surface (i.e. the lower surface) of the
thermal interface layer 146 is in contact with a heating element of an aerosol generation device in use and transmits heat from the heating element to thewick 140 that sits on the inner surface of thethermal interface layer 146 in thewick assembly 136. A thermally insulating seal (not shown), such as a silicone sealant, is used to glue thethermal interface layer 146 to the bottom surface of theend cover 106, which prevents or minimises heat from being conducted into thealuminium end cover 106. - Similar to the first embodiment, the
wick 140 may include a number of air channels (not shown) at the lower surface of thewick 140 where thewick 140 interfaces with thethermal interface layer 146 to improve air and heat distribution through thewick 140. Aplug 150 is optionally provided to block the opening of theend cover nozzle 126 at its bottom surface, or alternatively theplug 150 may be part of the aerosol generation device in which theconsumable cartridge 102 is inserted. -
Figure 10 illustrates in schematic form aprocess 200 to form an aluminium body, such as theupper bodies end cover 106 of the second embodiment. - At
step 202, analuminium disc 250 is cut out from a sheet roll of aluminium metal. The size of thedisc 250 is equal to the surface area of the upper part of aconsumable cartridge disc 250 may be cut out from the roll of aluminium using a stamp process. - At step 204 a
punch tool 252 is used to strike the centre of thedisc 250 to form anozzle 254 in thedisc 250. Multiple punches may be required to draw thenozzle 254 to a desired length shown atstep 206. Lubrication, such as oil or grease, may be applied to prevent any tearing of thedisc 250. In order to form a tapered wall, several punch tools of decreasing diameter may be used as thenozzle 254 is drawn out of thedisc 250. It will be understood that thedisc 250 is placed on a suitable holder duringstep 204 to prevent the material around thenozzle 254 from deforming during the punching process. - At
step 208, adifferent punch tool 256 having a socket-style or tube-shaped form is used to form theouter wall 258 of the body. As above, multiple punches may be required to draw thedisc 250 around thenozzle 254 to a desired length, and multiple punch tools of different internal diameters may be used, as shown atstep 210, to draw out theouter wall 258 and ensure a smooth outer profile. Atstep 212 theouter wall 258 is drawn to a length greater than the length of thenozzle 254 to form the body.
Claims (15)
- A consumable cartridge for an aerosol generation device, comprising:an aluminium body having a nozzle arranged along a longitudinal axis inside of the aluminium body, the nozzle configured to deliver generated aerosol to a user;a liquid reservoir comprising an aerosol generating liquid, the liquid reservoir positioned radially outwardly with respect to the nozzle within the aluminium body;a wick assembly comprising a wick and an opening, the wick configured to draw the aerosol generating liquid from the liquid reservoir through the opening; andan aluminium end cover connected to the aluminium body so as to encase the liquid reservoir and the wick assembly.
- The consumable cartridge of claim 1, wherein the wick assembly comprises a seal arranged between the wick assembly and the liquid reservoir.
- The consumable cartridge of claims 1 or 2, wherein the wick assembly comprises an airflow path from outside of the consumable cartridge to the nozzle.
- The consumable cartridge of claim 3 comprising one or more air inlet holes in the aluminium body and/or the aluminium end cover.
- The consumable cartridge of claims 3 or 4, wherein the wick assembly comprises one or more liquid traps along the airflow path.
- The consumable cartridge of any of the preceding claims, wherein the wick assembly further comprises a condensation trap arranged between the wick and the nozzle.
- The consumable cartridge of any of the preceding claims, wherein the wick assembly further comprises a thermal interface layer arranged between the wick and one or more holes in the aluminium end cover.
- The consumable cartridge of any of the preceding claims, wherein the wick assembly is arranged radially inwardly with respect to the aluminium end cover.
- The consumable cartridge of any of the preceding claims, wherein the wick comprises one or more air channels.
- The consumable cartridge of any of the preceding claims wherein a cross-sectional area of the nozzle increases along the longitudinal axis in a direction to the user.
- The consumable cartridge of any of the preceding claims, wherein the aluminium body or aluminium end cover is shaped to fasten into the aerosol generation device by a push-fit mechanism.
- The consumable cartridge of any of the preceding claims, wherein the aluminium end cover is connected to the aluminium body by a seamed edge connection.
- The consumable cartridge of any of the preceding claims, wherein an inner surface of the aluminium body is coated.
- The consumable cartridge of any of the preceding claims, wherein each of the aluminium body and the aluminium end cover is made of a single piece of aluminium.
- A method of manufacturing a consumable cartridge of any of claims 1 to 14, the method comprising the steps of:providing a first aluminium disc;punching through the first aluminium disc to form a nozzle;drawing the first aluminium disc around the nozzle to form a body around the nozzle, defining a liquid reservoir around the nozzle in the body;filling the liquid reservoir with an aerosol generating liquid;enclosing the liquid reservoir with a wick assembly comprising a wick and an opening; andconnecting a second aluminium disc to the body of the first aluminium disc so as to encase the liquid reservoir and the wick assembly.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP22195653.5A EP4338619A1 (en) | 2022-09-14 | 2022-09-14 | Consumable cartridge for an aerosol generation device |
PCT/EP2023/075099 WO2024056704A1 (en) | 2022-09-14 | 2023-09-13 | Consumable cartridge for an aerosol generation device |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP22195653.5A EP4338619A1 (en) | 2022-09-14 | 2022-09-14 | Consumable cartridge for an aerosol generation device |
Publications (1)
Publication Number | Publication Date |
---|---|
EP4338619A1 true EP4338619A1 (en) | 2024-03-20 |
Family
ID=83319360
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP22195653.5A Pending EP4338619A1 (en) | 2022-09-14 | 2022-09-14 | Consumable cartridge for an aerosol generation device |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP4338619A1 (en) |
WO (1) | WO2024056704A1 (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160374399A1 (en) * | 2013-12-23 | 2016-12-29 | James Monsees | Vaporizer apparatus |
US20180343923A1 (en) * | 2017-06-06 | 2018-12-06 | Shenzhen Smoore Technology Limited | Atomizer and electronic cigarette with the same |
US20190174827A1 (en) * | 2017-12-08 | 2019-06-13 | Altria Client Services Llc | Multi-component aerosol-generating device with impact absorbing part |
WO2021028395A1 (en) * | 2019-08-12 | 2021-02-18 | Jt International Sa | A cartridge for an electronic cigarette, an electronic cigarette, and an assembly method for an electronic cigarette |
EP3782488A1 (en) * | 2019-08-23 | 2021-02-24 | Nerudia Limited | A substitute smoking consumable |
-
2022
- 2022-09-14 EP EP22195653.5A patent/EP4338619A1/en active Pending
-
2023
- 2023-09-13 WO PCT/EP2023/075099 patent/WO2024056704A1/en unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160374399A1 (en) * | 2013-12-23 | 2016-12-29 | James Monsees | Vaporizer apparatus |
US20180343923A1 (en) * | 2017-06-06 | 2018-12-06 | Shenzhen Smoore Technology Limited | Atomizer and electronic cigarette with the same |
US20190174827A1 (en) * | 2017-12-08 | 2019-06-13 | Altria Client Services Llc | Multi-component aerosol-generating device with impact absorbing part |
WO2021028395A1 (en) * | 2019-08-12 | 2021-02-18 | Jt International Sa | A cartridge for an electronic cigarette, an electronic cigarette, and an assembly method for an electronic cigarette |
EP3782488A1 (en) * | 2019-08-23 | 2021-02-24 | Nerudia Limited | A substitute smoking consumable |
Also Published As
Publication number | Publication date |
---|---|
WO2024056704A1 (en) | 2024-03-21 |
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