US20230180830A1 - Aerosol Generating System - Google Patents

Aerosol Generating System Download PDF

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Publication number
US20230180830A1
US20230180830A1 US17/925,487 US202117925487A US2023180830A1 US 20230180830 A1 US20230180830 A1 US 20230180830A1 US 202117925487 A US202117925487 A US 202117925487A US 2023180830 A1 US2023180830 A1 US 2023180830A1
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Prior art keywords
conically shaped
fresh air
grooves
heating element
airflow channel
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US17/925,487
Inventor
Claude Zominy
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JT International SA
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JT International SA
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Publication of US20230180830A1 publication Critical patent/US20230180830A1/en
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    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/44Wicks
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/42Cartridges or containers for inhalable precursors
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46Shape or structure of electric heating means
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/48Fluid transfer means, e.g. pumps
    • A24F40/485Valves; Apertures
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24FSMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/10Devices using liquid inhalable precursors

Definitions

  • the present disclosure relates to elements for an aerosol generating system and for producing an aerosol or vapor for inhalation by a user.
  • the present disclosure relates more particularly to an aerosol generating system with a conically shaped heating element and a corresponding vaporizable material capsule cartridge for holding a vaporizable material substance for producing an aerosol or vapor.
  • aerosol generating systems also known as e-cigarettes, e-cigs (EC), electronic nicotine delivery systems (ENDS), electronic non-nicotine delivery systems (ENNDS), electronic smoking devices (ESDs), personal vaporizers (PV), inhalation devices, vapes, which can be used as an alternative to conventional smoking articles such as lit-end cigarettes, cigars, and pipes, is becoming increasingly popular and widespread.
  • a specific type of aerosol generating systems makes use of a conically shaped heating element, and a correspondingly designed capsule of smoking substance that fits on the conically shaped heating element.
  • the specific aerosol generating system also requires to have a well-designed airflow system configured to collect and receive vaporized vaporizable material, i.e., vaporizable material which is heated and hence aerosolized by the conically shaped heating elements, and directs the aerosolized vaporizable material toward the mouthpiece to be inhaled by an intended user.
  • vaporized vaporizable material i.e., vaporizable material which is heated and hence aerosolized by the conically shaped heating elements
  • the invention provides an aerosol generating system comprising a conically shaped heating element configured to generate an aerosol by evaporating a vaporizable material on a slanted surface, and a vaporizable material capsule configured to contain a vaporizable material, whereby the vaporizable material capsule comprises a conically shaped contacting element having a slanted surface configured to mate with the conically shaped heating element in use.
  • An interfacing layer is arranged in a gap between the slanted surfaces of both the heating element and contacting element, and the interfacing layer contacts the slanted surfaces of both the heating element and contacting element, the interfacing layer comprising a porous material configured to wick vaporizable material from the slanted surface of the contacting element to the slanted surface of the heating element, and an airflow management system is arranged in the vicinity of the interfacing layer, including fresh air grooves and airflow channel grooves in the walls of the conically shaped contacting element and/or in the slanted surface of the conically shaped heating element, and configured respectively to conduct fresh air or the aerosol.
  • the fresh air grooves and the airflow channel grooves are in the slanted surface of the conically shaped heating element, the fresh air grooves and the airflow channel grooves having respectively a first determined width and a second determined width and extending between the cone basis and the cone top, and being arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel groove, one heating zone.
  • the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh air grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one airflow channel groove, one heating zone; and the fresh air grooves are arranged opposite of every heating zone.
  • the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves and the fresh air grooves have respectively a first determined width and a second determined width, and are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
  • FIG. 1 contains a schematic sectional view of a vaporizable material capsule mated with a conically shaped heating element, according to an example embodiment of the invention.
  • FIG. 2 contains a schematic rolled out view of a section through a conically shaped heating element with airflow management features according to an example embodiment of the invention.
  • FIG. 3 contains a schematic sectional view of an example airflow management configuration according to the invention.
  • FIG. 4 contains yet another schematic sectional view of an example configuration according to the invention.
  • FIG. 6 shows the conically shaped heating element from FIG. 5 , inserted into an example embodiment of a vaporizable material capsule’s cavity according to the invention.
  • the aerosol generating system 100 is, for example, to be used in or included in an aerosol generating device, an inhalation device or an electronic cigarette (not shown in FIG. 1 ).
  • the vaporizable material capsule 102 is configured to contain a vaporizable material 103 , which in use may flow out towards the slanted surface 104 .
  • the vaporizable material capsule 102 comprises a conically shaped contacting element, in this example formed as a cavity delimited by a slanted surface 105 complementary in shape to that of the heating element and thus configured to mate with the conically shaped heating element 101 along its slanted surface 104 .
  • a fluidic passage (not represented in FIG. 1 ) for the vaporizable material 103 located inside the vaporizable material capsule 102 may be enabled towards a space delimited by the slanted surface 104 , 105 of the heating element and contacting element respectively.
  • the vaporizable material capsule 102 and/or the conically shaped heating element may further comprise at least one fresh air groove (not represented in FIG. 1 but will be discussed in detail further along the description).
  • the at least one fresh air groove is configured to provide fresh air in vicinity of the wicking element 106 and airflow channel groove, the fresh air groove arriving through an air inlet of the aerosol generating device (the two latter are not represented in FIG. 1 ).
  • Arrows A and B show examples of locations at a periphery of the vaporizable material capsule 102 and conically shaped heating element 101 , where fresh air may be provided to flow into the at least one fresh air groove.
  • FIG. 2 shows a schematic view of the periphery of the conically shaped heating element 101 and interfacing layer 106 of FIG. 1 , along a section shown by dotted line 108 in FIG. 1 , in an exemplary embodiment.
  • the periphery would normally be of circular shape but has been rolled out flat in FIG. 2 for a better readability.
  • the layer of wicking element 106 is represented as a fiat layer, which covers the convex slanted surface 104 , also represented as a flat surface/line here.
  • a side 207 of the interfacing wicking layer 106 opposite to that of the convex slanted surface 104 is configured to cover the concave slanted surface of the vaporizable material capsule (both not represented in FIG.
  • An airflow management system arranged here on the convex slanted surface 104 is configured in the vicinity of the interfacing layer 106 , and comprises a plurality of fresh air grooves 200 and airflow channel grooves 201 arranged in the wail of the conically shaped heating element 101 , and configured respectively to conduct fresh air or the aerosol as explained hereinabove.
  • the conically-shape heating element 101 comprises a cone basis, i.e., a first end of the cone that has the larger diameter, and a cone top, i.e., a second end of the cone opposite to the first end and being either of sharp of truncated constituency.
  • the cone top is truncated, but this has no particular incidence for the invention.
  • the conically shaped heating element 101 comprises a plurality of distinct heating zones 203 that are configured to occupy corresponding circumferential arc portions 204 on the convex slanted surface 104 . While the cone basis and the cone top are not illustrated in FIG. 2 , it should be said that each of the plurality of distinct heating zones 203 extends between the cone basis and the cone top.
  • the fresh air grooves 200 and the airflow channel grooves 201 have respectively a first determined width 205 and a second determined width 206 and extend between the cone basis and the cone top. Similar as the distinct heating zones 203 , the fresh air grooves 200 and the airflow channel grooves 201 also extend between the cone basis and the cone top and are arranged around the circumference of the conically shaped heating element 101 . Together with the distinct heating zones they form a plurality of groups comprising in this order: one fresh air groove 200 , one heating zone 203 , one airflow channel groove 201 , one heating zone 203 . The illustration in FIG. 2 contains two of such groups, one more fresh air channel 200 and a few more heating zones 203 .
  • the configuration of fresh air grooves 200 , airflow channels 201 and heating zones 203 according to the invention enables an efficient airflow management in the aerosol generating system comprising a conically-shape heating element 101 .
  • Vaporizable material that has flown into the wicking element 106 is heated in the areas adjacent to the heating zone 203 and evaporated to aerosol which is evacuated in the airflow channel grooves 201 that face the wicking element 106 and guided towards the vapor conduit.
  • the fresh air grooves 200 enable fresh air to be provided and hence the airflow process may be sustained.
  • the configuration according to the invention enables an efficient airflow management by means of a configuration of grooves and heating zones that are distributed all around the circumference of the conically shaped heating element, whereby grooves are exclusively comprised in the conically shaped heating element in the specific example embodiment illustrated in FIG. 2 . Further examples will be explained in the following paragraphs.
  • FIG. 2 may be used to discuss a further example embodiment, although this is not explicitly illustrated.
  • the wicking element 106 is located between the convex slanted surface 104 of the heating element 101 and a concave slanted surface 105 of the contacting element from a vaporizable material capsule, surface which is located on a side of the wicking element 106 opposite to that where the convex slanted surface is located.
  • Further all fresh air grooves 200 and airflow channel grooves 201 are to be comprised on the side of the concave slanted surface, i.e., on the side of the vaporizable material capsule.
  • the manner in which the airflow is managed in this further example embodiment is somewhat similar to the airflow management in FIG. 2 explained in the preceding paragraph, and this offers similar advantages.
  • the main difference is that the grooves need to be manufactured into the vaporizable material capsule.
  • FIG. 3 illustrates yet another example embodiment according to the invention, which illustrates a top-view of a section through the conically shaped heating element 101 , including for a better understanding also a representation of the location of the cone top (the smaller circle in the middle).
  • the illustration shows a circumference of the conically shaped heating element 101 delimited by the convex slanted surface 104 and a circumference of the vaporizable material capsule delimited by the concave slanted surface 105 , and the layer of wicking element 106 in between.
  • the heating zones 203 are comprised on the side of the conically shaped heating element 101 , together with the airflow channel grooves 201 , while the fresh air grooves 200 are comprised on the side of the vaporizable material capsule.
  • the conically shaped cavity of the vaporizable material capsule is delimited at its opening by an opening circumference that has the larger diameter, and at the other end of the cone by a bottom.
  • the fresh air grooves 200 extend between the opening circumference and the bottom.
  • All grooves and heating zones together form a plurality of groups comprising in this order: one fresh air groove 200 , one heating zone 203 , one airflow channel groove 201 , one heating zone 203 .
  • the illustration in FIG. 3 contains three such groups.
  • FIG. 3 may be used to discuss a further example embodiment, although this is not explicitly illustrated.
  • the airflow channel grooves are replaced by fresh air grooves, and vice-versa.
  • FIG. 4 illustrates yet another example embodiment according to the invention, which, similar to FIG. 3 illustrates a top view of a section through the conically shaped heating element 101 .
  • a part of the wall 400 from the vaporizable material capsule, delimited by concave slanted surface 105 is represented.
  • the heating zones 203 are comprised on the side of the conically shaped heating element 101 , together with airflow channel grooves 201 , while the fresh air grooves 200 are comprised on the side of the vaporizable material capsule. All grooves and heating zones together form a plurality of groups comprising in this order: one airflow channel groove 201 , one heating zone 203 .
  • Each of the groups further comprises one fresh air channel 200 which is arranged opposite of the heating zone 203 .
  • the illustration in FIG. 4 comprises three such groups.
  • FIG. 4 may be used to discuss a further example embodiment, although this is not explicitly illustrated. In this further example embodiment, it should be considered that the airflow channel grooves are replaced by fresh air grooves, and vice-versa.
  • the layer of wicking element 106 has an opening respectively located between each heating zone 203 and each fresh air groove 200 . This may improve the efficiency of the airflow from the fresh air groove 200 to each of the surrounding airflow channel grooves 201 , as the portion of wicking element 106 that the air travels through the wicking element to flow from one groove to another groove is shorter than if the wicking element had covered the whole heating zone 203 along the circumference. However, it may be desirable to actually extend the wicking element 106 over the heating element in orderto adjust a resistance to air flow from one groove to another, and this may be part of a further preferred embodiment that is not illustrated in the figures.
  • FIG. 5 shows yet another example embodiment of a conically shaped heater element in a sectional top-view, the viewing angle being similar as that from FIG. 3 and FIG. 4 .
  • the heating zones 203 are comprised on the circumference of the heating element 101 , and the whole circumference is covered by a layer of wicking element 106 .
  • FIG. 6 illustrates the conically shaped heating element of FIG. 5 as inserted in the cavity of a vaporizable material capsule 102 , whereby the layer of wicking element is covered up by part of the vaporizable material capsule’s wall.
  • the fresh air grooves 200 and the airflow channel grooves 201 are comprised in the vaporizable material capsule 102 .
  • All grooves and heating zones together form a plurality of groups comprising in this order: one airflow channel groove 201 , one heating zone 203 .
  • Each of the groups further comprises one fresh air channel 200 which is arranged opposite of the heating zone 203 .
  • the illustration in FIG. 6 comprises three such groups.
  • An advantage of the example embodiment illustrated in FIG. 6 is that all the grooves are part of the vaporizable material capsule 102 , which typically may be a disposable part of the aerosol generating system. Hence, they are renewed at each change of the vaporizable material capsule, and are always comparatively clean, as compared to grooves located on the side of the conically shaped heating element, which have a longer life cycle and hence run a greater probability of becoming clogged over time.
  • a further advantage of the present invention is that holding the liquid in a separate portion than the gap has the advantage to not continuously heat up the whole reservoir that may not be good for the taste of the generated aerosol.
  • a further advantage of the present invention is that the porous layer is localized inside the cone, that is easier and more efficient as liquid will remain in the porous area.
  • a further advantage is that having grooves on the slanted surface of the conically shaped heating element allows to optimize the vapor/airflow path volume compare to prior art with limited airflow/vapor capability due to space restriction.

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Abstract

An aerosol generating system comprises a conically shaped heating element (101) configured to generate an aerosol by evaporating a vaporizable material on a slanted surface (104), and a vaporizable material capsule (102) configured to contain a vaporizable material (103), whereby the vaporizable material capsule comprises a conically shaped contacting element having a slanted surface (105) configured to mate with the conically shaped heating element in use. An interfacing layer (106) is arranged in said gap contacting the slanted surfaces of both the heating element and contacting element, the interfacing layer comprising a porous material configured to wick vaporizable material from the slanted surface of the contacting element to the slanted surface of the heating element, and an airflow management system is arranged in the vicinity of the interfacing layer, including fresh air grooves (200) and airflow channel grooves (201) in the walls of the conically shaped contacting element and/or in the slanted surface of the conically shaped heating element, and configured respectively to conduct fresh air or the aerosol.

Description

    FIELD OF THE INVENTION
  • The present disclosure relates to elements for an aerosol generating system and for producing an aerosol or vapor for inhalation by a user. The present disclosure relates more particularly to an aerosol generating system with a conically shaped heating element and a corresponding vaporizable material capsule cartridge for holding a vaporizable material substance for producing an aerosol or vapor.
  • BACKGROUND
  • The use of aerosol generating systems, also known as e-cigarettes, e-cigs (EC), electronic nicotine delivery systems (ENDS), electronic non-nicotine delivery systems (ENNDS), electronic smoking devices (ESDs), personal vaporizers (PV), inhalation devices, vapes, which can be used as an alternative to conventional smoking articles such as lit-end cigarettes, cigars, and pipes, is becoming increasingly popular and widespread. The most commonly used e-cigarettes are usually battery powered and use a resistance heating element to heat and atomize a liquid containing nicotine and/or flavorants (also known as e-cigarette liquid, e-cig liquids, e-liquid, juice, vapor juice, smoke juice, e-juice, e-fluid, vape oil), to produce an aerosol (often called vapor) which can be inhaled by a user.
  • In the conventional e-cigarettes described above, the liquid is put into contact with a resistance heating element after flowing through small channels, where it is heated and vaporized. The flowing is realized for example via a wick, a mesh or another type of porous element, which has a plurality of small channels that transport the liquid from a reservoir to the heating element. This heating element together with the porous element, a reservoir that contains the vaporizable material, and a mouthpiece are usually arranged within a disposable capsule, cartridge or pod, that is discarded or refilled once the vaporizable material has been consumed by the user, and usually removably connects to a main body that includes a rechargeable battery.
  • A specific type of aerosol generating systems makes use of a conically shaped heating element, and a correspondingly designed capsule of smoking substance that fits on the conically shaped heating element.
  • The specific aerosol generating system also requires to have a well-designed airflow system configured to collect and receive vaporized vaporizable material, i.e., vaporizable material which is heated and hence aerosolized by the conically shaped heating elements, and directs the aerosolized vaporizable material toward the mouthpiece to be inhaled by an intended user.
  • U.S. Publication US2018/0332897A1 relates to aerosol delivery devices. The disclosed devices don’t have any interfacing layer comprising a porous material configured to wick the e-liquid from the slanted surface of the contacting element to the slanted surface of the heating element. The liquid is held in the “gap” (the porous element 836/811) already, meaning that it doesn’t need to be transported to that place anymore. As disclosed in this prior art document, the airflow path is central to the cone and “capsule”. Furthermore, it is not between the heater cone and the capsule cone. Paragraph 96 and FIG. 9 of this document mention that the airflow path can be redirected between the cones. This makes the purpose rather clear. Also, the porous layer is outside of the capsule and extends out clearly of the cone. With this concept, the liquid will flow all around the capsule and be subject to extra heating. Further, in the present document grooves are not located in the slanted surface of the conically-shape heating element.
  • One aim of the invention is to address the issue of realizing an airflow system for the specific type of aerosol generating system that makes use of a conically shaped heating element.
  • Consequently, the background art presents a number of deficiencies and problems and the present disclosure seeks to address these difficulties.
  • SUMMARY
  • The invention provides an aerosol generating system comprising a conically shaped heating element configured to generate an aerosol by evaporating a vaporizable material on a slanted surface, and a vaporizable material capsule configured to contain a vaporizable material, whereby the vaporizable material capsule comprises a conically shaped contacting element having a slanted surface configured to mate with the conically shaped heating element in use. An interfacing layer is arranged in a gap between the slanted surfaces of both the heating element and contacting element, and the interfacing layer contacts the slanted surfaces of both the heating element and contacting element, the interfacing layer comprising a porous material configured to wick vaporizable material from the slanted surface of the contacting element to the slanted surface of the heating element, and an airflow management system is arranged in the vicinity of the interfacing layer, including fresh air grooves and airflow channel grooves in the walls of the conically shaped contacting element and/or in the slanted surface of the conically shaped heating element, and configured respectively to conduct fresh air or the aerosol.
  • In a preferred embodiment, the conically shaped heating element comprises a cone basis and a cone top, and a plurality of distinct heating zones occupying a corresponding circumferential arc portion on the slanted surface, each extending between the cone basis and the cone top, and the conically shaped contacting element has an opening circumference delimiting the contacting element at the side configured to enter in mating arrangement with the conically shaped heating element, and a bottom at the opposite extremity of the opening circumference, and the conically shaped heating element is removably mated with the vaporizable material capsule.
  • In a further preferred embodiment, the fresh air grooves and the airflow channel grooves are in the slanted surface of the conically shaped heating element, the fresh air grooves and the airflow channel grooves having respectively a first determined width and a second determined width and extending between the cone basis and the cone top, and being arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel groove, one heating zone.
  • In a further preferred embodiment, the fresh air grooves and the airflow channel grooves are in the slanted surface of the conically shaped contacting element, the fresh air grooves and the airflow channel grooves having respectively a first determined width and a second determined width and extending between the opening circumference and the bottom, and being arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
  • In a further preferred embodiment, the fresh air grooves are in the slanted surface of the conically shaped heating element, and the airflow channel grooves are in the wall of the conically shaped contacting element, whereby the fresh air grooves extend each between the cone basis and the cone top, and the airflow channel grooves extend between the opening circumference and the bottom, further whereby the fresh air grooves are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone; and the airflow channel grooves are arranged opposite of every heating zone.
  • In a further preferred embodiment, the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh air grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one airflow channel groove, one heating zone; and the fresh air grooves are arranged opposite of every heating zone.
  • In a further preferred embodiment, the fresh air grooves are in the slanted surface of the conically shaped heating element, and the airflow channel grooves are in the wall of the conically shaped contacting element, whereby the fresh air grooves extend each between the cone basis and the cone top, and the airflow channel grooves extend between the opening circumference and the bottom, further whereby the fresh air grooves and the airflow channel grooves have respectively a first determined width and a second determined width, and are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
  • In a further preferred embodiment, the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves and the fresh air grooves have respectively a first determined width and a second determined width, and are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
  • In a further preferred embodiment, the conically shaped heating element is a male element and the conically shaped contacting element of the capsule is a female element.
  • In a further preferred embodiment, the conically shaped heating element is a female element and the conically shaped contacting element of the capsule is a male element.
  • The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description with reference to the attached drawings showing some preferred embodiments of the invention.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain features of the invention.
  • FIG. 1 contains a schematic sectional view of a vaporizable material capsule mated with a conically shaped heating element, according to an example embodiment of the invention.
  • FIG. 2 contains a schematic rolled out view of a section through a conically shaped heating element with airflow management features according to an example embodiment of the invention.
  • FIG. 3 contains a schematic sectional view of an example airflow management configuration according to the invention.
  • FIG. 4 contains yet another schematic sectional view of an example configuration according to the invention.
  • FIG. 5 shows a top view on a section of a conically shaped heating element as an example of a heating element for use in the invention.
  • FIG. 6 shows the conically shaped heating element from FIG. 5 , inserted into an example embodiment of a vaporizable material capsule’s cavity according to the invention.
  • Herein, identical reference numerals are used, where possible, to designate identical elements that are common to the Figures. Also, the images are simplified for illustration purposes and may not be depicted to scale.
  • DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
  • In the present detailed description of preferred embodiments, the term vaporizable material capsule will be used to designate any one of a consumable, cartridge, capsule or article CR that includes a chamber or reservoir containing or holding at least one vaporizable material or at least one vapor or aerosol generating substance. The term vaporizable material is used to designate vapor or any material that is vaporizable at a temperature up to 400° C., preferably up to 350° C., for example aerosol generating liquid, gel, wax and the like.. The term wicking element will be used to also designate a wick or any other suitable porous material such as a porous ceramic, a mesh, a foam, a sponge-like material.
  • An exemplary embodiment of an aerosol generating system 100 according to the present disclosure is shown, in FIG. 1 . FIG. 1 depicts an exemplary schematic view of the aerosol generating system 100 that comprises a conically shaped heating element 101 and a vaporizable material capsule 102, both illustrated in a symbolic representation.
  • The aerosol generating system 100 is, for example, to be used in or included in an aerosol generating device, an inhalation device or an electronic cigarette (not shown in FIG. 1 ).
  • The conically shaped heating element 101 is configured in the represented example as a male component formed as a solid frustum to generate an aerosol (the aerosol is not represented in FIG. 1 ) by evaporating vaporizable material 103 on a slanted surface 104. The process of evaporating vaporizable material to generate the aerosol is well known in the art and will not be described herein in more detail.
  • The vaporizable material capsule 102 is configured to contain a vaporizable material 103, which in use may flow out towards the slanted surface 104. The vaporizable material capsule 102 comprises a conically shaped contacting element, in this example formed as a cavity delimited by a slanted surface 105 complementary in shape to that of the heating element and thus configured to mate with the conically shaped heating element 101 along its slanted surface 104. A fluidic passage (not represented in FIG. 1 ) for the vaporizable material 103 located inside the vaporizable material capsule 102 may be enabled towards a space delimited by the slanted surface 104, 105 of the heating element and contacting element respectively.
  • A size and shape of the conically shaped cavity are configured such that they substantially match the conically shaped heating element 101 at a time of mating. A determined gap between the convex slanted surface 104 and the concave slanted surface 105 is configured to accommodate for example, an interfacing layer of a wicking element 106 such as a mesh or other porous material, covering at least a part of the respective slanted surfaces 104, 105. This is useful to receive the vaporizable material 103 inside the wicking element 106 and evaporate it in a known manner.
  • The vaporizable material capsule 102 and/or the conically shaped heating element 101 may comprise at least one airflow channel groove (not represented in FIG. 1 but will be discussed in detail further along the description). The at least one airflow channel groove is configured to collect and receive vaporized vaporizable material, i.e., vaporizable material which is heated and hence aerosolized by the conically shaped heating element 101, and directs the aerosolized vaporizable material through a vapor conduit 107, which in turn enables the aerosol to reach an aerosol delivery port such as a mouthpiece, to be inhaled by an intended user (mouthpiece and user not represented in FIG. 1 ).
  • The vaporizable material capsule 102 and/or the conically shaped heating element may further comprise at least one fresh air groove (not represented in FIG. 1 but will be discussed in detail further along the description). The at least one fresh air groove is configured to provide fresh air in vicinity of the wicking element 106 and airflow channel groove, the fresh air groove arriving through an air inlet of the aerosol generating device (the two latter are not represented in FIG. 1 ). Arrows A and B show examples of locations at a periphery of the vaporizable material capsule 102 and conically shaped heating element 101, where fresh air may be provided to flow into the at least one fresh air groove.
  • FIG. 2 shows a schematic view of the periphery of the conically shaped heating element 101 and interfacing layer 106 of FIG. 1 , along a section shown by dotted line 108 in FIG. 1 , in an exemplary embodiment. The periphery would normally be of circular shape but has been rolled out flat in FIG. 2 for a better readability. Hence the layer of wicking element 106 is represented as a fiat layer, which covers the convex slanted surface 104, also represented as a flat surface/line here. A side 207 of the interfacing wicking layer 106 opposite to that of the convex slanted surface 104 is configured to cover the concave slanted surface of the vaporizable material capsule (both not represented in FIG. 2 ) at the time of mating between the heating element and the vaporizable material capsule, as shown in FIG. 1 . An airflow management system arranged here on the convex slanted surface 104 is configured in the vicinity of the interfacing layer 106, and comprises a plurality of fresh air grooves 200 and airflow channel grooves 201 arranged in the wail of the conically shaped heating element 101, and configured respectively to conduct fresh air or the aerosol as explained hereinabove.
  • As implied by the geometrical properties of a cone, the conically-shape heating element 101 comprises a cone basis, i.e., a first end of the cone that has the larger diameter, and a cone top, i.e., a second end of the cone opposite to the first end and being either of sharp of truncated constituency. In the example of FIG. 1 the cone top is truncated, but this has no particular incidence for the invention. Returning back to FIG. 2 , this illustrates that the conically shaped heating element 101 comprises a plurality of distinct heating zones 203 that are configured to occupy corresponding circumferential arc portions 204 on the convex slanted surface 104. While the cone basis and the cone top are not illustrated in FIG. 2 , it should be said that each of the plurality of distinct heating zones 203 extends between the cone basis and the cone top.
  • Further in the example illustrated in FIG. 2 , the fresh air grooves 200 and the airflow channel grooves 201 have respectively a first determined width 205 and a second determined width 206 and extend between the cone basis and the cone top. Similar as the distinct heating zones 203, the fresh air grooves 200 and the airflow channel grooves 201 also extend between the cone basis and the cone top and are arranged around the circumference of the conically shaped heating element 101. Together with the distinct heating zones they form a plurality of groups comprising in this order: one fresh air groove 200, one heating zone 203, one airflow channel groove 201, one heating zone 203. The illustration in FIG. 2 contains two of such groups, one more fresh air channel 200 and a few more heating zones 203.
  • The configuration of fresh air grooves 200, airflow channels 201 and heating zones 203 according to the invention enables an efficient airflow management in the aerosol generating system comprising a conically-shape heating element 101. Vaporizable material that has flown into the wicking element 106 is heated in the areas adjacent to the heating zone 203 and evaporated to aerosol which is evacuated in the airflow channel grooves 201 that face the wicking element 106 and guided towards the vapor conduit. The fresh air grooves 200 enable fresh air to be provided and hence the airflow process may be sustained. The configuration according to the invention enables an efficient airflow management by means of a configuration of grooves and heating zones that are distributed all around the circumference of the conically shaped heating element, whereby grooves are exclusively comprised in the conically shaped heating element in the specific example embodiment illustrated in FIG. 2 . Further examples will be explained in the following paragraphs.
  • The example illustrated in FIG. 2 may be used to discuss a further example embodiment, although this is not explicitly illustrated. For this, it should be considered that the wicking element 106 is located between the convex slanted surface 104 of the heating element 101 and a concave slanted surface 105 of the contacting element from a vaporizable material capsule, surface which is located on a side of the wicking element 106 opposite to that where the convex slanted surface is located. Further all fresh air grooves 200 and airflow channel grooves 201 are to be comprised on the side of the concave slanted surface, i.e., on the side of the vaporizable material capsule. The manner in which the airflow is managed in this further example embodiment is somewhat similar to the airflow management in FIG. 2 explained in the preceding paragraph, and this offers similar advantages. The main difference is that the grooves need to be manufactured into the vaporizable material capsule.
  • FIG. 3 illustrates yet another example embodiment according to the invention, which illustrates a top-view of a section through the conically shaped heating element 101, including for a better understanding also a representation of the location of the cone top (the smaller circle in the middle). The illustration shows a circumference of the conically shaped heating element 101 delimited by the convex slanted surface 104 and a circumference of the vaporizable material capsule delimited by the concave slanted surface 105, and the layer of wicking element 106 in between. The heating zones 203 are comprised on the side of the conically shaped heating element 101, together with the airflow channel grooves 201, while the fresh air grooves 200 are comprised on the side of the vaporizable material capsule.
  • As implied by the geometrical properties of a cone, the conically shaped cavity of the vaporizable material capsule is delimited at its opening by an opening circumference that has the larger diameter, and at the other end of the cone by a bottom. The fresh air grooves 200 extend between the opening circumference and the bottom.
  • All grooves and heating zones together form a plurality of groups comprising in this order: one fresh air groove 200, one heating zone 203, one airflow channel groove 201, one heating zone 203. The illustration in FIG. 3 contains three such groups.
  • The example illustrated in FIG. 3 may be used to discuss a further example embodiment, although this is not explicitly illustrated. In this further example embodiment, it should be considered that the airflow channel grooves are replaced by fresh air grooves, and vice-versa.
  • FIG. 4 illustrates yet another example embodiment according to the invention, which, similar to FIG. 3 illustrates a top view of a section through the conically shaped heating element 101. One difference with FIG. 3 is that in FIG. 4 a part of the wall 400 from the vaporizable material capsule, delimited by concave slanted surface 105 is represented. The heating zones 203 are comprised on the side of the conically shaped heating element 101, together with airflow channel grooves 201, while the fresh air grooves 200 are comprised on the side of the vaporizable material capsule. All grooves and heating zones together form a plurality of groups comprising in this order: one airflow channel groove 201, one heating zone 203. Each of the groups further comprises one fresh air channel 200 which is arranged opposite of the heating zone 203. The illustration in FIG. 4 comprises three such groups.
  • The example illustrated in FIG. 4 may be used to discuss a further example embodiment, although this is not explicitly illustrated. In this further example embodiment, it should be considered that the airflow channel grooves are replaced by fresh air grooves, and vice-versa.
  • In FIG. 4 the layer of wicking element 106 has an opening respectively located between each heating zone 203 and each fresh air groove 200. This may improve the efficiency of the airflow from the fresh air groove 200 to each of the surrounding airflow channel grooves 201, as the portion of wicking element 106 that the air travels through the wicking element to flow from one groove to another groove is shorter than if the wicking element had covered the whole heating zone 203 along the circumference. However, it may be desirable to actually extend the wicking element 106 over the heating element in orderto adjust a resistance to air flow from one groove to another, and this may be part of a further preferred embodiment that is not illustrated in the figures.
  • FIG. 5 shows yet another example embodiment of a conically shaped heater element in a sectional top-view, the viewing angle being similar as that from FIG. 3 and FIG. 4 . In this embodiment, the heating zones 203 are comprised on the circumference of the heating element 101, and the whole circumference is covered by a layer of wicking element 106. FIG. 6 illustrates the conically shaped heating element of FIG. 5 as inserted in the cavity of a vaporizable material capsule 102, whereby the layer of wicking element is covered up by part of the vaporizable material capsule’s wall. In this example, the fresh air grooves 200 and the airflow channel grooves 201 are comprised in the vaporizable material capsule 102. The actual distribution of the grooves and channels is similar to that encountered in the example of FIG. 4 and is as follows. All grooves and heating zones together form a plurality of groups comprising in this order: one airflow channel groove 201, one heating zone 203. Each of the groups further comprises one fresh air channel 200 which is arranged opposite of the heating zone 203. The illustration in FIG. 6 comprises three such groups.
  • An advantage of the example embodiment illustrated in FIG. 6 is that all the grooves are part of the vaporizable material capsule 102, which typically may be a disposable part of the aerosol generating system. Hence, they are renewed at each change of the vaporizable material capsule, and are always comparatively clean, as compared to grooves located on the side of the conically shaped heating element, which have a longer life cycle and hence run a greater probability of becoming clogged over time.
  • A further advantage of the present invention is that holding the liquid in a separate portion than the gap has the advantage to not continuously heat up the whole reservoir that may not be good for the taste of the generated aerosol.
  • A further advantage of the present invention is that the porous layer is localized inside the cone, that is easier and more efficient as liquid will remain in the porous area.
  • A further advantage is that having grooves on the slanted surface of the conically shaped heating element allows to optimize the vapor/airflow path volume compare to prior art with limited airflow/vapor capability due to space restriction.
  • Implementations described herein are not intended to limit the scope of the present disclosure but are just provided to illustrate possible realizations.
  • While the invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments, and equivalents thereof, are possible without departing from the sphere and scope of the invention. Accordingly, it is intended that the invention not be limited to the described embodiments and be given the broadest reasonable interpretation in accordance with the language of the appended claims. The features of any one of the above described embodiments may be included in any other embodiment described herein.

Claims (10)

1. An aerosol generating system comprising
a conically shaped heating element configured to generate an aerosol by evaporating a vaporizable material on a slanted surface, and
a vaporizable material capsule configured to contain a vaporizable material, whereby the vaporizable material capsule comprises a conically shaped contacting element having a slanted surface configured to mate with the conically shaped heating element in use,
wherein an interfacing layer is arranged in a gap between the slanted surfaces of both the heating element and contacting element, and the interfacing layer contacting the slanted surfaces of both the heating element and contacting element, the interfacing layer comprising a porous material configured to wick vaporizable material from the slanted surface of the contacting element to the slanted surface of the heating element, and
wherein an airflow management system is arranged in the vicinity of the interfacing layer, including fresh air grooves and airflow channel grooves in the walls of the conically shaped contacting element and/or in the slanted surface of the conically shaped heating element, and configured respectively to conduct fresh air or the aerosol.
2. The aerosol generating system of claim 1, wherein
the conically shaped heating element comprises a cone basis and a cone top, and a plurality of distinct heating zones occupying a corresponding circumferential arc portion on the slanted surface, each extending between the cone basis and the cone top, and the conically shaped contacting element has an opening circumference delimiting the contacting element at the side configured to enter in mating arrangement with the conically shaped heating element, and a bottom at the opposite extremity of the opening circumference, and the conically shaped heating element is removably mated with the vaporizable material capsule.
3. The aerosol generating system of claim 2, wherein
the fresh air grooves and the airflow channel grooves are in the slanted surface of the conically shaped heating element, the fresh air grooves and the airflow channel grooves having respectively a first determined width and a second determined width and extending between the cone basis and the cone top, and being arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel groove, one heating zone.
4. The aerosol generating system of claim 2, wherein
the fresh air grooves and the airflow channel grooves are in the slanted surface of the conically shaped contacting element, the fresh air grooves and the airflow channel grooves having respectively a first determined width and a second determined width and extending between the opening circumference and the bottom, and being arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
5. The aerosol generating system of claim 2, wherein
the fresh air grooves are in the slanted surface of the conically shaped heating element, and the airflow channel grooves are in the wall of the conically shaped contacting element, whereby the fresh air grooves extend each between the cone basis and the cone top, and the airflow channel grooves extend between the opening circumference and the bottom, further whereby the fresh air grooves are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone; and the airflow channel grooves are arranged opposite of every heating zone.
6. The aerosol generating system of claim 2, wherein
the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh air grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one airflow channel groove, one heating zone; and the fresh air grooves are arranged opposite of every heating zone.
7. The aerosol generating system of claim 2, wherein
the fresh air grooves are in the slanted surface of the conically shaped heating element, and the airflow channel grooves are in the wall of the conically shaped contacting element, whereby the fresh air grooves extend each between the cone basis and the cone top, and the airflow channel grooves extend between the opening circumference and the bottom, further whereby the fresh air grooves and the airflow channel grooves have respectively a first determined width and a second determined width, and are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
8. The aerosol generating system of claim 2, wherein
the airflow channel grooves are in the slanted surface of the conically shaped heating element, and the fresh grooves are in the wall of the conically shaped contacting element, whereby the airflow channel grooves extend each between the cone basis and the cone top, and the fresh air grooves extend between the opening circumference and the bottom, further whereby the airflow channel grooves and the fresh air grooves have respectively a first determined width and a second determined width, and are arranged around the circumference of the conically shaped heating element in a plurality of groups comprising in this order: one fresh air groove, one heating zone, one airflow channel, one heating zone.
9. The aerosol generating system according to any one of the preceding claims, wherein the conically shaped heating element is a male element and the conically shaped contacting element of the capsule is a female element.
10. The aerosol generating system according to any one of claims 1-8, wherein the conically shaped heating element is a female element and the conically shaped contacting element of the capsule is a male element.
US17/925,487 2020-05-28 2021-05-26 Aerosol Generating System Pending US20230180830A1 (en)

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