US20230284702A1

US20230284702A1 - Vapour Generation Device Vaporisation Component

Info

Publication number: US20230284702A1
Application number: US18/007,222
Authority: US
Inventors: Alec Wright; Andrew Robert John ROGAN; Kyle ADAIR; Olayiwola Olamiposi Popoola; Gordon Montgomery
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2020-07-29
Filing date: 2021-07-28
Publication date: 2023-09-14
Also published as: US20230284698A1; US20230270174A1; CA3186460A1; WO2022023428A1; CA3186481A1; EP4188137A1; CA3186470A1; EP4188136A1; WO2022023430A1; EP4188135A1; WO2022023429A1

Abstract

A vaporisation component of a vapour generation device is provided. The vaporisation component comprises an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance. The evaporator component has a first surface over which air flows in an airflow channel of a vapour generation device in a direction toward a mouthpiece. At least a portion of the first surface is non-flat with respect to the airflow channel so as to interfere with an airflow in the airflow channel and affect a distribution of droplets in the generated vapour flow.

Description

FIELD OF INVENTION

The present invention relates to vapour generation devices, and more specifically heaters for vapour generation devices.

BACKGROUND

Vapour generating devices, such as electronic cigarettes, are becoming increasingly popular consumer products.
Heating devices for vaporisation or aerosolisation are known in the art. Such devices typically include a heater arranged to heat a vaporisable product. In operation, the vaporisable product is heated with the heater to vaporise the constituents of the product for the consumer to inhale. In some examples, the product may comprise tobacco in a capsule or may be similar to a traditional cigarette, in other examples the product may be a liquid, or liquid contents in a capsule.
There is a need to improve the experience of the consumer of such products; an object of the present invention is to address this need by improving the quality of the vapour flow. There is also a need to improve evaporator operation; another object of the invention is to address this.

SUMMARY

In a first aspect, there is provided a vaporisation component of a vapour generation device, wherein the vaporisation component comprises:
an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance, the evaporator component having a first surface over which air flows in an airflow channel of a vapour generation device in a direction toward a mouthpiece, wherein at least a portion of the first surface is non-flat with respect to the airflow channel so as to interfere with an airflow in the airflow channel and affect a distribution of droplets in the generated vapour flow.
In this way, the interference with the airflow due to the non-flat first surface of the evaporator component increases the mixing of the airflow with the droplets. Consequently, a more even distribution of droplets in the airflow can be achieved. This homogenises the output combination of air, vapour and droplets from a mouthpiece of a vapour generation device comprising the vaporisation component. This increased mixing of hot droplets with the cool airflow also reduces overall vapour temperature, which can improve the user experience. The non-flat surface also allows for the airflow to be directed toward the surface, rather than across the surface; this increases the probability of removing droplets from the region around the surface earlier in their formation. As such, an increased mixing of the airflow with the droplets is achieved; this also limits the growth of droplets and reduces the likelihood of coalescence between droplets thereby inhibiting the formation of droplets that are undesirably large. Furthermore, the non-flat surface causes air to flow across the surface at differing velocities at different locations compared to a flat surface; this causes different forces to be applied to droplets proximal to the surface as they are carried away from the surface by the airflow. These differing forces applied to different droplets can cause a beneficial variation in droplet size. Smaller droplets aid in nicotine delivery to the lungs, and large droplets improve flavour delivery to the mouth. These technical advantages combine to improve the experience of a user of a vapour generation device that incorporates the vaporisation component.
Preferably, the evaporator component further comprises one or more evaporator channels arranged therethrough to connect the first surface to a reservoir configured to store the vaporisable substance, and wherein the evaporator channels are configured to transport the vaporisable substance from the reservoir to openings in the first surface.
In this way, the interference with the airflow due to the non-flat first surface increases the probability of removing droplets from the region around the first surface earlier in their formation. This firstly helps to inhibit droplets from blocking the evaporator channels, and secondly helps to inhibit droplets coalescing to form larger droplets that may cause greater blockages to one or more of the evaporator channels. Inhibiting the blockage of the one or more evaporator channels by droplets improves the operation of the evaporator component.
Preferably, the evaporator component is a block with one or more through-holes passing through the block to form the one or more evaporator channels arranged through the block.
Preferably, the evaporator component is a heater and the one or more evaporator channels are arranged through the heater.
Preferably, the non-flat portion of the first surface has a curved profile.
Preferably, the non-flat portion of the first surface comprises a plurality of curved profiles.
Preferably, the curved profile is curved in at least one dimension of the first surface.
Preferably, the curved profile is curved in two dimensions of the first surface.
Preferably, the curved profile is substantially concave.
Preferably, the curved profile is substantially convex.
Preferably, the curved profile comprises convex and concave portions.
Preferably, the non-flat portion of the first surface linearly tapers inward to the airflow channel in the direction of airflow, or wherein the first surface linearly tapers inward to the airflow channel in a direction opposite to the direction of airflow.
Preferably, the first surface further comprises a plurality of recessed portions configured to interfere with an airflow in the airflow channel and affect a distribution of droplets in the vapour flow.
In this way, the recessed portions can control micro-scale airflow over the first surface. This can further contribute to the interference with the airflow in the airflow channel and affect the distribution of droplets in the generated vapour flow as the recessed portions change the airflow over the first surface.
Preferably, the first surface has hydrophobic properties.
In this way, the hydrophobic properties help to inhibit the build-up of droplets on the surface of the evaporator component. The repulsion of the droplets due to the hydrophobicity aids in removing the droplets from the surface of the evaporator component when combined with the airflow in the airflow channel. The build-up of droplets on the surface of the evaporator component can negatively impact the operation of the evaporator component; the removal of the droplets, aided by the hydrophobic properties, helps to negate this issue thereby improving the performance of the evaporator component.
Preferably, the vaporisation component further comprises a reservoir configured to house the vaporisable substance, the reservoir in connection with a second surface of the evaporator component, wherein the second surface is distinct from the first surface.
In a second aspect, there is provided a cartridge for use with a vapour generating device, the cartridge comprising the vaporisation component of the first aspect.
In this way, the vaporisation component can form part of a consumable cartridge and can be replaceable in a vapour generation device. In particular, this can be beneficial when changing to a vaporisable substance of a different flavour, in a new cartridge, as a new evaporator component would be used and the generated vapour would not be contaminated with residual flavouring from the previous vaporisable substance.
In a third aspect, there is provided a vapour generating device comprising the vaporisation component of the first aspect or the cartridge of the second aspect.
In a fourth aspect, there is provided a vaporisation component of a vapour generation device, wherein the vaporisation component comprises:

- an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance, the evaporator component having a first surface over which air flows in an airflow channel of a vapour generation device in a direction toward a mouthpiece, wherein the first surface comprises a plurality of recessed portions configured to interfere with an airflow in the airflow channel and affect a distribution of droplets in the generated vapour flow.

In this way, the recessed portions in the first surface of the evaporator component can control micro-scale airflow over the first surface. This interference with the airflow in the airflow channel affects the distribution of droplets in the generated vapour flow as the recessed portions change the airflow over the first surface. This provides a more homogenous output from a mouthpiece of an vapour generation device incorporating the vaporisation component. The interference with the airflow provided by the recessed portions also reduces coalescence of droplets, thereby inhibiting the formation of undesirably large droplets, as the droplets a carried away from the first surface before such coalescence can occur. The interference with the airflow provided by the recessed portions is also advantageous in that it increases the mixing of hot droplets with the cool air in the airflow so as to reduce the overall vapour temperature. Each of these advantages can contribute to improving the quality of the vapour output that is inhaled by the user of a vapour generation device incorporating a vaporisation component having an evaporator component with recessed portions.
Preferably, the evaporator component further comprises one or more evaporator channels arranged therethrough to connect the first surface to a reservoir configured to store the vaporisable substance, and wherein the evaporator channels are configured to transport the vaporisable substance from the reservoir to openings in the first surface.
In this way, the interference with the airflow due to the recessed portions in the first surface increases the probability of removing droplets from the region around the first surface earlier in their formation. This firstly helps to inhibit droplets from blocking the evaporator channels, and secondly helps to inhibit droplets coalescing to form larger droplets that may cause greater blockages to one or more of the evaporator channels. Inhibiting the blockage of the one or more evaporator channels by droplets improves the operation of the evaporator component.
Preferably, the evaporator component is a block with one or more through-holes passing through the block to form the one or more evaporator channels arranged through the block.
Preferably, the evaporator component is a heater and the one or more evaporator channels are arranged through the heater.
Preferably, openings of the one or more evaporator channels are alternately arranged with the plurality of recessed portions in the first surface.
In this way, droplets formed at each of the one or more evaporator channels have recessed portions in close proximity that will interfere with the airflow to draw the droplets away from the evaporator channels.
Preferably, the plurality of recessed portions are a plurality of dimples in the first surface.
Preferably, the recessed portions are hemispherical or substantially hemispherical in shape.
Preferably, a recessed portion is arranged to provide a circular airflow in the proximity of the recessed portion when air flows over the first surface.
Preferably, a recessed portion has a depth of 1 to 10 mm.
Preferably, at least a portion of the first surface is non-flat with respect to the airflow channel so as to interfere with an airflow in the airflow channel and affect a distribution of droplets in the generated vapour flow.
In this way, the interference with the airflow due to the non-flat first surface increases the mixing of the airflow with the droplets. This can further contribute to the interference with the airflow in the airflow channel and affect the distribution of droplets in the generated vapour flow as the non-flat shape changes the airflow over the first surface.
Preferably, the plurality of recessed portions are arranged in the non-flat portion of the first surface.
In this way, the combined effect of the recessed portions and non-flat shape on the airflow over the first surface can be emphasised.
Preferably, the non-flat portion of the first surface has a curved profile.
Preferably, the first surface has hydrophobic properties.
In this way, the hydrophobic properties help to inhibit the build-up of droplets on the surface of the evaporator component. The repulsion of the droplets due to the hydrophobicity aids in removing the droplets from the surface of the evaporator component when combined with the airflow in the airflow channel. The build-up of droplets on the surface of the evaporator component can negatively impact the operation of the evaporator component; the removal of the droplets, aided by the hydrophobic properties, helps to negate this issue thereby improving the performance of the evaporator component.
Preferably, the hydrophobic properties are provided by a hydrophobic layer.
Preferably, the vaporisation component further comprises a reservoir configured to house the vaporisable substance, the reservoir in connection with a second surface of the evaporator component, wherein the second surface is distinct from the first surface.
In a fifth aspect, there is provided a cartridge for use with a vapour generating device, the cartridge comprising the vaporisation component of the fourth aspect.
In this way, the vaporisation component can form part of a consumable cartridge and can be replaceable in a vapour generation device. In particular, this can be beneficial when changing to a vaporisable substance of a different flavour, in a new cartridge, as a new evaporator component would be used and the generated vapour would not be contaminated with residual flavouring from the previous vaporisable substance.
In a sixth aspect, there is provided a vapour generating device comprising the vaporisation component of the fourth aspect or the cartridge of the fifth aspect.
In a seventh aspect, there is provided a vaporisation component of a vapour generation device, wherein the vaporisation component comprises:

- an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance, the evaporator component having a first surface over which air flows in a vapour generation device, wherein the first surface comprises hydrophobic properties configured to repel droplets from the vapour flow.

In this way, the hydrophobic properties help to inhibit the build-up of droplets on the surface of the evaporator component. The repulsion of the droplets aids in removing the droplets from the first surface when combined with an airflow over the first surface. The build-up of droplets on the surface of the evaporator component can negatively impact the operation of the evaporator component; the removal of the droplets, brought about by the hydrophobic properties, helps to negate this issue thereby improving the operation of the evaporator component.
Preferably, the evaporator component further comprises one or more evaporator channels arranged therethrough to connect the first surface to a reservoir configured to store the vaporisable substance, and wherein the evaporator channels are configured to transport the vaporisable substance from the reservoir to openings in the first surface.
In this way, the hydrophobic properties provide for repelling droplets so as to inhibit the pooling of droplets on the first surface of the evaporator component; pooled droplets can block the one or more evaporator channels. Inhibiting the build-up or pooling of such droplets improves the operation of the evaporator component.
Preferably, the evaporator component is a block with one or more through-holes passing through the block to form the one or more evaporator channels arranged through the block.
Preferably, the evaporator component is a heater and the one or more evaporator channels are arranged through the heater.
Preferably, the first surface comprises a structured surface configured to provide hydrophobic properties.
Preferably, the structured surface is a micro-structured and/or nano-structured surface.
Preferably, the structured surface comprises a hierarchical structured surface comprising a micro-scale roughness covered by a nano-scale roughness.
Preferably, the first surface further comprises a hydrophobic layer at least partially coating the structured surface.
Preferably, the evaporator component comprises a hydrophobic layer at least partially forming the first surface.
Preferably, the hydrophobic layer comprises at least one of a high temperature polymer, a ceramic, a rare earth oxide, grafted organic molecules or polymers.
Preferably, the hydrophobic properties are provided by a chemical coating added to the first surface of the evaporator. Alternatively, the hydrophobic properties are provided by a physical treatment applied to the first surface of the evaporator.
Alternatively, the hydrophobic properties are provided by a combination of a chemical coating added to the first surface of the evaporator and a physical treatment applied to the first surface of the evaporator.
Preferably, the hydrophobic properties are configured to provide a contact angle for a droplet of greater than or equal to 150°.
In this way, the hydrophobic properties can exhibit superhydrophobicity aiding in the removal of droplets from the first surface of the evaporator component.
Preferably, the vaporisation component further comprises a reservoir configured to house the vaporisable substance, the reservoir in connection with a second surface of the evaporator component, wherein the second surface is distinct from the first surface.
In an eighth aspect, there is provided a cartridge for use with a vapour generating device, the cartridge comprising the vaporisation component of the seventh aspect.
In this way, the vaporisation component can form part of a consumable cartridge and can be replaceable in a vapour generation device. In particular, this can be beneficial when changing to a vaporisable substance of a different flavour, in a new cartridge, as a new evaporator component would be used and the generated vapour would not be contaminated with residual flavouring from the previous vaporisable substance.
In a ninth aspect, there is provided a vapour generating device comprising the vaporisation component of the seventh aspect or the cartridge of the eighth aspect.
In a tenth aspect, there is provided a method of fabricating a vaporisation component of a vapour generation device, wherein the vaporisation component comprises an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance, the evaporator component having a first surface over which air flows in a vapour generation device, the method comprising:

- modifying the first surface to provide hydrophobic properties configured to repel droplets from the vapour flow.

In this way, a vaporisation component having an evaporator component with hydrophobic properties is provided. These hydrophobic properties help to inhibit the build-up of droplets on the surface of the evaporator component. The repulsion of the droplets aids in removing the droplets from the first surface when combined with an airflow over the first surface. The build-up of droplets on the surface of the evaporator component can negatively impact the operation of the evaporator component; the removal of the droplets, brought about by the hydrophobic properties, helps to negate this issue thereby improving the operation of the evaporator component.
Preferably, modifying the first surface comprises patterning the first surface such that first surface comprises a structured surface configured to provide hydrophobic properties.
Preferably, modifying the first surface comprises applying a hydrophobic layer to the first surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:

FIG. 1A is a conceptual cross-sectional view of a portion of a vaporisation component for a vapour generation device;

FIG. 1B is a conceptual cross-sectional view of a vaporisation component integrated into a portion of a vapour generation device;

FIG. 2A is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 2B is a conceptual cross-sectional view of a vaporisation component integrated into a portion of a vapour generation device;

FIG. 3 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 4 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 5 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 6 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 7 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 8 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 9 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface;

FIG. 10A is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a plurality of recessed portions in a surface;

FIG. 10B is a conceptual plan view of a portion of a vaporisation component with an evaporator component having a plurality of recessed portions in a surface;

FIG. 100 is a conceptual cross-sectional view of a vaporisation component integrated into a portion of a vapour generation device;

FIG. 11 is a conceptual cross-sectional view of a portion of a vaporisation component with an evaporator component having a non-flat surface with a plurality of recessed portions;

FIG. 12A is a conceptual cross-sectional view of an vaporisation component with a hydrophobic layer arranged on the first surface of the evaporator component;

FIG. 12B is a conceptual cross-sectional view of a vaporisation component having a structured first surface with a hydrophobic layer arranged on the structured first surface of the evaporator component; and

FIG. 12C is conceptual perspective view of the vaporisation component of FIG. 12A.

DETAILED DESCRIPTION

A vapour generation device is a device arranged to heat a vapour generating product to produce a vapour for inhalation by a consumer. In a specific example, a vapour generating product can be a liquid which forms a vapour when heated by the vapour generation device. A vapour generation device can also be considered an electronic cigarette, or aerosol generation device. In context of the present disclosure, the terms vapour and aerosol can be used interchangeably. A vapour generating product, or aerosol generating product, can be a liquid or a solid such as a fibrous material, or a combination thereof, that when heated generates a vapour or aerosol.
FIG. 1A shows a cross-sectional diagram of a portion of a vaporisation component 100 for a vapour generation device.
The vaporisation component 100 comprises an evaporator component 102 and a reservoir 116. The reservoir 116 is arranged to store a liquid vapour generating product. The evaporator component 102 (hereinafter referred to as the evaporator) can be considered as an evaporator block or heater, and in an example can be formed from silicon. FIG. 1B shows a conceptual cross-sectional diagram of the evaporator 102 integrated into a portion 180 of a vapour generation device.
The evaporator 102 has a first surface 104 that faces toward the airflow channel 128 of the vapour generation device. The airflow channel 128 of the vapour generation device is a channel through which air flows substantially in a direction 118 toward a mouthpiece 120 when a consumer draws upon the mouthpiece 120; that is, the airflow channel 128 connects air inlets (not shown) to the mouthpiece 120 for the passage of air through the device. The airflow channel 128 is arranged to transport generated vapour to the mouthpiece 120 through which the vapour is inhaled. The first surface 104 of the evaporator 102 can be arranged in the airflow channel 128, and in the example of FIGS. 1A and 1B can form a portion of an internal sidewall of the airflow channel 128. The cross-section of FIGS. 1A and 1B are viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120.
In an example, the evaporator can be a micro-electro-mechanical system (MEMS) evaporator; this evaporator can be silicon-based at least in part.
The evaporator 102 has a second surface 106 on a separate face to the first surface 104. In the example of FIGS. 1A and 1B the second surface 106 is on an opposing face to the first surface 104. The second surface 106 of the of the evaporator 102 is arranged to be in connection with the reservoir 116.
A plurality of channels 108 are arranged through the evaporator 102 to connect a set of first openings 110 in the first surface 104 to a corresponding set of second openings 112 in the second surface 106. That is, each of these evaporator channels 108 is a through-hole that passes through the evaporator 102 with one end of each evaporator channel 108 forming a first opening 110 in the first surface 104 and the other end of each evaporator channel 108 forming a second opening 112 in the second surface 106. These evaporator channels 108 can be in an array type arrangement and of micrometre scale.
The evaporator channels 108 are arranged to draw liquid from the reservoir 116 through the second openings 112, through the evaporator channels 108, and to the first openings 110 by capillary force.
Any suitable number of evaporator channels 108, with corresponding numbers of first 110 and second openings 112, can be arranged in the evaporator 102. In some examples there may be one evaporator channel 108, in other examples there may be a plurality of evaporator channels 108.
In some examples, an optional wicking material 114 can be incorporated into the vaporisation component 100, and in particular can be arranged between the second surface 106 of the evaporator 102 and the reservoir 116. The wicking material 114 can aid in the transfer of liquid from the reservoir 116 to the second openings 112 in the second surface 106. In this way, the reservoir 116 can either be in direct connection with the second surface 106 of the evaporator 102, or in connection connected with the second surface 106 by way of the wicking material 114.
For clarity, only the evaporator 102 of the vaporisation component 100 is shown in FIG. 1B, the reservoir 116 and optional wicking material 114 are not shown but can readily be included.
In operation, liquid is drawn from the reservoir 116 into the second openings 112 in the second surface 106 of the evaporator 102 and into and through the evaporator channels 108 by capillary action. A potential is applied to the evaporator 102 by a heater control circuit (not shown) so as to heat the evaporator 102. In turn the evaporator 102 heats the liquid, through the sidewalls of the evaporator channels 108, as the liquid is drawn through the evaporator channels 108 to create a vapour. The vapour then exits the evaporator channels 108 as a vapour flow through the first openings 110 in the first surface 104 and enters the airflow channel 128 of the vapour generation device. This vapour flow can also include liquid droplets 124 from the evaporator channels 108.
In the example of FIG. 1B, the first surface 104 of the evaporator 102 partially defines an internal wall of the airflow channel 128. The airflow channel 128 can be considered as a tube or passageway, defined by internal walls, through which the air and vapour travels to the mouthpiece 120. An opposing internal wall 122 of the airflow channel is also shown in FIG. 1B, the opposing internal wall 122 at least partially forms part of the internal wall of the airflow channel 128 opposite to the first surface 104 of the evaporator 102. Further internal walls, that complete the definition of the airflow channel 128, connect the first surface 104 of the evaporator and the opposing wall 122. For clarity, these further internal walls are not shown in the cut-away section in FIG. 1B.
When a consumer draws on the mouthpiece 120, air is brought into the airflow channel 128 through air inlets (not shown) connected to the airflow channel 128 and distal from the mouthpiece 120 so as to create a pressure change that draws the generated vapour flow to the mouthpiece 120, in the airflow 118 as it passes over the first surface 104, for inhalation by the consumer.
For clarity, sections of the body of the vapour generation device are not shown in FIG. 1B, including portions containing control electronics, a power source such as a battery, and the electronics connecting the evaporator to the control electronics and power source.
The vaporisation component 100 of FIG. 1 , including the evaporator 102, reservoir 116 and optional wicking material 114, can be a single component. In some examples, the vaporisation component 100 is a component of the vapour generation device, with the reservoir 116 being refillable. In other examples, the vaporisation component 100 of FIG. 1 (including the evaporator 102, reservoir 116 and optionally the wicking material 114) can be comprised in a removable cartridge for the vapour generation device that can be detached from the vapour generation device (such as when the reservoir 116 is empty of liquid). In this example, the vaporisation component 100 can be a replaceable consumable, alternatively the reservoir 116 can be refilled.
In other examples, the evaporator 102 can be a component of the vapour generation device, and the reservoir 116 (and optionally the wicking material 114) can form a removable component that can be detached from the vapour generation device (such as when the reservoir 116 is empty of liquid).
The shape of at least a portion of the first surface 104 of the evaporator 102 described with reference to FIGS. 1A and 1B can be modified so as to interfere with and perturb the airflow 118 within the airflow channel 128 as it flows substantially toward the mouthpiece 120. This interference with the airflow affects the distribution of liquid droplets 124 in the generated vapour flow. FIGS. 2 to 9 , present various examples of vaporisation components 200, 300, 400, 500, 600, 700, 800, 900 with non-flat first surfaces of the evaporator, with respect to the airflow channel 128, which provide such an interference with the airflow. The vaporisation components of FIGS. 2 to 9 comprise the features described with reference to the vaporisation component 100 of FIGS. 1A and 1B (as in some cases denoted by the common reference numerals), but with a non-flat first surface for the evaporator. The vaporisation components of FIGS. 2 to 9 can be integrated into a vaporisation device as described with reference to FIGS. 1A and 1B. A non-flat evaporator surface causes the cross-section of the airflow channel 128 to be non-consistent in shape along its length when travelling toward the mouthpiece 120. A non-flat evaporator surface can increase the amount of airflow that hits the surface compared to a flat evaporator surface.
FIG. 2A shows a cross-sectional diagram of a portion of a vaporisation component 200 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The first surface 204 of the evaporator 202 is non-flat in that it is concavely shaped relative to the airflow channel 128 to provide the first surface 204 with a curved profile. That is, the evaporator 202 has a concavely curved portion 230 extending inward to evaporator 202 in the first surface 204. Along the direction toward the mouthpiece 120, the first surface 204 follows a curved profile that first curves away from the centre of the airflow channel 128, and then back toward the centre of the airflow channel 128. This concavely curved profile interferes with the airflow 218 as the airflow 218 moves over the first surface 204 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 through the airflow channel 128, as indicated the arrow 118 depicting the effect on the airflow 218. That is, the concavely curved first surface 204 perturbs the airflow 218 as it flows substantially toward the mouthpiece 120.
FIG. 2B presents a conceptual cross-sectional diagram of a portion 280 of a vapour generation device with a similar arrangement to that described with reference to FIG. 1B, but including the evaporator 202 described with reference to FIG. 2A (for clarity the reservoir 116 and optional wicking material 114 are not shown). The concavely curved first surface 204 of the evaporator 202 interferes with the airflow 218 as it passes through the airflow channel 128 over the first surface 204. This increases the Reynolds number of the airflow 218. Consequently, the distribution of the liquid droplets 124 included in the vapour flow from the first openings 110 of the evaporator channels 108 is affected by this interference to the airflow 218.
The interference with the airflow 218 due to the non-flat first surface 204 increases the mixing of the airflow 218 with the droplets 124. Consequently, a more even distribution of droplets 124 in the airflow 218 can be achieved. This homogenises the output combination of air, vapour and droplets from the mouthpiece 120 thereby improving the experience for the user of the device. Furthermore, this increased mixing of hot droplets 214 with the cool airflow 218 reduces overall vapour temperature, which can improve the user experience.
The non-flat first surface 204 allows for the airflow 218 to be directed toward the first surface 204, rather than only across the surface as in FIG. 1 . This, therefore, increases the probability of removing droplets 124 from the region around the first surface 204 earlier in their formation. That is, the an increased mixing of the airflow 218 with the droplets 124 is achieved that allows for the droplets 124 to be more readily moved away from the first openings 110 in the first surface 204 of the evaporator 202; this limits the growth of droplets 124 and reduces the likelihood of coalescence between droplets 124 thereby inhibiting the formation of droplets 124 that are undesirably large.
Another advantage of the non-flat first surface 204 is realised in that the non-flat first surface 204 causes the air to flow across the surface 204 at differing velocities at different locations compared to a flat first surface. This causes different forces to be applied to droplets 124 in the vapour flow as they are carried away from the first surface 204. These differing forces applied to different droplets 124 can cause a beneficial variation in droplet size. Smaller droplets aid in nicotine delivery to the lungs, and large droplets improve flavour delivery to the mouth. By providing droplets 124 of varying sizes, in the output to the user of the device, the user experience is improved.
FIGS. 3 to 9 present other examples of vaporisation components with non-flat surfaces that also provide these advantageous effects.
FIG. 3 provides an example of a vaporisation component 300 with an alternative curved profile to FIG. 2 , and shows a cross-sectional diagram of a portion of the vaporisation component 300 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The first surface 304 of the evaporator 302 is non-flat in that it is convexly shaped relative to the airflow channel 128 to provide the first surface 304 with a curved profile. That is, the evaporator 302 has a convexly curved portion 330 extending inward to the airflow channel 128. Along the direction toward the mouthpiece 120, the first surface 304 follows a curved profile that first curves inward toward the centre of the airflow channel 128, and then curves outward away from the centre of the airflow channel 128. This convexly curved profile interferes with the airflow 318 as the airflow 318 moves over the first surface 304 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128, as indicated arrow 318 depicting the effect on the airflow. That is, the convexly curved first surface 304 perturbs the airflow 118 as it flows substantially toward the mouthpiece 120.
FIG. 4 provides an example of a vaporisation component 400 with an alternative curved profile to FIGS. 2 and 3 , and shows a cross-sectional diagram of a portion of the vaporisation component 400 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The first surface 404 of the evaporator 402 is non-flat in that it comprises a plurality of concavely shaped regions 430 relative to the airflow channel 128 to provide the first surface 404 with a curved profile. That is, the evaporator 402 has a plurality of concavely curved portions 430 extending inward to evaporator 402 in the first surface 404. In FIG. 4 two concavely shaped regions 430 are present, the skilled person will however understand that the plurality of concavely shaped regions 430 can comprise more than two concavely shaped regions. Along direction toward the mouthpiece 120, the first surface 404 follows a curved profile that first curves away from the centre of the airflow channel 128, then back toward the centre of the airflow channel 128, then away from the centre of the airflow channel 128, and then back toward the centre of the airflow channel 128 again. The plurality of concavely shaped regions 430 interfere with the airflow 418 as the airflow 418 moves over the first surface 404 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128, as indicated arrow 418 depicting the effect on the airflow. That is, the plurality of concavely shaped regions 430 in the first surface 404 perturb the airflow 418 as it flows substantially toward the mouthpiece 120. In related examples, the first surface can alternatively comprise a plurality of convexly curved portions, or a combination of at least one concavely curved portion and at least one convexly curved portion in the direction along the airflow channel 128 toward the mouthpiece 120.
FIG. 5 provides an example of a vaporisation component 500 with a sloped non-flat first surface 504 of the evaporator 502, and shows a cross-sectional diagram of a portion of the vaporisation component 500 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The sloped non-flat first surface 504 linearly tapers inwardly to the airflow channel 128 in the direction along the airflow channel 128 toward the mouthpiece 120, i.e. the first surface linearly tapers inward toward the centre of airflow channel 128 in the substantial direction of the airflow 518. This tapering of the first surface 504 interferes with the airflow 518 as the airflow 518 moves over the first surface 504 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128, rather the airflow 518 is partially guided inwardly to the centre of the airflow channel 128 as indicated arrow 518 depicting the effect on the airflow. That is, the linearly tapering first surface 504 perturbs the airflow 518 as it flows substantially toward the mouthpiece 120.
FIG. 6 provides an example of a vaporisation component 600 with a sloped non-flat first surface 604 of the evaporator 602, and shows a cross-sectional diagram of a portion of the vaporisation component 600 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The sloped non-flat first surface 604 linearly tapers inwardly toward the centre of the airflow channel 128 in a direction along the airflow channel 128 away from the mouthpiece 120, i.e. the first surface linearly tapers inward toward to the centre of the airflow channel 128 opposite to the substantial direction of the airflow 618. This tapering of the first surface 604 interferes with the airflow 618 as the airflow 618 moves over the first surface 604 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128, rather the airflow 618 is partially guided outwardly from the centre of the airflow channel as indicated arrow 618 depicting the effect on the airflow. That is, the linearly tapering first surface 604 perturbs the airflow 118 as it flows substantially toward the mouthpiece 120.
In alternatives to FIGS. 5 and 6 the tapering can be curved rather than linear.
The examples described with reference to FIGS. 2 to 6 comprise first surfaces that are non-flat in a direction toward the mouthpiece 120 along the airflow channel 128. FIGS. 7 to 9 present various examples of non-flat first surfaces of the evaporator in a direction perpendicular to the direction toward the mouthpiece 120 along the airflow channel 128, which can also provide such an interference with the airflow.
When the first surface is non-flat only in one direction, it can be considered as non-flat in one dimension. The non-flat first surfaces of any of FIGS. 2 to 6 , which are non-flat in the direction toward the mouthpiece 120 along the airflow channel 128, can be combined with the non-flat first surfaces of any of FIGS. 7 to 9 , which are non-flat in the direction perpendicular to the direction toward the mouthpiece 120 along the airflow channel 128. In this way, the first surface can be non-flat in two dimensions.
FIG. 7 provides an example of a vaporisation component 700 with a convexly shaped non-flat first surface 704 of the evaporator 702, and shows a cross-sectional diagram of a portion of a vaporisation component 700 for a vapour generation device viewed in a direction along the airflow channel 128 toward the mouthpiece 128. The first surface 704 of the evaporator 702 is convexly shaped relative to the airflow channel 128 to provide the first surface 704 with a curved profile. That is, the evaporator 702 has a convexly curved portion 730 extending inward toward the centre of the airflow channel 128. In a direction across the airflow channel 128, perpendicular to the direction toward the mouthpiece 120, the first surface 704 follows a curved profile that it first curves inward toward the centre of the airflow channel 128, and then outward away from the centre of the airflow channel 128. This convexly curved profile 730 interferes with the airflow as the airflow moves over the first surface 704 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128. That is, the convexly curved first surface 704 perturbs the airflow as it flows substantially toward the mouthpiece 120.
FIG. 8 provides an example of a vaporisation component 800 with a concavely shaped non-flat first surface 804 of the evaporator 802, and shows a cross-sectional diagram of a portion of a vaporisation component 800 for a vapour generation device viewed in a direction along the airflow channel 128 toward the mouthpiece 120. The first surface 804 of the evaporator 802 is concavely shaped relative to the airflow channel 128 to provide the first surface 804 with a curved profile. That is, the evaporator 802 has a concavely curved portion 830 extending inward to the evaporator 802. In a direction across the airflow channel 128, perpendicular to the direction toward the mouthpiece 120, the first surface 804 follows a curved profile that it first curves outward away from centre of the airflow channel 128, and then back inward toward the centre of the airflow channel 128. This concavely curved profile 830 interferes with the air flow as the airflow moves over the first surface 804 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128. That is, the concavely curved first surface 804 perturbs the airflow as it flows substantially toward the mouthpiece 120.
FIG. 9 provides an example of a vaporisation component 900 with a non-flat first surface defined by a plurality of concavely shaped regions 930. FIG. 9 shows a cross-sectional diagram of a portion of a vaporisation component 900 for a vapour generation device viewed in a direction along the airflow channel 128 toward the mouthpiece 120. The first surface 904 of the evaporator 902 is non-flat in that it comprises a plurality of concavely shaped regions 930 relative to the airflow channel 128 to provide the first surface 904 with a curved profile. That is, the evaporator 902 has a plurality of concavely curved portions 930 extending inward to evaporator 902 in the first surface 904. In FIG. 9 two concavely shaped regions 930 are present, the skilled person will however understand that the plurality of concavely shaped regions 930 can comprise more than two concavely shaped regions. In a direction across the airflow channel 128, perpendicular to the direction toward the mouthpiece 120, the first surface 904 follows a curved profile that first curves away from the centre of the airflow channel 128, then back toward the centre of the airflow channel 128, then away from the centre of the airflow channel 128, and then back toward the centre of the airflow channel 128 again. The plurality of concavely shaped regions 930 interfere with the airflow as the airflow moves over the first surface 904 such that the air no longer flows in a direct or unperturbed manner when substantially flowing toward the mouthpiece 120 in the airflow channel 128. That is, the plurality of concavely shaped regions 930 in the first surface 904 perturb the airflow as it flows substantially toward the mouthpiece 120. In related examples, the first surface can alternatively comprise a plurality of convexly curved portions, or a combination of at least one concavely curved portion and at least one convexly curved portion in the direction across the airflow channel perpendicular to the direction toward the mouthpiece.
In some examples, only a portion of the first surface of the evaporator may be non-flat in the manner described with reference to FIGS. 2 to 9 , in other example the entire first surface of the evaporator may be non-flat in the manner described with reference to FIGS. 2 to 9 . In some examples, the first surface of the evaporator can include multiple non-flat regions by comprising any combination of one or more of the non-flat profiles described with references to FIGS. 2 to 9 in such multiple non-flat regions.
Alternatively or additionally to the features of the vaporisation components described with reference to FIGS. 1 to 9 , the first surface of the evaporator of the vaporisation component can be modified so as to interfere with and perturb the airflow within the airflow channel as it flows substantially toward the mouthpiece by arranging a plurality of recessed portions in the first surface. The vaporisation component of FIGS. 10A-C comprises the features described with reference to the vaporisation component 100 of FIGS. 1A and 1B (as in some cases denoted by the common reference numerals), but with recessed portions 1050 in the first surface 1004 of the evaporator 1002. The vaporisation components of FIG. 10 can be integrated into a vaporisation device as described with reference to FIGS. 1A and 1B. The recessed portions 1050, or dimples, can control micro-scale airflow 1018′ over the first surface 1004 of the evaporator 1002. This interference with the airflow 1018 in the airflow channel 128 affects the distribution of droplets 124 in the generated vapour flow as the recessed portions 1050 change the airflow 1018 over the first surface 1004.
FIG. 10A shows a cross-sectional diagram of a portion of a vaporisation component 1000 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. FIG. 10B shows a corresponding top down plan view of a portion of the vaporisation component 1000.
The first surface 1004 of the evaporator 1002 has a plurality of recessed portions 1050. These recessed portions 1050 are configured to interfere with the airflow 1018 in the airflow channel 128 as it flows toward the mouthpiece 120. The recessed portions 1050 can be considered as dimples in the first surface 1004. The recessed portions 1050 in FIGS. 10A-C are hemispherical or substantially hemispherical shaped recesses 1050 in the first surface 1004. These recessed portions 1050 are configured to create an array of regions in which the airflow 1018 over the first surface 1004 is perturbed to form at least partially circular pockets, or vortexes, of airflow 1018′. The airflow 1018 across the first surface 1004 flows downward into the recessed portions 1050, and is ejected from the recessed portions 1050 in a circular or vortex-like manner 1018′ such that this perturbed airflow 1018′ is directed substantially toward the centre of the airflow channel 128.
Whilst the recessed portions 1050 are described as being hemispherical in shape, with reference to FIG. 10 , it will be understood that the recessed portions 1050 may alternatively be shaped as any portion of a sphere or spheroid, or any other suitable shape that perturbs the airflow 1018 over the first surface 1004 such that the perturbed airflow is directed substantially toward the centre of the airflow channel 128.
FIG. 10B shows the recessed portions 1050 arranged in a uniform, grid-like manner in the first surface 1004. In some examples, the recessed portions 1050 can be arranged in such a uniform manner across the entire first surface 1004 of the evaporator 1002. In other examples, the recessed portions 1050 can be arranged in an unordered manner across the entire first surface 1004. In further examples, the recessed portions 1050 may be arranged in one or more regions of the first surface 1002 in either an ordered or unordered manner. In yet another example, the first surface 1004 may comprise recessed portions 1050 arranged in combinations of ordered and unordered regions.
FIG. 10C presents a conceptual cross-sectional diagram of a portion 1080 of a vapour generation device with a similar arrangement to that described with reference to FIG. 1B, but including the evaporator 1002 described with reference to FIGS. 10A and 10B (for clarity the reservoir and optional wicking material are not shown). As is shown, the airflow 118 over the first surface 1004 of the evaporator 1002 is perturbed to create vortex-like or circular regions of airflow 1018′ due to shape of the recessed portions 1050. These regions of circular airflow 1018′ cause liquid droplets 124 in vapour flow to be carried away from the first surface 1004 when they are ejected from the first openings 110 of the evaporator channels 108.
The recessed portions 1050 provide similar advantages to the non-flat first surfaces described with references to FIGS. 2 to 9 . The interference with the airflow 1018 provided by the recessed portions 1050, creating the circular regions of airflow 1018′, improves the mixing of the droplets 124 in the airflow 1018 thereby providing a more homogenous output from the mouthpiece 120 for the consumer. This interference with the airflow 1018 provided by the recessed portions 1050 also reduces coalescence of droplets 124, thereby inhibiting the formation of undesirably large droplets, as the droplets 124 are carried away from the first surface 1004 before such coalescence can occur. The interference with the airflow 1018 provided by the recessed portions 1050 is also advantageous in that it increases the mixing of hot droplets 124 with the cool air in the airflow 1018 so as to reduce the overall vapour temperature. Each of these advantages can contribute to improving the quality of the vapour output that is inhaled by the user of a vapour generation device comprising a vaporisation component having an evaporator 1002 with recessed portions 1050.
The recessed portions 1050 are arranged in close proximity to the first openings 110 of the evaporator channels 108. More specifically, in the example of FIGS. 10A-C, the recessed portions 1050 and the first openings 110 are alternately arranged in the first surface 1004. In other examples, the recessed portions 1050 and first openings 110 may be arranged in any other suitable pattern such that droplets in the vapour are suitably carried away from the first surface 1004 of the evaporator 1002.
In an examples, the recessed portions 1050 can have depths ranging from 1 to 10 mm. The recessed portions 1050 could, however, have other suitable depths for perturbing the airflow 1018 across the first surface 1004.
Whilst FIGS. 10A-C depict the recessed portions 1050 in a flat first surface 1004, similar to that of FIG. 1 , in other examples the recessed portions 1050 can be arranged in a non-flat first surface, or a non-flat portion of the first surface, such as the non-flat first surfaces (or non-flat portions of first surfaces) described with reference to FIGS. 2 to 9 . In this way, the combination of the non-flat surface and the recessed portions can be used to interfere with the airflow in the airflow channel 128.
A particular example of such an arrangement is presented in FIG. 11 which shows a cross-sectional diagram of a portion of a vaporisation component 1100 for a vapour generation device viewed along a direction perpendicular to the direction along the airflow channel 128 toward the mouthpiece 120. The first surface 1104 of the evaporator 1102 is similar to that of FIG. 2 in that the first surface 1104 is non-flat in having a region 1130 that is concavely shaped relative to the airflow channel 128 so as to provide a curved profile. The concave region 1130 of the first surface 1104 further comprises a plurality of recessed portions 1150 within the concave region 1130.
Whilst FIG. 11 shows a first surface 1104 having a non-flat region 1130 that substantially coincides with the arrangement of the recessed portions 1150 such that recessed portions 1150 are within the non-flat region 1130, various other arrangements of recesses in combination with non-flat surfaces can be achieved. In an example, at least one region of the first surface can be non-flat in one or more of the manners described with respect to FIGS. 2 to 9 , with at least another region of the first surface comprising recessed portions as described with reference to FIG. 10 . In another example, at least one region of the first surface can be non-flat in one or more of the manners described with respect to FIGS. 2 to 9 and at least one sub-region within this region can comprise the recessed portions described with reference to FIG. 10 . In yet another example, at least one region of the first surface can comprise recessed portions as described with reference to FIG. 10 , and at least one sub-region within this region can be non-flat in one or more of the manners described with reference to FIGS. 2 to 9 .
The first surface of the evaporator described with reference to FIGS. 1 to 11 can be further modified to comprise hydrophobic properties. Droplets from the generated vapour flow may condense on the surface of the evaporator; the hydrophobic properties are configured to repel droplets on the first surface by the Lotus effect. Advantageously, the hydrophobic properties help to inhibit the build-up of droplets on the evaporator surface. The repulsion of the droplets aids in removing the droplets from the first surface when combined with the airflow in the airflow channel. The build-up of droplets on the evaporator surface can negatively impact the operation of the evaporator; the removal of the droplets, aided by the hydrophobic properties, helps to negate this issue. In an example, the hydrophobic properties can provide superhydrophobicity with a contact angle for liquid droplets in excess of 150°.
In examples, the hydrophobic properties can be provided by a hydrophobic layer, a structured surface, or a combination thereof. In some examples, the hydrophobic properties can be provided by adding a chemical coating to the first surface of the evaporator. In other examples, the hydrophobic properties can be provided by applying a physical treatment to the first surface of the evaporator. In further examples, the hydrophobic properties can be provided by a combination of adding a chemical coating and applying a physical treatment to the first surface of the evaporator.
At least a portion of the first surface of the evaporator can be a hydrophobic structured surface; this hydrophobic structured surface can comprise micro-structuring and/or nano-structuring by patterning the first surface of the evaporator such that the structuring is integrated into the evaporator itself. That is to say, the first surface of the evaporator is modified to comprise a plurality of micro-scale and/or nano-scale features that provide hydrophobic properties; this can be achieved by the features providing a microscale and/or nanoscale roughness on the surface.
Alternatively or additionally to the structured surface being integrated into the evaporator itself, at least a portion of the first surface of the evaporator can have a hydrophobic layer arranged thereon to provide or further contribute to the hydrophobic properties. This hydrophobic layer can be considered as a separate material, with a hydrophobic properties, that at least partially coats the first surface of the evaporator. In this way, the hydrophobic layer at least partially forms the first surface. In examples, the hydrophobic layer can comprise at least one of a high temperature polymer, a rare earth oxide or ceramic, grafted organic molecules such as those comprising a fluoro-alkyl or alkyl chain (self-assembled monolayer) or polymers such as Teflon-like polymers; such layers can be deposited onto a silicon evaporator for example. The hydrophobic layer can be micro-patterned or nano-patterned when formed on the first surface of the evaporator, thereby forming a micro-structured or nano-structured surface in the hydrophobic layer itself. In an example, this patterning of the hydrophobic layer can be achieved with photoresist processes such photolithographic patterning.
The dimensions of the aforementioned structures of the surface (achieved either by the structuring being integrated into the evaporator itself, or the structuring being in the hydrophobic layer) may range from the order of hundreds of nanometres to hundreds of micrometres. The requisite dimensions can be determined based upon the desired contact angle of the liquid. In some examples the structured surface can comprise a hierarchical structure. Such a hierarchical structured surface is defined by a micro-scale roughness, wherein the features providing the micro-scale roughness are themselves covered by a nano-scale roughness. The structured surfaces can allow a liquid droplet on the surface to be in the Cassie-Baxter state, thereby exhibiting superhydrophobicity.
As described above, the hydrophobic properties of the surface can be provided by the hydrophobic layer arranged on the first surface of the evaporator (i.e. in the absence of surface structuring integrated into the evaporator itself). FIG. 12A presents a cross-sectional diagram of an evaporator 1202A with a hydrophobic layer 1250. The evaporator of FIG. 12A comprises the features described with reference to the vaporisation component 100 of FIGS. 1A and 1B (as in some cases denoted by the common reference numerals), but with the addition of the hydrophobic layer 1250, and is integratable into a vaporisation component and vapour generation device in accordance with that described with reference to FIGS. 1A and 1B. In the example of FIG. 12A, the hydrophobic layer 1250 is itself patterned to form a plurality of micro/nanostructures. As is depicted, the hydrophobic layer 1250 repels the liquid droplet 1260 on the first surface 1204 such that contact angle is created. The airflow in the airflow channel 128 can then move the liquid droplet 1260 along the airflow channel 128. FIG. 12C presents a three-dimensional perspective diagram of a region of the evaporator 1202A showing the hydrophobic layer 1250 in combination with the evaporator channels 108 and first openings 110 in the evaporator 1202A.
In other examples as described above, the hydrophobic properties of the surface can be provided by the structured surface integrated into the evaporator (i.e. in the absence of the hydrophobic coating). In further examples the hydrophobic properties can be provided by a combination of both a hydrophobic layer and a structured surface integrated into the evaporator, for example by at least partially coating the structured surface with the hydrophobic layer as is depicted in FIG. 12B. FIG. 12B presents a variation of FIG. 12A and shows a cross sectional diagram of an evaporator 1202B having a first surface 1204B that has a plurality of micro/nano-structures 1252 integrated into it that are coated with a hydrophobic layer 1250. The evaporator of FIG. 12B comprises the features described with reference to the vaporisation component 100 of FIGS. 1A and 1B (as in some cases denoted by the common reference numerals), but with the addition of the plurality of micro/nano-structures 1252 and the hydrophobic layer 1250, and is integratable into a vaporisation component and vapour generation device in accordance with that described with reference to FIGS. 1A and 1B. The micro/nano-structures 1252 combine with the hydrophobic layer 1250 to provide the hydrophobic properties that repel the liquid droplet 1260.
An exemplary method for fabricating a vaporisation component with an evaporator having a first surface with hydrophobic properties can comprise modifying the first surface of the evaporator to provide hydrophobic properties configured to repel droplets from the vapour flow. In a specific example, modifying the first surface can comprise patterning the first surface of the evaporator such that the first surface comprises a structured surface configured to provide the hydrophobic properties. Alternatively or additionally, modifying the first surface can comprise applying a hydrophobic layer to the first surface of the evaporator, for example by a deposition technique. In another example, modifying the first surface can comprise patterning the hydrophobic layer such that the structured surface is in the hydrophobic layer.
The hydrophobic properties described can be incorporated into the evaporators described with reference to each of FIGS. 1 to 11 . When liquid is drawn through the evaporator channels 108 it may pool on the evaporator surface, either by condensation from the vapour flow, or through not having been sufficiently heated in the evaporator channels 108. This pooling can then block the evaporator channels 108 and prevent the evaporator channels 108 drawing more liquid through by capillary force. The hydrophobic properties are particularly beneficial when incorporated into the first surface of the evaporators described with reference to FIGS. 1 to 11 as the hydrophobic properties provide a repulsion of any liquid on the first surface of the evaporator, thereby inhibiting the pooling of any liquid on the first surface and reducing or preventing such blockages of the evaporator channels 108.
When incorporated into the evaporators described with reference to FIGS. 2 to 11 , the first surface of the evaporator can provide an interference with the airflow in the airflow channel so as to affect the distribution of droplets in the vapour flow by way of the non-flat surface and/or the recessed portions. This can combine with the repulsion of liquid droplets on the first surface provided by the hydrophobic properties. For example, the perturbed airflow can project the repelled liquid droplets into the vapour flow.
An advantage that can be realised through this combination of features is that the non-flat first surface and/or the recessed portions in the first surface improve the mixing and distribution of droplets in the vapour flow, and the hydrophobic properties contribute to aiding the droplets to be carried away from the first surface for incorporation into the vapour flow, and inhibiting the loss of vapour or droplets from the vapour flow due to condensation on the first surface, by way of the hydrophobicity providing for the repulsion of such droplets. This combination of effects is particularly beneficial in enhancing the experience of the consumer by providing a desirable distribution of droplets in the vapour inhaled by the consumer.
Another advantage that can be realised through this combination of features is that the hydrophobic first surface can contribute to inhibiting the blockage of the evaporator channels 108 by repelling condensed liquid droplets from the surface of the evaporator. The perturbed airflow, provided by the non-flat first surface and/or the recessed portions in the first surface can then carry these repelled liquid droplets away from the first surface of the evaporator. This also decreases the chance of coalescence of these repelled droplets on the first surface forming larger droplets that could negatively impact the efficiency of the evaporator operation, for example through blocking evaporator channels and/or affecting the heating profile of the evaporator.
Whilst the description relating to FIGS. 2 to 12 has been described with reference to an evaporator having evaporator channels passing therethrough, the shapes, structures and modifications of the first surfaces described with reference to FIGS. 2 to 12 can be readily applied to any other type of evaporator or heater in a vapour generation device, aerosol generation device, or electronic cigarette as appropriate.
It will be readily understood that the features of any of the embodiments described herein can be readily combined with the features of any of the other embodiments described herein without falling outside of the scope of the present disclosure. In particular, any features described with reference to any one of the examples of evaporators and vaporisation components of FIGS. 1 to 12 can be readily combined with the other examples of evaporators and vaporisation components of FIGS. 1 to 12 .

Claims

1. A vaporisation component of a vapour generation device, wherein the vaporisation component comprises:

an evaporator component configured to generate a vapour flow by vaporising a vaporisable substance, the evaporator component having a first surface over which air flows in an airflow channel of the vapour generation device in a direction toward a mouthpiece, wherein at least a portion of the first surface is non-flat with respect to the airflow channel so as to interfere with an airflow in the airflow channel and affect a distribution of droplets in the generated vapour flow.

2. The vaporisation component of claim 1, wherein the evaporator component further comprises one or more evaporator channels arranged therethrough to connect the first surface to a reservoir configured to store the vaporisable substance, and wherein the evaporator channels are configured to transport the vaporisable substance from the reservoir to openings in the first surface.

3. The vaporisation component of claim 2, wherein the evaporator component is a block with one or more through-holes passing through the block to form the one or more evaporator channels arranged through the block.

4. The vaporisation component of claim 1, wherein the non-flat portion of the first surface has a curved profile.

5. The vaporisation component of claim 4, wherein the non-flat portion of the first surface comprises a plurality of curved profiles.

6. The vaporisation component of claim 4, wherein the curved profile is curved in at least one dimension of the first surface.

7. The vaporisation component of claim 4, wherein the curved profile is curved in two dimensions of the first surface.

8. The vaporisation component of any one of claim 4, wherein the curved profile is substantially concave.

9. The vaporisation component of any one of claim 4, wherein the curved profile is substantially convex.

10. The vaporisation component of any one of claim 4, wherein the curved profile comprises convex and concave portions.

11. The vaporisation component of claim 1, wherein the non-flat portion of the first surface linearly tapers inward to the airflow channel in a direction of the airflow, or wherein the first surface linearly tapers inward to the airflow channel in a direction opposite to the direction of the airflow.

12. The vaporisation component of claim 1, wherein the first surface further comprises a plurality of recessed portions configured to interfere with the airflow in the airflow channel and affect the distribution of droplets in the vapour flow.

13. The vaporisation component of claim 1, wherein the first surface has hydrophobic properties.

14. The vaporisation component of claim 1, further comprising a reservoir configured to house the vaporisable substance, the reservoir being in connection with a second surface of the evaporator component, wherein the second surface is distinct from the first surface.

15. A cartridge for use with a vapour generating device, the cartridge comprising the vaporisation component of claim 1.

16. A vapour generating device comprising the vaporisation component of claim 1.

17. A vapour generating device comprising the cartridge of claim 15.