WO2016023824A1

WO2016023824A1 - Smoking article

Info

Publication number: WO2016023824A1
Application number: PCT/EP2015/068261
Authority: WO
Inventors: James Reed; Philip WATKINSON
Original assignee: Essentra Filter Products Development Co. Pte. Ltd; Essentra Filter Products Limited
Priority date: 2014-08-15
Filing date: 2015-08-07
Publication date: 2016-02-18
Also published as: GB201414550D0

Abstract

A connector (20) comprising: a longitudinally extending insulating body (21) defining at least one channel extending longitudinally through the longitudinally extending insulating body (21); a first conducting element (24) which extends through the insulating body (21) from a first end (21d) of the insulating body (21) to the second end (21u) of the insulating body (21) and which extends beyond the first and second ends of the insulating body (21) to form a first element downstream connector (24d) at the first end (21d) of the insulating body (21) and a first element upstream connector (24u) at the second end (21u) of the insulating body (21); and a second conducting element (26) which extends through the insulating body (21) from the first end (21d) of the insulating body (21) to the second end (21u) of the insulating body (21) and which extends beyond the first and second ends of the insulating body (21) to form a second element downstream connector (26d) at the first end (21d) of the insulating body (21) and a second element upstream connector (26u) at the second end (21u) of the insulating body (21).

Description

SMOKING ARTICLE

The present invention relates to smoking articles, for example electronic cigarettes (herein referred to as "e-cigarettes"), and components for use therewith or therein. The present invention also relates to improvements to the assembly of electronic cigarettes.

Current generation e-cigarettes tend to follow the same design concept, comprising three main sections - battery, atomizer and cartridge. It is also possible to combine the atomizer and cartridge in a single unit known as a cartomizer, or combine all three (as in disposable rather than reusable products). A generic e-cigarette construction includes these components contained within an outer plastic body. A printed circuit board (PCB) and a battery are located at the upstream end of the device and a cartridge reservoir containing the liquid to be vaporised is located at the mouth end of the device. An atomizer that incorporates a heater element is positioned between these two end sections, and a wicking element (around which the heater element is normally wound) is in contact with the reservoir to enable liquid to flow from the reservoir to the heater section where it can be vaporised on demand from a signal from the PCB.

Current e-cigarettes are tricky to assemble, e.g. because there are numerous unwieldy electrical and physical connections to be made. This results in a propensity for product failure, either due to faulty electrical welding or to liquid leakage caused by inadequate sealing. Furthermore, these products tend to be unsuitable for automated manufacture. As a result, products are mainly assembled by hand by operators requiring a high degree of dexterity. This adds to possibility of product failure as well as increasing product variability (another well-known shortcoming with e-cigarettes).

There is a need for components which simplify the assembly of e-cigarettes, enabling manufacturing stages to be carried out in an automated rather than a manual fashion and also reducing the possibility of failure due to electrical or sealing faults.

According to the present invention in a first aspect there is provided a connector [e.g. for (use in) a smoking article] comprising:

a longitudinally extending (e.g. substantially cylindrical, e.g. substantially annular) insulating body defining at least one (e.g. hollow) channel extending longitudinally through the longitudinally extending insulating body (e.g. from a first end of the insulating body to the second end of the insulating body);

a first conducting element which extends (e.g. longitudinally) through the insulating body from a first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a first element downstream connector at the first end of the insulating body and a first element upstream connector at the second end of the insulating body; and a second conducting element which extends (e.g. longitudinally) through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a second element downstream connector at the first end of the insulating body and a second element upstream connector at the second end of the insulating body.

The connector may be for (use in) an electronic smoking article, e.g. an electronic cigarette (e-cig or e-cigarette), personal vaporiser (PV) or electronic nicotine delivery system (ENDS).

Preferably the longitudinally extending (e.g. substantially cylindrical, e.g.

substantially annular) insulating body is a rigid insulating body. Preferably the

longitudinally extending (e.g. substantially cylindrical, e.g. substantially annular) insulating body comprises plastic, ceramic or other (e.g. inert) insulating material.

Preferably the insulating body is substantially annular (a longitudinally extending substantially annular insulating body), defining a hollow channel of circular cross section which extends longitudinally through the longitudinally extending insulating body (e.g. from a first end of the insulating to the second end of the insulating body). The circular cross section of the channel is preferably of 1 to 1.5 mm diameter, for example 1.2 mm diameter. The channel (e.g. of circular cross section) allows passage of air through the insulating body (e.g. through the cartomizer).

According to an example of the present invention there is provided a connector [e.g. for (use in) a smoking article] comprising:

a longitudinally extending substantially annular insulating body defining a channel of circular cross section extending longitudinally therethrough (e.g. from a first end of the insulating body to the second end of the insulating body);

a first conducting element which extends (e.g. longitudinally) through the insulating body from a first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a first element downstream connector at the first end of the insulating body and a first element upstream connector at the second end of the insulating body; and

a second conducting element which extends (e.g. longitudinally) through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a second element downstream connector at the first end of the insulating body and a second element upstream connector at the second end of the insulating body. Preferably the first and second conducting elements are rigid. Preferably the first and second conducting elements comprise a stamped zinc plated steel wire.

In some examples/aspects of the invention, it is preferred that the portion of the first and/or second conducting elements which extends through the insulating body (i.e. the portions of the first and/or second elements which do not protrude beyond the first and second ends of the insulating body) is wholly enclosed (e.g. encased, e.g. surrounded by) the insulating body. The first conducting element may extend through and be held (i.e. fixed) within the insulating body and/or the second conducting element may extend through and be held (i.e. fixed) within the insulating body. It will be appreciated that connectors according to the invention may include first and second conducting elements which pass through and are held within (that is, are fixed within) the (e.g. rigid) insulating body, with the first and second upstream connectors extending (e.g. rigidly) from the end of the insulating body for connection to the battery, and the first and second downstream connectors extending (e.g. rigidly) from the end of the insulating body for connection to the heating element. This construction advantageously avoids issues associated with handling and soldering of conventional delicate cylindrical wires, as in the prior art construction (see Fig 1 and discussion below). Furthermore the heating element (around the wick) can be formed in a continuous winding process because the heating element (and wick) is positioned directly across (and connected to) the ends of first and second downstream connectors, rather than to leading and trailing wire ends (as with the prior art construction).

It will be appreciated that connectors according to the invention may be in the form of a single piece (or one/single component) connector comprising the longitudinally extending insulating body and the first and second conducting elements (e.g. wherein the first and second conducting elements are held (that is, fixed) in place within the insulating body). Such one piece connectors may include first and second conducting elements which pass through and are held within (that is, are fixed within) the (e.g. rigid) insulating body, with the first and second upstream connectors extending (e.g. rigidly) from the end of the insulating body for connection to the battery, and the first and second downstream connectors extending (e.g. rigidly) from the end of the insulating body for connection to the heating element. This construction advantageously avoids issues associated with handling and soldering of conventional delicate cylindrical wires, and the one piece nature may enable the manufacturing stages to be carried out in an automated rather than a manual fashion and may also reduce the possibility of failure due to electrical faults.

Preferably the first element downstream connector and second element

downstream connector are blade shaped.

Preferably the first element upstream connector and second element upstream connector are blade shaped (e.g. so as to connect directly with the battery element or connector for the battery element).

The connector may further comprise a heating element (e.g. a resistance wire, e.g. a heating coil) connected between the first element downstream connector and second element downstream connector. The heating element (e.g. a resistance wire, e.g. a heating coil) may be e.g. welded directly or crimped to the first element downstream connector and second element downstream connector.

Preferably the connector further comprises a wicking element arranged in close proximity to, or touching, at least a portion of the heating element. Preferably the heating element is in the form of a helix or coil and at least portion of the wicking element extends through the helix/coil. Preferably the heating element is wound around the wicking element. The wicking element may be in contact with a fluid reservoir to enable fluid (e.g. liquid) to flow (by a wicking action) from the reservoir to the heating element (where it may be vaporised by heating the heating element on demand from a signal from the PCB).

Preferably the fluid is a liquid. The fluid may be any fluid (e.g. e-liquid) which is known for use with electronic cigarettes. The fluid may comprise a solvent (for example one or more of glycerol, propylene glycol, water). The fluid may include flavouring agent and/or nicotine (e.g. dissolved in the solvent). The fluid may include 1 to 10% nicotine (by weight).

The connector may include a sealing element to prevent reduce leakage of fluid

(e.g. between the heating element and the battery/power source).

According to the present invention in a further aspect, there is provided a smoking article comprising a connector comprising:

a second conducting element which extends (e.g. longitudinally) through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a second element downstream connector at the first end of the insulating body and a second element upstream connector at the second end of the insulating body.

According to the present invention in a still further aspect, there is provided a smoking article comprising: a housing; a heating element (e.g. located within the housing); a power source (e.g. a battery) for at least the heating element (e.g. located within the housing); a fluid reservoir (e.g. located within the housing); and a wicking element which transfers fluid from the fluid reservoir to the heating element; and a connector comprising: a longitudinally extending (e.g. substantially cylindrical, e.g. substantially annular) insulating body defining at least one (e.g. hollow) channel extending longitudinally through the longitudinally extending insulating body (e.g. from a first end of the insulating body to the second end of the insulating body);

a second conducting element which extends (e.g. longitudinally) through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a second element downstream connector at the first end of the insulating body and a second element upstream connector at the second end of the insulating body. The first element downstream connector and the second element downstream connector may be connected to the heating element. The first element upstream connector and the second element upstream connector may be connected to the power source (e.g. battery).

Preferably the smoking article is an electronic cigarette (e-cig or e-cigarette), personal vaporizer (PV) or electronic nicotine delivery system (ENDS).

The heating element may comprise a resistance wire of resistance 2.20 to 2.5 Ω (e.g. 2.38 Ω), the resistance wire being formed as a coil or helix having 6 to 8, preferably 7, turns.

The present invention will now be illustrated with reference to the following

Examples and the attached drawings in which FIGURE 1 provides a diagrammatic illustration (not to scale and in a vertical rather than in the more usual horizontal orientation) of the main features of a prior art e-cigarette product, FIGURE 1 A showing a detail of Figure 1 ; FIGURE 2 shows a view of a connector for an e-cigarette according to an example of the invention; and FIGURE 3 shows a view of a connector for an e-cigarette according to a different example of the invention.

The Figure 1 construction is fairly generic and numerous examples of products with the same basic construction are known in the prior art.

The illustrated e-cigarette components are enclosed within a tubular body, as is well known in the art but not shown. As seen in Figure 1 , at one end (the upstream end) of the e-cigarette, there is a PCB assembly 1 (well known in the art) which detects that a user is drawing on the downstream (mouth) end of the tubular body. A 3.7V cylindrical lithium ion battery 3, located downstream of the PCB assembly 1 , powers the device. An annular spacer 5 (made of plastic) is located downstream of the battery 3. The annular spacer 5 has a central channel 5a of circular cross section extending therethrough to allow air to flow through the spacer. Downstream of spacer 5, a heating element 7 in the form of a nickel chrome resistance heater wire is located around fibreglass wicking element 9, and positioned in a hollow tubular heat shield 8 as is well known in the art.

As best seen in Fig 1A, the heating element 7 includes a nickel chrome resistance heater wire 7 which is wound around a fibreglass wick material 9 with two exposed lengths of wire 7a left extending from the coil.

As can be seen in figure 1 , wires 15, 16 are soldered onto the PCB 1 and battery 3 and these wires 15, 16 pass along and are fixed to the side of the battery by tape 17. The wires 15, 16 are then fed past the plastic spacer 5 (that includes an air inlet 5a) situated at the downstream end of the battery. The exposed ends 7a of the heating element are crimped onto the ends of battery wires 15, 16 to connect the battery 3 and PCB 1 to the heating element.

The ends 9a of the wick (wicking element) 9 extend into a tubular reservoir 12 defined by walls 12a which includes the fluid, e-liquid (not shown).

A heat shield 10 is located in the reservoir, as is well known. Downstream of the reservoir, a seal is provided, together with an end cap at the downstream (mouth) end for hygiene and convenience (not shown).

In use, as is well known, the user draws on the product and the heater 7 is activated by the PCB 1. Air enters the device (as the user draws on the end) and e-liquid is transferred from the reservoir 12 to heater 7 by wicking over or through wick (wicking element) 19, where it is vaporised by the heating element 7 and delivered to the consumer.

It will be appreciated that the known e-cigarettes (such as those shown in Figure 1 ) are tricky to assemble because there are numerous unwieldy electrical and physical connections to be made (e.g. connecting wires 15, 16 to ends 7a of the element; winding wire 7 around wicking element 9 etc.). This results in a propensity for product failure, either due to faulty electrical welding or to liquid leakage caused by inadequate sealing.

Furthermore, these products tend to be unsuitable for automated manufacture.

The present invention provides a means of automating a number of manufacturing operations, whilst reducing the number and complexity of components and connections. The following describes two examples - one primarily intended for use in disposable e- cigarettes and the other for use in reusable e-cigarettes.

Figure 2 shows a connector according to the invention, as may be used in a reusable product, e.g. in a cartomizer for an e-cigarette. The connector 20 of Figure 2 includes a longitudinally extending substantially annular insulating body 21 defining a hollow channel of circular cross section (e.g.1.2mm diameter) extending longitudinally through the longitudinally extending insulating body from the upstream end of the insulating body to the downstream end of the insulating body. The channel allows air to flow through the insulating body 21. The insulating body 21 is made of ceramic, but may also be made of plastics material. The connector includes first and second conducting elements 24, 26 in the form of two flat wire elements (e.g. nickel plated steel stamped wire connectors) held within the rigid body.

The connector includes a first conducting element 24 which extends longitudinally through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a first element downstream connector 24d at the downstream end 21 d of the insulating body and a first element upstream connector 24u at the upstream end of the insulating body 21 u.

The connector includes a second conducting element 26 which extends (e.g.

longitudinally) through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends (protrudes) beyond the first and second ends of the insulating body to form a second element downstream connector 26d at the downstream end 21 d of the insulating body and a second element upstream connector 26u at the upstream end 21 u of the insulating body.

As can be seen in Fig 2, the first element upstream connector 24u and second element upstream connector 26u are shaped so they connect directly with a socket connector 29 for the battery housing.

The connector 20 further comprises a heating element 31 (a resistance wire, e.g. a heating coil) connected across the first element downstream connector 24d and second element downstream connector 26d so as to link the two. The heating element 31 is welded directly or crimped to the first element downstream connector 24d and second element downstream connector 26d. The connector also comprises a wicking element 33 arranged in close proximity to, or touching, at least a portion of the heating element. The heating element 31 is in the form of a helix or coil and, as seen in Figure 2, a portion of the wicking element 33 extends through the helix/coil. In use, the wicking element is in contact with a fluid reservoir (not shown) to enable fluid (e.g. liquid) to flow (by a wicking action) from the reservoir to the heating element (where it may be vaporised by heating the heating element on demand from a signal from the PCB).

It will be appreciated that the connector of the invention makes the electrical connection between the battery (not shown) and the heater 31 using stamped zinc plated steel wire conductor elements 24, 26 which pass through and are held within a rigid body, thereby avoiding issues associated with the handling and soldering of conventional delicate cylindrical wires. Furthermore, the heater element 31 and wicking element 33 can be formed in a continuous winding process, because the wick is positioned directly across the end of the stamped wire rather than to leading and trailing wire ends.

The central portion of the wicking element 33 extends through the heating element 31 , whilst the two open ends connect with the surrounding reservoir material as usual. This direct welding simplifies assembly and enables greater automation when linked to a suitable continuous winding mechanism for the heating element 31.

The first element upstream connector 24u and second element upstream connector

26u may be of different shapes as shown in Figure 2 to facilitate connection to the battery and enhance leak protection. A screw threaded connector 29 provides the interface between the battery component and the connector assembly 21. This provides more leak protection than the splayed out plastic spacer 5 of Figure 1 as well as facilitating more automated manufacture of the device. The ends of the first element upstream connector 24u and second element upstream connector 26u form a direct electrical connection with the battery when they are inserted into the threaded connector 29, as would be readily understood by the skilled person.

The connector 20, element 29 and battery are then inserted into the plastic tube that encases the final device, after which the porous reservoir is pushed over the assembly (in the conventional manner) to create the finished cartomizer (prior to filling with liquid).

Figure 3 shows a connector according to the invention for use with a disposable product. In disposable products there is no need to replace the cartomizer and a simplified means of connection to the battery is preferred. This is illustrated in Figure 3, in which it can be seen that elongated connectors are required. The same reference numerals as Figure 2 are used for like components in Figure 3.

The connector 20 of Figure 3 includes a longitudinally extending substantially annular insulating body 21 defining a hollow channel of circular cross section (e.g.1.2mm diameter) extending longitudinally through the longitudinally extending insulating body from the upstream end of the insulating body to the downstream end of the insulating body. The channel allows air to flow through the insulating body 21 . The insulating body 21 is made of ceramic, but may also be made of plastics material. The connector 20 also includes a seal 37 abutted to the insulating body 21.

The connector 20 includes first and second conducting elements 24, 26 in the form of two flat wire elements (e.g. nickel plated steel stamped wire connectors) held within the rigid body.

The connector includes a second conducting element 26 which extends (e.g.

As can be seen in Fig 3, the first element upstream connector 24u and second element upstream connector 26u are shaped so they fit around the battery 35 (i.e. so the battery can be placed between the connectors). As shown, the first element upstream connector 24u and second element upstream connector 26u are lengthened and modified to connect direct to the battery, rather than requiring separate wires as in conventional devices.

As with the embodiment of Figure 2, it will be appreciated that the connector of the invention makes the electrical connection between the battery (not shown) and the heater 31 using stamped zinc plated steel wire conductor elements 24, 26 which pass through and are held within a rigid body, thereby avoiding issues associated with the handling and soldering of conventional delicate cylindrical wires. Furthermore, the heater element 31 and wicking element 33 can be formed in a continuous winding process, because the wick is positioned directly across the end of the stamped wire rather than to leading and trailing wire ends.

The element 37 provides leak protection.

The connector 20 and battery are then inserted into the plastic tube that encases the final device, after which the reservoir (of fixed dimension) is inserted into the opening (as with the known disposable products). The spacing of the reservoir and the heater/wick sub-assemblies is controlled dimensionally during the process.

This invention is primarily intended for use in e-cigarettes. Products that heat rather than burn tobacco '(ΗΝΒ') are also known and it is considered that this invention can be suitably adapted for HNB products. The heater elements in such products tend to be larger and this can be accommodated by having the heater wire windings in the same orientation as the main body of the device so that both length and diameter can be increased. To enable such an increase in size, the two element downstream conductors would terminate at different distances from the downstream end of the rigid body and the heating element extends in a longitudinal direction between these two ends of the element downstream conductors with a tobacco substrate material in close proximity to this heater wire.

Claims

1. A connector comprising:

a longitudinally extending insulating body defining at least one channel extending longitudinally through the longitudinally extending insulating body;

a first conducting element which extends through the insulating body from a first end of the insulating body to the second end of the insulating body and which extends beyond the first and second ends of the insulating body to form a first element downstream connector at the first end of the insulating body and a first element upstream connector at the second end of the insulating body; and

a second conducting element which extends through the insulating body from the first end of the insulating body to the second end of the insulating body and which extends beyond the first and second ends of the insulating body to form a second element downstream connector at the first end of the insulating body and a second element upstream connector at the second end of the insulating body.

2. A connector according to claim 1 wherein the longitudinally extending insulating body is a rigid insulating body.

3. A connector according to claim 1 or claim 2 wherein the longitudinally extending insulating body comprises plastic, ceramic or other (e.g. inert) insulating material.

4. A connector according to any preceding claim wherein the insulating body is substantially annular, defining a hollow channel of circular cross section which extends longitudinally through the longitudinally extending insulating body.

5. A connector comprising:

a longitudinally extending substantially annular insulating body defining a channel of circular cross section extending longitudinally therethrough;

6. A connector according to any preceding claim wherein the first and second conducting elements are rigid.

7. A connector according to any preceding claim wherein the first and second conducting elements comprise a stamped zinc plated steel wire.

8. A connector according to any preceding claim further comprising a heating element connected between the first element downstream connector and second element downstream connector.

9. A connector according to claim 8 wherein the heating element is welded directly or crimped to the first element downstream connector and second element downstream connector.

10. A connector according to any preceding claim further comprising a wicking element.

1 1 . A connector according to any preceding claim further comprising a wicking element in close proximity to, or touching, at least a portion of the (or a) heating element.

12. A connector according to any preceding claim further comprising a sealing element to prevent/reduce leakage of fluid.

13. A connector according to any preceding claim wherein the first element upstream connector and second element upstream connector are blade shaped.

14. A connector according to any preceding claim wherein the first conducting element extends through and is held (i.e. fixed) within the insulating body and the second conducting element extends through and is held (i.e. fixed) within the insulating body.

15. A connector according to any preceding claim which is in the form of a single piece connector comprising the longitudinally extending insulating body and the first and second conducting elements.

16. A connector substantially as described herein with reference to the attached Figures 2 and 3.

17. A smoking article comprising a connector according to any preceding claim.

18. A smoking article including a connector comprising:

19. A smoking article comprising: a housing; a heating element; a power source for at least the heating element; a fluid reservoir; and a wicking element which transfers fluid from the fluid reservoir to the heating element; and a connector; the connector comprising: a longitudinally extending insulating body defining at least one channel extending longitudinally through the longitudinally extending insulating body;

20. A smoking article according to claim 19 wherein the first element downstream connector and the second element downstream connector are connected to the heating element.

21. A smoking article according to claim 19 or claim 20 wherein the first element upstream connector and the second element upstream connector may be connected to the power source (e.g. battery).