WO2022084186A1

WO2022084186A1 - A vapour generating system

Info

Publication number: WO2022084186A1
Application number: PCT/EP2021/078642
Authority: WO
Inventors: Herman HIJMA
Original assignee: Jt International Sa
Priority date: 2020-10-23
Filing date: 2021-10-15
Publication date: 2022-04-28
Also published as: US20230371598A1; EP4231862A1; CA3196133A1

Abstract

A vapour generating system (1) comprises a base part (10) including a heating element (18) and a cartridge (12) releasably connectable to the base part (10). The cartridge (12) comprises a liquid store (32) for storing a vapour generating liquid, first and second vaporization zones (48a, 48b) physically separated from each other and in communication with the liquid store (32) for receiving vapour generating liquid from the liquid store (32), and a heat transfer unit (42) configured to transfer heat from the heating element (18) to the first and second vaporization zones (48a, 48b) to vaporize vapour generating liquid in the first and second vaporization zones (48a, 48b).

Description

A VAPOUR GENERATING SYSTEM

Technical Field

The present disclosure relates generally to a vapour generating system configured to heat a vapour generating liquid to generate a vapour which cools and condenses to form an aerosol for inhalation by a user of the system. Embodiments of the present disclosure relate in particular to a vapour generating system comprising a reusable base part and a cartridge configured to be used with reusable base part.

Technical Background

The term vapour generating system (or more commonly electronic cigarette or e- cigarette) refers to a handheld electronic device that is intended to simulate the feeling or experience of smoking tobacco in a traditional cigarette. Electronic cigarettes work by heating a vapour generating liquid to generate a vapour that cools and condenses to form an aerosol which is then inhaled by the user. Accordingly, using e-cigarettes is also sometimes referred to as “vaping”. The vapour generating liquid usually comprises nicotine, propylene glycol, glycerine and flavourings.

Typical e-cigarette vaporizing units, i.e. systems or sub-systems for vaporizing the vapour generating liquid, utilize a cotton wick and heating element to produce vapour from liquid stored in a capsule or tank. When a user operates the e-cigarette, liquid that has soaked into the wick is heated by the heating element, producing a vapour which cools and condenses to form an aerosol which may then be inhaled. To facilitate the ease of use of e-cigarettes, cartridges are often used. These cartridges are often configured as “cartomizers”, which means an integrated component formed from a liquid store (reservoir), a liquid transfer element (e.g. a wick) and a heater. Electrical connectors may also be provided to establish an electrical connection between the heating element and a power source. Such cartridges may be disposable, i.e. not intended to be capable of reuse after the supply of liquid in the reservoir has been exhausted. Alternatively, they may be reusable, being provided with means allowing the reservoir to be refilled with a new supply of vapour generating liquid. Particularly in the case of disposable cartridges, it is desirable to reduce the number and complexity of their components, thereby reducing waste and making the manufacturing process simpler and cheaper.

It has, therefore, been proposed to provide a vapour generating system in which a heating element is integrated into a reusable base part and in which a disposable cartridge is releasably connectable to the base part such that the vapour generating liquid in the reservoir can be heated by the heating element in the base part. Integrating the heating element into the reusable base part allows the cartridge structure to be simplified. There is, however, a need to further improve the energy efficiency of this type of vapour generating system and the present disclosure seeks to address this need.

Summary of the Disclosure

According to a first aspect of the present disclosure, there is provided a vapour generating system comprising: a base part including a heating element; and a cartridge releasably connectable to the base part, the cartridge comprising: a liquid store for storing a vapour generating liquid; first and second vaporization zones in communication with the liquid store for receiving vapour generating liquid from the liquid store; and a heat transfer unit configured to transfer heat from the heating element to the first and second vaporization zones to vaporize vapour generating liquid in the first and second vaporization zones.

The base part may include a power supply unit, e.g. a battery, connected to the heating element. In operation, upon activating the vapour generating system, the power supply unit electrically heats the heating element of the base part, which then provides its heat by conduction to the heat transfer unit of the cartridge. The heat transfer unit, in turn, provides the heat to the first and second vaporization zones, resulting in vaporization of the vapour generating liquid. Vapour created during this process is transferred from the first and second vaporization zones via a vapour outlet channel in the cartridge so that it can be inhaled by a user of the vapour generating system. The first and second vaporization zones are physically separated from each other. The provision of physically separated first and second vaporization zones in which vapour generating liquid from the liquid store is heated provides for more effective and controlled vapour generation. The energy efficiency of the vapour generating system is thereby also improved.

In general terms, a vapour is a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms ‘aerosol’ and ‘vapour’ may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

The heating element may contact the heat transfer unit in a first contact zone to transfer heat to the first vaporization zone and may contact the heat transfer unit in a second contact zone to transfer heat to the second vaporization zone. Heat is thereby transferred efficiently from the heating element to the first and second vaporization zones.

The heat transfer unit may comprise a first heat transfer element positioned in the first contact zone and may comprise a second heat transfer element positioned in the second contact zone. By using first and second heat transfer elements, heat is transferred efficiently from the heating element to the first and second heating zones, thereby maximising the energy efficiency of the vapour generating system.

The heat transfer unit may consist of one heat transfer element having a first part positioned in the first contact zone and a second part positioned in the second contact zone. By using a single heat transfer element to transfer heat from the heating element to the first and second vaporization zones, the structure of the cartridge may be simplified and the manufacturability of the cartridge thereby improved. The first and second parts of the heat transfer element may be separated by a thermal barrier. The provision of a thermal barrier allows the heating of the first and second parts of the heat transfer element, and hence the heating of the first and second vaporization zones, to be carefully controlled and optimized.

The first and second vaporization zones may be located oppositely with respect to a longitudinal axis of the vapour generating system. This may facilitate manufacture and assembly of the vapour generating system.

The vapour generating system may further comprise a first sorption member at least partially disposed in the first vaporization zone for absorbing vapour generating liquid from the liquid store and may comprise a second sorption member at least partially disposed in the second vaporization zone for absorbing vapour generating liquid from the liquid store. The heat transfer unit may contact the first and second sorption members respectively in the first and second vaporization zones to vaporize the absorbed vapour generating liquid. This is a continuous process, in which vapour generating liquid from the liquid store is continuously absorbed by the first and second sorption members. As noted above, vapour created during this process is transferred from the first and second vaporization zones via a vapour outlet channel in the cartridge so that it can be inhaled by a user of the vapour generating system.

The liquid store may include first and second liquid outlets. The first and second vaporization zones may be in communication respectively with the first and second liquid outlets for receiving vapour generating liquid from the liquid store. The first and second liquid outlets may help to provide a controlled flow of vapour generating liquid from the liquid store to the first and second vaporization zones, thereby facilitating vapour generation in the first and second vaporization zones.

The heating element and the heat transfer unit may define a mating profile in at least the first and second contact zones. The mating profile facilitates alignment of the heating element and the heat transfer unit, thus maximising heat transfer from the heating element to the heat transfer unit in the first and second contact zones and, in turn, maximising the energy efficiency of the vapour generating system.

The mating profile may comprise a plurality of cooperating mating surfaces. For example, the mating profile may comprise a convex profile section and a complementary concave profile section. The heating element may be formed with the convex profile section and the heat transfer unit may be formed with the concave profile section. The mating profile may be a generally V-section profile. The provision of a convex profile section and a complementary concave profile section, and in particular a V-section profile, may provide a good balance between manufacturability and alignment capability.

The vapour generating liquid may comprise polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. The vapour generating liquid may contain nicotine and may, therefore, be designated a nicotine-containing liquid. The vapour generating liquid may contain one or more additives, such as a flavouring.

The sorption member can be made of any material or a combination of materials being able to perform sorption and/or absorption of another material, and can be made, for example, of one or more of the following materials: fibre, glass, aluminium, cotton, ceramic, cellulose, glass fibre wick, stainless steel mesh, polyethylene (PE), polypropylene, polyethylene terephthalate (PET), poly(cyclohexanedimethylene terephthalate) (PCT), polybutylene terephthalate (PBT), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), and BAREX®, etc.

The heat transfer unit may comprise a thermally conductive material, for example, a metal such as aluminium, copper, etc.

The heating element may comprise an electrically resistive material. The heating element may include a ceramic material, for example tungsten and alloys thereof. The use of a ceramic material conveniently helps to rigidity the heating element. The heating element may be at least partially encapsulated in, or coated with, a protective material, such as glass.

The heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such embodiments, the metal may be formed as a track between two layers of suitable insulating materials. A heating element formed in this manner may be used both as a heater and a temperature sensor.

The heating element may include a temperature sensor embedded therein or attached thereto.

The power supply unit, e.g. battery, may be a DC voltage source. For example, the power supply unit may be a Nickel-metal hydride battery, a Nickel cadmium battery, or a Lithium based battery, for example a Lithium-Cobalt, a Lithium-Iron-Phosphate, a Lithium-Ion or a Lithium-Polymer battery.

The base part may further comprise a processor associated with electrical components of the vapour generating system, including the battery.

The cartridge may further comprise: a cartridge housing at least partially including the liquid store and the first and second vaporization zones, and a vapour outlet channel extending along the cartridge housing and in fluid communication with the first and second vaporization zones. The first and second vaporization zones may be physically separated on opposite sides of the vapour outlet channel. The cartridge housing may have a proximal end configured as a mouthpiece end which is in fluid communication with the first and second vaporization zones via the vapour outlet channel and a distal end associated with the heat transfer unit. The mouthpiece end may be configured for providing the vaporized liquid to the user. The heat transfer unit may be disposed at the distal end. The heat transfer unit may be substantially perpendicular to the vapour outlet channel. The liquid store may be juxtaposed with the vapour outlet channel extending between the first and second vaporization zones and the mouthpiece end. The liquid store may be disposed around the vapour outlet channel.

The cartridge housing may be made of one or more of the following materials: aluminium, poly ether ether ketone (PEEK), polyimides, such as Kapton®, polyethylene terephthalate (PET), polyethylene (PE), high-density polyethylene (HDPE), polypropylene (PP), polystyrene (PS), fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyoxymethylene (POM), polybutylene terephthalate (PBT), Acrylonitrile butadiene styrene (ABS), Polycarbonates (PC), epoxy resins, polyurethane resins and vinyl resins.

Brief Description of the Drawings

Figure 1 is a diagrammatic view of a vapour generating system comprising a base part and a cartridge;

Figure 2 is a perspective view of a first example of a cartridge;

Figure 3 is a cutaway view of the cartridge shown in Figure 2 showing first and second vaporization zones;

Figure 4 is an enlarged cutaway view of a base portion of the cartridge shown in Figure 3 with first and second sorption members removed from the first and second vaporization zones;

Figure 5 is a diagrammatic perspective view of part of the base portion of Figure 4 showing a second plug member and first and second heat transfer elements;

Figure 6 is a diagrammatic perspective view of part of a second example of a cartridge, showing a second plug member, a single heat transfer element and first and second sorption members;

Figure 7 is a diagrammatic perspective view of the heat transfer element of Figure 6; and

Figure 8 is a diagrammatic perspective view of a heating element of the base part. Detailed Description of Embodiments

Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

Referring initially to Figure 1, there is shown diagrammatically a vapour generating system 1 for vaporizing a vapour generating liquid to generate a vapour (or aerosol) for inhalation by a user of the system 1. The vapour generating system 1 comprises a base part 10 and a cartridge 12 thermically connected to the base part 10. The base part 10 is thus the main body part of the vapour generating system 1 and is preferably re-usable.

The base part 12 comprises a housing 14 accommodating a power supply unit in the form of a battery 16 connected to a resistive heating element 18 located at a first end 14a of the housing 14. The first end 14a of the housing 14 has an interface 15 configured for matching a corresponding interface of the cartridge 12. The battery 16 is configured for providing the heating element 18 with the necessary electrical power for its operation, allowing it to become heated to a required temperature. The battery 16 is also connected to a processor 20, enabling the required power supply for its operation. The processor 20 is connected to the heating element 18 and controls its operation.

Referring additionally to Figures 2 to 5, in a first example the cartridge 12 comprises a cartridge housing 22 having a proximal end 24 and a distal end 26. The proximal end 24 may constitute a mouthpiece end configured for being introduced directly into a user's mouth and may, therefore, also be designated as the mouth end 24. In some embodiments, a mouthpiece may be fitted to the proximal end 24. However, it is also possible to configure the vapour generating system 1 with a separate mouthpiece portion, releasably connectable to the base part 10 and whereby the cartridge 12 is enclosed inside the vapour generating system 1.

The cartridge 12 comprises abase portion 28 and a liquid storage portion 30. The liquid storage portion 30 comprises a liquid store 32, configured for containing therein a vapour generating liquid, and a vapour outlet channel 34. The vapour generating liquid may comprise an aerosol-forming substance such as propylene glycol and/or glycerol and may contain other substances such as nicotine and acids. The vapour generating liquid may also comprise flavourings such as, e.g., tobacco, menthol, or fruit flavour. The liquid store 32 may extend generally between the proximal end 24 and the distal end 26, but is spaced from the distal end 26. The liquid store 32 may surround, and coextend with, the vapour outlet channel 34.

As best seen in Figures 3 and 4, the base portion 28 of the cartridge 12 may be configured to sealingly close off the distal end 26 of the cartridge 12. The base portion 28 comprises a plug assembly 36 comprising first and second plug members 36a, 36b. The plug assembly 36, and more specifically the first plug member 36a, closes the distal end 26 of the cartridge housing 22 and thereby retains the vapour generating liquid in the liquid store 32. The first plug member 36a is provided with a circumferential surface 46 that is in contact with the inner circumferential surface of the liquid store 32. The first plug member 36a may be formed of a material with an elasticity that provides a sealing effect when the circumferential surface 46 contacts the inner circumferential surface of the liquid store 32. For example, the first plug member 36a may comprise rubber or silicone. Alternatively, the first plug member 36a may comprise a thermoplastic material which enables the first plug member 36a and the liquid store 32 to be joined together by, e.g., ultrasonic welding. The first plug member 36a comprises a connecting portion 44 which is configured to sealingly connect to a distal end 34a of the vapour outlet channel 34 as shown in Figures 3 and 4.

The cartridge 12 includes first and second vaporization zones 48a, 48b formed in the base portion 28. The first and second vaporization zones 48a, 48b are positioned on opposite sides of the vapour outlet channel 34, i.e., oppositely with respect to a longitudinal axis of the vapour generating system 1, to physically separate the first and second vaporization zones 48a, 48b from each other. A first sorption member 38a can be positioned in the first vaporization zone 48a and a second sorption member 38b can be positioned in the second vaporization zone 48b as shown in Figure 3, although the use of sorption members 38a, 38b is not essential. In the illustrated example, the first sorption member 38a absorbs vapour generating liquid from the liquid store 32 via one or more first liquid outlets 50a formed in the first plug member 36a and the second sorption member 38b absorbs vapour generating liquid from the liquid store 32 via one or more second liquid outlets 50b formed in the first plug member 36a.

The cartridge 12 includes a heat transfer unit 42 which is configured to transfer heat from the heating element 18 of the base part 10 to the first and second vaporization zones 48a, 48b to vaporize liquid in the first and second vaporization zones 48a, 48b. In the first example of the cartridge illustrated in Figures 2 to 5, the heat transfer unit 42 consists of a first heat transfer element 42a positioned in a first contact zone 40a adjacent to the first vaporization zone 48a and a second heat transfer element 42b positioned in a second contact zone 40b adjacent to the second vaporization zone 48b. The first heat transfer element 42a contacts the first sorption member 38a in the first contact zone 40a to transfer heat to the first sorption member 38a and vaporize vapour generating liquid absorbed from the liquid store 32 via the one or more first liquid outlets 50a. Similarly, the second heat transfer element 42b contacts the second sorption member 38b in the second contact zone 40b to transfer heat to the second sorption member 38b and vaporize vapour generating liquid absorbed from the liquid store 32 via the one or more second liquid outlets 50b.

The first and second heat transfer elements 42a, 42b can be mounted on the second plug member 36b in the first and second contact zones 40a, 40b, and the first and second sorption members 38a, 38b can be disposed between the first plug member 36a and the respective first and second heat transfer element 42a, 42b in the respective first and second vaporization zones 48a, 48b. The first and second heat transfer elements 42a, 42b can have a stepped surface profile, for example formed by a plurality of ridges and grooves, as shown in Figures 3 to 5 so that the first and second heat transfer elements 42a, 42b are only in partial contact with the respective first and second sorption members 38a, 38b. The use of a stepped surface profile is not, however, essential and the first and second heat transfer elements 42a, 42b could instead have a flat surface profile or a surface profile with only a single ridge, for example a V-section profile.

When the base part 10 and the cartridge 12 are assembled together as shown schematically in Figure 1, the heating element 18 of the base part 10 contacts the first and second heat transfer elements 42a, 42b of the cartridge 12, such that the cartridge 12 is thermically connected to the base part 10. In operation, the heating element 18 is resistively heated by the power from the battery 16 and provides its heat to the first and second heat transfer elements 42a, 42b via conduction, so that the first and second heat transfer elements 42a, 42b are heated independently of each other by the heating element 18. The heat from the first and second heat transfer elements 42a, 42b is then transferred respectively to the first and second sorption members 38a, 38b, mainly by conduction. Thus, the first and second sorption members 38a, 38b are heated indirectly by the first and second heat transfer elements 42a, 42b, and not directly by the heating element 18 of the base part 10. The heating element 18 in the base part 12 ideally needs to attain a temperature of around 500°C in order to transfer enough heat such that the interface between the first and second sorption members 38a, 38b and the first and second heat transfer elements 42a, 42b reaches a temperature at which vaporization occurs (typically between 200°C and 250°C). As a result of heating of the first and second sorption members 38a, 38b, the vapour generating liquid absorbed therein from the liquid store 32 is vaporized in the first and second vaporization zones 48a, 48b, and the vapour escapes from the first and second vaporization zones 48a, 48b via the vapour outlet channel 34 when a user sucks on the proximal (mouth) end 24 of the cartridge 12. The vapour cools and condenses as it flows through the vapour outlet channel 34 to form an aerosol that can be inhaled by a user via the proximal (mouth) end 24.

The cartridge 12 includes first and second air inlets 52a, 52b to allow air to flow respectively to the first and second vaporization zones 48a, 48b during use of the vapour generating system 1 when a user sucks on the proximal (mouth) end 24 of the cartridge 12 as described above. In the illustrated example, the first and second air inlets 52a, 52b are formed in the second plug member 36b and allow air to flow to the first and second vaporization zones 48a, 48b along paths formed between the first and second plug members 36a, 36b. Other configurations are, however, entirely within the scope of the present disclosure.

Referring now to Figures 6 to 8, there is shown part of a second example of a cartridge which is similar to the cartridge 12 described above but which employs an alternative heat transfer unit 42 consisting of a single heat transfer element 54 configured to transfer heat from the heating element 18 of the base part 10 to the first and second vaporization zines 48a, 48b. As best seen in Figure 7, the heat transfer element 54 includes a generally V-section profile 56 with an upper convex profile section 58 in contact with the first and second sorption members 38a, 38b in the first and second vaporization zones 48a, 48b and a lower concave profile section 60 configured to contact a corresponding convex profile section 62 of the heating element 18 (see Figure 8).

When the base part 10 and the cartridge 12 are assembled together as shown schematically in Figure 1, the heating element 18 shown in Figure 8 contacts the heat transfer element 54 in a first contact zone 40a to transfer heat to the first vaporization zone 48a and contacts the heat transfer element 54 in a second contact zone 40b to transfer heat to the second vaporization zone 48b. Thus, the heat transfer element 54 has a first part 54a positioned in the first contact zone 40a adjacent to the first vaporization zone 38a and a second part 54b positioned in the second contact zone 40b adjacent to the second vaporization zone 38b. The first part 54a of the heat transfer element 54 is contacted by the first sorption member 38a and thus transfers heat from the heating element 18 to the first sorption member 38a to vaporize absorbed vapour generating liquid in the first vaporization zone 48a. The second part 54b of the heat transfer element 54 is contacted by the second sorption member 38b and thus transfers heat from the heating element 18 to the second sorption member 38b to vaporize absorbed vapour generating liquid in the second vaporization zone 48b.

In order to minimise heat transfer between the first and second parts 54a, 54b of the heat transfer element 54, the first and second parts 54a, 54b can be separated by a thermal barrier 66, for example in the form of an opening formed in the heat transfer element 54.

Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

Claims

1. A vapour generating system (1) comprising: a base part (10) including a heating element (18); and a cartridge (12) releasably connectable to the base part (10), the cartridge (12) comprising: a liquid store (32) for storing a vapour generating liquid; first and second vaporization zones (48a, 48b) in communication with the liquid store (32) for receiving vapour generating liquid from the liquid store (32), wherein the first and second vaporization zones (48a, 48b) are physically separated from each other; and a heat transfer unit (42) configured to transfer heat from the heating element (18) to the first and second vaporization zones (48a, 48b) to vaporize vapour generating liquid in the first and second vaporization zones (48a, 48b).

2. A vapour generating system according to claim 1, wherein the heating element (18) contacts the heat transfer unit (42) in a first contact zone (40a) to transfer heat to the first vaporization zone (48a) and in a second contact zone (40b) to transfer heat to the second vaporization zone (48b).

3. A vapour generating system according to claim 2, wherein the heat transfer unit (42) comprises a first heat transfer element (42a) positioned in the first contact zone (40a) and a second heat transfer element (42b) positioned in the second contact zone (40b).

4. A vapour generating system according to claim 2, wherein the heat transfer unit (42) consists of one heat transfer element (54) having a first part (54a) positioned in the first contact zone (40a) and a second part (54b) positioned in the second contact zone (40b).

5. A vapour generating system according to claim 4, wherein the first and second parts (54a, 54b) of the heat transfer element (54) are separated by athermal barrier (66).

6. A vapour generating system according to any preceding claim, wherein the first and second vaporization zones (48a, 48b) are located oppositely with respect to a longitudinal axis of the vapour generating system (1).

7. A vapour generating system according to any preceding claim, further comprising a first sorption member (38a) at least partially disposed in the first vaporization zone (48a) for absorbing vapour generating liquid from the liquid store (32) and a second sorption member (38b) at least partially disposed in the second vaporization zone (48b) for absorbing vapour generating liquid from the liquid store (32), wherein the heat transfer unit (42) contacts the first and second sorption members (38a, 38b) respectively in the first and second vaporization zones (48a, 48b) to vaporize the absorbed vapour generating liquid.

8. A vapour generating system according to any preceding claim, wherein the liquid store (32) includes first and second liquid outlets (50a, 50b) and the first and second vaporization zones (48a, 48b) are in communication respectively with the first and second liquid outlets (50a, 50b) for receiving vapour generating liquid from the liquid store (32).

9. A vapour generating system according to any of claims 2 to 8, wherein the heating element (18) and the heat transfer unit (42) define a mating profile (56) in at least the first and second contact zones (40a, 40b).

10. A vapour generating system according to claim 9, wherein the mating profile (56) comprises a plurality of cooperating mating surfaces.

11. A vapour generating system according to claim 9 or claim 10, wherein the mating profile (56) comprises a convex profile section (62) and a complementary concave profile section (60). - 16 -

12. A vapour generating system according to claim 11 , wherein the heating element (18) is formed with the convex profile section (62) and the heat transfer unit (42) is formed with the concave profile section (60).

13. A vapour generating system according to any of claims 9 to 12, wherein the mating profile (56) is a generally V-section profile.