WO2023104703A1

WO2023104703A1 - An aerosol generating system

Info

Publication number: WO2023104703A1
Application number: PCT/EP2022/084387
Authority: WO
Inventors: Alec WRIGHT; Peter LOVEDAY
Original assignee: Jt International Sa
Priority date: 2021-12-09
Filing date: 2022-12-05
Publication date: 2023-06-15

Abstract

An aerosol generating system (1) comprises a vaporizer unit (14, 114) including a 5 heater (34) for heating and vaporizing an aerosol generating liquid and a cartridge (16, 116) including a liquid store (24) for containing an aerosol generating liquid. The cartridge (16, 116) is removably couplable to the vaporizer unit (14, 114). The cartridge (16, 116) includes a resiliently deformable valve (48) having a closed position for preventing the flow of aerosol generating liquid from the liquid store (24) through the valve (48) when the cartridge (16, 116) is not coupled to the vaporizer unit (14, 114). The vaporizer unit (14, 114) is configured to contact an external surface (58) of the resiliently deformable valve (48) as the cartridge (16, 116) is coupled to the vaporizer unit (14, 114) to deform the valve (48) and move it from the closed position towards an open position in which aerosol generating liquid can flow from the liquid store (24) through the valve (48). The resiliently deformable valve (48) includes first and second portions (50, 52) biased together into contact with each other when the cartridge (16, 116) is not coupled to the vaporizer unit (14, 114) and the resiliently deformable valve (48) is in the closed position, and the first and second portions (50, 52) are configured to be deflected away from each other to define an opening (60) between the first and second portions (50, 52) as the cartridge (16, 116) is coupled to the vaporizer unit (14, 114) to move the resiliently deformable valve (48) from the closed position towards the open position.

Description

AN AEROSOL GENERATING SYSTEM

Technical Field

The present disclosure relates generally to an aerosol generating system, for example an electronic cigarette, for heating an aerosol generating liquid to generate a vapour which may cool and condense to form an aerosol for inhalation by a user of the system. The aerosol generating system may comprise an aerosol generating device and a cartridge for containing a supply of aerosol generating liquid.

Technical Background

Aerosol generating devices, such as electronic cigarettes or “e-cigarettes” as they are commonly known, have gained in popularity over recent years as an alternative to traditional smoking articles, like cigarettes, cigars, and cigarillos. Aerosol generating devices work by heating an aerosol generating liquid to generate a vapour that cools and condenses to form an aerosol which is then inhaled by the user. The aerosol generating liquid usually contains one or more of nicotine, propylene glycol, glycerine and flavourings.

Conventional aerosol generating devices usually include a vaporizer unit to heat and vaporize the aerosol generating liquid. Conventional vaporizer units typically employ a wicking element, e.g., a cotton or ceramic wick, to transfer aerosol generating liquid by capillary action from a liquid store to a heating element which is often in the form of a heating coil wrapped around the wicking element or a resistive heating track coated onto the wicking element. When a user operates the aerosol generating device, aerosol generating liquid that has soaked into the wicking element is heated by the heating element and volatized to form a vapour which may then be entrained in an airflow through the device and which may cool and condense to form an aerosol that is inhaled by a user.

To facilitate the ease of use of aerosol generating devices, cartridges are often used. These cartridges are often configured as “cartomizers”, which means an integrated component comprising a liquid store, a liquid transfer element (e.g., a wicking element) and a heater. Electrical connectors may also be provided to establish an electrical connection between the heater and a power source. However, the complexity and numerous components of such cartridges are associated with drawbacks, such as complex and costly manufacturing and/or assembly processes. The disposal and/or recyclability of such cartridges also presents a challenge because they comprise numerous plastic and metallic components.

In view of the above, it would be desirable to provide an aerosol generating system which allows the use of cartridges having a simplified structure such that the manufacturability and/or assembly and/or recyclability of the cartridges can be improved and additionally in which leakage of aerosol generating liquid from the cartridges can be prevented and the cost of the exchangeable part of the device can be significantly reduced.

Summary of the Disclosure

According to a first aspect of the present disclosure, there is provided an aerosol generating system comprising: a vaporizer unit including a heater for heating and vaporizing an aerosol generating liquid; and a cartridge including a liquid store for containing an aerosol generating liquid, the cartridge being removably couplable to the vaporizer unit; wherein the cartridge includes a resiliently deformable valve having a closed position for preventing the flow of aerosol generating liquid from the liquid store through the resiliently deformable valve when the cartridge is not coupled to the vaporizer unit and the vaporizer unit is configured to contact an external surface of the resiliently deformable valve as the cartridge is coupled to the vaporizer unit to deform the resiliently deformable valve and thereby move it from the closed position towards an open position in which aerosol generating liquid can flow from the liquid store through the resiliently deformable valve.

The vaporizer unit, and in particular the heater, is configured to heat the aerosol generating liquid to volatise at least one component of the aerosol generating liquid and thereby generate a vapour which may cool and condense to form an aerosol for inhalation by a user of the aerosol generating system. The present disclosure is particularly applicable to a portable (hand-held) aerosol generating system.

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.

By separating the vaporizer unit from the cartridge, the number of components within the cartridge is reduced and, thus, the structure of the cartridge can be simplified and the cost reduced. The recyclability of the cartridge can also be facilitated or improved. Furthermore, the vaporizer unit can be re-used with multiple cartridges, avoiding the need to discard and replace components within the vaporizer unit each time a depleted cartridge is replaced. The resiliently deformable valve also ensures that there is no leakage of the aerosol generating liquid from the liquid store prior to coupling of the cartridge to the vaporizer unit.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the present disclosure.

The vaporizer unit may include a valve actuating member. The valve actuating member may be arranged to contact the external surface, e.g., an external side surface, of the resiliently deformable valve to deform the resiliently deformable valve and thereby move it from the closed position towards the open position as the cartridge is coupled to the vaporizer unit. The resiliently deformable valve is opened by a simple contact or pressure applied to its external surface by the valve actuating member. This is advantageous because the valve actuating member does not penetrate the resiliently deformable valve and does not, therefore, contact the aerosol generating liquid as it flows through the resiliently deformable valve. Thus, the valve actuating member is not contaminated by the aerosol generating liquid, allowing cartridges containing different aerosol generating liquids to be coupled to the vaporizer unit without any crosscontamination.

The valve actuating member may comprise a recess in which the resiliently deformable valve may be located when the cartridge is coupled to the vaporizer unit. The recess may include a tapered side wall. The tapered side wall may taper towards the resiliently deformable valve and may be configured to contact the external surface of the resiliently deformable valve as a result of the coupling of the cartridge with the vaporizer unit, to deform the resiliently deformable valve. The tapering of the side wall tends to pinch or squeeze the resiliently deformable valve and thereby move it from the closed position towards the open position. The resiliently deformable valve is, therefore, opened in a simple and reliable manner as the cartridge is coupled to the vaporizer unit.

The tapered side wall may be configured to contact a side wall of the resiliently deformable valve to deform the resiliently deformable valve and thereby move it from the closed position towards the open position. A simple and reliable opening of the resiliently deformable valve is thereby achieved.

The resiliently deformable valve may include first and second portions which may be biased together when the cartridge is not coupled to the vaporizer unit or no pressure is exerted on the valve by the valve actuating member and the resiliently deformable valve is in the closed position. When the first and second portions are biased together, the first and second portions contact each other and thus provide a good sealing effect, thereby ensuring that aerosol generating liquid cannot flow through the resiliently deformable valve when it is in the closed position. The first and second portions may be configured to be deflected away from each other to define an opening, such as an orifice or slit, between the first and second portions as the cartridge is coupled to the vaporizer unit to move the resiliently deformable valve from the closed position towards the open position. Deflection of the first and second portions away from each other provides a simple, yet effective, opening of the resiliently deformable valve by allowing aerosol generating liquid to flow through the opening, e.g., orifice or slit, between the deflected first and second portions of the valve.

In a mode, the recess of the valve actuating member comprises shoulders configured for forcing apart first and second portions of the resiliently deformable valve. The shoulders may preferably be provided in a recess of the valve actuating member. The shoulders may advantageously be provided in an annular bottom of the recess and may be combined with the tapered side wall of the recess.

The resiliently deformable valve may be selected from the group consisting of a duckbill valve, a slit valve and a membrane valve. The resiliently deformable valve may be made of silicone or rubber. Such materials allow a good sealing effect to be achieved, for example due to contact between the first and second portions of the resiliently deformable valve.

The heater may comprise a capillary element and heating element in contact with each other. For example, the heater may be a coil-and-wick heater or a ceramic heater. For example, the vaporizer unit may include a liquid transfer element, such as a wick, and the heater may comprise a heating coil which extends around the liquid transfer element. The liquid transfer element facilitates the transfer of aerosol generating liquid from the liquid store to the heating element where it is heated to form a vapour.

The vaporizer unit may comprise a vaporization chamber and the heater may be positioned in or adjacent to the vaporization chamber. The vaporizer unit may include an air inlet communicating with the vaporization chamber, for example with an inlet of the vaporization chamber. The cartridge may include a vapour outlet channel in communication with an outlet of the vaporization chamber. The vapour generated in the vaporization chamber may cool and condense to form an aerosol as it flows along the vapour outlet channel, from the vaporization chamber towards an end of the vapour outlet channel. The end of the vapour outlet channel may comprise a mouthpiece. The aerosol generating liquid may comprise polyhydric alcohols and mixtures thereof such as glycerine and/or propylene glycol. The aerosol generating liquid may contain nicotine or nicotine salts. The aerosol generating liquid may contain one or more additives, such as a flavouring. The flavouring may include Ethylvanillin (vanilla), menthol, cherry, Isoamyl acetate (banana oil) or similar, for instance.

The aerosol generating liquid may be vaporised by heating the aerosol generating liquid up to its boiling point by the heater, such as a temperature up to 400°C, preferably up to 350°C.

Brief Description of the Drawings

Figure 1 is a diagrammatic view of an aerosol generating system;

Figure 2 is a diagrammatic cross-sectional view of a first example of a vaporizer unit and cartridge prior to coupling of the cartridge to the vaporizer unit;

Figure 3 is a diagrammatic cross-sectional view similar to Figure 2 with the cartridge coupled to the vaporizer unit;

Figures 4a and 4b are diagrammatic cross-sectional views along the line A- A of Figure 2 and B-B of Figure 3 showing a resiliently deformable valve respectively in a closed position and an open position;

Figure 5a is a diagrammatic perspective view of a second example of a vaporizer unit and cartridge prior to coupling of the cartridge to the vaporizer unit with the resiliently deformable valve in a closed position;

Figure 5b is a diagrammatic cross-sectional view of the second example of a vaporizer unit and cartridge prior to coupling of the cartridge to the vaporizer unit with the resiliently deformable valve in a closed position;

Figure 6a is diagrammatic perspective cut-away view of the second example of the cartridge and vaporizer unit shown in Figures 5a and 5b with the cartridge coupled to the vaporizer unit and the resiliently deformable valve in an open position; and

Figure 6b is a diagrammatic cross-sectional view similar to Figure 5b with the cartridge coupled to the vaporizer unit and the resiliently deformable valve in an open position. 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.

As described hereinafter, example implementations of the present disclosure relate to an aerosol generating system, in particular a portable hand-held smoking system such as an electronic cigarette. The aerosol generating system typically comprises an aerosol generating device and a cartridge containing an aerosol generating liquid. Aerosol generating devices according to the present disclosure use electrical energy to heat and volatise the aerosol generating liquid, without combusting the aerosol generating liquid and/or without significant chemical alteration of the aerosol generating liquid, to form an inhalable aerosol or vapour; and components of such device have the form of articles that most preferably are sufficiently compact to be considered hand-held devices. The use of the aerosol generating device does not result in the production of smoke in the sense that the vapour or aerosol does not result from by-products of combustion or pyrolysis of tobacco, but rather, the use of the aerosol generating device results in the production of a vapour or aerosol due to volatilization or vaporization of certain components incorporated in the aerosol generating liquid.

In some example implementations, the aerosol generating device may be characterized as an electronic cigarette in which the aerosol generating liquid may comprise propylene glycol or glycerine or a combination thereof. Aerosol generating devices (or systems) within the meaning of the present disclosure may transport the volatilized components of the aerosol generating liquid in an airflow through the aerosol generating device to a user of the device, the user of the device being able to activate or deactivate the generation of aerosol and to control the duration, velocity and volume of the airflow by means of a puffing or inhaling action.

Referring to Figure 1, there is shown diagrammatically an example of an aerosol generating system 1 comprising an aerosol generating device 10 in the form of a power supply portion 12, a vaporizer unit 14 and a cartridge 16. The aerosol generating device 10 typically has an elongate and possibly substantially cylindrical shape. Other shapes are, however, entirely within the scope of the present disclosure.

The power supply portion 12, which can also be referred to as a main body or control body or battery assembly, of the aerosol generating system 1, is advantageously configured as a re-usable unit. The power supply portion 12 comprises a power source 18 (e.g., a battery) and a controller 20 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microprocessor, individually or as part of a microcontroller, and the like) to control the operation of the aerosol generating system 1, and more particularly the operation of the vaporizer unit 14.

The vaporizer unit 14 is configured to heat and vaporize an aerosol generating liquid. The vaporizer unit 14 can form an integral part of the power supply portion 12 or can be a separate unit that is releasably connected to the power supply portion 12 via a releasable connection 22, for example to allow removal and replacement of the vaporizer unit 14. The releasable connection 22 (where present) can be, for example, a snap-fit connection, a threaded connection, a bayonet connection or a magnetic connection.

The cartridge 16 includes a liquid store 24 for containing an aerosol generating liquid. As noted above, the aerosol generating liquid may comprise an aerosol -forming substance such as propylene glycol and/or glycerol and may contain other substances such as nicotine, nicotine salts and acids. The aerosol generating liquid may also comprise flavourings such as, e.g., tobacco, menthol or fruit flavour. As best seen in Figures 2 and 3, the liquid store 24 may surround, and coextend with, a vapour outlet channel 26. The vapour outlet channel 26 has an outlet 28 at a mouth end 30 of the aerosol generating system 1 through which an inhalable aerosol is delivered to a user.

The vaporizer unit 14 includes a wicking element 32 and a heater 34 in the form of a resistive heating coil 36 that is wound helically around the outside of the wicking element 32. Together, the wicking element 32 and the resistive heating coil 36 form a coil-and-wick heater 34 that is located in a vaporization chamber 38 of the vaporizer unit 14. The wicking element 32 is configured to convey aerosol generating liquid from the liquid store 24 to the heating coil 36 so that the conveyed aerosol generating liquid can be heated and vaporized when an electric current from the power source 18 is passed through the resistive heating coil 36. The vaporizer unit 14 includes a conduit 42 having at least one liquid inlet 44 which is aligned with a corresponding liquid outlet 46 of the cartridge 16 when the cartridge 16 is coupled to the vaporizer unit 14. The coil-and-wick may also be replaced by another type of heater such as a ceramic heater, for example, as described in EP 3516972 Al.

The cartridge 16 includes a resiliently deformable valve 48 positioned in each liquid outlet or portion of conduit 46. The valve 48 adopts a closed position when the cartridge 16 is not coupled to the vaporizer unit 14 and adopts an open position when the cartridge 16 is coupled to the vaporizer unit 14. In the closed position, when the cartridge 16 is not coupled to the vaporizer unit 14, the resiliently deformable valve 48 prevents the flow of aerosol generating liquid from the liquid store 24 through the valve 48. In the open position, when the cartridge 16 is coupled to the vaporizer unit 14, the resiliently deformable valve 48 permits the flow of aerosol generating liquid from the liquid store 24 through the valve 48 and to the vaporizer unit 14.

The resiliently deformable valve 48 is typically formed of a silicone or rubber material and, as shown in Figure 4a, comprises first and second portions 50, 52 which are biased together when the valve 48 is in the closed position. In particular, the example of Figure 4a corresponds to a valve being at rest with no pressure applied thereon in the perpendicular direction (i.e. an opening pressure direction P, Figure 4b) to the direction of the first and second portions 50, 52. When no external pressure is applied on the valve 48 in the opening pressure direction, the first and second portions 50, 52 are biased together and into contact with each other so that the flow of aerosol generating liquid from the liquid store 24 through the valve 48 is prevented, thus avoiding unintended leakage of aerosol generating liquid from the liquid store 24. In the example of Figure 4a representing a slit valve at rest, the biasing together of the first and second portions 50, 52 corresponds to the closing or re-closing of the slit of the valve due to the contact between the first and second portions 50, 52. The cartridge 16 includes a valve actuating member 54. In the illustrated example, the valve actuating member 54 comprises a recess 56 in the vaporizer unit 14 in which the resiliently deformable valve 48 is located when the cartridge 16 is coupled to the vaporizer unit 14. When the cartridge 16 is coupled to the vaporizer unit 14, the resiliently deformable valve 48 enters into the recess 56 and an external surface 58 of the valve 48 is contacted and deformed (e.g., by pinching or pressing the side wall 59 in the opening pressure direction P) to deflect the first and second portions 50, 52 away from each other as shown in Figure 4b and thereby move the valve 48 from the closed position shown in Figures 2 and 4a to the open position shown in Figures 3 and 4b in which an opening 60, such as an orifice or slit, is created to allow the flow of aerosol generating liquid through the valve 48. A simple, yet reliable and effective opening, of the resiliently deformable valve 48 is thus achieved by the simple action of coupling the cartridge 16 to the vaporizer unit 14. Conversely, during the process of uncoupling the cartridge 16 from the vaporizer unit 14, the valve 48 is moved out of the recess 56 thereby removing the external pressure applied in the opening pressure direction P and allowing the resilient bias of the first and second portions 50, 52 to return them to the position best seen in Figure 4a in which the first and second portions 50, 52 are biased together and into contact with each other to prevent the flow of aerosol generating liquid through the valve 48.

Referring now to Figures 5 and 6, there is shown a second example of a cartridge 116 and vaporizer unit 114 which is similar to the cartridge 16 and vaporizer unit 14 described above. Some components of the cartridge 116 and vaporizer unit 114, such as the liquid store 24, wicking element 32 and resistive heating coil 36 have been omitted from Figures 5 and 6 for simplicity, but these components may be as described above with reference to Figures 1 to 3.

The recess 56 (valve actuating member 54) in which the resiliently deformable valve 48 is located has a tapered side wall 62 which tapers in a longitudinal direction away from an end face 66 of the vaporizer unit 114. The tapered side wall 62 provides for an optimal deflection away from each other of the first and second portions 50, 52 of the resiliently deformable valve 48 as the cartridge 116 is coupled to the vaporizer unit 114. In some examples, the recess 56 can include an inwardly directed inclined shoulder portion 64 which is configured to press on the front side of the valve 48. More precisely, inwardly protruding shoulders are positioned in the recess 56, preferably on an annular bottom. The shoulders are so configured for forcing the first and second portions 50, 52 apart in the deflected position and an enlargement of the opening 60 which allows liquid flow.

The resiliently deformable valve 48 can be recessed from an end face 68 of the cartridge 116 as best seen in Figures 5a and 5b, thus avoiding the possibility of accidental deformation (and hence opening) of the valve 48 during handling of the cartridge 116. In other words, there is no deformable part of the valve 48 protruding from the end face 68 of the cartridge 116. Thus, the tapered side wall 62 that forms the recess 56 (valve actuating member 54) projects from the end face 66 of the vaporizer unit 114 so that it can enter into a correspondingly shaped cavity 70 in the cartridge 116 that surrounds the valve 48. The shaped cavity 70 also provides proper guidance to the valve actuating member 54 thus ensuring a better control of the opening of the valve 48.

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. An aerosol generating system (1) comprising: a vaporizer unit (14, 114) including a heater (34) for heating and vaporizing an aerosol generating liquid; and a cartridge (16, 116) including a liquid store (24) for containing an aerosol generating liquid, the cartridge being removably couplable to the vaporizer unit; wherein the cartridge (16, 116) includes a resiliently deformable valve (48) having a closed position for preventing the flow of aerosol generating liquid from the liquid store (24) through the resiliently deformable valve (48) when the cartridge (16, 116) is not coupled to the vaporizer unit (14, 114) and the vaporizer unit (14, 114) is configured to contact an external surface (58) of the resiliently deformable valve (48) as the cartridge (16, 116) is coupled to the vaporizer unit (14, 114) to deform the resiliently deformable valve (48) and thereby move it from the closed position towards an open position in which aerosol generating liquid can flow from the liquid store (24) through the resiliently deformable valve (48); wherein the resiliently deformable valve (48) includes first and second portions (50, 52) biased together into contact with each other when the cartridge (16, 116) is not coupled to the vaporizer unit (14, 114) and the resiliently deformable valve (48) is in the closed position, and the first and second portions (50, 52) are configured to be deflected away from each other to define an opening (60) between the first and second portions (50, 52) as the cartridge (16, 116) is coupled to the vaporizer unit (14, 114) to move the resiliently deformable valve (48) from the closed position towards the open position.

2. An aerosol generating system according to claim 1, wherein the vaporizer unit (14, 114) includes a valve actuating member (54) arranged to contact the external surface (58) of the resiliently deformable valve (48) to deform the resiliently deformable valve (48) and thereby move it from the closed position towards the open position as the cartridge (16, 116) is coupled to the vaporizer unit (14, 114).

3. An aerosol generating system according to claim 2, wherein the valve actuating member (54) comprises a recess (56) in which the resiliently deformable valve (48) is located when the cartridge (16, 116) is coupled to the vaporizer unit (14, 114).

4. An aerosol generating system according to claim 3, wherein the recess (56) includes a tapered side wall (62) which tapers towards the resiliently deformable valve (48) and is configured to contact the external surface (58) of the resiliently deformable valve (48) to deform the resiliently deformable valve (48).

5. An aerosol generating system according to claim 4, wherein the tapered side wall (62) is configured to contact a side wall (59) of the resiliently deformable valve (48) to deform the resiliently deformable valve (48).

6. An aerosol generating system according to any preceding claim, wherein the opening (60) is an orifice or a slit.

7. An aerosol generating system according to claim 2, wherein the valve actuating member (54) comprises shoulders (64) configured for forcing apart the first and second portions (50, 52) of the resiliently deformable valve (48).

8. An aerosol generating system according to any preceding claim, wherein the resiliently deformable valve (48) is selected from the group consisting of a duckbill valve, a slit valve and a membrane valve.

9. An aerosol generating system according to any preceding claim, wherein the resiliently deformable valve (48) is made of silicone or rubber.

10. An aerosol generating system according to any preceding claim, wherein the heater (34) comprises a coil-and-wick heater or a ceramic heater.