WO2023227589A1

WO2023227589A1 - A cartridge for a vapour generating device and its packaging

Info

Publication number: WO2023227589A1
Application number: PCT/EP2023/063768
Authority: WO
Inventors: Christoph Lungenschmied; Broderick COBURN
Original assignee: Jt International Sa
Priority date: 2022-05-26
Filing date: 2023-05-23
Publication date: 2023-11-30

Abstract

A cartridge (4) for a vapour generating device having a housing (6) with an air inlet (22), an air outlet (26), at least one air channel (24) extending from the air inlet to the air outlet, a liquid reservoir (10) for containing a vapour generating liquid and a vaporization chamber (12/16) in communication with the liquid reservoir, at least part of an inner surface of the housing being provided with a barrier coating (100) applied by a chemical vapour deposition process. A removable or breakable seal is provided over a fluid outlet of the housing.

Description

A CARTRIDGE FOR A VAPOUR GENERATING DEVICE AND ITS PACKAGING

Technical Field

The present disclosure relates generally to a vapour generating device, such as an electronic cigarette. Embodiments of the present disclosure relate in particular to a cartridge for an electronic cigarette and to its packaging.

Technical Background

Electronic cigarettes are an alternative to conventional cigarettes. Instead of generating a combustion smoke, they vaporize a liquid which can be inhaled by a user. The liquid typically comprises an aerosol-forming substance, such as glycerine or propylene glycol, that creates the vapour when heated. Other common substances in the liquid are nicotine and various flavourings.

The electronic cigarette is a hand-held inhaler system, typically comprising a mouthpiece section, a liquid store and a power supply unit. Vaporization is achieved by a vaporizer or heater unit which typically comprises a heating element in the form of a heating coil and a fluid transfer element such as a wick. Vaporization occurs when the heater heats the liquid in the wick until the liquid is transformed into vapour.

Conventional cigarette smoke comprises nicotine as well as a multitude of other chemical compounds generated as the products of partial combustion and/or pyrolysis of the plant material. Electronic cigarettes on the other hand deliver primarily an aerosolized version of an initial starting e-liquid composition comprising nicotine and various food safe substances such as propylene glycol and glycerine, etc., but are also efficient in delivering a desired nicotine dose to the user. Electronic cigarettes need to deliver a satisfying amount of vapour for an optimum user experience whilst at the same time maximizing energy⁷ efficiency.

WO2017/179043 discloses one example of an electronic cigarette comprising a disposable cartridge containing the e-liquid composition and a reusable base part. The cartridge has a simplified structure which is achieved by keeping the main heating element in the re-usable base part, while the cartridge is provided with a heat transfer unit. The heat transfer unit is configured to transfer heat from the heating element to the proximity of liquid in the cartridge to produce a vapour for inhalation by a user. This arrangement enables re-fill cartridges to be provided while the base part is re-used.

The current packaging solution for these types of disposable cartridges is very’ wasteful. Generally, the cartridges (also known as capsules or pods) are packaged in primary packaging (e.g., blister packs) as well as a secondary packaging. The overall barrier properties of this packaging dictates shelf life of the product and consists of the following:

1) Primary' packaging which provides the bulk of the barrier properties, typically manufactured from materials with very' high-barrier properties, such as aluminum and/or polyvinylidene chloride (PVDC) coated PET in a blister pack format containing multiple refill cartridges. Alternatively, the cartridge or pod packaging may comprise flow-wrap using very' high-barrier properties.

2) Shelf ready secondary packaging, which provides product information and is in a format to enable shelf compatibility, commonly comprising cardboard with folds for receiving the blister pack. This secondary packaging provides minimal barrier properties due to the low-barrier materials used and its open construction.

3) The cartridge or pod itself, which provides very low barrier properties due to two main reasons. Firstly, many’ current cartridges require an open design to provide an air-path for air flow through the cartridge and to allow mixing with the vaporised e-liquid. This requirement exposes the e-liquid to the environment. Secondly, the cartridge materials that are used to house the e-liquid have challenging requirements, such as high chemical resistance to prevent migration of harmful chemical components or substances to the content of e-liquid in quantities which would change the composition of the e-liquid or the aerosol and thereby increase the risk for consumers. With chemical resistance, cost, and compatibility with high-volume manufacturing as drivers, the traditional candidate polymer materials, such as thermoplastics, do not provide sufficient barrier properties to maintain e-liquid freshness or quality at thicknesses that are acceptable from a cost point of view or consumable size (wall thicknesses should be less than 2 mm, preferably' less than 1 mm). Example materials used for pod housings such as polypropylene (PP), polycarbonate (PC), polyesters (such as PET or PEN (poly(ethylene 2,6-naphthalate))) and co-polyesters (such as Tritan) only provide medium to low gas and/or vapor barrier properties (e.g. oxygen transmission rate (OTR) > 4 cm³/m²/24hr; water vapor transmission rate (WVTR) > 4 g/m²/24hr).

However, the need to provide both blister-pack primary packaging in addition to cardboard secondary packaging in order to achieve satisfactory barrier properties and shelflife is both wasteful and environmentally unfriendly. Less packaging would contribute to a product that is cheaper to produce and more sustainable.

It is an object of the present disclosure to provide improved disposable cartridges and packaging for use with a vapour generating device, as well as methods for producing the cartridges and packaging that aim to overcome, or at least alleviate, the above-mentioned drawbacks.

Summary⁷ of the Disclosure

A first aspect of the present invention provides a cartridge for a vapour generating device, the cartridge being configured to connect to a base part to provide an operable device, the cartridge comprising: a housing having at least a liquid reservoir for containing a vapour generating liquid and an interface for connection to the base part; wherein at least part of an inner surface of the housing is provided with a barrier coating.

Any type of cartridge for a vapour generating device may be provided with the barrier coating on at least part of an inner surface of the housing in accordance with the first aspect of the invention. As noted above, typically cartridges are made from polymers, such as thermoplastics. Therefore a cartridge comprising a housing made of a polymer material, such as a thermoplastics material, may be provided with the barrier coating on at least part of an inner surface of the housing in accordance with the first aspect of the invention. It will be understood that “made of a polymer material” as used herein should not be taken to imply that the cartridge must be made exclusively of a polymer material. However, the barrier coatings described herein have particular utility⁷ when applied to parts of an inner surface of a housing that are made from a polymer material, due to the low barrier properties of traditional candidate polymer materials, as discussed above. In embodiments, the cartridge may be configured to thermally, electrically or inductively connect to the base part. For example, an electrically connectable cartridge may comprise a wick and coil cartridge or a ceramic heater cartridge as is known in the art. In contrast, a thermally connectable cartridge has heat energy transferred from a heat source provided in the base part. An inductively connectable cartridge has energy⁷ transferred from an induction coil provided in the base part to a susceptor provided in the cartridge, the susceptor generating heat for vaporisation of the liquid.

The cartridge may⁷ further comprise at least one air channel extending from an air inlet to an air outlet; the housing having a vaporisation chamber in communication with the liquid reservoir, the at least one air channel extending from the air inlet, through the vaporisation chamber to the air outlet and wherein the inner surface of the housing provided with the barrier coating comprises at least the liquid reservoir.

Alternatively, the cartridge may be one that is connectable to the base part to provide an operable device via liquid transfer. The barrier coating according to the invention may be applied to any⁷ ty pe of cartridge for a vapour generating device.

The film coating provides a barrier between materials of the housing and the atmosphere, reducing or eliminating degradation of the vapour generating liquid. Preferably, the inner surface of the housing provided with the barrier film coating comprises the liquid reservoir. As noted above, the liquid reservoir may⁷ be made from a polymer material, such as a thermoplastic material, such that the inner surface of a polymer reservoir is provided with the barrier coating. However, one or more other inner surfaces of the housing, such as an inner surface of the air channel, may⁷ be provided with the barrier coating in addition to the inner surface of the reservoir. In some embodiments, substantially- all internal surfaces of the housing may⁷ be provided with the film coating.

The film coating preferably has a thickness of less than lOOnm, more preferably having a thickness of 10- lOOnm.

The film coating may⁷ be applied to the inner surface by⁷ any⁷ suitable means but preferably⁷ is a vapour deposition coating, more preferably a chemical vapour deposition coating, most preferably plasma-enhanced chemical vapor deposition coating. Alternatively, an atomic layer deposition method (ALD) or molecular layer deposition method may be used. Preferably, the coating is selected from at least one of silicon oxide (SiOx), diamond-like carbon (DLC), silicon oxy carbide (SiOC) and silicon nitride, most preferably being silicon oxy carbide (SiOC).

An undercoating may be provided between the inner surface of the housing of the cartridge and the barrier coating to aid adhesion of the coating to the surface. An organosilane may be used for the undercoating layer. An example of a suitable undercoating is 3- aminopropyltrimethoxysilane (3APTMS).

In embodiments, the inner surface of the housing is provided with multiple layers of the barrier coating, preferably wherein multiple barrier layers are separated by softer interlayers, for example being formed from organo-silicone precursors, to decouple defects that may exist in coatings deposited by vapour deposition techniques caused by intrinsic or extrinsic roughness of the surface to be coated.

In a preferred embodiment, the cartridge further comprises a fluid outlet between the liquid reservoir and an exterior of the housing, wherein a separate seal is provided over the fluid outlet. Preferably, the seal comprises a removable or breakable seal extending across the fluid outlet.

A second aspect of the present invention provides a vapour generating device comprising a base part, a cartridge and a power supply, wherein the cartridge comprises a cartridge according to the first aspect of the present invention connected to the base part via the interface to provide an operable device.

The inner barrier coating and optional fluid outlet seal enables a cartridge according to the invention to be packaged directly in recyclable secondary packaging such as cardboard packaging, removing the need for a sealed blister pack or similar.

To this end, a third aspect of the present invention provides packaging for at least one cartridge of a vapour generating device, the packaging comprising an outer package comprising a recyclable cardboard packaging container and an inner package comprising a barrier coating applied directly to an inner surface of the cartridge.

The cardboard packaging container may be in the form of, for example, a rectangular box.

The container may be formed from a blank provided with appropriate fold lines. A removable or breakable seal is preferably provided over a fluid outlet of the cartridge. Optionally, film wrapping may be provided around the cardboard packaging container, such as heat shrunk film or other suitable wrapping. Multiple internally coated cartridges may be provided in a single packaging container.

A fourth aspect of the present invention provides a method for applying a barrier coating to an inner surface of a cartridge for a vapour generating device, the method comprising:

(a) placing at least a liquid resen-’ oir part of at least one cartridge for a vapour generating device in a coating chamber;

(b) applying a vacuum to at least a liquid reservoir of the cartridge to evacuate at least the interior of the reservoir;

(c) introducing a coating precursor gas into at least the liquid reservoir of the cartridge;

(d) supplying energy’ to cause deposition of the coating onto at least the inner surface of the liquid resery’oir;

(e) releasing the vacuum; and

(f) removing the coated cartridge from the coating chamber.

The Ape of energy’ applied in the process is dependent upon the type of deposition method implemented for application of the barrier coating. For example, for plasma enhanced chemical vapour deposition of the coating, radio frequency electromagnetic yvaves are supplied as is knoyvn in the art.

The method may further comprise applying an undercoat to at least the inner surface of the liquid reservoir prior to application of the barrier coating. Multiple layers of the barrier coating may be applied to the inner surface. The barrier layers may be separated by softer layers (for example, from organo-silicone precursors) to decouple defects yvhich may form in the individual layers of the barrier coating. These multiple layers may be deposited yvithout breaking the vacuum (see: Christoph Lungenschmied, Gilles Dennler, Grzegorz Czeremuszkin, Mohamed Latreche, Helmut Neugebauer and Niyazi Serdar Sariciftci, “Flexible Encapsulation for Organic Solar Cells” in Proc, of SPIE Vol. 6197, 619712 (2006))

A removable or breakable seal is preferably applied across a fluid outlet of the cartridge postcoating. Additionally, the cartridge may also be provided yvith a thermal interface membrane extending at least partially across the fluid outlet, preferably being provided internally of the fluid outlet seal. One or more cartridges may then be placed in secondary⁷ packaging.

In the context of this disclosure, a vapour generating device preferably comprises an electronic cigarette. As used herein, the term “electronic cigarette” may include an electronic cigarette configured to deliver an aerosol to a user, including an aerosol for inhalation/vaping. An aerosol for inhalation/vaping may refer to an aerosol with particle sizes of 0.01 to 20 pm. The particle size may be between approximately 0.015 pm and 20 pm. The electronic cigarette may be portable.

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.

It is to be appreciated that the cartridge and the base part may include any one or more components conventionally included in these parts of a vapour generating device. All or some of the internal cavities of the cartridge may be provided with the barrier coating according to the invention, albeit coating of only the inner surface of the liquid reservoir should suffice.

Dependent upon the ty pe of cartridge, a fluid transfer medium may be provided in the cartridge betyveen the liquid reservoir and a heat source for absorbing liquid transferred to the vaporization chamber from the reservoir. The fluid transfer medium 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 folloyving materials: fibreglass, aluminium, cotton, ceramic, cellulose and glass fibre yvick.

The cartridge housing may⁷ have a proximal end configured as a mouthpiece end yvhich is in fluid communication yvith the vaporization chamber via the air flow⁷ channel and a distal end provided yvith the interface for interconnection yvith the base part. The mouthpiece end may be configured for providing the vaporized liquid to the user.

In one embodiment, the liquid reservoir may⁷ be provided in the main body of the cartridge yvith the air flow channel extending from an inlet provided at the base and one side of the cartridge, along the base of the cartridge to the vaporization chamber and up one side of the cartridge to the air outlet located centrally at the mouthpiece end. Alternatively, the liquid reservoir may be disposed around the air flow channel.

The cartridge housing, or at least the liquid reservoir, may be made of one or more of the following polymer materials: poly ether ether ketone (PEEK), polyimides, such as Kapton®, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), 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), polylactic acid (PLA), epoxy resins, co-polyesters, polyurethane resins and vinyl resins.

The base part of the device may include a power supply unit, e.g. a battery, connected to a heat source. The heat source may be provided in the base part or in the cartridge. In operation, upon activating the electronic cigarette, the power supply unit electrically heats the heat source, such as a heating element, which then, in turn, provides heat for evaporation of the vapour generating liquid in the reservoir, optionally via a fluid transfer medium. As this process is continuous, liquid from the liquid reservoir is continuously evaporated. Vapour created during the above process is transferred from the vaporization chamber via the air flow channel in the cartridge so that it can be inhaled via the outlet by a user of the device. Once the liquid in the liquid reservoir is used up, the cartridge may be disconnected from the base part and a new cartridge fitted, enabling the reuse of the base part.

If the heat source is provided in the base part, the heat source may comprise a protruding heater extending from the base part so that, in use, the heater extends into the chamber of the cartridge, optionally breaking the outlet seal and/or deforming the membrane around the heater.

In an alternative embodiment, the base part may be electrically connected to a heater provided inside the cartridge, such as in the commercially available wick and coil arrangement known in the art.

The power supply unit, e.g. battery, may be a DC voltage source. For example, the pow er supply unit may be aNickel-metal hydride battery, a Nickel cadmium battery⁷, 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 electronic cigarette, including the battery.

Brief Description of the Drawings

Figure 1 illustrates a base part and disposable cartridge of a vapour generating device according to the prior art, arranged side-by-side;

Figure 2 is a schematic diagram illustrating a reservoir unit and contact unit that interconnect to form a cartridge of the type shown in Figure 1;

Figure 3 A is a schematic cross-sectional diagram through an alternative type of cartridge according to an embodiment of the present invention;

Figure 3B is a perspective view of the exterior of the cartridge shown in Fi gure 3A;

Figure 4 is a schematic diagram illustrating a process for coating an inner surface of a cartridge according to an embodiment of the present invention;

Figure 5A is a schematic diagram illustrating a cartridge and a base part of a pulmonary delivery⁷ device according to an embodiment of the present invention; and

Figure 5B is a schematic diagram illustrating a cartridge and a base part of a pulmonary⁷ delivery device according to yet another embodiment of the present invention.

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 and in which like features are denoted yvith the same reference numerals.

The present invention relates to a vapour generating device, such as an electronic cigarette for vaporizing a liquid, and in particular relates to the packaging for such a device. The electronic cigarette can be used as a substitute for a conventional cigarette. An example of a prior art device is shown in Figures 1 and 2 of the accompanying drawings, the electronic cigarette comprising a base part 2 and a disposable cartridge 4 (also referred to in the art as a “capsule” or “pod”) having a heat source which is electrically connectable to the base part. The base part is thus the main body part of the electronic cigarette and is generally re-usable. In other embodiments, the base part may include the heat source and the cartridge is thermally connectable to the base part.

The base part 2 generally comprises a housing accommodating therein a power supply unit in the form of a battery⁷, the base part being connectable to the cartridge or pod 4. The cartridge 4 comprises two parts 6, 9, the first part comprising a reservoir unit 6 and the second part comprising a contact unit 9 (see Figure 2). The first part of the cartridge (capsule or pod) 6 has a main body’ forming a liquid storage reservoir 10 having an open distal end 6a for connection to the contact unit and a proximal end yvhich includes a mouthpiece 8 configured for introduction directly’ into a user's mouth (shoyvn only’ in Figure 1). The liquid storage portion or liquid reservoir 10 is configured for containing therein the liquid to be vaporized. The 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 liquid may’ also comprise flavourings such as e.g. tobacco, menthol or fruit flavour. The liquid store may extend between the proximal end towards the distal end and a vapour transfer channel 24 may extend from an inlet positioned on the base part or cartridge to an outlet 26 provided at the top of the cartridge. A vaporisation zone 16 extends betyveen the liquid store and the base of the cartridge, the vaporisation zone being in fluid communication with the vapour transfer channel 24. hi Figures 1 and 2, the vapour transfer channel 24 extends through the centre of the of the cartridge but it could also extend around a side of the liquid storage portion 10, as shoyvn in Figures 3A and 3B.

The contact unit contains a heater unit 14 and electrical contacts 17 (see Figure 2). This part of the cartridge is attached to the reservoir unit 6 after filling the reservoir with liquid. The gaps created at the interface between the tyvo parts are sealed in an air-tight manner, for example using appropriate adhesives or ultrasonic welding. When the base part is attached to the cartridge, power is supplied to the heater unit 14 via the contacts to heat up the liquid and allow vapour to be released through the outlet 26. Once the liquid has been spent, a neyv cartridge may’ be attached to the base part and the spent cartridge discarded. These disposable cartridges are generally bought in multi-packs and must be carefully and satisfactorily packaged to prevent any leakage or contamination of the liquid contents. Water vapour and oxygen can permeate into an e-liquid pod with detrimental consequences. Oxygen can degrade nicotine and flavour compounds found in the e-liquid and water dilutes it and reduces its boiling point. Therefore, the cartridges are elaborately packaged in materials that act as a barrier to water vapour and oxygen to maintain the e-liquid quality during storage. This barrier is achieved using aluminium foil and blister pack trays made from PVDC (Poly-Vinylidene Chloride). These packages are wasteful and expensive. It also renders the packaging non-recyclable due to the aluminium being difficult to remove from the trays, the size of the materials being small for aluminium and plastic streams and the PVDC being considered a contaminant in PET recycling.

The present invention addresses this problem by providing an effective barrier on the cartridge itself, removing the need to provide cartridges sealed in a blister pack prior to placement in secondary-⁷ packaging, such as cardboard packaging. Thus, this enables cheaper, simpler and less wasteful packaging options with improved sustainability. The invention provides a unique form of packaging in the cartridge or pod space and reduces the amount of air available to degrade the e-liquid to that of the small headspace in the pod, rather than the larger air space of the blister in the tray. This is achieved by⁷ providing an internal barrier coating on the inner surface of the cartridge/pod. A thin (<100nm, preferably⁷ 10-100nm) barrier coating is applied to the inside of the cartridge by⁷ an industrial chemical vapour deposition (CVD) process, such as plasma-enhanced CVD to increase the barrier properties of the housing material of the cartridge by⁷ a factor of around 10, preferably- more. A similar coating process is already used in the food and beverage industry⁷ to coat inside PET bottles and therefore is food contact safe and may⁷ enable a recycled or bio-derived pod material to acquire food contact grade.

This type of interior coating may be deposited on inner surfaces of any type of cartridge, capsule or pod, such as that shown in Figures 1 and 2. The reservoir unit 6 is coated on the inside with the thin film coating (not shown) to protect the e-liquid in the resen-⁷ oir 10 from oxygen and moisture. The contact unit 9 should provide barrier properties that are at least as good as those of the reservoir unit. This is achieved, for example, by using the right material at the right thickness or by also applying a thin coating onto the surface of the contact unit 9. An alternative type of cartridge 4 is shown in Figures 3A and 3B. Identical features to those discussed in relation to Figures 1 and 2 are provided with the same reference numerals for the sake of simplicity. Again, this type of cartridge is provided with a thin inner coating 100 on the inner surfaces of the cartridge, most notably the reservoir or liquid storage portion 10. This type of cartridge does not contain the heater unit which is instead provided in the base part (not shown). The heating element is provided in the intended upper part of the base which is at least partially receivable within the cartridge or capsule 4. The upper end of the housing of the base part has an interface configured for matching a corresponding interface of the cartridge and may include one or more connectors for mechanically coupling the cartridge to the base part. The battery⁷ is configured for providing the heating element with the necessary⁷ power for its operation, allowing it to become heated to a required temperature.

The battery⁷ may’ also be connected to a controller, enabling the required power supply for its operation and the controller may be operationally⁷ connected to the heater unit.

The cartridge (capsule or pod) 4 comprises a cartridge housing 6 having a distal end for connection to the base part and a proximal end which includes a mouthpiece 8 configured for introduction directly into a user's mouth. The cartridge housing includes a liquid reservoir or storage portion 10 containing therein the liquid to be vaporized. The liquid store may⁷ extend between the proximal end towards the distal end and a vapour transfer channel 24 may⁷ extend from an inlet 22 to an outlet 26 provided at the top of the cartridge. A vaporisation zone 16 extends between the liquid store and the base of the cartridge, the vaporisation zone in fluid communication with the vapour transfer channel 24. In the embodiment of Figures 3 A and 3B, the vapour transfer channel 24 extends around a side of the liquid storage portion 10 but other configurations may⁷ be used, such as a channel through the centre of the liquid reservoir, as shown in Figures 1 and 2.

Additionally, the cartridge 4 is provided with a fluid transfer medium 12, such as a porous wick which extends between the liquid store and the vaporisation channel. Upon connection of the interfaces between the cartridge and the base part of the device, the heater unit protrudes into the chamber immediately below the base of the porous wick, providing a thermal connection between the parts thereby⁷ enabling heating of the liquid in the wick until the liquid is transformed into vapour. An interface membrane 50 is provided over an opening at the base of the housing which deforms around the heat source of the base part when this is connected to the cartridge. All inner surfaces of the cartridge, including the vapour transfer channel 24 and the liquid reservoir 10 are provided with the coating, as illustrated by the bold line 100 in Figure 3 A. However, it is to be appreciated that the coating may only be applied to certain inner surfaces, most notably those of the reserv oir 10.

Figures 4a-4e of the accompanying drawings illustrates a process for coating the internal surfaces of a cartridge according to the present invention. The cartridge or reservoir unit 6 of the cartridges are placed in a coating chamber 200 (see Figure 4a) and a vacuum is applied to remove air from the interior of the cartridges (see Figure 4b) A coating precursor gas 220 is then introduced into the region of the cartridge to which a coating is to be applied (see Figure 4c), such as the liquid reservoir 6 or to the entire interior to coat all internal surfaces. Energy is then applied (Figure 4d) to cause deposition of the coating onto the internal surface or surfaces. Once coating is completed, the vacuum is released (Figure 4e) and the coated cartridge 6 can be removed from the chamber 200 for filling with the e-liquid and placement within secondary packaging. Deposition (4c and 4d) can be enhanced by the application of radio-frequency plasma. Although differences in processes for coating cartridges may be found among the current plasma-assisted CVD technologies, they have the basic process concept in common, that is, place the cartridge or a reservoir unit of the cartridge into a vacuum chamber, and evacuate the chamber; supply material gas into the cartridge or reservoir unit; apply electromagnetic waves to the inside of the cartridge or reservoir unit so that the material gas is decomposed into a plasma state; allow the plasma to form a thin barrier film on the inner surface of the cartridge or reservoir unit; release the chamber to atmospheric pressure and remove the coated cartridge or reservoir unit.

Suitable coating materials for application by this process include SiOx, DLC (diamond-like carbon) and SiOC. These are compatible with the recycling processes of PET. SiOC and DLC are preferred due to their stability at higher pH due to the basic properties of e-liquids (around pH 9). In this respect, nicotine is quite basic unless provided as a “nicotine salt”. It is to be appreciated that multiple layers of the coating may be provided, if necessary, preferably being separated by “buffer” layers. It may also be beneficial to provide an undercoating prior to application of the barrier coating to increase adhesion of the coating to the plastic surface of the pod. For example, an undercoating of an organosilane, an example being 3-aminopropyltrimethoxysilane (3APTMS). As mentioned above, multiple layers of the thin barrier coating may be applied to the inner surface of at least the reservoir portion of the cartridge. These barrier layers may be separated by softer layers (from organo-silicone precursors) to decouple defects that may exist in the individual layers. In this respect, it is known that silicon-based dielectric coatings deposited by PECVD may have sub-micron size structural defects (pinholes) present in the barrier coating caused by intrinsic or extrinsic surface roughness. Alternating these barrier films with buffer layers reduces these defects considerably, by smoothing of the coated surface, reduction of mechanical damage and increasing thermal stability. These multiple layers may be deposited without breaking the vacuum (see Lungenschmied, C et AL, “Flexible Encapsulation for Organic Solar Cells” in Proc, of SPIE, May 2006, Vol. 6197, 619712-1).

It is to be appreciated that it is also necessary⁷ to provide a high grade seal over the opening of the cartridge/pod to prevent e-liquid degradation prior to use. This seal area cannot be coated using the same deposition step. Instead, a removable or breakable seal should be provided over the fluid outlet. As schematically⁷ shown in Figures 5A, in one embodiment the inner surface of the reservoir portion of the cartridge 4 is provided with a thin film barrier coating 80 and the outlet is sealed with a removable seal 60a that includes a tab 60b for easy release, enabling the seal to be peeled off (see arrow A) before inserting the heat source 20 of the base part 2 into the cartridge. Alternatively, a breakable seal 70 may⁷ be provided across the fluid outlet, as shown in Figure 4B. This seal may be pierced by⁷ the heat source 20 of the base part 2 upon its connection to the cartridge 4 (see arrow B).

Thus, the present invention provides a new ty pe of packaging for one or more cartridges wherein the primary⁷ packaging comprises internally⁷ coating inner surfaces of the cartridge and optionally applying a seal across a fluid outlet of the cartridge. The cartridge may then be packaged in secondary⁷ recyclable packaging.

The skilled person will realize that the present invention by no means is limited to the described exemplary⁷ embodiments. The mere fact that certain measures are recited in mutually⁷ different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Moreover, the expression "comprising" does not exclude other elements or steps. Other non-limiting expressions include that "a" or "an" does not exclude a plurality⁷ and that a single unit may⁷ fulfil the functions of several means. Any⁷ reference signs in the claims should not be construed as limiting the scope. Finally, while the invention has been illustrated in detail in the drawings and in the foregoing description, such illustration and description is considered illustrative or exemplary⁷ and not restrictive; the invention is not limited to the disclosed embodiments.

Claims

CLAIMS:

1. A cartridge (4) for a vapour generating device, the cartridge being configured to connect to a base part (2) to provide an operable device, the cartridge comprising: a housing (6) having a liquid reservoir (10) for containing a vapour generating liquid and an interface for connection to the base part, at least the liquid reservoir being made of thermoplastics; wherein an inner surface of the liquid reservoir is provided with a barrier coating (80, 100).

2. The cartridge as claimed in claim 1 wherein one or more other inner surfaces of the housing are provided with the barrier coating (80, 100) in addition to the inner surface of the liquid reservoir.

3. The cartridge as claimed in claim 1 or claim 2 wherein the barrier coating (80, 100) has a thickness of less than lOOnm, preferably 10-100nm.

4. The cartridge as claimed in any one of claims 1 to 3 wherein the barrier coating (80, 100) is selected from a vapour deposition coating, an atomic layer deposition coating and a molecular layer deposition coating, preferably a chemical vapour deposition coating, more preferably a plasma enhanced chemical deposition coating.

5. The cartridge as claimed in any one of the preceding claims wherein the barrier coating (80, 100) is selected from at least one of silicon oxide (SiOx), silicon nitride, diamond-like carbon (DLC) and silicon oxy carbide (SiOC).

6. The cartridge as claimed in any one of the preceding claims, wherein an undercoating is provided between the inner surface of the housing of the cartridge and the barrier coating to aid adhesion of the coating to the surface.

7. The cartridge as claimed in claim 6 wherein the undercoating is an organosilane, preferably 3-aminopropyltrimethoxysilane (3APTMS).

8. The cartridge as claimed in any one of the preceding claims, wherein the cartridge is configured to thermally, electrically or inductively connect to the base part via the interface.

9. The cartridge as claimed in any one of the preceding claims, wherein the housing of the cartridge further comprises an air inlet (22), at least one air channel (24) extending from the air inlet to an air outlet (26) and a vaporisation chamber (16) in communication with the liquid reservoir (10), the at least one air channel (24) extending from the air inlet (22), through the vaporisation chamber (16) to the air outlet (26).

10. The cartridge as claimed in any one of the preceding claims, the cartridge further comprising a fluid outlet between the liquid reservoir and an exterior of the housing, wherein a removable or breakable seal (60a) is provided over the fluid outlet.

11. The cartridge as claimed in any one of the preceding claims wherein the inner surface of the housing is provided with multiple layers of the barrier coating (80, 100), preferably being separated by buffer layers, preferably wherein the buffer layers comprise an organosilane.

12. Packaging for at least one cartridge of a vapour generating device, the packaging comprising an outer package comprising a recyclable cardboard packaging container and an inner package comprising a cartridge (4) having a barrier coating (80, 100) applied directly to an inner surface of the cartridge, preferably wherein a removable or breakable seal (60a) is provided over a fluid outlet of the cartridge.

13. A method for applying a barrier coating (80, 100) to an inner surface of a cartridge (4) for a vapour generating device, the method comprising:

(a) placing at least a liquid reservoir part of at least one cartridge for a vapour generating device in a coating chamber;

(b) applying a vacuum to at least the liquid reservoir of the cartridge to evacuate at least the interior of the reservoir;

(d) supplying energy to cause deposition of the coating onto at least the inner surface of the liquid reservoir;

(e) releasing the vacuum; and

(f) removing the coated cartridge from the coating chamber.

14. The method according to claim 13, wherein step (d) comprises supplying radiofrequency electromagnetic waves to at least the inner surface of the liquid reservoir to cause plasma-enhanced chemical vapour deposition of the coating.

15. The method according to claim 13 or claim 14, further comprising applying an undercoat to at least the inner surface of the liquid reservoir prior to application of the barrier coating.