Patent Application
20230399134
The present disclosure relates generally to a cartridge for 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 method of filling a cartridge for a vapour generating system with a vapour generating liquid.
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. Particularly in the case of disposable cartridges, but also in the case of re-fillable cartridges, it is desirable to reduce the number and complexity of the cartridge components, thereby reducing waste and making the manufacturing process simpler and cheaper.
According to a first aspect of the present disclosure, there is provided a method of filling a cartridge for a vapour generating system, the cartridge comprising a reservoir for storing a vapour generating liquid, the method comprising:
The cartridge is intended for use with a vapour generating system configured to heat the vapour generating liquid to volatise at least one component of the vapour generating liquid and thereby generate a vapour which cools and condenses to form an aerosol for inhalation by a user of the vapour generating system. The present disclosure is particularly applicable to a portable (hand-held) vapour generating system, by which it is meant that a user is able to hold and support the system unaided, in a single hand.
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.
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 introducing vapour generating liquid into the reservoir via the first opening and simultaneously venting air from the reservoir via the second opening, filling of the reservoir can be readily achieved without subjecting the reservoir to an overpressure. Sealing of the first and second openings is then readily achieved by the simple step of positioning first and second valves in the corresponding first and second openings.
The cartridge may further comprise a vaporization chamber. Step (iii) may comprise positioning first and second one-way valves in the first and second openings to seal the first and second openings to prevent the escape of vapour generating liquid from the reservoir and to allow air to flow to the vaporization chamber through the first and second one-way valves. The first and second one-way valves have a dual functionality, namely preventing the escape of vapour generating liquid from the reservoir and allowing air to flow to the vaporization chamber, and thus both the structure of the cartridge and manufacture/assembly are simplified.
The cartridge may further comprise first and second air inlets in communication with the vaporization chamber. Step (iii) may comprise positioning the first and second one-way valves in the first and second air inlets to permit airflow through the first and second air inlets to the vaporization chamber. A reliable airflow to the vaporization chamber is assured through the first and second air inlets by the corresponding first and second one-way valves.
Each of the first and second one-way valves may include a first sealing portion and a second sealing portion. Step (iii) may comprise: positioning the first sealing portion of each first and second one-way valve in the corresponding first and second opening to seal the first and second openings; and positioning the second sealing portion of each first and second one-way valve in the corresponding first and second air inlet to allow one-way airflow through the first and second air inlets to the vaporization chamber. The first and second sealing portions provide each one-way valve with the dual functionality described above. In particular, the first sealing portion prevents the escape of vapour generating liquid from the reservoir by sealing the first and second openings whilst the second sealing portion allows air to flow to the vaporization chamber through the first and second air inlets. The structure of the cartridge and manufacture/assembly are thereby further simplified.
The second sealing portion may be positioned upstream of the first sealing portion in an airflow direction towards the vaporization chamber. The first sealing portion, which prevents the escape of vapour generating liquid from the reservoir, does not obstruct airflow to the vaporization chamber through the first and second air inlets.
The cartridge may include a proximal end and a distal end. The first and second openings may be positioned at the distal end. Steps (i) and (ii) may be performed with the cartridge oriented such that the distal end is positioned above the proximal end. By positioning the first and second openings in an uppermost position, filling of the reservoir with vapour generating liquid via the first opening and venting of air from the reservoir via the second opening can be performed reliably without any unwanted leakage of vapour generating liquid from the reservoir.
Step (i) may comprise introducing the vapour generating liquid into the reservoir via a filling needle or a filling tube. This may facilitate filling of the reservoir with the vapour generating liquid.
According to a second aspect of the present disclosure, there is provided a cartridge for a vapour generating system, the cartridge comprising:
The first opening allows vapour generating liquid to be introduced into the reservoir whilst the second opening allows air to be simultaneously vented from the reservoir.
This allows the reservoir to be easily filled without subjecting the reservoir to an overpressure. By preventing the escape of vapour generating liquid from the reservoir and at the same time allowing air to flow to the vaporization chamber, the first and second one-way valves have a dual functionality thus simplifying the structure of the cartridge and improving its manufacturability and ease of assembly.
The cartridge may further comprise first and second air inlets in communication with the vaporization chamber. The first and second one-way valves may be positioned in the first and second air inlets to permit airflow through the first and second air inlets to the vaporization chamber. A reliable airflow to the vaporization chamber is assured through the first and second air inlets by the corresponding first and second one-way valves.
Each of the first and second one-way valves may include a first sealing portion and a second sealing portion. The first sealing portion of each first and second one-way valve may be positioned in the corresponding first and second opening to seal the first and second openings. The second sealing portion of each first and second one-way valve may be positioned in the corresponding first and second air inlet to allow one-way airflow through the first and second air inlets to the vaporization chamber. The first and second sealing portions provide each one-way valve with the dual functionality described above. In particular, the first sealing portion prevents the escape of vapour generating liquid from the reservoir by sealing the first and second openings whilst the second sealing portion allows air to flow to the vaporization chamber through the first and second air inlets. The structure of the cartridge is thereby simplified.
The second sealing portion may be positioned upstream of the first sealing portion in an airflow direction towards the vaporization chamber. The first sealing portion, which prevents the escape of vapour generating liquid from the reservoir, does not obstruct airflow to the vaporization chamber through the first and second air inlets.
The cartridge may include a proximal end and may include a distal end, and the first and second openings may be positioned at the distal end. As noted above, filling of the reservoir with vapour generating liquid via the first opening and venting of air from the reservoir via the second opening is thereby facilitated, in particular when the cartridge is oriented such that the distal end is positioned above the proximal end.
The cartridge may further comprise a sorption member at least partially disposed within the vaporization chamber for absorbing vapour generating liquid from the reservoir, for example via a liquid outlet. The cartridge may further comprise a heat transfer unit which may contact the sorption member to heat the sorption member and vaporize the absorbed vapour generating liquid. This is a continuous process, in which vapour generating liquid from the reservoir is continuously absorbed by the sorption member.
Vapour generated during this process is transferred from the vaporization chamber via a vapour outlet channel in the cartridge so that it can be inhaled by a user of the vapour generating system.
The cartridge may be configured to thermically connect to a base part having at least one heating element. The heat transfer unit may be configured, when the cartridge is thermically connected to the base part, to transfer heat from the heating element to the sorption member to vaporize vapour generating liquid absorbed by the sorption member.
According to a third aspect of the present disclosure, there is provided a vapour generating system comprising:
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 sorption member, resulting in vaporization of the vapour generating liquid absorbed therein. The heating element may be separated from the vaporization chamber by the heat transfer unit.
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 rigidify 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 reservoir and the vaporization chamber, and a vapour outlet channel extending along the cartridge housing and in fluid communication with the vaporization chamber. The cartridge housing may have a proximal end configured as a mouthpiece end which is in fluid communication with the vaporization chamber 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 (i.e., vapour or aerosol) 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 reservoir may be juxtaposed with the vapour outlet channel extending between the vaporization chamber and the mouthpiece end. The reservoir may be disposed around the vapour outlet channel.
The cartridge housing may be made of one or more of the following materials: aluminium, polyether 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.
Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.
Referring initially to
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 interface 15 may, for example, be in the shape of a tubular cartridge seating and can comprise a connector for releasably connecting the cartridge 12 to the cartridge seating. 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
The cartridge 12 comprises a base portion 28 and a liquid storage portion 30. The liquid storage portion 30 comprises a reservoir 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 reservoir 32 may extend generally between the proximal end 24 and the distal end 26, but is spaced from the distal end 26. The reservoir 32 may surround, and coextend with, the vapour outlet channel 34.
As best seen in
The first plug member 36a is provided with a circumferential surface 46 that is in contact with the inner circumferential surface of the reservoir 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 reservoir 32. For example, the first plug member 32a 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 reservoir 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
The cartridge 12 includes a vaporization chamber 48 defined between the first plug member 36a and the heat transfer unit 42. The sorption member 38 is positioned in the vaporization chamber 48. The first plug member 36a includes a plurality of circumferentially spaced liquid outlets 50 which provide a controlled flow of vapour generating liquid from the reservoir 32 to the sorption member 38 positioned in the vaporization chamber 48 adjacent to the liquid outlets 50.
The sorption member 38 is positioned in the vaporization chamber 48 between the liquid outlets 50 and the heat transfer unit 42. The sorption member 38 is configured, on the one hand, for absorbing therein some of the vapour generating liquid from the reservoir 32, and, on the other hand, for being heated by the heat transfer unit 42 thereby allowing the vapour generating liquid absorbed therein to be vaporized in the vaporization chamber 48.
When the base part 10 and the cartridge 12 are assembled together as shown in
The cartridge 12 comprises first and second openings 52, 54 in communication with the reservoir 32 which allow the reservoir 32 to be filled with vapour generating liquid. Specifically, the first opening 52 allows vapour generating liquid to be introduced into the reservoir 32 whilst the second opening 54 allows air to be vented from the reservoir 32 whilst it is being filled with vapour generating liquid via the first opening 52. Thus, overpressure inside the reservoir 32 is avoided during filling and the reservoir 32 can be easily filled with vapour generating liquid. In the illustrated example, the first and second openings 52, 54 are at the distal end 26 of the cartridge housing 22 and are formed in the first plug member 36a.
The cartridge 12 also comprises first and second air inlets 56, 58 to allow air to flow to the vaporization chamber 48 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 56, 58 are formed in the second plug member 36b and allow air to flow to the vaporization chamber 48 along a path formed between the first and second plug members 36a, 36b as shown in
The cartridge 12 comprises first and second one-way valves 60, 62, both of which include a first sealing portion 60a, 62a and a second sealing portion 60b, 62b. When the first and second one-way valves 60, 62 are fitted to the cartridge as shown in
The second sealing portions 60b, 62b, which may comprise a duck bill valve or a similar non-return valve, allow air to flow to the vaporization chamber 48 through the first and second air inlets 56, 58, but do not allow air to flow in the opposite direction. As shown in
As illustrated in
Step S1 is performed with the cartridge 12 oriented as shown in
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”.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20203482.3 | Oct 2020 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/078644 | 10/15/2021 | WO |
