EVAPORATOR DEVICE FOR AN INHALER, AND METHOD FOR PRODUCING AN INHALER
20230320417 · 2023-10-12
Inventors
Cpc classification
International classification
Abstract
A vaporizer device for an inhaler, in particular for an electronic cigarette product or a medical inhaler, comprising: a vaporizer film, which in turn comprises a layer system with a polymer film and at least one metal film which contacts the polymer film over its surface and is designed as a heating element a liquid reservoir, and a wick structure, which is configured to supply the vaporizer film with liquid from the liquid reservoir, wherein the vaporizer film comprises at least one first receiving opening for receiving liquid and at least one dispensing opening for dispensing vaporized liquid, wherein the vaporizer film is in contact with the wick structure via the base surface, wherein the vaporizer film forms at least one supply channel, via which the at least one first receiving opening can be supplied with liquid from the wick structure.
Claims
1-22. (canceled)
23. A vaporizer device for an inhaler, comprising: a vaporizer film, wherein the vaporizer film comprises a layer system with a polymer film and at least one metal foil, wherein the at least one metal foil makes surface contact with the polymer film and is designed as a heating element, a liquid reservoir, and a wick structure, which is arranged to supply the vaporizer film with liquid from the liquid reservoir, wherein the vaporizer film comprises at least one first receiving opening for receiving liquid and at least one dispensing opening for dispensing vaporized liquid, wherein the vaporizer film is in contact with the wick structure via a base surface, wherein the vaporizer film forms at least one supply channel, via which the at least one first receiving opening can be supplied with liquid from the wick structure.
24. The vaporizer device according to claim 23, wherein the at least one supply channel is formed by a fold of the vaporizer film.
25. The vaporizer device according to claim 24, wherein the fold comprises two opposing folding surfaces which are connected to one another via at least one folding edge, wherein at least 20% of the two opposing folding surfaces are aligned parallel to each other.
26. The vaporizer device according to claim 24, wherein a plurality of folds are provided, wherein the folds of the plurality of folds are spaced apart by an intermediate portion of the vaporizer film.
27. The vaporizer device according to claim 23, wherein at least one second receiving opening is provided, which is arranged on the base surface, wherein the at least one second receiving opening can be supplied with liquid directly via the wick structure.
28. The vaporizer device according to claim 23, wherein at least 20% of the areal extent of the vaporizer film forms the at least one supply channel.
29. The vaporizer device according to claim 23, wherein the at least one supply channel is configured to direct the liquid from the wick structure along a main flow direction to the at least one first receiving opening, wherein the main flow direction encloses an angle between 30° and 150° with the base surface.
30. The vaporizer device according to claim 23, wherein an extension (b) of the at least one supply channel in orthogonal direction with respect to the base surface corresponds to at least 5 times a height (a) of the vaporizer film.
31. The vaporizer device according to claim 23, wherein the at least one supply channel is dimensioned such that the liquid is transferred from the wick structure to the at least one first receiving opening under action of capillary forces.
32. The vaporizer device according to claim 1, wherein a support element is provided, on an upper side of which the vaporizer film is arranged, and on a lower side of which the liquid reservoir is arranged, wherein an opening is provided for receiving the wick structure, wherein the opening fluidically connects the upper side to the lower side.
33. The vaporizer device according to claim 23, wherein the base surface is a flat surface.
34. The vaporizer device according to claim 23, wherein the base surface is a partial shell surface of a cylinder.
35. The vaporizer device according to claim 34, wherein the wick structure comprises a cylindrical shape with a longitudinal axis, wherein the wick structure is surrounded by the base surface of the vaporizer film, wherein a main flow direction of the at least one supply channel extends in a radial direction with respect to the longitudinal axis of the wick structure.
36. The vaporizer device according to claim 35, wherein the vaporizer film is surrounded by an outer ring so that a flow channel is formed between the vaporizer film and the outer ring.
37. An inhaler, comprising a vaporizer device according to claim 23.
38. A cartridge for an inhaler, comprising a vaporizer device according to claim 23.
39. A method for operating a vaporizer device, comprising: providing a vaporizer device according to claim 23, providing an electrical heating voltage to the vaporizer film to generate the vaporized liquid.
40. A method for manufacturing a vaporizer device, wherein the vaporizer device comprises a vaporizer film arranged on a support element, wherein the vaporizer film forms at least one supply channel, with which the vaporizer film can be supplied via a wick structure with liquid to be vaporized from a liquid reservoir, wherein the supply channel is formed by a fold of the vaporizer film, wherein the method comprises the following steps: a) providing a base material for manufacture of the vaporizer film comprising a substrate of polyimide with a copper lamination applied thereto on one side; b) patterning the copper lamination by an etching process so that a copper pattern is formed on the substrate; c) applying a polyimide cover layer to a side of the substrate with the copper pattern; d) creating a passage opening through which an upper side of the vaporizer film is fluidically connectable to a lower side of the vaporizer film via a laser; e) incising a folding edge via a laser so that an incision is formed; f) folding the vaporizer film along the incised folding edge; and g) joining the folded vaporizer film to the support element.
41. The method according to claim 40, wherein in step b) the following sub-steps are carried out: b1) applying a photoresist to the copper lamination; b2) exposure of the photoresist in predefined areas; b3) developing the photoresist so that remaining photoresist forms a protective layer for the copper lamination in the predefined areas; b4) applying an etchant to a side with the developed photoresist so that the copper lamination remains on the substrate only in the predefined areas; b5) removing the remaining photoresist.
42. The method according to claim 40, wherein in step c) applying the polyimide cover layer is carried out by lamination in a vacuum press.
43. The method according to claim 40, wherein in step e) contacting points for supplying the vaporizer film with an electrical heating voltage are additionally exposed via the laser.
44. The method according to claim 40, wherein in step e) the vaporizer film is additionally cut to size for connection to the support element.
Description
[0064] The invention will be explained below with reference to preferred embodiments with reference to the accompanying figures. Thereby shows
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[0076] Of course, it is in principle also possible to provide two or more liquid reservoirs 6.
[0077] The support element 18 comprises an opening 21 into which the wick structure 7 is inserted. Thus, the liquid to be vaporized can be conveyed from the liquid reservoir 6 by means of the wick structure 7 through the opening 21 to the vaporizer film 2. Furthermore, the liquid reservoir 6 comprises a bar 41 via which the wick structure 7 can be pressed in between the liquid reservoir 6 and the vaporizer film 2. In the embodiments shown, a fleece, for example a glass fiber fleece, is provided as the wick structure 7.
[0078] The vaporizer film 2, or a metal foil 5 included therein, which is operable as a heating element, is preferably connected to the support element 18 via a connecting means 25 in the form of a soldered or sintered connection.
[0079] An exemplary illustration of the vaporizer film 2 is shown schematically in
[0080] The vaporizer film 2 is perforated so that a first receiving opening 8 on a lower side 40 can be fluidically connected to a dispensing opening 9 on an upper side 27. The first receiving opening 8 and the dispensing opening 9 thus together form a respective fluid-permeable passage opening 26.
[0081] The wick structure 7 shown in
[0082] The metal foil 5 according to
[0083] As can be seen from
[0084] The supply channel 11 is formed by a fold 14 of the vaporizer film 2, which is shown enlarged in a cross-sectional view in
[0085] Preferably, the extension b of the fold 14 in a direction orthogonal to an adjacent base surface 10 of the vaporizer film 2 is at least 5 times the height a of the vaporizer film 2. This results in a more spatially pronounced design of the vaporizer film 2 in comparison to the otherwise only planar arranged vaporizer films 2 from the prior art.
[0086] The fold 14 is designed in such a way that it is oriented perpendicularly with respect to the base surface 10 or to an upper side 19 of the support element 18, comp.
[0087] Thus, the supply channel 11 formed by the fold 14 is also oriented perpendicularly with respect to the base surface 10. This configuration of the fold 14 results in a main flow direction 13 of the fluid within the supply channel 11. The main flow direction 13 is the flow direction in which the majority of the fluid flows from the wick structure 7 to a first receiving opening 8 within the at least one supply channel 11. Accordingly, the main flow direction 13 is also oriented orthogonally with respect to the base surface 10 adjacent to the fold 14.
[0088] The two first receiving openings 8 are provided at the folding surfaces 15, so that the fluid-permeable passage openings 26 are flowed through in a direction which is oriented parallel to the base surface 10.
[0089] Further, the fold 14 in
[0090] The passage openings 26 shown in
[0091] When the vaporizer device 1 of
[0092] Furthermore, it can be seen from
[0093] The combination of first receiving openings 8, which are supplied via the supply channel 11, and second receiving openings 12, which are supplied directly via the wick structure 7, allows vaporized liquid to be dispensed in different spatial directions, so that overall the surface area of the vaporizer film 2 that can be used for vaporization via the dispensing openings 9 is increased. Thus, the total amount of vaporization per inhalation puff can be increased.
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[0095] Each of the two folds 14a and 14b comprises two first receiving openings 8 and dispensing openings 9 associated therewith. Of course, the number of receiving openings 8 and the number of passage openings 26 correlating therewith can be varied as desired, as has already been explained in the embodiment according to
[0096] Furthermore, the intermediate portion 17 also comprises at least one second receiving opening 12, which is supplied with liquid directly via the wick structure 7. In addition, a further second receiving opening 12 is provided to the left of the first fold 14a and to the right of the second fold 14b, respectively. This arrangement has proved to be advantageous because vaporized liquid can flow around each of the folds 14a and 14b on both sides starting from the second receiving openings 12, and at the same time an additional flow around the folds 14a and 14b is made possible starting from the first receiving openings 8 which are associated with the folds 14a and 14b directly. In this way, the amount of vaporization per inhalation puff can be significantly increased and, at the same time, the thermal decoupling of the metal foil 5 with respect to the wick structure 7 or the two liquid reservoirs 6 can be increased due to the insulating effect of the liquid column present in the supply channels 11 of the first and second folds 14a and 14b.
[0097] Of course, more than two folds 14a and 14b may be provided, further increasing the effect. Where multiple folds 14a and 14b are provided, they are preferably aligned parallel to each other, i.e. the folding edges 16 of the multiple folds 14a and 14b are aligned parallel to each other. Furthermore, for example, all main flow directions 13 in the supply channels 11 formed by the folds 14 are oriented orthogonally to the base surfaces 10 adjacent to the respective fold 14.
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[0099] In the embodiment according to
[0100] Of course, in addition to the passage openings 26 associated with the folds 14, passage openings 26 can also be provided which are supplied with liquid directly via the wick structure 7, i.e. via a second receiving opening 12. For example, at least one passage opening 26 can be provided between each fold 14, which is supplied with liquid via a second receiving opening 12.
[0101] In the case of a cylindrical wick structure 7, the base surface 10 is not flat but a curved surface. In this case, if the main flow direction 13 in the supply channel 2 is oriented orthogonally to the adjacent base surface 10, then in the cross-sectional view shown in
[0102] The corresponding liquid reservoir 6, which supplies liquid to the wick structure 7, is not shown in
[0103] In the embodiment according to
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[0105] The subsequent process step b), in which the copper lamination 34 is patterned to produce a copper pattern 42, is subdivided into process steps b1) to b5). In process step b1), a photoresist 34 is laminated onto the copper lamination 33, which is exposed in predefined areas in process step b2). This can be done, for example, by appropriate direct illumination or by means of a mask. In process step b3), the photoresist 34 is developed, i.e. only a resist mask resulting from the exposure remains on the copper lamination 33; the remaining photoresist 34 is removed. In process step b4), an etchant is applied to the side with the developed photoresist 34 so that the copper lamination is etched away at the areas where there is no protection by the resist mask formed by the photoresist 34. A copper pattern 42 is thus formed from the copper lamination 33 covering the entire surface. In process step b5), the remaining photoresist 34 is then removed so that only the copper pattern 42 remains on the substrate 32. Preferably, the copper pattern 42 comprises a meander shape. The result of process step b), namely the copper pattern 42 deposited on the substrate 32, is shown schematically in
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[0107] In process step d), the intermediate product now present, comprising the substrate 32, the copper pattern 42 and the polyimide cover layer 36, is then perforated by means of a laser, so that fluidic connections are formed between the upper side 27 and the lower side 12. In this way, the passage openings 26 are formed, which connect the first and second receiving openings 8 and 12 respectively with the dispensing openings 9; see also
[0108] In process step e1), a folding edge 16 is then additionally incised by means of a laser, wherein a resulting incision 37 preferably completely penetrates the polyimide cover layer 36, the substrate 32 is preferably only partially incised. In process step e2), several contacting points 38 are exposed by means of the laser, i.e. the polyimide cover layer 36 is removed by the laser at the corresponding point until part of the copper pattern 42 is exposed.
[0109] If necessary, the vaporizer film 2 can still be cut or trimmed as an intermediate step so that it comprises the correct size for connecting to the support element 18.
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[0114] Due to the curvature 39 of the vaporizer film 2 generated in the process step c), the fold 14 in the state connected to the support element 18 comprises a prestress, which results in the fold 14 comprising a more stable structure and the sharp folding edge 16 can also be maintained permanently, as for example in operation, in transport situations or in case of improper handling. It can further be seen that the vaporizer film 2 is connected to the upper side 19 of the support element 18. The vaporizer film 2 comprises four passage openings 26a, 26b (not visible rear side of the fold 14), 26c and 26d, wherein two passage openings 26a and 26b are each supplied with liquid to be vaporized through a first receiving opening 8 (comp.
[0115] As described above, the metal foil 5 formed by the copper pattern 42 comprises meander-shaped patterns within the polymer foil 4 formed by the substrate 32 and the polyimide cover layer 36, wherein the meander-shaped patterns comprise separately controllable sections. Separately controllable means that the respective section comprises separate contacting points 38 and thus the heating voltage applied to the respective section is individually adjustable. For this purpose, the respective section is electrically insulated from the other sections of the copper pattern 42. A separately controllable section of the copper pattern 42 is referred to as a controllable channel. Each of these sections forms an ohmic heater, wherein it has been found advantageous if each separately drivable section of the metal foil 5 or metal pattern 42 comprises a resistance between 1 and 3Ω, for example about 2Ω. Preferably, the embodiment in
[0116] By attaching the vaporizer film 2 to the support element 18 and/or to the wick structure 7 by means of the connecting means 25, the vaporizer film 2 can be reliably held in the transformed position.
[0117] With the vaporizer device 1 according to