Cartomizer for an Aerosol Generating Device with Leakage Prevention

Abstract

A cartomizer for an aerosol generating device includes a container for holding at least one reservoir configured to containing a vaporizable material; a vaporizing chamber fluidly connected to a mouth end by a vapor passage; a liquid transport element, in particular a porous capillary member, extending from inside the at least one reservoir to inside the vaporizing chamber to convey the vaporizable material from the at least one reservoir to the inside of the vaporizing chamber; and an air inlet arranged to supply the vaporizing chamber with air in use; wherein a leakage collecting chamber is arranged between the vaporizing chamber and the air inlet to collect vaporizable material from the vaporizing chamber and the leakage collecting chamber includes at least one liquid stopping or barrier wall arranged between the leakage collecting chamber and the air inlet, in particular at least one through-hole of the air inlet, forming an overflow.

Claims

1. A cartomizer (1) for an aerosol generating device, the cartomizer comprising: a container for holding at least one reservoir configured to contain a vaporizable material; a vaporizing chamber fluidly connected to a mouth end by a vapor passage; a liquid transport element extending from inside the at least one reservoir to inside the vaporizing chamber in order to convey the vaporizable material from the at least one reservoir to the inside of the vaporizing chamber; an air inlet arranged to supply the vaporizing chamber with air in use; wherein a leakage collecting chamber is arranged between the vaporizing chamber and the air inlet to collect vaporizable material from the vaporizing chamber, and the leakage collecting chamber comprises at least one liquid stopping or barrier wall, arranged between the leakage collecting chamber and the air inlet, in particular at least one through-hole of the air inlet, forming an overflow, and wherein the cartomizer further comprises a center leakage collecting chamber provided between the air inlet and the leakage collecting chamber.

2. The cartomizer according to claim 1, wherein the air inlet comprises an air conduit or chimney at the bottom of the container and upstream the at least one through-hole, forming a second liquid stopping or barrier wall arranged between the first liquid stopping or barrier wall and the at least one through-hole.

3. The cartomizer according to claim 2, wherein the air conduit or chimney protrudes inside the leakage collecting chamber.

4. The cartomizer according to claim 2, wherein the center leakage collecting chamber is defined or formed by the air conduit or chimney and the first liquid stopping or barrier wall.

5. The cartomizer according to claim 4, wherein the center leakage collecting chamber and the leakage collecting chamber are at least partially separated from each other by the first liquid stopping or barrier wall including at least one connecting hole or groove fluidly connecting the center leakage collecting chamber with the leakage collecting chamber, wherein the connecting hole or groove is preferably arranged with a predetermined axial distance to the bottom of the container.

6. The cartomizer according to claim 5, wherein the predetermined axial distance from the at least one connecting hole or groove to the bottom of the container is smaller than an axial distance of the at least one through-hole to the bottom of the container.

7. The cartomizer according to claim 1, wherein the leakage collecting chamber further comprises at least one air outlet arranged at an axial distance relative to the at least one through-hole of the air inlet, wherein the at least one air outlet of the leakage collecting chamber is arranged axially closer to the bottom of the container than the at least one through-hole of the air inlet.

8. The cartomizer according to claim 7, wherein the air outlet of the leakage collecting chamber is transversally distant from the air inlet.

9. The cartomizer according to claim 7, wherein the air outlet of the leakage collecting chamber protrudes by a conduit inside the leakage collecting chamber and/or inside the vaporizing chamber.

10. The cartomizer according to claim 1, wherein the leakage collecting chamber comprises two air outlets communicating with the vaporizing chamber and arranged on each side of the air inlet, wherein the air outlets are aligned in a plane of extension of the liquid transport element.

11. The cartomizer according to claim 1, wherein the leakage collecting chamber is arranged between a first seal arranged for holding the liquid transport element and a bottom holder of the container arranged for holding electrical connectors.

12. The cartomizer according to claim 11, wherein the liquid transport element is held by the first seal and a second seal, wherein the second seal preferably at least partially, in particular completely, separates the at least one reservoir from the vaporizing chamber.

13. The cartomizer according to claim 12, wherein the at least one air outlet is formed inside the first seal.

14. The cartomizer according to claim 1, wherein the leakage collecting chamber has a larger transversal cross section than a transversal cross-section of the vaporizing chamber.

15. The cartomizer according to claim 11, wherein the liquid transport element is held by the first seal and a second seal, wherein the second seal at least partially separates the at least one reservoir from the vaporizing chamber, and wherein the first seal includes air channels that fluidly connect the center leakage collecting chamber with the leakage collecting chamber or the leakage collecting chambers.

16. The cartomizer according to claim 1, wherein the liquid transport element comprises a porous capillary member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which:

[0033] FIG. 1 shows a sectional view of a conventional aerosol generating device having a housing consisting of a control body and a tank;

[0034] FIG. 2 shows a schematic sectional view of the interior of a cartomizer for an aerosol generating device according to a first embodiment of the present invention;

[0035] FIG. 3 shows a schematic sectional view of a detail of the device shown in FIG. 2;

[0036] FIG. 4 shows a vertical and a horizontal schematic sectional view of the device shown in FIG. 2, illustrating the air flow through the cartomizer;

[0037] FIG. 5 shows a schematic spatial view of the bottom part of the device shown in FIG. 2;

[0038] FIG. 6 shows a schematic sectional view of a detail of the device shown in FIG. 2 when inserted into an aerosol generating device; and

[0039] FIG. 7 shows a schematic spatial view of a whole aerosol generating device including the cartomizer according to the present invention without the outside casing.

DETAILED DESCRIPTION

[0040] Embodiments of the present disclosure will now be explained with reference to the drawings. It will be apparent to those skilled in the field of aerosol generating devices from this disclosure that the following description of the embodiments is provided for illustration only and not for the purpose of limiting the disclosure as defined by the appended claims. Features of the embodiments described below can also be used to further characterize the device defined in the claims.

[0041] Modifications of features can be combined to form further embodiments. Features described in individual embodiments can be provided in a single embodiment if they are not incompatible. Likewise, features described in a single embodiment can be provided in several embodiments individually or in any suitable sub-combination. As used in the specification and the appended claims, the singular forms “a”, “an”, “the” and the like include plural referents unless the context clearly dictates otherwise.

[0042] The same reference numerals listed in different figures refer to identical, corresponding or functionally similar elements.

[0043] As described hereinafter, example implementations of the present disclosure relate to cartomizers for aerosol generating devices or aerosol delivery devices. Aerosol generating devices according to the present invention use electrical energy to heat a material (preferably without combusting the material to any significant degree and/or without significant chemical alteration of the material) to form an inhalable substance or vapor; and components of such device have the form of articles that most preferably are sufficiently compact to be considered hand-held devices. That is, use of components of preferred aerosol generating devices does not result in the production of smoke in the sense that aerosol results principally from by-products of combustion or pyrolysis of tobacco, but rather, use of those devices preferably results in the production of vapors resulting from volatilization or vaporization of certain components incorporated therein.

[0044] In some example implementations, components of aerosol generating devices may be characterized as electronic cigarettes, and those electronic cigarettes preferably incorporate aerosolisable liquid (e.g. propylene glycol, polyhydric alcohol), tobacco and/or tobacco materials derived at least partially from tobacco, and hence deliver tobacco derived components in aerosol or vapor form to a user. In more detail, aerosol generating devices within the meaning of the present invention may transport the volatilized particles in an airflow through the aerosol generating device, in particular through the cartomizer, 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 puffing or inhaling action.

[0045] FIG. 1 illustrates a known aerosol generating or delivery device 200 including a control body 202 and a tank 204. As shown in FIG. 1, the control body 202 can be formed of a control body shell 206 that can include a control component 208 (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microprocessor, individually or as part of a micro-controller, and the like), a flow sensor 210, a battery 212, and one or more light-emitting diodes (LEDs) 214, and such components can be variably aligned. Moreover, the tank 204 can be formed of a tank shell 216 enclosing a reservoir 218 that is in fluid communication with a liquid transport element 220 adapted to wick or otherwise transport an aerosol precursor composition stored in the reservoir housing to a heater 222 (sometimes referred to as a heating element). A valve may be positioned between the reservoir and heater and configured to control an amount of aerosol precursor composition passed or delivered from the reservoir to the heater. The known device is provided with a mouthpiece 224 having an opening defined therein and which may be coupled to the tank shell 216 to allow for egress of formed aerosol from the tank 204. The shown device 200, in particular the control body 202 and the tank 204, include a coupler 230 having a cavity 232 therein. A base 228 of the tank is adapted to engage the coupler and includes a projection 234 to fit within the cavity.

[0046] Aerosol generating devices of the present invention generally include a number of components provided within an outer body or shell, which may be referred to as an outside casing or housing. The overall design of the outside casing can vary, and the format or configuration of the outside casing that can define the overall size and shape of the aerosol generating device can vary. For some aerosol generating devices, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, unitary housing, or the elongated housing can be formed of two or more separable bodies. For example, an aerosol generating device can include an elongated shell or body (outside casing) that can be substantially tubular in shape and, as such, resemble the shape of conventional cigarettes or cigars. In one implementation, all of the components of the aerosol generating device are contained within a single housing. Alternatively, an aerosol delivery device can comprise two or more housings that are joined and are separable.

[0047] Aerosol generating devices of the present invention can be formed of an outside casing or shell that is not substantially tubular in shape but may be formed to substantially greater transversal dimensions. The outside casing or shell can be configured to include a mouthpiece and/or may be configured to receive a separate shell (e.g. a cartridge, a tank) that can include consumable elements, such as a liquid aerosol former, and can include a vaporizer.

[0048] FIG. 2 shows a schematic sectional view of the interior of a cartomizer 1 for an aerosol generating device 100 according to a first embodiment of the present invention. As can be taken from FIG. 2, the cartomizer 1 is generally a container 10 or cartridge that can be at least partially inserted into a receiving cavity of an aerosol generating device and that provides the functionalities of generating an aerosol or vapor from a vaporizable material or liquid stored therein. For example, a cartomizer can be a pre-manufactured and pre-filled cartridge that comprises at least one reservoir 11 for containing the vaporizable material or liquid from which the aerosol or vapor can be generated. For the purpose of generating said aerosol or vapor, the cartomizer 1 may further comprise a heater which is arranged to heat at least a fraction of the vaporizable material or liquid so as to vaporize an amount of it for, in turn, generating the aerosol or vapor. The heater may comprise any one and combination of a wire, a resistive element, a coil, and a susceptor being heatable by induction. The cartomizer 1 further comprises an air conduct and/or a mouthpiece (mouth end) 13 so as to allow a user to inhale the generated aerosol, preferably as a mixture with air from the environment.

[0049] In the shown embodiment the heater is formed by a wire that is wound around a liquid transport element 15, in particular a capillary-type wick, such as bundle of cotton filaments, and located within a vaporizing chamber 12. It should further be mentioned that the vaporizing chamber 12 is fluidly connected to the mouth end 13, in particular an opening provided in the mouth end 13, via a vapor passage 14. In other words, vapor generated by the heater can be provided via the vapor passage 14 and the opening in the mouth end 13 to a user. In the shown embodiment the cartomizer 1 is only provided with one reservoir 11 which surrounds the vapor passage 14, the heater and the liquid transport element 15. Both ends of the wick 15 reach into the reservoir 11, in particular into the vaporizable material stored inside the reservoir 11, on opposing sides and thereby convey, wick or otherwise transport the vaporizable material from the reservoir 11 to the heater which is positioned inside the vaporizing chamber 12.

[0050] As also can be seen in FIG. 2, the cartomizer 1 is provided with an air inlet 16 which is arranged on the bottom, in particular in a bottom holder 17, of the container 10. The air inlet 16 is configured to supply the vaporizing chamber 12 with ambient air, which is sucked into the vaporizing chamber 12 during use of the aerosol generating device 100.

[0051] FIG. 2 also shows that the cartomizer 1 is additionally provided with a leakage collecting chamber 20 that is arranged in an airflow direction of the ambient air sucked into the cartomizer, namely from the air inlet 16 towards the vaporizing chamber, between the vaporizing chamber 12 and the air inlet 16 to collect vaporizable material leaking from the vaporizing chamber 12.

[0052] Since the air path of the ambient air sucked into the cartomizer 1 through the air inlet 16 is the only unsealed connection between the environment and the vaporizing chamber 12, besides the vapor passage 14, the air path is the main source of possible leakage.

[0053] As indicated in FIG. 3, which is a schematic sectional view of a detail of the device 1 shown in FIG. 2, by the arrows, vaporizable material or liquid leaking from the wick 15 drops onto a first sealing 30 that is configured to hold or fix the wick 15 within the vaporizing chamber 12, in particular together with a second sealing 31, and to form a part, in particular a bottom portion, of the vaporizing chamber 12. Thereby, the leaked vaporizable material or liquid is collected at the bottom of the vaporizing chamber 12. The first sealing 30 is provided with two air outlets 21 that are formed by two channels or through-holes that go through the first sealing 30, in particular in a direction parallel to the axial direction of the cartomizer 1. It should also be noted that the two air outlets 21 are arranged at an axial distance relative to a through-hole 16a of the air inlet 16. Accordingly, the leaked vaporizable material or liquid collected at the bottom of the vaporizing chamber 12 flows through one of the air outlets 21 to the leakage collecting chamber 20 or one of the leakage collecting chambers 20.

[0054] As can be taken from FIG. 4, the air inlet 16 is provided with two through-holes 16a, which are aligned in a direction perpendicular to the axial direction of the cartomizer 1, which extends in FIG. 4 in view direction, in other words, in a direction into the paper.

[0055] FIGS. 3 and 4 also show that the two air outlets 21 are arranged on each side of the air inlet 16, in particular an air conduit or chimney 19 that forms the air inlet 16 and is provided at the bottom of the container 10. Moreover, the two air outlets 21 are aligned in a vertical plane (in FIGS. 3 and 4) of extension of the liquid transport element 15.

[0056] Hence, as indicated by the arrows in FIG. 3, the leaked vaporizable material flows through the two air outlets 21 and reaches the leakage collecting chambers 20, which are also provided on each side of the air conduit or chimney 19 of the air inlet 16. It should also be noted that the second sealing 31 separates the reservoir 11 from the vaporizing chamber 12, ensuring that the vaporizable material only reaches the heater via the wick 15.

[0057] FIG. 4 shows a vertical and a horizontal schematic sectional view of the cartomizer 1 shown in FIG. 2, illustrating the air flow through the cartomizer 1. As shown in the right view, the ambient air entering the cartomizer 1 through the two through-holes 16a reaches a center leakage collecting chamber 22 that is provided in the bottom holder 17 of the container 10. In airflow direction, the center leakage collecting chamber 22 is arranged between the air inlet 16 and the (main) leakage collecting chamber(s) 20. Meaning, the center leakage collecting chamber 22 is arranged between a side wall of the chimney 19 and a transversal wall of the first seal 30, forcing air to travel to the sides (as indicated by arrows in FIG. 4). In other words, as shown in the right view, the air entering the center leakage collecting chamber 22 flows through four air channels 30a which are provided in the first seal 30 thereby reaching the (main) leakage collecting chamber(s) 20. As shown in the right view of FIG. 4, the four air channels 3a are arranged in a double-T form.

[0058] FIG. 5 shows a schematic spatial view of the bottom part of the device shown in FIG. 2, in particular of the bottom holder 17 of the container 10. It should also be noted that the conduit or chimney 19 of the air inlet 16 forms part of the bottom holder 17. Moreover, as FIG. 5 illustrates, the center leakage collecting chamber 22 and the two (main) leakage collecting chambers 20, which are arranged on each side of the center leakage collecting chamber 22, are separated from each other by at least one liquid stopping or barrier wall (here a first liquid stopping or barrier wall 23) including four connecting holes 25 (in this embodiment formed by cuts or grooves formed in the partition wall) that fluidly connect the center leakage collecting chamber 22 with the leakage collecting chambers 20. Since the connecting holes (cuts or grooves) are provided with a predetermined distance to the bottom of the container 10, leaked vaporizable material that is collected inside the (main) leakage collecting chambers 20 is prevented from entering the center leakage collecting chamber 22, even in extreme cartomizer orientations. In other words, the two first liquid stopping or barrier walls 23, each provided on one side of the chimney 19, form overflows between the two (main) leakage collecting chambers 22 and the center leakage collecting chamber 22. Hence, ensuring that leaked vaporizable material accumulated in the two (main) leakage collecting chambers 22 does not or at least only very unlikely reach the center leakage collecting chamber 22.

[0059] Moreover, as it is also apparent from FIGS. 3, 4 and 5, the two air outlets 21, in particular bottom or upstream openings of them, are provided closer to the bottom of the container 10 than the through-holes 16a of the air inlet 16, thereby ensuring that leaked vaporizable material collected inside the (main) leakage collecting chambers 20 does not close the air path, in particular the air path connecting the through-holes 16a of the air inlet 16 with the air outlets 21 via the leakage collecting chambers 20.

[0060] Yet, as shown in FIGS. 4 and 5, even in case leaked vaporizable material would reach the center leakage collecting chamber 22, since the through-holes 16a of the inlet 16 are provided on the top of the conduit or chimney, the distance between the bottom of the center leakage collecting chamber 22 and the through-holes 16a is maximized, thereby reducing the likelihood of leaked vaporizable material reaching the through-holes 16a. In other words, the air conduit or chimney 19, in particular a side wall thereof, forms a second liquid stopping or barrier wall 24 that is arranged between the first liquid stopping or barrier wall 23 and the two through-holes 16a of the air inlet 16. Hence, in the unlikely event that a very small amount of leaked vaporizing material reaches the center leakage collecting chamber 22, the second liquid stopping or barrier wall forms a further overflow that ensures that no leaked vaporizing material reaches the air inlet 16.

[0061] FIG. 6 shows a schematic sectional view of a detail of the cartomizer 1 shown in FIG. 2 when inserted into an aerosol generating device 100. It should also be noted that the aerosol generating device 100 is provided with electrical contacts 105 such as “pogo pins” that are configured to contact the electrical connectors 18 of the cartomizer in order to provide the heater of the cartomizer 1 with electrical power. As FIG. 6 also shows, the electrical connectors 18 also contact magnets 104 which are provided within an inner frame 102 of the aerosol generating device 100. Yet, in order to provide the wire of the heater with electrical power, the cartomizer 1 is further provided with lead wires 40 that electrically connect the wire with the electrical connectors 18.

[0062] FIG. 7 shows a schematic spatial view of a whole aerosol generating device 100 including the cartomizer according to the present invention, where only the outside casing of the aerosol generating device is not shown for illustrating purposes. The shown aerosol generating device 100 includes a mouthpiece which is part of the cartomizer 1 for guiding the generated vapor to a user, the cartomizer 1, a battery 101, a sealing arrangement 103 and an inner frame 102 for holding the battery 101 inside the device 100. It should also be noted that the aerosol generating device 100 has an elongated shape, in which a receiving cavity for the cartomizer 1, a power supply device, in particular the battery 101, and a main electronic circuit board are arranged in this order from a first, proximal end (mouth end) to a second, distal end. Consequently, the power supply device, in particular battery 101, is located at approximately the center of the device 100, so that it is particularly well balanced.

REFERENCE LIST

[0063] 1 Cartomizer [0064] 10 Container (Shell) [0065] 11 Reservoir [0066] 12 Vaporizing chamber [0067] 13 Mouth end [0068] 14 Vapor passage [0069] 15 Liquid transport element (Wick) [0070] 16 Air inlet [0071] 16a Through-hole (of the air inlet) [0072] 17 Bottom holder (of the container) [0073] 18 Electrical connectors [0074] 19 Air conduit or chimney [0075] 20 Leakage collecting chamber(s) [0076] 21 Air outlet (of the leakage collecting chamber) [0077] 22 Center leakage collecting chamber [0078] 23 First liquid stopping or barrier wall [0079] 24 Second liquid stopping or barrier wall [0080] 25 Connecting hole or groove [0081] 30 First seal [0082] 30a Air channels [0083] 31 Second seal [0084] 40 Lead Wires [0085] 100 Aerosol generating device [0086] 101 Battery [0087] 102 Inner frame [0088] 103 Sealing arrangement [0089] 104 Magnets [0090] 105 Electrical contacts