VAPORIZER UNIT FOR A VAPORIZER DEVICE OF AN INHALER

Abstract

The invention relates to a vaporizer unit (21) for a vaporizer device (2) of an inhaler, in particular of an electronic cigarette (1), the vaporizer unit (21) consisting of a material that comprises at least one thermoplastic, preferably a high-performance thermoplastic. The invention also relates to a method for producing such a vaporizer unit (21).

Claims

1. A vaporizer unit (21) for a vaporizer device (2) of an inhaler, in particular an electronic cigarette (1), characterized in that the vaporizer unit (21) consists of a material comprising at least one thermoplastic material, preferably a high-performance thermoplastic.

2. The vaporizer unit according to claim 1, characterized in that a melting temperature of the at least one thermoplastic material is greater than about 180° C., preferably greater than about 250° C.

3. The vaporizer unit according to claim 1 or 2, characterized in that a glass transition temperature of the at least one thermoplastic material is greater than about 80° C., preferably greater than about 150° C.

4. The vaporizer unit according to any one of claims 1 to 3, characterized in that the material of the vaporizer unit (21) comprises at least one of the following thermoplastic materials: a polyaryletherketone (PAEK), preferably polyetheretherketone (PEEK); a poly sulfone, preferably polysulfone (PSU) and/or polyethersulfone (PES) and/or polyphenylsulfone (PPSU); a polyimide (PI), preferably polyetherimide (PEI) and/or polyamide-imide (PAI); polyphenylene sulfide (PPS); polyamide (PA); polyphenylene ether (PPE); polyphthalamide (PPA).

5. The vaporizer unit according to any one of claims 1 to 4, characterized in that the vaporizer unit (21) consists substantially entirely of at least one polyaryletherketone, preferably polyetheretherketone.

6. The vaporizer unit according to any one of claims 1 to 5, characterized in that the vaporizer unit (21) has an open porosity of about 30% to 96%, preferably of about 50% to 95%, particularly preferably of about 65% to 94%.

7. The vaporizer unit according to any one of claims 1 to 6, characterized in that the vaporizer unit (21) is self-supporting.

8. The vaporizer unit according to any one of claims 1 to 7, characterized in that the material of the vaporizer unit (21) comprises at least one additive.

9. The vaporizer unit according to any one of claims 1 to 8, characterized in that the material of the vaporizer unit (21) comprises at least one electrically conductive additive, the at least one electrically conductive additive preferably being a metal, graphite, graphene, silicon carbide or activated carbon.

10. The vaporizer unit according to any one of claims 1 to 9, characterized in that the vaporizer unit (21) is formed to be cylindrical, preferably circular cylindrical.

11. The vaporizer unit according to any one of claims 1 to 10, characterized in that a surface (3) of the vaporizer unit (21) is provided at least in certain sections with at least one electrically conductive coating (4).

12. The vaporizer unit according to one of claims 1 to 11, characterized in that the vaporizer unit (21) is formed at least in certain sections, preferably substantially entirely, as a textile structure, preferably as a flat or spatial fabric, the textile structure comprising at least one fiber and/or at least one filament comprising the at least one thermoplastic material.

13. The vaporizer unit according to claim 12, characterized in that the at least one fiber and/or the at least one filament consist or consists substantially entirely of at least one polyaryletherketone, preferably polyetheretherketone.

14. The vaporizer unit according to claim 12 or 13, characterized in that the at least one fiber and/or the at least one filament has or have a diameter of less than 1000 μm, preferably less than 500 μm, particularly preferably less than 300 μm.

15. The vaporizer unit according to any one of claims 12 to 14, characterized in that the textile structure is formed to be wick-like.

16. A vaporizer device (2) for an inhaler, in particular an electronic cigarette (1), having at least one vaporizer unit (21) according to any one of claims 1 to 15.

17. The vaporizer device (2) according to claim 16, characterized in that a heating device (24) is provided, the heating device (24) being arranged in or on the vaporizer unit (21).

18. The vaporizer device according to claim 16 or 17, characterized in that the vaporizer device (2) comprises a receiving chamber (22) for a liquid, the vaporizer unit (21) being in communication with the liquid.

19. An inhaler, in particular electronic cigarette (1), having at least one vaporizer device (2) according to any one of claims 16 to 18.

20. A mouthpiece (30) for an inhaler, in particular an electronic cigarette (1), having at least one vaporizer device (2) according to any one of claims 16 to 18.

21. A method for producing a vaporizer unit (21) according to any one of claims 1 to 11, characterized in that a mixture comprising at least one thermoplastic material, preferably a high-performance thermoplastic, is provided, the mixture being heated until the mixture has melted at least superficially or a melt forms, at least one vaporizer unit (21) being formed from the at least superficially melted mixture or the melt.

22. The method according to claim 21, characterized in that the mixture comprises at least one electrically conductive additive—preferably a metal, graphite, graphene, silicon carbide or activated carbon—which is mixed with the at least one thermoplastic material to provide the mixture.

23. The method according to claim 21 or 22, characterized in that the mixture comprises at least one additive which is mixed with the at least one thermoplastic material to provide the mixture.

24. The method according to claim 23, characterized in that the mixture comprises at least one soluble solid, preferably a salt, the at least one soluble solid being mixed with the at least one thermoplastic material to provide the mixture, wherein after molding the at least one vaporizer unit (21), the at least one soluble solid is at least partially, preferably substantially entirely, dissolved out of the vaporizer unit (21).

25. The method according to any one of claims 21 to 24, characterized in that the at least one thermoplastic material is a powdery or flaky polyaryletherketone, preferably polyetheretherketone.

26. The method according to claim 25, characterized in that the mass fraction of the powdery or flaky polyaryletherketone in the mixture is about 4% to 65%, preferably about 5% to 55%, particularly preferably about 6% to 45%.

27. The method according to claim 25 or 26, characterized in that powdery polyetheretherketone is mixed with sodium chloride, the mass fraction of the powdery polyetheretherketone in the mixture preferably being about 4% to 65%, particularly preferably about 5% to 55%, more particularly preferably about 6% to 45%, an average particle size of the powdery polyetheretherketone preferably being smaller than about 1000 μm, particularly preferably smaller than about 100 μm.

28. The method according to any one of claims 21 to 27, characterized in that the mixture is heated to a maximum temperature between about 350° C. and about 450° C., preferably to about 370° C., the mixture preferably being exposed to the maximum temperature for a residence time of up to 4 h, particularly preferably about 0.5 h to 1.5 h.

29. The method for producing a vaporizer unit (21) according to any one of claims 12 to 15, characterized in that at least one fiber and/or at least one filament comprising the at least one thermoplastic material are or is processed to form a textile structure, preferably a flat or spatial fabric, the vaporizer unit (21) or a part thereof being molded from the textile structure.

30. The method according to claim 29, characterized in that a thread and/or yarn comprising the at least one fiber and/or the at least one filament are or is processed to form the textile structure.

31. The method according to claim 29 or 30, characterized in that the processing is carried out using at least one of the following methods: spinning, weaving, warp-knitting, knitting, braiding, felting, joining.

32. The method according to any one of claims 29 to 31, characterized in that in the step of molding the vaporizer unit (21), the textile structure is cut to size with a tempered blade.

33. The method according to any one of claims 21 to 32, characterized in that at least one electrically conductive coating (4) is applied at least in certain section onto a surface (3) of the vaporizer unit (21).

34. The method according to claim 33, characterized in that the at least one electrically conductive coating (4) is applied onto the surface (3) of the vaporizer unit (21) by electroplating.

35. The method according to claim 33 or 34, characterized in that the at least one electrically conductive coating (4) is applied onto the surface (3) of the vaporizer unit (21) by vapor deposition.

Description

[0084] Further details and advantages of the present invention are explained based on the following description of the figures. In the figures:

[0085] FIG. 1 shows an exemplary embodiment of an inhaler in the form of an electronic cigarette in a front view,

[0086] FIG. 2 shows a sectional view through an electronic cigarette according to FIG. 1,

[0087] FIG. 3 shows an enlarged detailed view of an area of FIG. 2,

[0088] FIG. 4 shows an enlarged detailed view of an area of FIG. 3,

[0089] FIG. 5 shows a side view of the vaporizer unit of FIG. 4,

[0090] FIG. 6 shows a schematic illustration according to FIG. 4,

[0091] FIG. 7 shows another exemplary embodiment of an inhaler in the form of an electronic cigarette in a front view,

[0092] FIG. 8 shows a sectional view through an electronic cigarette according to FIG. 7,

[0093] FIG. 9 shows an enlarged detailed view of an area of FIG. 8,

[0094] FIG. 10 shows an enlarged detailed view of an area of FIG. 9,

[0095] FIG. 11 shows a side view of the vaporizer unit of FIG. 10,

[0096] FIG. 12 shows a schematic illustration according to FIG. 9,

[0097] FIGS. 13-17 show exemplary embodiments of proposed vaporizer units,

[0098] FIG. 18 shows an exemplary embodiment of a vaporizer device, and

[0099] FIG. 19 shows an exemplary embodiment of a vaporizer unit formed as a textile structure.

[0100] FIG. 1 shows an exemplary embodiment of an inhaler in the form of an electronic cigarette 1 in a front view.

[0101] The electronic cigarette 1 comprises a first housing part 10, in which an energy storage in the form of a secondary battery 14, which is not visible in this illustration, and a control electronics 15 of the electronic cigarette 1, which is also not visible here, are accommodated. Furthermore, a control element 11 in the form of a push button for operating the electronic cigarette 1 and a charging connection 13 for charging the secondary battery 14 are attached to the first housing part 10. The first housing part 10 also has an air inlet 12 (here in the form of a plurality of holes arranged one above the other in the housing) through which ambient air can be introduced into the interior of the electronic cigarette 1 by sucking at a mouthpiece 30 of the electronic cigarette 1.

[0102] The electronic cigarette 1 furthermore comprises a second housing part 20 which can be screwed to the first housing part 10. The second housing part 20 accommodates a vaporizer device 2 for vaporizing a liquid, which is not visible in this illustration. A mouthpiece 30, through which vaporized liquid can be removed when the electronic cigarette 1 is activated, is arranged on the second housing part 20.

[0103] FIG. 2 shows a schematic sectional view through an electronic cigarette 1 according to FIG. 1. Particularly visible in this illustration are the secondary battery 14 and the control electronics 15 which are located inside the first housing part 10. Also visible is the vaporizer device 2, which is arranged in the second housing part 20. The vaporizer device 2 comprises a vaporizer unit 21 and a receiving chamber 22 in the form of a tank containing liquid to be vaporized. The vaporizer unit 21 projects into the receiving chamber 22 and is in communication with the liquid inside.

[0104] FIG. 3 shows an enlarged detailed view of the area marked and designated by D1 in FIG. 2.

[0105] The vaporizer unit 21 protrudes into the receiving chamber 22 containing the liquid and, together with a circumferential seal 27 arranged around an end region of the vaporizer unit 21, delimits the receiving chamber 22. The vaporizer unit 21 is self-supporting and, in this example, is made substantially entirely of PEEK. The vaporizer unit 21 has an open porosity of about 80%.

[0106] A tubular channel 26 which also delimits the receiving chamber 22 runs through the vaporizer unit 21 and the receiving chamber 22 so that the liquid cannot flow into the interior of channel 26. In this example, the vaporizer unit 21 is circular-cylindrical and a portion of the channel 26 in the vaporizer unit 21 is formed as a through-hole 23 passing through the vaporizer unit 21 in a longitudinal direction. Inside the vaporizer unit 21, in this example inside the through-hole 23 passing through the vaporizer unit 21, a heating device 24 in the form of a heating coil is arranged. The heating device 24 is connected to the control electronics 15 via electrical contacts 28a (e.g. a positive voltage connection) and 28b (e.g. a negative voltage connection). When actuating the electric cigarette 1 via the control element 11, current is conducted via the control electronics 15 from the secondary battery 14 into the heating device 24 via the electrical contacts 28a, 28b, thereby heating the heating device 24. Due to the porosity of the vaporizer unit 21, liquid, with which the vaporizer unit 21 is in communication, enters the vaporizer unit 21. The heating of the heating device 24 results in vaporization of the liquid in the vaporizer unit 21. By the user sucking on the mouthpiece 30 of the electronic cigarette 1, air is sucked from outside the electronic cigarette 1 through the air inlet 12 into the interior of the electronic cigarette 1. The air flows through the channel 26 with the air absorbing the vaporized liquid. The mixture 25 of air and vaporized liquid continues to flow through the channel 26 and leaves the electronic cigarette 1 through the mouthpiece 30.

[0107] FIG. 4 shows an enlarged detailed view of the area marked and designated by D2 in FIG. 3. Here, the through-hole 23 in the vaporizer unit 21, which forms a portion of the channel 26, is clearly visible. The heating device 24 is arranged in the through-hole 23 and electrically contacted by two electrical contacts 28a, 28b. A circumferential seal 27 is arranged at an end area of the vaporizer unit 21 so that when the vaporizer unit 21 with the circumferential seal 27 is inserted into the receiving chamber 22, the receiving chamber 22 is delimited and sealed at the end face.

[0108] FIG. 5 shows a side view of the vaporizer unit 21 in FIG. 4.

[0109] FIG. 6 shows a schematic illustration according to FIG. 4 in which in particular the flow of air A, vaporized liquid B and mixture 25 of air A and vaporized liquid B through the through-hole 23 of the vaporizer unit 21 is illustrated.

[0110] FIG. 7 shows another exemplary embodiment of an inhaler in the form of an electronic cigarette 1 in a front view. The electronic cigarette 1 consists of a first housing part 10 and a mouthpiece 30 which can be inserted into the first housing part 10. An air inlet 12, which is not visible here, through which air from the environment can enter the interior of the electronic cigarette 1 when the electronic cigarette 1 is operated, is arranged on the first housing part 10.

[0111] FIG. 8 shows a schematic sectional view through an electronic cigarette 1 according to FIG. 7. Visible in this illustration are in particular the secondary battery 14 and the control electronics 15, which are arranged inside the first housing part 10. Also visible is the vaporizer device 2 which is arranged in the removable mouthpiece 30. The vaporizer device 2 comprises a vaporizer unit 21 and a receiving chamber 22 in the form of a tank containing liquid to be vaporized. The vaporizer unit 21 is formed to be substantially circular-cylindrical and protrudes with both end portions into the receiving chamber 22 so that it is in communication with the liquid in the receiving chamber 22 via both end regions.

[0112] FIG. 9 shows an enlarged detailed view of the area marked and designated by D3 in FIG. 8.

[0113] The vaporizer unit 21 is self-supporting and in this example consists substantially entirely of PEEK. The vaporizer unit 21 has an open porosity of about 75%. Both end regions of the vaporizer unit 21 protrude into the receiving chamber 22 which contains the liquid. Due to the porosity of the vaporizer unit 21, liquid can thus penetrate from the receiving chamber 22 into the cavities of the vaporizer unit 21. The vaporizer unit 21 is arranged at a seal 27 in the form of a sealing lid which delimits the receiving chamber 22.

[0114] A tubular channel 26 which also delimits the cavity 22 runs through the cavity 22 thereby preventing the liquid from flowing into the interior of the channel 26. The vaporizer unit 21 is arranged in front of an orifice of the channel 26. A heating device 24 in the form of a heating coil which, in this example, is wrapped around a portion of the vaporizer unit 21 is arranged on the vaporizer unit 21. The heating device 24 is connected to the control electronics 15 via electrical contacts 28a (e.g. a positive voltage connection) and 28b (e.g. a negative voltage connection).

[0115] The electric cigarette 1 of this example can be activated by a vacuum sensor, which is not illustrated, which is connected to the control electronics 15. By the user sucking on the mouthpiece 30 of the electronic cigarette 1, air from outside the electronic cigarette 1 is sucked through the air inlet 12 into the interior of the electronic cigarette 1. Furthermore, when sucking on the mouthpiece 30, a negative pressure is created inside the electronic cigarette 1 which is detected by the negative pressure sensor, whereupon the electronic cigarette 1 is activated by the control electronics 15. In doing so, current is conducted via the control electronics 15 from the secondary battery 14 to the heating device 24 via the electrical contacts 28a, 28b thereby heating up the heating device 24. Due to the porosity of the vaporizer unit 21, liquid, with which the vaporizer unit 21 is in communication, enters the vaporizer unit 21. Heating up the heating device 24 results in that the liquid vaporizes in the vaporizer unit 21. The sucked-in air flows through or around the vaporizer unit 21 with the air absorbing the vaporized liquid. The mixture 25 of air and vaporized liquid flows into the orifice of the channel 26 and further through the channel 26 and leaves the electronic cigarette 1 through the mouthpiece 30.

[0116] FIG. 10 shows an enlarged detailed view of the area marked and designated by D4 in FIG. 9. Here, the vaporizer unit 21, around which the heating device 24 is wrapped in the form of a heating coil, is clearly visible. The heating device 24 is electrically contacted by two electrical contacts 28a, 28b which extend up to the seal 27 in the form of a seal cover and protrude slightly beyond the seal cover to simplify contacting. The shape of the seal cover corresponds to the shape of an end face of the receiving chamber 22 so that when the seal cover is placed on the receiving chamber 22, the receiving chamber 22 is delimited and sealed at the end face.

[0117] FIG. 11 shows a side view of the vaporizer unit 21 in FIG. 10.

[0118] FIG. 12 shows a schematic illustration of a vaporizer unit 21 according to FIG. 9 in which in particular the flow of air A, vaporized liquid B and mixture 25 of air A and vaporized liquid B is illustrated.

[0119] FIG. 13 shows a proposed vaporizer unit 21 in a longitudinal section. The vaporizer unit 21 is formed to circular cylindrical and has a through-hole 23 running therethrough so that the vaporizer unit 21 takes on the overall shape of a round tube. In this example, the entire surface 3 of the vaporizer unit 21—thus, the inner wall of the through-hole 23, the outer surface of the vaporizer unit 21 and the end faces of the vaporizer unit 21—is provided with an electrically conductive coating 4. In this example, the electrically conductive coating 4 constitutes a heating device 24 which can be connected to a corresponding power supply via electrical contacts 28a (e.g. a positive voltage connection) and 28b (e.g. a negative voltage connection).

[0120] FIG. 14 shows another exemplary embodiment of a proposed vaporizer unit 21 in a longitudinal section. This vaporizer unit 21 is also formed to be circular tube-shaped, but not the entire surface 3 of the vaporizer unit 21 is coated with an electrically conductive coating 4. Only the end faces of the vaporizer unit 21 are each provided with an electrically conductive coating 4. In this example, the material of the vaporizer unit 21 comprises an electrically conductive additive so that the vaporizer unit 21 is electrically conductive in itself. Thus, the vaporizer unit 21 itself in combination with the two electrically conductive coatings 4 form a heating device 24 which can be connected to a power supply via the electrical contacts 28a, 28b.

[0121] The vaporizer units 21 according to FIGS. 13 and 14 are particularly suitable for use in an electronic cigarette 1 according to FIG. 1.

[0122] FIG. 15 shows an exemplary embodiment of a vaporizer unit 21 in a longitudinal section and in a side view. The vaporizer unit 21 is formed to be substantially circular cylindrical. In this example, the surface 3 of the vaporizer unit 21 is coated in certain sections with an electrically conductive coating 4. Specifically, the outer surface of the circular cylindrical vaporizer unit 21 is provided with an electrically conductive coating 4. In this example, the electrically conductive coating 4 constitutes a heating device 24 which can be connected to a power supply via electrical contacts 28a, 28b.

[0123] FIG. 16 shows another exemplary embodiment of a vaporizer unit 21 in a longitudinal section and in a side view. The vaporizer unit 21 is formed to be substantially circular cylindrical. The material of the vaporizer unit 21 comprises an electrically conductive additive, so that the vaporizer unit 21 is electrically conductive in itself. Two separate, circumferential electrically conductive coatings 4 are applied to the lateral surface of the vaporizer unit 21. In connection with the two electrically conductive coatings 4, the vaporizer unit 21 forms a heating device 24 which can be connected to a power supply via electrical contacts 28a, 28b.

[0124] FIG. 17 shows another exemplary embodiment of a vaporizer unit 21 in a longitudinal section and in a side view. The vaporizer unit 21 is formed to be substantially circular cylindrical. The material of the vaporizer unit 21 comprises an electrically conductive additive, so that the vaporizer unit 21 is electrically conductive in itself. Two electrically conductive coatings 4 that are separated from each other and run along a longitudinal extent of the vaporizer unit 21 are applied to the outer surface of the vaporizer unit 21. In connection with the two electrically conductive coatings 4, the vaporizer unit 21 forms a heating device 24 which can be connected to a power supply via electrical contacts 28a, 28b.

[0125] FIG. 18 shows an exemplary embodiment of a vaporizer device 2 in a longitudinal section and in a side view. The vaporizer device 2 comprises two circular cylindrical vaporizer units 21 spaced apart from each other in the longitudinal direction and a heating device 24 in the form of an electrically conductive wire which is integrated in both vaporizer units 21 and connects both vaporizer units 21 to each other. The heating device 24 can be connected to a power supply via electrical contacts 28a, 28b.

[0126] FIG. 19 shows another exemplary embodiment of a vaporizer unit 21 in a front view and in a side view. In this example, the vaporizer unit 21 is formed as a textile structure in the form of a PEEK fabric. The vaporizer unit 21 has a wick-like structure so that it is able to optimally hold and transport a liquid for an electronic cigarette. In this example, the PEEK fabric is woven from PEEK filament with a diameter of about 38 μm. The round geometry was produced using conventional weaving processes.

[0127] The vaporizer units 21 according to FIGS. 15 to 17 and 19 and the vaporizer device 2 according to FIG. 18 are particularly suitable for use in an electronic cigarette 1 according to FIG. 7.