Evaporator

Abstract

An evaporator for an aerosol generating device is described. The evaporator comprises a heating body (101) comprising a plurality of channels (102) arranged through the heating body between an inlet surface (103) and an outlet surface (104). The channels are configured to transport liquid from the inlet surface through the heating body by capillary action. The heating body comprises electrically conductive material (120) and the evaporator further comprises circuitry (116) for providing a current through the electrically conductive material to provide resistive heating of the heating body to evaporate a liquid passing through the channels. The heating body and circuitry are configured to provide a positive temperature gradient across the heating body from the inlet surface to the outlet surface.

Claims

1. An evaporator for an aerosol generating device comprising: a heating body comprising a plurality of channels arranged through the heating body between an inlet surface and an outlet surface, the channels configured to transport liquid from the inlet surface through the heating body by capillary action; wherein the heating body comprises electrically conductive material and the evaporator further comprises circuitry for providing a current through the electrically conductive material to provide resistive heating of the heating body to evaporate a liquid passing through the channels; wherein the heating body and circuitry are configured to provide a positive temperature gradient across the heating body from the inlet surface to the outlet surface.

2. The evaporator of claim 1 wherein the heating body comprises one or more layers of electrically conductive material arranged to provide the positive temperature gradient across the heating body.

3. The evaporator of claim 1 wherein the electronically conductive material is arranged as a resistive heating layer at the outlet surface.

4. The evaporator of claim 1 wherein resistivity of the heating body varies across the heating body to provide the temperature gradient when a current is provided to the heating body.

5. The evaporator of claim 4 wherein the evaporator comprises a plurality of heating layers, wherein at least two of the plurality of heating layers have a different resistivity.

6. The evaporator of claim 1 wherein the heating body comprises a semiconductor or ceramic wherein the dopant concentration is configured to provide the positive temperature gradient when a current is provided to the heating body.

7. The evaporator of claim 6 wherein the heating body comprises a layer of increased dopant concentration at the outlet surface.

8. The evaporator of claim 1 wherein the heating body comprises a plurality of heating layers arranged sequentially between the inlet surface and the outlet surface; wherein the heating layers are heated to different temperatures to provide the temperature gradient.

9. The evaporator of claim 8 wherein the heating layers comprise a semiconductor material where the dopant concentration differs between the plurality of heating layers.

10. The evaporator of claim 8 comprising a layer of insulation between two neighbouring heating layers.

11. The evaporator of claim 1 wherein a diameter of one or more channels of the heating body decreases in a direction between the inlet surface and the outlet surface.

12. The evaporator of claim 1 wherein the temperature gradient is configured such that a liquid passing through the channels evaporates closer to the outlet surface than the inlet surface.

13. The evaporator of claim 1 wherein the evaporator is configured to provide a temperature at the inlet surface of 40° C. or more and a temperature at the outlet surface of between 200° C. and 350° C.

14. The evaporator of claim 1 further comprising a liquid store in fluid communication with the inlet surface of the heating body such that liquid is drawn from the liquid store through the heating body during use.

15. The evaporator of claim 1 wherein a diameter of the channels is between 5 μm and 200 μm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] An example of an evaporator assembly and vapour generation device in accordance with the invention will now be described with reference to the accompanying drawings, in which:

[0027] FIG. 1a is an perspective view of an embodiment of an evaporator assembly in accordance with the invention. FIG. 1b is a cross-sectional view of this same assembly.

[0028] FIG. 2 is a perspective view of an exemplary evaporator assembly of the invention comprising a resistive heating layer at the outlet surface.

[0029] FIG. 3 is an exemplary evaporator assembly of the invention comprising a plurality of heating layers arranged sequentially between the inlet surface and outlet surface.

[0030] FIG. 4 is an exemplary evaporator assembly of the invention comprising a plurality of heating layers and further comprising layers of insulation between each pair of neighbouring heating layers.

[0031] FIG. 5 is an exemplary evaporator assembly of the invention wherein the heating body comprises an electrically conductive material and the heater comprises the heating body and circuitry.

[0032] FIG. 6 is a cross-sectional view of an exemplary evaporator assembly comprising channels having a decreasing diameter in a direction between the inlet surface and the outlet surface.

[0033] FIG. 7 is an evaporator assembly according to the invention further comprising a liquid store.

[0034] FIG. 8 shows schematically an embodiment of an aerosol generating device comprising the evaporator of the invention.

DETAILED DESCRIPTION

[0035] An aerosol or vapour generating device is a device arranged to heat a vapour generating product to produce a vapour for inhalation by a consumer. In a specific example, a vapour generating product can be a liquid which forms a vapour when heated by the vapour generation device. A vapour generating device can also be referred to as an electronic cigarette or aerosol generation device. In the context of the present disclosure, the terms vapour and aerosol can be used interchangeably. A vapour generating product, or aerosol generating product, can be a liquid or a solid such as a fibrous material, or a combination thereof, that when heated generates a vapour or aerosol. The vapour generating product may also be referred to as an e-liquid.

[0036] FIGS. 1a and 1b are perspective and cross-sectional views of an embodiment of an evaporator assembly in accordance with the invention. The evaporator comprises a heating body 101 with a plurality of channels 102 arranged through the heating body 101 between an inlet surface 103 and an outlet surface 104. In this example, the plurality of channels 102 is sufficiently narrow (i.e. has a sufficiently small cross-sectional area in the x-y plane) that when it receives a vapourisable liquid, the vapourisable liquid can travel along the channels from the inlet surface 103 to the outlet surface 104 by capillary action. The dashed arrow 105 illustrates the direction of the flow of vapourisable liquid.

[0037] The evaporators of the invention provide resistive heating of the heating body to evaporate a liquid passing through the channels when in use. In particular the heating body comprises electrically conductive material which is heatable by resistive heating by passing a current through the heating body. Therefore the evaporator can be considered to include a heater comprising the heating body 101, either entirely or partially. When the heating body 101 is heated by passing a current through the electrically conductive material of the heating body, a positive temperature gradient is generated across the heating body 101 from the inlet surface to the outlet surface 104. When the evaporator is in use in an aerosol generating device, this temperature gradient causes the e-liquid to change viscosity as it rises through the channels 102 from the inlet surface 103 to the outlet surface 104. Changing the temperature through the channels 102 affects the rate at which the vapourisable liquid heats up as it passes through the channels 102. As an e-liquid is exposed to increasing temperature as it passes through the channels 102, it heats in a more controlled way compared to evaporators that expose e-liquids to a uniform temperature. As a result, e-liquids with a range of viscosities can be used as the viscosities are effectively normalised.

[0038] At the inlet surface 103, e-liquids of a range of viscosities can be taken up into the channels 102 of the heating body 101, however, when these e-liquids of variable viscosities reach the outlet surface 104, they are normalised to have effectively the same viscosity for evaporation. This improves the choice of compatible e-liquids to users of the device and improves the flow of the e-liquids, providing an enhanced user experience.

[0039] The temperature gradient also mitigates clogging problems associated with known aerosol generating devices. In the present invention, the temperature increase of the e-liquid is better controlled as it passes through the channels, and any bubble generation occurs only close to the outlet of the channels and not throughout the entire channels. This provides improved flow of e-liquids, reduced noise caused by bubble generation and increased longevity of the aerosol generating device.

[0040] FIG. 2 shows the structure of an evaporator assembly suitable for use in embodiments of the invention. A plurality of channels 102 extends through the heating body 101 between an inlet surface 103 and an outlet surface 104. In this example, the evaporator comprises a resistive heating layer 106 on the outlet surface 104. The resistive heating layer 106 is arranged to preferentially heat the outlet surface 104 of the heating body 101 when in use, thereby providing a positive temperature gradient from the inlet surface 103 to the outlet surface 104.

[0041] FIG. 3 is an exemplary evaporator assembly suitable for use in embodiments of the invention. In this example, a plurality of heating layers 108-113 are arranged sequentially between the inlet surface 103 and outlet surface 104 of the heating body. Like in the examples discussed above, a plurality of channels 102 extend through the heating body 101 in the z direction. The heating body is arranged to heat the heating layers 108-113 to different temperatures to provide a temperature gradient.

[0042] FIG. 4 is an exemplary evaporator assembly of the invention comprising a plurality of heating layers 114 and further comprising layers of insulation 115 between two heating layers 114. The heating layers 114 preferably have different temperatures. The layers of insulation 115 reduce the transfer of thermal and/or electrical energy through the heating body 101. This reduces the heat that transfers from the heating layers 114 positioned closer to the outlet surface 104 that have a higher temperature than the heating layers 114 positioned closer to the inlet surface 103. As a result, the temperature gradient is effectively maintained.

[0043] The layers of insulation 115 also enable a separate current to be applied to each heating layer 114, as electrons will not freely flow through the insulator layers 115 separating each heating layer 114. This set-up enables the evaporator to adopt a variety of different temperature profiles through the thickness of the heating body 101, as some heating layers 115 may be turned on or off as desired. Consequently, the steepness of the temperature gradient may be optimised to vapourise a variety of e-liquids.

[0044] FIG. 5 is an exemplary evaporator assembly suitable for use in embodiments of the invention wherein the heating body 101 comprises an electrically conductive material 120 and circuitry 116 for providing a current through the heating body. The electrically conductive material may be selected from metals, semiconductors, ceramics, conductive polymers and graphene based materials. Preferably, the electrically conductive material is silicon based. The circuitry may comprise a rechargeable battery as its power source. In preferred embodiments, the resistivity of the heating body 101 increases across the thickness of the heating body 101 in the direction from the inlet surface 103 to the outlet surface 104. The increased resistivity causes an increased temperature when a current is passed through the heating body, aiding in the formation of the required temperature gradient of the invention. In some embodiments, this may be achieved by the heating body having a plurality of heating layers, wherein at least two of the plurality of heating layers have a different resistivity. In some embodiments, each heating layer may have a different resistivity. In other examples, a resistivity gradient may be provided across the heating body.

[0045] In preferred embodiments, the heating body comprises a semiconductor or ceramic, wherein the dopant concentration is configured to provide a positive temperature gradient when a current is provided to the heating body. The doped semiconductor or ceramic may be a predominantly negative (n-type) charge carrier, with electrons being the majority carriers. Alternatively, the doped semiconductor or ceramic may be a predominantly positive (p-type) charge carrier, with positive holes being the majority carrier. Preferably, there is increased dopant concentration at the outlet surface, providing increased resistivity of the heating body in the z direction. This results in an increased temperature when a current is passed through the heating body, thereby forming the required temperature gradient.

[0046] As shown in previous examples, the heating body may comprise stacked heating layers arranged sequentially between the inlet surface and the outlet surface, and may optionally comprise one or more layers of insulation between the heating layers. The heating layers may be formed of an electrically conductive material. When the evaporator assembly comprises a circuitry and layers of insulation separating two heating layers comprising electrically conductive materials, each heating layer may be individually connected to the circuitry to enable the flow of electrons to these materials for heat generation.

[0047] FIG. 6 is a cross-sectional view of an exemplary evaporator assembly according to the invention comprising channels 102 having a decreasing diameter in a direction from the inlet surface 103 to the outlet surface 104. This results in the opening to the channels 102 at the inlet surface 103 having a wider diameter 118a than the corresponding opening to the channels 102 at the outlet surface 104, which have a narrower diameter 118b. During use in an aerosol generating device, e-liquid flows through the channels 102 from the wider opening of the channel 118a at the inlet surface 103, vapourises within the channel upon exposure to an increasing temperature across the thickness of the heating body 101, and exits in vapour state through the channel through the narrower opening 118b at the outlet surface 104. As the vapour is forced to pass through a narrower channel opening 118b, a more powerful stream of vapour is released from the evaporator device. This results in stronger flow of vapour through the aerosol generation device when a user inhales from the device.

[0048] FIG. 7 is an evaporator assembly according to the invention further comprising a liquid store 119 in fluid communication with the inlet surface 103 of the heating body 101. The liquid store can hold e-liquid formulations, which may comprise colourants, flavourings, tobacco and other chemical components in the liquid. When in use, the liquid is drawn from the liquid store 119 through channels 102 of the heating body 101. The evaporator assembly may comprise a wick positioned between the liquid store 119 and the inlet surface 103 of the heating body 101. The wick may be formed of a material capable of continually absorbing liquid from the liquid store towards the inlet surface 103. Such materials may be porous. The wick therefore aids in maintaining the fluid communication of the liquid in the liquid store 119 with the inlet surface 103 of the heating body 101.

[0049] FIG. 8 shows schematically an aerosol generating device 120 comprising the evaporator 100 of the invention with a positive temperature gradient through the thickness of the heating body 101 from the inlet surface 103 to the outlet surface 104. An airflow channel 121 extends through the aerosol generating device 120, and the evaporator assembly 100 described above is arranged such that the outlet surface 104 is exposed to the interior of the airflow channel 121. The evaporator assembly 100 receives a vapourisable liquid from a liquid store 119. Air can be drawn into the airflow channel 121 through an inlet 122 and travel through the airflow channel along the direction indicated by the arrow 123. As the air passes the outlet surface 104 of the evaporator assembly, droplets of the vapourisable liquid are drawn away from the outlet surface 104 by the airflow. This produces a vapour of the vapourisable liquid. The vapour continues to travel along the airflow channel 121 and exits the vapour generation device via an outlet 124. The outlet may be provided with a mouthpiece, allowing the airflow to be generated by a user drawing on the device 120 at the mouthpiece.

[0050] In this example, the evaporator 100 is in communication with an electronic controller 125. Indeed, the electronic controller 125 could incorporate one or more control circuits that may be connected so as to provide a controlled current to provide the resistive heating of the heating body. If the evaporator comprises multiple heating layers, separate control circuits may be connected to each heating layer. The electronic controller 125 can also be configured to control other components of the aerosol generating device 120. The aerosol generating device 120 also has a power source, for example a rechargeable battery 126. The power source is configured to supply power to the components of the evaporator assembly 101 and the electronic controller 125, and can also power other components of the vapour generation device 120, for example valves and reheaters in the airflow channel or lights for displaying information about the operation of the device 120. In preferred embodiments, the temperature gradient is configured such that a liquid passing through the channels evaporates closer to the outlet surface than the inlet surface. When in use in an aerosol generating device, the e-liquid will enter the channel openings at the inlet surface and travel over half way through the thickness of the heating body through the channels as a liquid before it reaches the temperature required for evaporation. Following evaporation, it will exit the evaporator through the outlet as a vapour. This feature minimises bubble generation throughout the channels, as any bubble generation occurs only close to the outlet of the channels and not closer to the inlet of the channels. In turn, this provides improved flow of e-liquids, reduced noise caused by bubble generation and increased longevity of the aerosol generating device due to minimised clogging.

[0051] E-liquids typically used in aerosol generating devices undergo a significant drop in viscosity upon heating. For example, an increase in temperature from 20° C. to 40° C. can cause a drop in viscosity of more than 50%. This aids in improved uptake of liquid through the channels by capillary action. Therefore, in preferred embodiments of the invention, the evaporator (i.e. the heating body and circuitry) is configured to provide a temperature at the inlet surface of 40° C. or more, preferably 45° C. or more, preferably 50° C. or more.

[0052] The evaporator is preferably configured to provide a temperature at the outlet surface. In order to undergo vapourisation, e-liquids typically require a temperature of 200-350° C. Therefore, preferably the e-liquid is exposed to a temperature between 240° C. and 300° C. at the outlet surface of the heating body, most preferably between 250° C. and 270° C. The temperature at the outlet surface must exceed that at the inlet surface in order for the required temperature gradient to be established.

[0053] The channels of the heating body preferably have a diameter between 5 μm and 200 μm, preferably between 10 μm and 190 μm, preferably between 50 μm and 150 μm, preferably between 70 μm and 130 μm. Diameters of this width have a sufficiently small cross-sectional area in the x-y plane that when it receives a vapourisable liquid when in use, the vapourisable liquid can travel along the channels from the inlet surface to the outlet surface by capillary action. The ability of the channels to transport liquid through capillary action may depend on both the viscosity of the liquid and the dimensions of the channels. The channels of the evaporator may each have the same diameter, or they may have different diameters to accommodate a wider range of e-liquid viscosities.

[0054] As outlined above, the diameter of the channels may decrease in the direction from the inlet surface to the outlet surface. In embodiments, the diameter of each of the channels decreases at the same degree across the thickness of the heating body. In alternative embodiments, the diameter of the channels may decrease at different degrees across the thickness of the heating body.

[0055] It is understood that a variety of arrangements of channels may be utilised. For example, the channels may be spaced in a regular array. This helps achieve a uniform rate of liquid transport through the channels. The array could be defined by a cellular structure, for example, in a honeycomb, grid or triangular structure. In some embodiments the channels may be arranged in parallel or off-set rows. The openings of the channels on the inlet surface and the outlet surface may adopt a variety of shapes, for example, circular, square, rectangular or hexagonal. Consequently, the cross-sectional shape of the channels in the x-y plane throughout the heating body may also adopt a variety of shapes.

[0056] The surface tension of the liquid allows the liquid to rise, or flow, through each channel via capillary action. Vapourisation of the liquid within the channel occurs when the liquid has travelled sufficiently far along the length of the channel and reaches the temperature required for vaporise.

[0057] The height that the liquid will rise to within a channel under capillary action is given by the following relationship:

[00001]$\begin{array}{cc}h=\frac{2\gamma \cos \theta }{\rho gr},& \mathrm{Eq}.1\end{array}$

[0058] where γ is the liquid-air surface tension (force/unit length), θ is the contact angle, ρ is the density of the liquid (mass/volume), g is the local acceleration due to gravity (length/square of time), and r is the radius of the channel. Thus, the thinner the channel in which the liquid can travel, the further up the channel it travels.

[0059] Different vapor-generating liquids typically have different surface tensions, contact angles, and density values and so, in accordance with Eq. 1 above, will rise to different heights within a given channel. Selective passage of liquids through the channels can therefore be achieved by making the channel height greater or less than an effective height for vaporization, for a given radius of channel. This selection effect can also be achieved by adjusting the radius of the channel for a given height. Thus, in the case of the present disclosure, variations in channel size provide the selective passage of liquids through the heating body.

[0060] Thus, having a heating body comprising a plurality of channels of different diameters means that a particular channel diameter can be used to selectively pass a liquid of specific properties through the channels. This can be achieved by optimally sizing each channel for use with a particular liquid type. The evaporator unit can therefore be thought of as a universal evaporator unit.

[0061] Advantageously, the different channel sizes allow a greater range of liquids to be vaporised by the same evaporator. This results in a more efficient evaporator because it is able to function with a greater range of liquids that can be stored in in the device. That is to say, one evaporator unit can be used with multiple different liquids. The channels having different channel diameters distributed across a single heating body therefore increases the versatility of the evaporator.

[0062] A further advantage of the evaporator unit is that the presence of the larger diameter channels also has the effect of reduced resistance-to-flow of the liquid, which allows for a sufficient amount of liquid supply (mainly through the larger channels) even when the heating body temperature is still low and the liquid viscosity remains high (i.e. at an initial stage of heater operation). It is understood that a higher viscosity liquid receives a greater friction force as it travels through the through-channels. This means that movement of the high viscosity liquid tends to be slow until it is heated up and its viscosity is reduced, resulting in limited amounts of liquid supply for vapourization at an initial stage of heater operation. However the combination of the large and small through-channels contributes to suitable amounts of liquid supply especially for the high viscosity liquid, throughout the heater unit operation period i.e. both at initial and later stages.

[0063] The inventors have found that alteration in both the temperature profile and the channel diameter across the thickness of the heating body allows the flow of the e-liquid to be better controlled, and liquids of different viscosities can be used in the same evaporator device as their viscosities are effectively normalised as they pass through the channels from the inlet surface to the outlet surface across a positive temperature gradient. As a result, consumers have greater versatility with a single device, as it provides compatibility with greater range of e-liquid products of different viscosities.