E-vaping system, a method of manufacturing a cartridge for use in e-vaping system, and a method of manufacturing an e-vaping system

Abstract

The e-vaping system includes a storage portion with a housing holding a pre-vapor formulation and a capillary medium, the housing defining a first opening. The e-vaping system further includes a heater assembly that is fluid permeable, the heater assembly including electrically conductive filaments arranged to define an air impingement surface, the electrically conductive filaments forming a mesh, the heater assembly extending across the first opening of the housing. The capillary medium is in contact with the heater assembly, where the capillary medium is configured to draw the pre-vapor formulation to the electrically conductive filaments. The capillary medium defines a second opening allowing an airflow to pass through the capillary medium.

Claims

1. An e-vaping system, comprising: a storage portion including a first housing holding a pre-vapor formulation and a capillary medium, the first housing defining a first opening; and a heater assembly that is fluid permeable, the heater assembly including electrically conductive filaments arranged to define an air impingement surface, the electrically conductive filaments forming a mesh, the air impingement surface being one of a funnel shape or a concave surface, the heater assembly extending across the first opening of the first housing, the capillary medium being in contact with the heater assembly, an epicenter of the air impingement surface extending into the capillary medium, the capillary medium being configured to draw the pre-vapor formulation to the electrically conductive filaments, the capillary medium defining a second opening allowing an airflow to pass through the capillary medium.

2. The e-vaping system of claim 1, wherein the air impingement surface is substantially non-planar.

3. The e-vaping system of claim 1, wherein the electrically conductive filaments define a third opening allowing the airflow to pass through the epicenter of the air impingement surface.

4. The e-vaping system of claim 3, wherein the second opening and the third opening are aligned with each other.

5. The e-vaping system of claim 1, wherein the air impingement surface is curved along one or more dimensions.

6. The e-vaping system of claim 1, wherein the air impingement surface is the concave shape, the concave shape being concave relative to a direction of the airflow as the airflow approaches the air impingement surface.

7. The e-vaping system of claim 1, wherein the air impingement surface is the funnel shape.

8. The e-vaping system of claim 1, wherein each filament, of the electrically conductive filaments, has a diameter or a thickness of 10 micrometers to 100 micrometers.

9. The e-vaping system of claim 1, wherein the capillary medium is cylindrically shaped, and the second opening runs longitudinally through a center-line of the capillary medium.

10. The e-vaping system of claim 1, wherein the e-vaping system is configured so that vapor is generated at the heater assembly, and the vapor is transported by the airflow through the second opening in the capillary medium.

11. The e-vaping system of claim 1, wherein the air impingement surface is curved or sloped to cause an enhanced mixing of the airflow with vapor that is generated by the heater assembly.

12. The e-vaping system of claim 3, wherein the heater assembly further includes, a first electrically conductive contact located at an interior of the electrically conductive filaments, the first electrically conductive contact being near the third opening, and a second electrically conductive contact located near an exterior of the electrically conductive filaments.

13. The e-vaping system of claim 12, wherein the first electrically conductive contact is positioned to extend through the third opening.

14. The e-vaping system of claim 1, wherein the e-vaping system includes, a main unit, the main unit including a power supply, and a cartridge that is removably coupled to the main unit, the storage portion and the heater assembly being in the cartridge.

15. The e-vaping system of claim 1, wherein the mesh is formed by at least one of weaving the electrically conductive filaments or combining the electrically conductive filaments into a lattice structure.

16. A method of manufacturing a cartridge for use in an e-vaping system, comprising: providing a housing with a storage portion, the housing defining a first opening; inserting a capillary medium in the storage portion; filling the storage portion with a pre-vapor formulation; forming a heater assembly that is fluid permeable, the heater assembly including electrically conductive filaments arranged to define an air impingement surface, the electrically conductive filaments forming a mesh, the air impingement surface being one of a funnel shape or a concave surface, the heater assembly extending across the first opening of the housing; and installing the heater assembly in the housing so that the heater assembly is in contact with the capillary medium, an epicenter of the air impingement surface extending into the capillary medium, the capillary medium being configured to draw the pre-vapor formulation to the electrically conductive filaments, the capillary medium defining a second opening allowing an airflow to pass through the capillary medium.

17. The method of claim 16, wherein the forming of the heater assembly includes, forming the air impingement surface to be in the funnel shape of the concave surface.

18. The method of claim 16, wherein the forming of the heater assembly includes, arranging the electrically conductive filaments in a flattened arrangement, and deforming the flattened arrangement to define the air impingement surface.

19. The method of claim 16, wherein the forming of the heater assembly includes, defining a third opening in the electrically conductive filaments, the third opening allowing the airflow to pass through the epicenter of the air impingement surface.

20. The method of claim 19, wherein the forming of the third opening includes aligning the third opening with the second opening.

21. The method of claim 16, wherein the forming of the heater assembly includes, forming the air impingement surface to be curved along one or more dimensions.

22. The method of claim 16, wherein the forming of the heater assembly includes, forming the air impingement surface to be the concave surface, the concave surface being concave relative to a direction of the airflow as the airflow approaches the air impingement surface.

23. The method of claim 16, wherein the forming of the heater assembly includes, forming the air impingement surface to be the funnel shape.

24. The method of claim 16, wherein the forming of the heater assembly includes, providing each filament, of the electrically conductive filaments, with a diameter or a thickness of 10 micrometers to 100 micrometers.

25. The method of claim 16, wherein the inserting of the capillary medium into the storage portion includes, forming the capillary medium into a cylindrical shape, the second opening running longitudinally through a center-line of the capillary medium.

26. The method of claim 16, further comprising: configuring the cartridge so that vapor is generated at the heater assembly, and the vapor is transported by the airflow through the second opening in the capillary medium.

27. The method of claim 16, wherein the forming of the heater assembly includes, forming the air impingement surface to be curved or sloped to cause an enhanced mixing of the airflow with vapor that is generated by the heater assembly.

28. The method of claim 19, wherein the forming of the heater assembly further includes, positioning a first electrically conductive contact at an interior of the electrically conductive filaments, the first electrically conductive contact being near the third opening, and positioning a second electrically conductive contact near an exterior of the electrically conductive filaments.

29. The method of claim 28, wherein the forming of the heater assembly further includes, positioning the first electrically conductive contact to extend through the third opening.

30. The method of claim 16, further comprising: affixing the heater assembly to the housing by at least one of heat sealing, gluing or welding.

31. The method of claim 16, wherein the forming of the heater assembly includes at least one of, weaving the electrically conductive filaments into the mesh, or combining the electrically conductive filaments into a lattice structure to form the mesh.

32. A method of manufacturing an e-vaping system, comprising: providing a main unit, the main unit including a power supply; and forming a cartridge by, providing a housing with a storage portion, the housing defining a first opening, inserting a capillary medium in the storage portion, filling the storage portion with a pre-vapor formulation, forming a heater assembly that is fluid permeable, the heater assembly including electrically conductive filaments arranged to define an air impingement surface, the electrically conductive filaments forming a mesh, the air impingement surface being one of a funnel shape or a concave surface, the heater assembly extending across the first opening of the housing, and installing the heater assembly in the housing so that the heater assembly is in contact with the capillary medium, an epicenter of the air impingement surface extending into the capillary medium, the capillary medium being configured to draw the pre-vapor formulation to the electrically conductive filaments, the capillary medium defining a second opening allowing an airflow to pass through the capillary medium; and configuring the cartridge to be removably coupled to the main unit.

33. The e-vaping system of claim 1, further comprising: a main unit with a second housing and a mouthpiece, the mouthpiece being on an end of the second housing, the mouthpiece defining an outlet, wherein the main unit defines a cavity configured to accept and contain a cartridge, the cartridge including the storage portion and the heater assembly, the air impingement surface facing the outlet once the cartridge is contained in the cavity and the main unit is in operational use.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;

(3) FIG. 2A is a perspective topside view of a heater assembly comprising a filament arrangement of curved shape with a central opening;

(4) FIG. 2B is a perspective topside view of a heater assembly comprising a filament arrangement of funnel shape with a central opening;

(5) FIG. 3 is a perspective topside view of a capillary medium comprising a first capillary medium and a second capillary medium with both having a central opening;

(6) FIG. 4A is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;

(7) FIG. 4B is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;

(8) FIG. 4C is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment; and

(9) FIG. 5 is a schematic illustration of a system, incorporating a cartridge comprising a heater assembly and a capillary medium, in accordance with an embodiment.

DETAILED DESCRIPTION

(10) Various example embodiments will now be described more fully with reference to the accompanying drawings in which some example embodiments are shown. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Thus, the embodiments may be embodied in many alternate forms and should not be construed as limited to only example embodiments set forth herein. Therefore, it should be understood that there is no intent to limit example embodiments to the particular forms disclosed, but on the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope.

(11) In the drawings, the thicknesses of layers and regions may be exaggerated for clarity, and like numbers refer to like elements throughout the description of the figures.

(12) Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

(13) It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).

(14) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” if used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.

(15) Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.

(16) Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may have rounded or curved features and/or a gradient (e.g., of implant concentration) at its edges rather than an abrupt change from an implanted region to a non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation may take place. Thus, the regions illustrated in the figures are schematic in nature and their shapes do not necessarily illustrate the actual shape of a region of a device and do not limit the scope.

(17) It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

(18) Although corresponding plan views and/or perspective views of some cross-sectional view(s) may not be shown, the cross-sectional view(s) of device structures illustrated herein provide support for a plurality of device structures that extend along two different directions as would be illustrated in a plan view, and/or in three different directions as would be illustrated in a perspective view. The two different directions may or may not be orthogonal to each other. The three different directions may include a third direction that may be orthogonal to the two different directions. The plurality of device structures may be integrated in a same electronic device. For example, when a device structure (e.g., a memory cell structure or a transistor structure) is illustrated in a cross-sectional view, an electronic device may include a plurality of the device structures (e.g., memory cell structures or transistor structures), as would be illustrated by a plan view of the electronic device. The plurality of device structures may be arranged in an array and/or in a two-dimensional pattern.

(19) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

(20) In order to more specifically describe example embodiments, various features will be described in detail with reference to the attached drawings. However, example embodiments described are not limited thereto.

(21) FIG. 1 shows a filament arrangement 30 according to one of the embodiments of the present disclosure. The filament arrangement 30 has a filament opening 32. A capillary medium 22 is in contact with the filament arrangement 30. The capillary medium has a capillary medium opening 28 that acts as an air duct through the capillary medium 22. Ambient air is guided in airflow 40 to the air impingement surface of the filament arrangement 30. The suction of the air duct through the capillary medium 22 causes an acceleration of the airflow so that the volatized vapors are drawn in an airflow 42 through the air duct.

(22) FIGS. 2A and 2B illustrate various shapes of filament arrangements 30, each having a filament opening 32 in a center portion of the filament arrangement 30.

(23) FIG. 2A shows a non-planar filament arrangement 30 that is curved along one dimension. The curved shape causes a whirling of the airflow 40 on the air impingement surface. This effect is further increased by the optional filament opening 32.

(24) FIG. 2B shows a non-planar filament arrangement 30 having a funnel shape with an optional filament opening 32 at the bottom of the funnel shaped filament arrangement 30. The funnel shape causes a whirling of the airflow 40 on the air impingement surface. This effect is further increased by the optional filament opening 32.

(25) FIG. 3 shows a capillary medium 22 to be used in an aerosol-generating system (electronic-vaping system, or e-vaping system). There are two separate capillary mediums 44, 46 in use. A larger body of a second capillary medium 46 is provided on an opposite side of the first capillary medium 44 that is in contact with the filament arrangement 30 of the heater assembly. Both the first capillary medium 44 and the second capillary medium 46 retain liquid aerosol-forming substrate (pre-vapor formulation). The first capillary medium 44, which contacts the filament arrangement, has a higher thermal decomposition temperature (at least 160 degrees Celsius or higher such as approximately 250 degrees Celsius) than the second capillary medium 46. The first capillary medium 44 effectively acts as a spacer separating the filament arrangement 30 from the second capillary medium 46 so that the second capillary medium is not exposed to temperatures above its thermal decomposition temperature. The first capillary medium 44 is flexible and may accommodate the non-planar shape of the heater assembly, such that the contact surface between the capillary medium and the heater assembly is increased or maximized.

(26) The thermal gradient across the first capillary medium is such that the second capillary medium is exposed to temperatures below its thermal decomposition temperature. The second capillary medium 46 may be chosen to have superior wicking performance to the first capillary medium 44, may retain more liquid per unit volume than the first capillary medium and may be less expensive than the first capillary medium. The capillary medium 22 comprises a capillary medium opening 28 acting as an air duct through the capillary medium 22.

(27) FIGS. 4A to 4C illustrate the combination of a filament arrangement 30 with two separate capillary mediums 44, 46 that guide the airflow 42 through an air duct defined by the capillary medium opening 28 after being mixed with volatized vapors on the surface of the filament arrangement 30. Alternatively, the airflow may be guided in the reverse direction, e.g., the ambient air may be guided as airflow 40 through the air duct to the surface of the filament arrangement 30.

(28) FIG. 4A shows a non-planar filament arrangement 30 of a funnel shape with a filament opening 32 at the bottom end of the filament arrangement 30, the filament opening 32 extending the capillary medium opening 28. The funnel shape creates turbulences and vortexes that encourage the mixing of the volatized vapors with the ambient air.

(29) FIG. 4B shows a non-planar filament arrangement 30 of a curved shape. The curved shape creates turbulences and vortexes that enhance mixing of the volatized vapors with the ambient air. The filament arrangement 30 of FIG. 4C largely corresponds to the filament arrangement 30 depicted in FIG. 2A, with the exception that the filament arrangement 30 of FIG. 4B does not exhibit a dedicated filament opening 32. Due to the interstices in the filament arrangement 30, the filament arrangement 30 is fluid and air permeable even without a dedicated filament opening 32. Therefore, the effect of suction or draw through the air duct of the capillary mediums 44, 46 is also given in the case where the capillary opening 28 is not extended by a filament opening 32.

(30) FIG. 4C corresponds to FIG. 4B with a filament arrangement 30 of a funnel shape without a dedicated filament opening 32. The funnel shape of the filament arrangement 30 accounts for whirling the air that arrives at the air impingement surface of the filament arrangement 30, thereby creating turbulences and vortexes that encourage the mixing of the volatized vapors with the ambient air. Due to the interstices in the filament arrangement 30, the filament arrangement 30 is fluid and air permeable even without a dedicated filament opening 32.

(31) In the embodiments depicted in FIGS. 4A and 4C, the lower portion of the filament arrangement 30 is in direct contact with the second capillary medium 46. Of course the size of capillary medium 44 can also be increased, such that it covers the complete filament arrangement 30, and such that direct contact between the filament arrangement 30 and the second capillary medium 46 is prevented.

(32) FIG. 5 is a schematic illustration of an aerosol-generating system, including a cartridge 20 with a heater assembly comprising a filament arrangement 30 according to one of the embodiments of the present disclosure and with a capillary medium 22 according to one of the embodiments of the present disclosure.

(33) The aerosol-generating system comprises an aerosol-generating device 10 and a separate cartridge 20. In this example, the aerosol-generating system is an electrically operated vaping system.

(34) The cartridge 20 contains an aerosol-forming substrate and is configured to be received in a cavity 18 within the device. Cartridge 20 should be replaceable by an adult vaper when the aerosol-forming substrate provided in the cartridge 20 is depleted. FIG. 5 shows the cartridge 20 just prior to insertion into the device, with the arrow 1 in FIG. 5 indicating the direction of insertion of the cartridge 20. The heater assembly with the filament arrangement 30 and the capillary medium 22 is located in the cartridge 20 behind a cover 26. The aerosol-generating device 10 is portable and has a size comparable to a conventional cigar or cigarette. The device 10 comprises a main body 11 and a mouthpiece portion 12. The main body 11 contains a power supply 14, for example a battery such as a lithium iron phosphate battery, control electronics 16 and a cavity 18. The mouthpiece portion 12 is connected to the main body 11 by a hinged connection 21 and can move between an open position as shown in FIG. 5 and a closed position. The mouthpiece portion 12 is placed in the open position to allow for insertion and removal of cartridges 20 and is placed in the closed position when the system is to be used to generate aerosol. The mouthpiece portion comprises a plurality of air inlets 13 and an outlet 15. In use, an adult vaper draws or puffs on the outlet to draw air from the air inlets 13, through the mouthpiece portion and the cartridge 20 to the outlet 15. Internal baffles 17 are provided to force the air flowing through the mouthpiece portion 12 past the cartridge.

(35) The cavity 18 has a circular cross-section and is sized to receive a housing 24 of the cartridge 20. Electrical connectors 19 are provided at the sides of the cavity 18 to provide an electrical connection between the control electronics 16 and battery 14 and corresponding electrical contacts 34/36 on the cartridge 20.

(36) Other cartridge designs incorporating a heater assembly with a filament arrangement 30 in accordance with this disclosure and a capillary medium 22 in accordance with this disclosure can now be conceived by one of ordinary skill in the art. For example, the cartridge 20 may include a mouthpiece portion 12, may include more than one heater assembly and may have any desired shape.

(37) Furthermore, a heater assembly in accordance with the disclosure may be used in systems of other types to those already described, such as humidifiers, air fresheners, and other aerosol-generating systems.

(38) The exemplary embodiments described above illustrate but are not limiting. In view of the above discussed exemplary embodiments, other embodiments consistent with the above exemplary embodiments will now be apparent to one of ordinary skill in the art.