AEROSOL-GENERATING SYSTEM WITH LEAKAGE PREVENTION

Abstract

An aerosol-generating system is provided, including: a first air inlet and an air outlet; a liquid storage portion holding a liquid aerosol-forming substrate and having a liquid outlet and a storage portion air inlet; an airflow passage from the first air inlet to the air outlet past the liquid outlet; a wick in the airflow passage at a distance from the liquid outlet and to receive liquid from the liquid storage portion in response to a pressure drop in the airflow passage at the liquid outlet; and a first heating element to heat the liquid in the wick, and the airflow passage extending from the first air inlet to the air outlet past the storage portion air inlet and past the liquid outlet such that air enters the liquid storage portion via the storage portion air inlet and then travels therethrough and exits at the liquid outlet.

Claims

1.-14. (canceled)

15. An aerosol-generating system, comprising: a first air inlet and an air outlet; a liquid storage portion holding a liquid aerosol-forming substrate, the liquid storage portion having a liquid outlet; an airflow passage from the first air inlet to the air outlet past the liquid outlet; a wick in the airflow passage arranged to receive liquid from the liquid storage portion in response to a pressure drop in the airflow passage at the liquid outlet; and a first heating element positioned to heat the liquid in the wick, wherein the wick is arranged at a distance from the liquid outlet, wherein the liquid storage portion further comprises a storage portion air inlet, and wherein the airflow passage extends from the first air inlet to the air outlet past the storage portion air inlet and past the liquid outlet such that air enters the liquid storage portion via the storage portion air inlet and then travels through the liquid storage portion and exits the liquid storage portion at the liquid outlet.

16. The aerosol-generating system according to claim 15, wherein the liquid outlet of the liquid storage portion opens in response to a pressure drop in the airflow passage.

17. The aerosol-generating system according to claim 15, further being configured to removably receive the liquid storage portion.

18. The aerosol-generating system according to claim 15, further comprising a cavity configured to receive an aerosol-generating article comprising a solid aerosol-forming substrate.

19. The aerosol-generating system according to claim 18, further comprising a second heating element arranged in the cavity for heating the solid aerosol-forming substrate.

20. The aerosol-generating system according to claim 18, further comprising a mouth-end portion and a main body, wherein the cavity is provided in the mouth-end portion, and wherein the liquid storage portion is arranged between the mouth-end portion and the main body.

21. The aerosol-generating system according to claim 20, further comprising a second heating element arranged in the cavity for heating the solid aerosol-forming substrate, wherein the main body comprises a power supply configured to power both the first heating element and the second heating element.

22. The aerosol-generating system according to claim 20, wherein the first heating element is provided in the mouth-end portion.

23. The aerosol-generating system according to claim 20, wherein the first air inlet is provided in the mouth-end portion.

24. The aerosol-generating system according to claim 15, further comprising a second air inlet that is fluidly connected to the storage portion air inlet.

25. The aerosol-generating system according to claim 24, further comprising a mouth-end portion and a main body, wherein the cavity is provided in the mouth-end portion, wherein the liquid storage portion is arranged between the mouth-end portion and the main body, and wherein the second air inlet is arranged in the main body.

26. The aerosol-generating system according to claim 15, wherein the first heating element comprises a susceptor material, which heats in response to an alternating magnetic field generated by an inductor arranged in the aerosol-generating system.

27. The aerosol-generating system according to claim 19, wherein the second heating element comprises a susceptor material, which heats in response to an alternating magnetic field generated by an inductor arranged in the aerosol-generating system.

28. The aerosol-generating system according to claim 26, wherein the inductor is a helical coil that surrounds both the first heating element and the second heating element.

29. The aerosol-generating system according to claim 27, wherein the inductor is a helical coil that surrounds both the first heating element and the second heating element.

Description

[0117] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0118] FIG. 1 schematically illustrates an aerosol-generating system according to an embodiment of the invention;

[0119] FIG. 2 shows a cross-sectional view of mouth-end portion with proximal part of liquid storage portion of an embodiment of an aerosol-generating system of the invention;

[0120] FIG. 3 shows a cross-sectional view of mouth-end portion with proximal part of liquid storage portion of an embodiment of an aerosol-generating system of the invention;

[0121] FIG. 4 shows an embodiment of an aerosol-generating system of the invention;

[0122] FIG. 5 shows a liquid storage portion of an embodiment of an aerosol-generating system of the invention;

[0123] FIG. 6 shows an embodiment of an aerosol-generating system of the invention.

[0124] FIG. 1 schematically shows an embodiment of an aerosol-generating system 10 of the invention. The system 10 comprises a mouth-end portion 20, a liquid storage portion 40, and a main body 50. The mouth-end portion 20 comprises a first air inlet 22 and an air outlet 24.

[0125] The liquid storage portion 40 holds a liquid aerosol-forming substrate. The liquid storage portion comprises a liquid outlet 42. An airflow passage extends from the first air inlet 22 to the air outlet 24 past the liquid outlet 42. The liquid storage portion 40 is fluidly connected with the airflow passage. The liquid outlet 42 of the liquid storage portion 40 opens in response to a pressure drop in the airflow passage, which is caused by a user puffing on the mouth-end portion at the air outlet 24. The liquid outlet 42 comprises a one-way valve to open in a direction from the liquid storage portion 40 towards the air outlet 24. The liquid storage portion 40 further comprises a storage portion air inlet 44.

[0126] The mouth-end portion 20 further comprises a wick 26 in the airflow passage arranged to receive liquid from the liquid storage portion 40 in response to a pressure drop in the airflow passage at the liquid outlet 42. The illustrated mouth-end portion 20 also comprises a first heating element 28 positioned to heat the liquid in the wick 26. The wick 26 is arranged at a distance d from the liquid outlet 42. In the embodiment of FIG. 1, the distance d between the wick 26 and the liquid outlet 42 is measured between a distal end of the wick 26 and a proximal end of the liquid outlet 42.

[0127] In the embodiment shown in FIG. 1, the first heating element is schematically illustrated as a coil which is wound around the wick 26. However, the first heating element may as well be of a different shape. The heating element 28 may be a resistively heated coil on a wick, but it may also be an inductively heated susceptor element, which heats up when penetrated by an alternating magnetic field that may be generated by an inductor coil (not illustrated).

[0128] The main body 50 comprises a second air inlet 52 that is fluidly connected to the storage portion air inlet 44 via a storage portion airflow passage 54. Thereby, an additional airflow through the liquid storage portion may be provided. Extraction of liquid from the liquid storage portion 40 via the liquid outlet 42 may be advantageously promoted.

[0129] The storage portion air inlet 44 opens in response to a pressure drop in the airflow passage extending from the first air inlet 22 to the air outlet 24 past the liquid outlet 42, thereby allowing air to flow from the second air inlet 52, through the storage portion airflow passage 54 and into the liquid storage portion 40, when a user puffs on the mouth-end portion 20 and therefore extracts liquid from the liquid storage portion 40 that is caught by the wick 26 due to the puffing action of the user. The storage portion air inlet 44 comprises a one-way valve to open in a direction from the second air inlet 52 towards the liquid storage portion 40.

[0130] FIG. 2 shows a cross-sectional view of mouth-end portion 20 and a proximal part of liquid storage portion 40 of an embodiment of an aerosol-generating system 10 of the invention. In the embodiment of FIG. 2, the first heating element 28 is provided in the mouth-end portion 20. The first heating element 28 comprises a susceptor material, which heats in response to an alternating magnetic field generated by an inductor 30 arranged in the aerosol-generating system 10. The inductor 30 is in the illustrated embodiment a helical coil that surrounds the first heating element 28. Also shown is a thermal insulator 32 positioned between the helical coil of the inductor 30 and the first heating element 28. The first heating element 28 further surrounds a wick 26. The wick 26 is arranged within the first heating element 28, and is in thermal contact with the first heating element 28. The first heating element 28 is thus positioned to heat the liquid in the wick 26. The illustrated heating element 28 may also be comprised of an assembly of longitudinal susceptor elements extending along the wick 26, where there is provided an air-gap between neighbouring susceptor elements.

[0131] Also shown in FIG. 2 is a proximal part of the liquid storage portion 40 being attached to the mouth-end portion 20. In the embodiment shown, the liquid storage portion 40 comprises a one-way valve at the liquid outlet 42. The wick 26 is arranged at a distance d from the liquid outlet 42. In the embodiment of FIG. 2, the distance d between the wick 26 and the liquid outlet 42 is measured between a distal end of the wick 26 and a proximal end of the liquid outlet 42. An airflow passage extends from the first air inlet 22 to the air outlet 24 past the liquid outlet 42. In response to a pressure drop in the airflow passage due to a user puffing on the mouth-end portion 20 at the air outlet 24 or on a mouthpiece (not shown), an airflow along the airflow passage from the air inlet 22 to through the air outlet 24 will result. Further, the liquid outlet 42 of the liquid storage portion 40 opens in response to the pressure drop in the airflow passage. Accordingly, the airflow in the airflow passage picks up droplets of liquid exiting the liquid outlet 42. The droplets are then transported from the liquid outlet 42 to the wick 26 via the airflow in the airflow passage. When the liquid is soaked in the wick 26, it is heated and volatilized. This volatilized liquid forms a super-saturated vapour-air mix that is allowed to cool down on its way towards the air outlet 24. During this cooling down of the vapour-air mix, aerosol is formed that is inhaled by a user performing the puffing.

[0132] FIG. 3 shows a cross-sectional view of mouth-end portion 20 and a proximal part of liquid storage portion 40 of an embodiment of an aerosol-generating system 10 of the invention. In difference to the embodiment of FIG. 2, the embodiment of FIG. 3 comprises a second heating element 34. The second heating element 34 comprises a susceptor material, which heats in response to an alternating magnetic field generated by inductor 30.

[0133] The aerosol-generating system further comprises a cavity 36 for receiving an aerosol-generating article comprising a solid aerosol-forming substrate (not shown in FIG. 3). The cavity 36 is provided in the mouth-end portion 20. The first heating element 28 is arranged within the cavity 36. The wick 26 is arranged within the first heating element 28. The first heating element 28 is arranged to heat the liquid in the wick 26. Alternatively or in addition, the first heating element 28 may heat an inside portion of a hollow cylindrical tube of an aerosol-generating article when the article is inserted into the cavity 36. The outer walls of the cavity 36 are formed by the susceptor material of the second heating element 34. The second heating element 34 is thus arranged surrounding the cavity 36. The first heating element 28 comprises a central susceptor arrangement arranged centrally within the cavity 36. The second heating element 34 comprises a peripheral susceptor arrangement arranged distanced from and around the central susceptor arrangement.

[0134] An aerosol-generating article to be inserted into the cavity may comprise a hollow cylindrical tube comprising a solid aerosol-forming substrate at its distal end thereof and a mouthpiece including a mouthpiece filter at its proximal end thereof. The distal end of the aerosol-generating article may be inserted into the cavity 36 such that the hollow cylindrical tube is arranged between the susceptor material of the first heating element 28 and the susceptor material of the second heating element 34. The aerosol-generating article can thus be coaxially sandwiched between the central susceptor arrangement and the peripheral susceptor arrangement. The aerosol-generating article may be heated by the second heating element 34. The aerosol-generating article may be additionally heated by the first heating element 28.

[0135] An optional bypass aperture 38 is provided in the airflow passage. The bypass aperture 38 is fluidly connected with the air outlet 24 via apertures in the susceptor material of the second heating element 34. For example, the second heating element 34 may comprise a plurality of separate heating blades arranged in a cylindrical configuration and the space between neighbouring heating blades may define the apertures. The heating blades may comprise a susceptor material. A bypass airflow passage extends from the bypass aperture 38 through the apertures in the susceptor material of the second heating element 34 into the aerosol-generating article and further to the air outlet 24. Airflow routes along the airflow passage and the bypass airflow passage are exemplified by means of meandering arrows in FIG. 6.

[0136] FIG. 4 shows an aerosol-generating system 10 according to an embodiment of the invention. The left-hand side of FIG. 4 shows the aerosol-generating system 10 in an assembled state. An aerosol-generating article 14 is inserted into the cavity 36. The middle of FIG. 4 shows the aerosol-generating system 10 in an exploded view, wherein mouth-end 20, liquid storage portion 40, and main body 50 are not attached to each other. The aerosol-generating system 10 is configured to removably receive the liquid storage portion 40. The proximal end of the main body 50 comprises a main body connector 56 for removably attaching the main body 50 to a storage portion main connector (not shown) of the liquid storage portion 40. The distal end of the mouth-end portion 20 comprises a corresponding connector (not shown) for removably attaching mouth-end portion 20 to a storage portion mouth-end connector 46 of the liquid storage portion 40. The right-hand side of FIG. 4 shows an optional mouthpiece 12 which may be attached onto the open end of the cavity 36 when no aerosol-generating article 14 is inserted into the cavity 36.

[0137] The aerosol-generating system 10 may enable three different modes of operation.

[0138] According to a first mode of operation shown at the left-hand side of FIG. 4, the liquid storage portion 40 is received in the system 10 and, additionally, an aerosol-generating article 14 is received in the cavity 36. Therefore, an inhalable aerosol may contain substances which are derived from the liquid storage portion 40 and, additionally, substances derived from the aerosol-forming substrate comprised in the aerosol-generating article 14.

[0139] According to a second mode of operation, the liquid storage portion 40 is not received in the system 10 and the distal end of mouth-end portion 20 is directly removably attached to the proximal end of main body 50. Further, an aerosol-generating article 14 is received in the cavity 36. Therefore, an inhalable aerosol may contain substances derived from the aerosol-forming substrate comprised in the aerosol-generating article 14, only.

[0140] According to a third mode of operation, the liquid storage portion 40 is received in the system 10, but no aerosol-generating article 14 is received in the cavity 36. Optionally, the mouthpiece 12 may be attached onto the open end of the cavity 36. Therefore, an inhalable aerosol may contain substances which are derived from the liquid storage portion 40, only.

[0141] A user may choose between the different modes of operation. Thereby, a modular aerosol-generating system 10 may be provided advantageously enabling three different modes of operations in one single system. Thus, it is not necessary for a user to carry three different systems for each mode of operation, but only one system. Also, a user may not need to buy three different systems, but only one system, which may be cost saving.

[0142] FIG. 5 shows a liquid storage portion 40 of an embodiment of an aerosol-generating system 10 of the invention. The liquid storage portion 40 comprises a liquid outlet 42 and a storage portion air inlet 44. The liquid storage portion 40 further comprises a storage portion mouth-end connector 46 for removably attaching the liquid storage portion 40 to the distal end of the mouth-end portion 20. The liquid storage portion 40 further comprises a storage portion main connector 48 for removably attaching the liquid storage portion 40 to a main body connector 56 at the proximal end of the main body 50. The liquid storage portion 40 of FIG. 5 may be used in the aerosol-generating system 10 of the embodiment of FIG. 4.

[0143] FIG. 6 shows an aerosol-generating system 10 according to an embodiment of the invention. The aerosol-generating system 10 comprises a mouth-end portion 20, a liquid storage portion 40, and a main body 50. A cavity 36 for receiving an aerosol-generating article (not shown) is provided in the mouth-end portion 20. The liquid storage portion 40 is arranged between the mouth-end portion 20 and the main body 50. The first heating element 28 is provided in the mouth-end portion 20. The second heating element 34 is provided in the mouth-end portion 20. The first air inlet 22 is provided in the mouth-end portion 20. Mouth-end portion 20 of FIG. 6 corresponds to mouth-end portion 20 of the embodiment of FIG. 3.

[0144] The main body 50 comprises a second air inlet 52 and is connected to the liquid storage portion 40 by the main body connector 56. The main body 50 comprises a high retention material 58 being arranged in proximity to the storage portion air inlet 44 for absorbing potential leaks of the liquid storage portion 40. The main body 50 further comprises a power supply 60 for powering both the first and second heating element 28, 34. Electrically connected to the power supply 60, the main body 50 further comprises a controller 62 for controlling the power supply 60. Additionally, the aerosol-generating system 10 comprises electrical connecting means 64 for electrically connecting the inductor 30 to the controller 62 and the power supply 60.

[0145] The aerosol-generating system 10 further comprises a second air inlet 52 that is fluidly connected to the storage portion air inlet 44. The second air inlet 52 is arranged in the main body 50.

[0146] The aerosol-generating system 10 provides different routes for the airflow as indicated by meandering arrows in FIG. 6. First and second routes for the airflow extend along the airflow passage and the bypass airflow passage as explained above with respect to the embodiment of FIG. 3. A third airflow route extends via an additional storage portion airflow passage extending from the second air inlet to the storage portion air inlet. The third airflow route further extends through the liquid contained in the liquid storage portion 40. By means of the third airflow route extraction of liquid from the liquid storage portion 40 via the liquid outlet 42 may be advantageously promoted.

[0147] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ±five percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.