SPLIT AIRFLOW SYSTEM FOR AN ELECTRICALLY HEATED SMOKING SYSTEM AND METHOD FOR GUIDING AN AIRFLOW INSIDE AN ELECTRICALLY HEATED SMOKING SYSTEM

Abstract

The split airflow system for an electrically heated smoking system for generating aerosol, the split airflow system having a downstream end comprises a first channel defining a first flow route and a second channel defining a second flow route. The first flow route directs ambient air from outside the system to the downstream end of the system. The second flow route directs ambient air from outside the system towards a preferably substantially flat, fluid permeable, heating element before conveying the ambient air to the downstream end. The first channel and the second channel define a total volume of ambient air passing through the system and the first channel provides at least 50 percent of the total volume of ambient air passing through the system. The invention also refers to a method for guiding an airflow in an electrically heated smoking system for generating aerosol and an electrically heated smoking system comprising the split airflow system.

Claims

1. A split airflow system for an electrically heated smoking system for generating aerosol, the split airflow system having a downstream end, the airflow system comprising: a first channel defining a first flow route; a second channel defining a second flow route; wherein the first flow route directs ambient air from outside the system to the downstream end of the system; wherein the second flow route directs ambient air from outside the system towards a substantially flat, fluid permeable heating element before conveying the ambient air to the downstream end, and wherein the first channel and the second channel define a total volume of ambient air passing through the system and the first channel provides at least 50 percent of the total volume of ambient air passing through the system.

2. Split airflow system according to claim 1, wherein the heating element is a heating element comprising a plurality of electrically conductive filaments such as a mesh heating element.

3. Split airflow system according to any one of the preceding claims, wherein the first channel provides between about 65 percent and about 95 percent, preferably between about 85 percent and about 89 percent, of the total volume of ambient air passing through the system.

4. Split airflow system according to any one of the preceding claims, wherein the first channel converges with an end portion of the second channel such that the first flow route joins the second flow route after the second flow route has directed ambient air past the heating element.

5. Split airflow system according to any one of claims 1 to 3, wherein the first channel and the second channel form distinct channels such that the first flow route and the second flow route direct ambient air from outside the system to the downstream end of the system separate from each other.

6. Split airflow system according to any one of the preceding claims, wherein at least a portion of the second channel and the heating element are arranged perpendicular to each other such that the at least a portion of the second channel directs ambient air to imping perpendicular onto the heating element.

7. Split airflow system according to any one of the preceding claims, wherein at least a portion of the second channel arranged downstream of the heating element, is arranged in the circumference of the heating element.

8. Method for guiding an airflow in an electrically heated smoking system for generating aerosol, the method comprising the steps of: directing ambient air from outside the system to a downstream end of the system along a first flow route; directing ambient air from outside the system towards a substantially flat, fluid permeable heating element before conveying the ambient air to the downstream end of the system along a second flow route; therein passing a total volume of ambient air through the system along the first flow route and along the second flow route, and passing at least 50 percent of the total volume of ambient air through the system along the first flow route.

9. Method according to claim 8, further comprising the step of joining ambient air of the first flow route and ambient air of the second flow route before the ambient air of the first flow route and of the second flow route reach the downstream end of the system.

10. Method according to claim 8, further comprising the step of keeping the first flow route separate from the second flow route.

11. Method according to any one of claims 8 to 10, comprising the step of directing the ambient air in the second flow route such that the ambient air in the second flow route impinges substantially perpendicularly onto the heating element.

12. Method according to any one of claims 8 to 11, further comprising the steps of: providing a liquid aerosol forming substrate; heating the heating element, thereby vaporizing liquid from the aerosol forming substrate and forming aerosol; letting the ambient air directed to the heating element by the second flow route pick up the formed aerosol before conveying the aerosol containing ambient air to the downstream end of the system.

13. Method according to any one of claims 8 to 12, further comprising the steps of: providing at least a portion of the first channel and at least a portion of the second channel inside a mouthpiece of the system, the downstream end of the system being a proximal end of the mouthpiece; guiding ambient air in the at least a portion of the second channel along a length of the mouthpiece in a direction towards the proximal end of the mouthpiece; performing an inversion of direction of the ambient air in the second channel; and guiding the ambient air in the direction of the heating element for impinging the ambient air onto the heating element.

14. Method according to claim 13, further comprising the step of guiding the ambient air in the at least a portion of the second channel along a central axis of the mouthpiece, and impinging the ambient air substantially centrally onto the heating element.

15. An electrically heated smoking system for generating aerosol comprising the split airflow system according to any one of claims 1 to 7, the smoking system comprising: a storage portion comprising a housing for holding a liquid aerosol-forming substrate, the housing having an open end, a substantially flat, fluid permeable heating element extending over the open end of the housing, a mouthpiece arranged adjacent the housing, the mouthpiece comprising an elongate body comprising an open distal end, the open distal end facing the housing, wherein the mouthpiece further comprises: a first channel, wherein the first channel comprises a first inlet opening arranged in a side wall of the elongate body and an outlet opening arranged at a proximal end of the elongate body for defining a first flow route directing ambient air from outside the system through the mouthpiece to the outlet opening, an end portion of a second channel extending between the open distal end of the elongate body and the proximal end of the elongate body, wherein the second channel is arranged in the smoking system and defines a second flow route, wherein the second flow route directs ambient air entering the smoking system to the heating element, where the ambient air is capable of picking up aerosol generated by vaporizing liquid through heating the heating element, before conveying the aerosol containing ambient air to the proximal end of the elongate body of the mouthpiece, and wherein the first channel and the second channel define a total volume of ambient air passing through the smoking system and the first channel provides at least 50 percent of the total volume of ambient air passing through the smoking system.

16. Smoking system according to claim 15, wherein the first channel converges with the end portion of the second channel downstream of the open distal end of the elongate body.

17. Smoking system according to claim 15, wherein the second channel comprises a second outlet opening arranged at the proximal end of the elongate body, and wherein second outlet opening is separate from the outlet opening of the first channel.

18. Smoking system according to any one of claims 15 to 17, wherein a second inlet opening of the second channel is arranged in the side wall of the elongate body.

19. Smoking system according to any one of claims 15 to 18, wherein the second channel comprises at least one second channel portion arranged downstream of the heating element carrying the aerosol containing ambient air, which at least one second channel portion is arranged in longitudinal direction along the circumference of the housing or of the mouthpiece.

20. Smoking system according to claim 19, wherein the second channel comprises a plurality of second channel end portions arranged in longitudinal direction along the circumference of the elongate body.

21. Smoking system according to any one of claims 15 to 20, wherein the substantially flat, fluid permeable heating element comprises a plurality of electrically conductive filaments.

Description

[0065] The invention is further described with regard to embodiments, which are illustrated by means of the following drawings, wherein:

[0066] FIG. 1 shows an embodiment of the split airflow system;

[0067] FIG. 2 shows another embodiment of a second flow route in the split airflow system;

[0068] FIG. 3 shows the cooling effect of different airflows on different heating element;

[0069] FIG. 4 shows temperature curves of differently powered heating elements;

[0070] FIG. 5 shows temperature curves at the outlet of the mouthpiece;

[0071] FIG. 6 shows average vapour saturation curves at the outlet of the mouthpiece;

[0072] FIG. 7 shows the ratio of droplet diameters at the outlet of the mouthpiece for total and split airflow geometries;

[0073] FIGS. 8a to 8f shows heating elements as may be used in the smoking system according to the invention;

[0074] FIG. 9a,9b are detailed views of the filaments of the heating elements, showing a meniscus of liquid aerosol-forming substrate between the filaments (FIG. 9a) and a capillary material extending between the filaments (FIG. 9b);

[0075] FIG. 10 shows a cross-section of a cartridge system with high retention-release material (HRM) and air passage through the HRM;

[0076] FIG. 11 shows a cross-section of another cartridge system with high retention-release material (HRM) and air passage through the cartridge;

[0077] FIG. 12 shows an exploded view of the cartridge system of FIG. 11;

[0078] FIG. 13 shows a cross-section of a cartridge system with a liquid and air passage through the liquid.

[0079] In FIG. 1 a cartridge 4 and mouthpiece 1 embodiment for an aerosol generating smoking system is shown. An elongate main housing 5 accommodates a cartridge with a tubular shaped cartridge housing 4 containing an aerosol-forming substrate, for example a liquid containing capillary material 41. The cartridge housing has an open proximal end 42. A heater 30, preferably, a substantially flat mesh heater, is arranged to cover the open proximal end of the cartridge housing 4. The heating element may or may not be in direct physical contact with the aerosol-forming substrate 41. A mouthpiece 1 having a substantially tubular shaped elongate body 15 is aligned with the main housing, the cartridge housing 4 and the heating element 30. The elongate body 15 has an open distal end facing the heater 30.

[0080] The embodiment shown in FIG. 1 comprises a second channel 10 defining a second flow route in the mouthpiece 1 leading incoming second ambient air 20 over the heater 30 and to air outlets 12 at a proximal end or mouth end of the mouthpiece 1, where a consumer puffs. Also a first channel 11 defining a first flow route is arranged in the mouthpiece 1. First ambient air 21 enters the first channel 11 through a first inlet 110 and is directly led to the outlets 12 without passing the heater 30. This first airflow 21 joins the second airflow 20 in the second channel 10 at a location 111 downstream of the heater 30 and upstream of the outlets 12. A most downstream portion of the second channel 10 is identical with the first channel 11. The second airflow 20 passes the heater 30, where aerosol formed by heating the heater and vaporizing liquid from the aerosol-forming substrate 41, and entrains the aerosol in the second airflow 21. The aerosol carrying second airflow is combined with the first airflow 21 at location 111. The first airflow 21 mixes with the aerosol carrying second airflow and cools it.

[0081] Second inlet 100 and first inlet 110 are both openings or bore holes in the mouthpiece 1 in a distal half of the elongate body 15 of the mouthpiece 1. The second flow route in an upstream second channel portion 101 runs in the elongate body parallel to the circumference of the elongate body to the proximal end of the mouthpiece. In a radially inwardly directing portion 102 of the second channel 10, the second airflow 20 is directed to the center of the elongate body and in a centrally arranged portion 103 of the second channel the second airflow 20 is directed to the heater 30 to impinge to the center 31 of the heater 30. The second airflow 20 passes over the heater 30 and spreads radially outwardly to several longitudinal end portions 104 of the second channel 10. The longitudinal end portions 104 are regularly arranged along the circumference within the elongate body.

[0082] In this embodiment a first flow route and a second flow route and a first channel and a second channel, respectively, are arranged entirely within the mouthpiece 1 of the aerosol generating system.

[0083] In FIG. 2 an embodiment of a cartridge 4 with heater 30 arranged at the bottom of the cartridge covering an open distal end 43 of the cartridge housing 41 is illustrated. A second inlet 100 is arranged in the main housing 5 and the ambient air is directly led in a radially inwardly directing portion 102 of the second channel to the center of the main housing. In a centrally arranged portion 103 of the second channel, the air is directed to impinge perpendicularly onto the heater 30. The air then passes the heater 30, entrains aerosol caused by heating the liquid in the aerosol-forming substrate 40 through the heater 30. The aerosol containing air is led to the proximal end of the cartridge 4 in several longitudinal portions 105 of the second channel 10 arranged between and along cartridge housing 41 and main housing 5. There, the aerosol containing second airflow is guided to and out of a single centrally arranged opening 52 in the main housing 5. A mouthpiece (not shown) may be arranged adjacent the main housing. Preferably, the mouthpiece then also has a centrally arranged opening and end portion 104 of second channel 10 to receive the aerosol containing second airflow and guide it to a single outlet opening 12 in the proximal end of the mouthpiece 1. In such an embodiment, a first channel 11 may basically be similar to the embodiment shown in FIG. 1. The first channel may be a separate channel in the mouthpiece or may comprise a radial bore that extends to the second channel in the mouthpiece such that the first airflow may be joined with the second airflow within the mouthpiece.

[0084] The data shown in FIG. 3 demonstrate the effect of cooling a mesh heater the more the higher a flow rate of air passing the mesh heater. Cooling rates were measured using different mesh heaters: Reking (45 micrometers/180 per inch), Haver (25 micrometers/200 per inch) and 3 strips Warrington (25 micrometers/250 per inch). Measurement data for the Reking heater are indicated by crosses, measurement data for the Haver heater are indicated by circles and measurement data for the 3 strips Warrington heater are indicated by triangles. All heaters were operated at three Watt. Temperature was measured with a thermocouple coupled to the heaters. Increasing the flow rate as indicated on the x-axis in liter per minute [L/min] results in a lower measured temperature on the mesh heater. Typical sizes of airflows in aerosol-generating systems can be approximated by standard smoking regimes, for example the Health Canada smoking regime, which leads to significant cooling of the heater. Exemplary smoking regimes such as Health Canada draw 55 ml of a mix of air and vapour over 2 seconds. An alternative regime is 55 ml over 3 seconds. Neither exemplary smoking regime mimics behaviour precisely but instead acts as a proxy to what an average user would draw.

[0085] Experiments with split airflow systems were preferably made with the first airflow having between 6/7 and 8/9 of the total volume of ambient air. The volume of ambient air directed to the heater had a volume between 1/7 and 1/9 of the total volume of ambient air, accordingly. About 85 percent to 89 percent of the total volume of ambient air is thus directly conveyed through the outlet of the mouthpiece, while only about 11 percent to about 15 percent of the total volume of airflow pass the heater.

[0086] Exemplary values for the channels as for example shown in the embodiment of FIG. 1, are:

[0087] Air inlet of the second channel: diameter 0.75 millimeter and total channel cross section 0.44 square millimeter.

[0088] Air inlet of first channel: diameter 1 millimeter times 4 and 3.14 square millimeter total channel cross section.

[0089] In the graph of FIG. 4, average temperatures at the heater versus time during one puff is shown. Curve 60 represents reference temperature data for the heater, where the total airflow is directed to the heater. Curve 70 represents temperature data for the heater in a split airflow system, where only one/seventh of the total airflow is directed to the heater. For the reference data the heater had been heated with 5 Watt, while the heater receiving a reduced airflow had been heated with 4 Watt. It can be seen that with a split airflow, energy of 1 Watt during the length of one puff may be saved.

[0090] FIG. 5 shows the effect of the split airflow onto the temperature of the aerosol carrying airflow at the outlet of the mouthpiece during one puff. These data refer to embodiments of mouthpieces, where the first airflow joins the aerosol carrying second airflow within the mouthpiece, as shown in FIG. 1. Temperature curve 61 represents outlet air temperatures for a heater powered with 5 Watt with the total airflow impinging on the heater. Temperature curve 71 represents outlet air temperatures for a heater powered with 4 Watt, where one/seventh of the total airflow only is directed to the heater. There are significant lower temperatures of the aerosol carrying airflow at the outlet of the mouthpiece due to the six/seventh volume of ‘fresh’ air joining the aerosol stream. Typically ‘fresh’ air mixed into the aerosol carrying airflow is at room temperature.

[0091] Significant difference may also be seen in the ratio of vapour pressure to the saturation pressure (Pvapor/Psaturation) of a glycerol solution at the outlet of the mouthpiece during one puff. This ratio is shown in FIG. 6. Curve 72 refers to pressure data at the outlet for the heater powered with 4 Watt, in the split airflow system with one/seventh of the total airflow directed to the heater. Curve 62 refers to pressure data at the outlet for the heater powered with 5 Watt with the total airflow impinging on the heater. The pressure ratio is higher for the split airflow embodiment due to the cooling effect. This represents a larger degree of super saturation of the glycerol solution, which favours aerosolization with smaller droplets. Simulation clearly predicts smaller droplet sizes for the cooler vapour of the split airflow embodiment compared to vapour of non-split or total airflow embodiments. These simulation data 67 are shown in FIG. 7 for one puff at the outlet of the mouthpiece. Y-Axis represents the ratio of droplet diameters for split airflow to total airflow systems. The ratios are calculated and shown as d_split/d_ref=T*Ln(S) ref/T*Ln(S) split versus time (in seconds) during one puff on the aerosol-generating system where T is the temperature expressed in degrees Kelvin and S is the saturation ratio which is a function of Pv and (T).

[0092] FIG. 8a is an illustration of a first heating element 30. The heating element comprises a mesh 36 formed from 304L stainless steel, with a mesh size of about 400 Mesh US (about 400 filaments per inch). The filaments have a diameter of around 16 micrometer. The mesh is connected to electrical contacts 32 that are separated from each other by a gap 33 and are formed from a copper foil having a thickness of around 30 micrometer. The electrical contacts 32 are provided on a polyimide substrate 34 having a thickness of about 120 micrometer. The filaments forming the mesh define interstices between the filaments. The interstices in this example have a width of around 37 micrometer, although larger or smaller interstices may be used. Using a mesh of these approximate dimensions allows a meniscus of aerosol-forming substrate to be formed in the interstices, and for the mesh of the heating element to draw aerosol-forming substrate by capillary action. The open area of the mesh, that is, the ratio of the area of interstices to the total area of the mesh is advantageously between 25 percent and 56 percent. The total resistance of the heating element is around 1 Ohm. The mesh provides the vast majority of this resistance so that the majority of the heat is produced by the mesh. In this example the mesh has an electrical resistance more than 100 times higher than the electrical contacts 32.

[0093] The substrate 34 is electrically insulating and, in this example, is formed from a polyimide sheet having a thickness of about 120 micrometer. The substrate is circular and has a diameter of 8 millimeter. The mesh is rectangular and has side lengths of 5 millimeter and 2 millimeter. These dimensions allow for a complete system having a size and shape similar to a convention cigarette or cigar to be made. Another example of dimensions that have been found to be effective is a circular substrate of diameter 5 millimeter and a rectangular mesh of 1 millimeter times 4 millimeter.

[0094] FIG. 8b and FIG. 8c are illustrations of other alternative heating elements. In the heating element of FIG. 8b the filaments 37 are bonded directly to substrate 34 and the contacts 32 are then bonded onto the filaments. The contacts 32 are separated from each other by insulating gap 33 as before, and are formed from copper foil of a thickness of around 30 micrometer. The same arrangement of substrate filaments and contacts can be used for a mesh type heater as shown in FIG. 8a. Having the contacts as an outermost layer can be beneficial for providing reliable electrical contact with a power supply.

[0095] The heating element of FIG. 8c comprises a plurality of heater filaments 38 that are integrally formed with electrical contacts 39. Both the filaments and the electrical contacts are formed from a stainless steel foil that is etched to define filaments 38. The contacts 39 are separated by a gap 33 except when joined by filaments 38. The stainless steel foil is provided on a polyimide substrate 34. Again the filaments 38 provide the vast majority of the resistance, so that the majority of the heat is produced by the filaments. In this example the filaments 38 have an electrical resistance more than 100 times higher than the electrical contacts 39.

[0096] FIGS. 8d to 8e show several heating elements having a mesh 36 fixed to and between two contact portions 35. The mesh is fixed on both sides to the contact portions 35. Each contact portion has a round outer circumference and two openings 351. The heating elements 30 may be attached to the housing of a cartridge or to a supporting substrate by theses openings 351, for example by screwing.

[0097] Capillary material 41 is advantageously oriented in the housing 4 to convey liquid to the heating element 30. When the cartridge is assembled, the heater filaments 36, 37, 38 may be in contact with the capillary material 41 and the aerosol-forming substrate can be conveyed directly to the mesh heater. FIG. 9a is a detailed view of the filaments 36 of the heating element, showing a meniscus 46 of liquid aerosol-forming substrate between the heater filaments 36. It can be seen that aerosol-forming substrate contacts most of the surface of each filament so that most of the heat generated by the heating element passes directly into the aerosol-forming substrate.

[0098] FIG. 9b is a detailed view, similar to FIG. 9a, showing an example of a capillary material 41 that extends into the interstices between the filaments 36. The capillary material 41 may be a capillary material arranged next to the or in contact with the heating element, preferably having a high temperature resistance. It can be seen that by providing a capillary material comprising fine threads of fibres that extend into the interstices between the filaments 36, transport of liquid to the filaments can be ensured.

[0099] In use the heating elements operate by resistive heating. Current is passed through the filaments 36,37,38, under the control of control electronics (not shown), to heat the filaments to within a desired temperature range. The mesh or array of filaments has a significantly higher electrical resistance than the electrical contacts 32,35 and electrical connectors (not shown) so that the high temperatures are localised to the filaments. The system may be configured to generate heat by providing electrical current to the heating element in response to a user puff or may be configured to generate heat continuously while the device is in an “on” state.

[0100] Different materials for the filaments may be suitable for different systems. For example, in a continuously heated system, graphite filaments are suitable as they have a relatively low specific heat capacity and are compatible with low current heating. In a puff actuated system, in which heat is generated in short bursts using high current pulses, stainless steel filaments, having a high specific heat capacity may be more suitable.

[0101] In FIG. 10 a cross section of a cartridge system, wherein a second flow route comprises an airflow directed through the cartridge is illustrated. A fluid permeable heater, for example a mesh heater 30, is provided to cover the open top of the housing 4. For sealing the top of the housing 4, a sealing layer 48, for example a polymer layer, is provided between the upper rim of the housing 4 and the heater 30. In addition, a sealing disc 47, for example a polymer disc, is provided on the top side of the heater 30. With the sealing disc 47 airflow through the heater may be controlled, in particular, airflow constraints may be provided. The sealing disc may also be arranged on the bottom side of the heater 30.

[0102] The cartridge housing 4 comprises a liquid containing high retention material or high release material (HRM) 41 serving as liquid reservoir and directing liquid towards the heater 30 for evaporation at the heater. A capillary disc 44, for example a fiber disc, is arranged between HRM 41 and heater 30. The material of the capillary disc 44 may be more heat resistant than the HRM 41 due to its closeness to the heater 30. The capillary disc is kept wet with the aerosol-forming liquid of the HRM to secure provision of liquid for vaporization if the heater is activated.

[0103] The housing 4 is provided with an air permeable bottom 45. The air permeable bottom is provided with an airflow inlet 450. The airflow inlet 450 allows air to flow through the bottom 45 into the housing in one and this direction only. No air or liquid may leave the housing through the air permeable bottom 45. The air permeable bottom 45 may for example comprise a semi-permeable membrane as airflow inlet 450 or may be a bottom cover comprising one or more one-way valves as will be shown below.

[0104] If low depression prevails on the side of the heater, as is the case during puffing, air may pass through the airflow inlet 450 into the cartridge. The airflow 20 will pass through the HRM 41 and through the heater 30. The aerosol containing airflow 20 will then flow to a downstream end of the aerosol generating device, preferably in a centrally arranged channel in a mouthpiece.

[0105] Side walls of the housing 4 may also be provided with lateral air permeable sections 46 for providing lateral airflows into the housing. Lateral air permeable sections 46 may be designed as the airflow inlets 450 in the air permeable bottom 45.

[0106] In FIG. 11 the arrangement and function of the cartridge system is basically the same as shown in FIG. 10. However, the HRM 41 is provided with a central opening 412. Air entering the airflow inlet 450 in the bottom 45 of the housing passes through the central opening 412. The airflow passes next to the HRM in the cartridge. With optional lateral air permeable sections 46 in the side wall of the housing 4, lateral airflow may be provided through the HRM 41.

[0107] In FIG. 12 an exploded view of cartridge system as in FIG. 11 is shown. A ring-shaped tubular HRM 41 is provided in the housing 4. The bottom 45 of the housing is a disc comprising a one-way valve 49 arranged in the center of the disc and aligned with the central opening 412 in the HRM 41. Such a one-way valve may for example be a commercially available valve, such as for example used in medical devices or in baby bottles.

[0108] FIG. 13 is a cross section of another embodiment of a cartridge system. Same reference numerals are used for the same or similar elements. In this embodiment, the housing 4 is filled with an aerosol-forming liquid 411. The housing may be made of metal, plastics material, for example a polymeric material, or glass. The valve 49 may directly be molded into the bottom 45 of the housing. The bottom 45 may also be provided with a cavity for air-tight assembly with the valve. Due to the valves preferably being made of a flexible material, tight assembly with the bottom material may be achieved.

[0109] In the above cartridge systems as described in FIGS. 10 to FIG. 13 the cartridge housing 4 may also be a separate cartridge container in addition to the cartridge housing as described for example in FIG. 1. Especially, a liquid 411 containing cartridge is a pre-manufactured product, which may be inserted into a cartridge housing provided in the aerosol generating system for receiving the pre-manufactured cartridge.