US20230232899A1

US20230232899A1 - An Aerosol Generating System and Device Including a Liquid Capsule and a Holder with a Heater

Info

Publication number: US20230232899A1
Application number: US17/927,482
Authority: US
Inventors: Claude Zominy
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2020-05-28
Filing date: 2021-05-26
Publication date: 2023-07-27
Also published as: EP4156994A1; CN115605101A; JP2023527620A; CA3170421A1; KR20230016618A; WO2021240397A1

Abstract

An electronic cigarette system including a liquid capsule having a reservoir for holding vaporizable material, a holder-facing surface, a vapor pipe with an vapor inlet at the holder-facing surface, an inhalation opening, a liquid exit port arranged at the holder-facing surface, and a capsule holder for removably receiving the liquid capsule. The capsule holder including a capsule accommodating opening, a heating device, and a mesh for being soaked with the vaporizable material. When the liquid capsule and the capsule holder are interconnected to each other, a fluid chamber is formed between an outer surface the capsule accommodating opening and the holder-facing surface and when the liquid capsule and the capsule holder are interconnected to each other, a fluidic connection path is formed from the reservoir to the fluid chamber via the liquid exit port, to reach the inhalation opening.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to European Patent Application No. EP20177259.7 that was filed on May 28, 2020, the entire contents thereof herewith incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present disclosure relates generally to aerosol or vapor generating systems and devices, more particularly systems and devices having a removable container element for storing a vaporizable material, and specific arrangement of heating elements for heating vaporizable material for these systems and devices, to produce an aerosol for inhalation by a user.

BACKGROUND

The use of aerosol generating systems, also known as e-cigarettes, e-cigs (EC), electronic nicotine delivery systems (ENDS), electronic non-nicotine delivery systems (ENNDS), electronic smoking devices (ESDs), personal vaporizers (PV), inhalation devices, vapes, which can be used as an alternative to conventional smoking articles such as lit-end cigarettes, cigars, and pipes, is becoming increasingly popular and widespread. The most commonly used e-cigarettes are usually battery powered and use a resistance heating element to heat and atomize a liquid containing nicotine and/or flavorants (also known as e-cigarette liquid, e-cig liquids, e-liquid, juice, vapor juice, smoke juice, e-juice, e-fluid, vape oil, hereinafter referred to as “e-liquid”), to produce an aerosol (often called vapor) which can be inhaled by a user.
In the conventional e-cigarettes described above, the liquid is put into contact through small channels to a resistance heating element where it is heated and vaporized, for example via a wick or other type of porous element, having a plurality of small channels that transport the liquid from a reservoir to the heating element. This heating element together with the porous element, a reservoir that contains the e-liquid, and a mouthpiece are usually arranged within a disposable cartridge or pod, that is discarded once the e-liquid has been consummated by the user, and usually removably connects to a main body that includes a rechargeable battery.
For example, in U.S. Patent Publication No. 2017/0333650, this reference herewith incorporated by reference in its entirety, shows an e-cigarette 10 is shown that has a disposable cartridge assembly 30, cartridge assembly 30 provided with mouthpiece 35, heating element 103 for heating source liquid to generate the aerosol by vaporization, and a reservoir 38 for holding the liquid, the cartridge assembly 30, cartridge assembly being removably connected to the e-cigarette 10 with cooperating engagement elements 21, 31. Heating element 103 is made of a sintered metal fiber material that forms a porous conducting material for the liquid in the form of a sheet, and has a main portion 103A with electrical contact extensions 103B at each end.
As another example, U.S. Pat. No. 9,675,118, this reference herewith incorporated by reference in its entirety, discusses an electronic cigarette 1 with a cylindrical housing 10, including a power supply assembly 70, an atomizer assembly 50, a reservoir 60 for holding the liquid solution, and a mouthpiece 20. An atomizer assembly 50 itself include an air flowing pipe 51, a wick 52, a heating member 53, a positioning sleeve 54, and a supporting pipe 55.
However, in the state of the art of atomizing or vaporizing cigarette systems and devices, the heating element for heating and vaporizing the e-liquid is usually fixedly associated with the liquid reservoir. This leads to a reservoir assembly, for example an e-liquid capsule or container, that are more expensive, more complex, and require an electric connection to the holder, and are therefore more prone to failure, are more costly to manufacture, and also difficult to recycle, leaving a larger carbon footprint for the emptied capsules that are disposed of in the trash. In light of these deficiencies of the state of the art, substantially improved atomizing or vaporizing cigarette systems and devices are desired.

SUMMARY

According to one aspect of the present invention, an electronic cigarette system is provided. Preferably, the electronic cigarette system includes a vaporizable material capsule including a reservoir for holding vaporizable material, a holder-facing surface, a vapor pipe with a vapor inlet at the holder-facing surface, an inhalation opening, and a liquid exit port arranged at the holder-facing surface, a capsule holder for removably receiving the liquid capsule, the capsule holder including a capsule accommodating opening, the capsule holder having a heating device, and a wicking element for being soaked with the vaporizable material. Moreover, preferably, when the liquid capsule and the capsule holder are interconnected to each other, a fluid chamber is formed between an outer surface the capsule accommodating opening of the capsule holder and the holder-facing surface of the liquid capsule, the fluid chamber having the wicking element arranged therein and exposed to a heating surface of the heating device. In addition, preferably, when the liquid capsule and the capsule holder are interconnected to each other, a fluidic connection path is formed from the reservoir to the fluid chamber via the liquid exit port, from the fluid chamber to the vapor pipe via the vapor inlet, to reach the inhalation opening.
According to another aspect of the present invention, an electronic cigarette system is provided. Preferably, the electronic cigarette system includes a first element having a liquid container for holding vaporizable material, a vapor pipe that is configured to at least partially traverse the liquid container, and a liquid exit port, and a second element including an opening for receiving the first element, a mechanism for opening the liquid exit port, and a heater, and a wicking element for being soaked with vaporizable material, wherein the mechanism for opening the liquid exit port is configured to open the liquid exit port when the first element is placed into the opening of the second element, and wherein the opening of the second element has a conical surface, the heater configured to heat the conical surface of the opening.
The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description with reference to the attached drawings showing some preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain features of the invention.

FIGS. 1A to 1E show different cross-sectional and perspective views of of an aerosol generating system 100 including an vaporizable material capsule 10 and a holder 50 having a heating device 70, with FIG. 1A showing a cross-sectional view of vaporizable material capsule 10 and holder 50 in a disconnected state, FIG. 1B showing a cross-sectional view of the of vaporizable material capsule 10 and holder 50 in a connected state, FIG. 1C showing a perspective view of an exemplary capsule 10 having a substantially round cross-section, FIG. 1D shows a transparent perspective view of the capsule receiving portion of the holder 50 showing two

different heating elements

72, 74 of the heating device 70, according to one aspect of the present invention, and FIG. 1E shows a cross-sectional side view of a variant of the aerosol generating system 100 with a wicking element 76 attached to capsule or cartridge 10;

FIGS. 2A to 2C show different exemplary cross-sectional side views of different types of

liquid exit ports

146, 246, 346 arranged at the capsule 10, and different types of

opening devices

178, 278, 378 arranged in the capsule receiving cavity or opening 80 of the holder 50, according to another aspect of the present invention;

FIGS. 3A to 3G show different exemplary cross-sectional side and top views of different arrangements of capsule 10, holder 50, and different arrangements and structures for embodying one or more venting holes 84 of capsule accommodating opening 80, with FIG. 3A showing a cross-sectional side view depicting side vents as holes 84 below the heater 70, FIG. 3B showing a cross-sectional side view with L-shaped vent channels 84 entering from a top face of holder 50 and entering opening 80 through holes of heater 70, FIG. 3C showing a side view and a top view in a direction of axis CA towards holder, showing cut-in recesses 84 as venting or air intake holes, and having venting channels 89 along a side surface 83 of opening 90, FIG. 3D showing a side view of a variant where cut-in recesses 84 for air intake are arranged at an edge of the capsule 10, FIG. 3E showing a cross-sectional side view of a variant where no seal 30 may be present, and the air intake is made by a gap 584 between capsule 10 and holder 50, FIG. 3F shows a cross-sectional view along line CS1 of FIG. 3E where grooves or channels 89 are formed at an inner surface of heater 70, with vapor channels 22 arranged in a star-like fashion, and FIG. 3G shows a cross-sectional, exemplary view of different channels at an interface area 90 between capsule 10 and holder 50, according to still another aspect of the present invention; and

FIGS. 4A to 4C show exemplary views of another embodiment of the capsule 410 for an electronic cigarette or vaporizing system 300, with capsule 410 having a closing ring 413 that allows to manually open and close a delivery of vaporizable material EL from reservoir 440 to wicking element 476, with FIG. 4B being a cross-sectional view along line CS2, and FIG. 4C being a cross-sectional view along line CS3, according to another aspect of the present invention.

Herein, identical reference numerals are used, where possible, to designate identical elements that are common to the figures. Also, the images are simplified for illustration purposes and may not be depicted to scale.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

FIGS. 1A to 1E show different cross-sectional and perspective views of an exemplary aerosol generating system 100 including an vaporizable material EL or liquid capsule or cartridge 10 for containing an vaporizable material EL and a holder 50 having a heating device 70. In the context of this description, capsule or cartridge 10 can be pre-filled with EL, and is a disposable or discardable part when capsule 10 is empty, while holder 50 can be a reusable part. But in a variant, capsule 10 can be refilled with EL once empty. In this respect, FIG. 1A shows a cross-sectional representation of the liquid capsule 10 having an inhalation side IS, in the present representation a top or upper side, with an inhalation port or opening 24 arranged therein, and a holder facing side HS having a liquid exit port 46 arranged therein, hereinafter represented as the bottom or lower side, and FIG. 1C shows a perspective view thereof. Liquid capsule 10 includes a traversing vapor pipe structure 20 with a centrally-arranged vapor pipe 21 that fluidically lead to inhalation opening 24, and is fluidically connected to one or more lateral conduits or tubes 22, the tubes 22 having an input port 28 arranged at a tapered or conically-shaped side wall 14 of the liquid capsule or cartridge 10. One or more input ports 28, one or more tubes 22, central vapor pipe 21, and inhalation opening 24 form elements of a downstream part of a fluidic pathway FP of the aerosol generating system 100, as further explained below. Liquid capsule 10 can have different shapes, for example when viewed in cross-sectional view along central axis CA, a rectangular shape, square shape, oval shape, irregular shape, but in the non-limiting embodiment represented by FIG. 1C a round cross-sectional shape is shown. In a variant where the cross-sectional area or shape of capsule or cartridge 10 is nor round or oval, but for example square or rectangular, or has a polyhedral shape, side walls 14 can be oblique or slanted relative to central axis CA.
Moreover, liquid capsule 10 can further include a reservoir structure 40 within the walls 12 of capsule 10, with an upper section 42 of the reservoir structure 40 that can be in fluidic connection with a lower section 44 of the reservoir structure 40, lower section being in fluidic connection with liquid exit port 46 that shown to be closed by a sealing member 48, for example but not limited to a pierceable membrane, an openable and closable valve element, a breakable barrier layer, a fluidic interconnection port. The liquid capsule 10 can be pre-filled with vaporizable material EL for use with holder 50. The term vaporizable material is used to designate any material that is vaporizable at a temperature up to 400° C., preferably up to 350° C., for example aerosol generating liquid, gel, wax and the like.
As shown in FIG. 1C, a plurality of input ports 28 can be arranged circumferentially around the conically-shaped side wall 14, each having a corresponding connection tube 22 that fluidically connects to central vapor pipe 21 in a star-like fashion. However, in a variant, there can be only one input port 28 and connection tubes 22, or two input ports 28 and two corresponding connection tubes 22, or any other number. In the variant shown, a sealing ring 30 in the form of a O-ring or sealing washer is provided around the circumference of the outer walls 12 of liquid capsule 10, for example partially located inside a circular groove around a cylindrical portion of outer wall 12, but in a variant, the sealing ring is provided inside capsule accommodating opening 80 of capsule holder 50, and is thereby nota part of capsule 10, or on both capsule 10 and holder 50.
In FIG. 1A, holder 50, at the capsule facing side CS is shown having capsule accommodating opening 80 that is shaped complementarily to a lower portion of liquid capsule 10 that facing the holder HS. For example, side walls 14 of holder facing section of liquid capsule 10 are tapered or conical, and side walls 83 of lower section 82 of capsule accommodating opening 80 are also tapered or conical, to match the shape of capsule 10. For embodiments where capsule 10 and capsule accommodating opening 80 have a rectangular, square or other flat-surfaced shapes, side walls 82 can be slanted or oblique relative to central axis CA. For example, side walls 14 and side walls 83 can be arranged to be concentrical to each other, having the same slope angle, i.e. appear in a cross-sectional view to be parallel to each other. Moreover, a heating device 70 is shown, having a first heating element 72 arranged at a central axis CA inside capsule accommodating opening 80, and a second heating element 74 is shown that is arranged at side walls 83 of capsule accommodating opening 80. Heating surface of first and second heating elements 72, 74 are arranged to be exposed to capsule accommodating opening 80, and a wicking element, structure, or layer 76 for example formed of a mesh layer, other type of mesh-like structure, such as but not limited to porous material, textile wick, cotton wick, is arranged on bottom wall 77 and on lower portions of an interior surface of side walls 83 of capsule accommodating opening 80. In the variant shown, wicking element 76 has a cup-like shape to cover the bottom wall 77 and lower sections of the side walls 83 of capsule accommodating opening 80, and is thereby attached to holder 50. However, in a variant, wicking element 76 can be attached to either side walls 14, bottom wall 17 or both of capsule 10, to be part of the disposable unit.
The provision of the complementary and conical or tapered shapes between wall 83 of capsule accommodating opening 80 and wall 14 of holder-facing side of capsule 10 provides for some specific advantages for operation of aerosol generating system 100. For example, the conically-shaped or tapered shape of capsule accommodating opening 80 allows for an easier manual insertion of capsule 10 to the opening 80, for example by an insertion direction corresponding to CA that is not perfectly parallel with central axis of opening 80 or longitudinal axis of holder 50. Upon full insertion of capsule 10 to opening 80, capsule 10 is guided by conical to tapered wall 83 for centering and final position and interconnection with holder 50. Moreover, the complementary and conical or tapered shapes also allow to provide for a linearly increasing compressive force on a wicking element 76 that is arranged between walls 14, 83, depending on a penetration depth of capsule 10 into holder 80. The portion of wicking element 76 can at least partially surround capsule 10 in the inserted position, for example to be circularly arranged around capsule 10. Upon insertion of capsule 10 to holder 50, this portion of wicking element 76 becomes sandwiched between conical or tapered wall 14 and conical or tapered wall 83, and further insertion pressure by a user on capsule 10 towards holder 50 will provide for a compressive force to wicking element 76, as illustrated in FIG. 1B. As wicking element 76 can be made of a porous, spongy, or absorptive compressible material, this compressive force can cause a reduction is thickness of a layer that forms wicking element 76, and a consequential increase and improvement of surface contact of external surfaces of wicking element 76 and conical or tapered shapes of walls 14, 83. This improved contact in turn can provide for a defined fluidic resistance between liquid exit port 46 of capsule 10 and the pores or other openings in wicking element 76, that can also lead to an improved and facilitated distribution of vaporizable or atomizable material EL, for providing a defined flow rate of EL from reservoir 40 of capsule 10 to wicking element 76 and heating element 70. In addition, the improved contact by compression can also provide for an improved heat transfer from second heating element 74 of heating element 70 to wicking element 76, by reducing a thermal resistance between heating element 70 and wicking element 76. The penetration depth of capsule 10 into capsule accommodating opening 80 for the operation can be limited and defined by a fastening mechanism (not shown), that allows to removably fasten capsule 10 to holder, as further described below. For example, the fastening mechanism can be used in combination by a type of penetration limiting mechanism, so that in an engaged position of capsule 10 with holder 50 for inhalation, a defined compressive force is applied to wicking element 76.
Wicking element 76 is formed to receive and distribute vaporizable material EL from liquid exit port 46 when capsule 10 is connected to holder 50, for example by capillary action of the vaporizable material EL. Wicking element 76 can be made of different types of materials and structures that can soak up vaporizable material EL that is delivered by liquid exit port 46 or provide for capillary force liquid distribution, for example a fibrous material, porous structure, perforated component, wick, cloth, fleece or other device or material that can soak up and fluidically distribute vaporizable material EL. Wicking element 76 can be attached inside capsule accommodating opening 80 to holder 50, can be attached to capsule 10, or can be a separate element that can be placed between holder 50 and capsule 10. In variant, there can be two different wicking elements 76, one attached to holder 50, and one attached to capsule 10.
In a variant, it is also possible that wall 83 of capsule accommodating opening 80 and wall 14 of holder-facing side of capsule 10 have different types of complementary shapes and surfaces, but still preserve the conical or tapered feature. For example, it is possible that a piecewise progressive tapered or conical shape is used for at least a portion of walls 14, 83, for example where the oblique angle of the surface relative to central axis CA increases with a portion of walls 14, 83 that are closer to the body part of holder 50, or a curved cross-sectional shape, for example a spherical shape of walls 14, 83.
In the variant shown, first heating element 72 is formed as a circular plate-like or disk-like device (see FIG. 1D) as a heating electrode that is operatively connected to a first power device 62, arranged at a center and bottom surface of capsule accommodating opening 80, having an upper surface thereof exposed and in contact with wicking element 76 (not shown in FIG. 1D), and second heating element 74 is formed as a circular band or ring around conically shapes side walls 83 forming a second heating electrode, operatively connected to a second power device 64, allowing for different temperature control of first and second heating element 72, 74. Second heating element 74 has a cylindrical inner surface that is configured to heat wicking element layer 76, for example by being in contact with wicking element 76. In a variant, first and second heating elements 72, 74 can also be partially or fully integrated to wicking element 76, for example but not limited to a meandering heating wire, heating plate, porous heating structure to be fully integral to wicking element 76. Also, to each heating element 72, 74, there can be a temperature sensor that is in operative contact or proximity for temperature measurement, operatively connected to microcontroller 68 of holder 50.
Moreover, at bottom wall 77 of capsule accommodating opening 80, an opening device 78 is provided for opening liquid exit port 46 when capsule 10 is connected to holder 50, placed at a location that matches with a location of liquid exit port 46 when capsule 10 and holder 50 are interconnected together. In the variant shown, liquid exit port 46 and opening device 78 are arranged at the central axis CA. Opening device 78 can be a type that can irreversibly open liquid exit port 46, for example a tube or cannula that has a sharp edge, for example a hollow needle, that allows to pierce an opening into a membrane or layer 48 that closes and seals liquid exit port 46. It is also possible that opening device 78 includes a structure that allows for reversible opening and closing of liquid exit port 46, for example a tab or column that can push against a valve structure that will open upon being pressured by tab or column, when capsule 10 is connected to holder 50, and upon removal of capsule 10 from holder 50 allows let liquid exit port 46 close. For example but not limited to, element 48 can be an elastic closable flap or lid that will close again upon removal of holder 50 and opening device 78, a ball or disk that is downwardly compressed by a spring for closure, or can be an expandable and elastic tube, some of these embodiments shown in FIGS. 2A-2C. In variant, liquid exit port 46 can be manually opened by user by a mechanism before interconnection of capsule 10 with holder 50.
Moreover, holder 50 can be equipped with a removable or fixedly installed battery 60 or other power source that provides for electric power to a data processor 68, for example a microcontroller, and to power switches or converters 62, 64 to provide for electric power to the first heating element 74 and the second heating element 72, respectively. Also, data processor 68 can be operatively connected to a variety of sensors, for example a presence sensor that allows to detect when capsule 10 is connected to holder 50, inhalation sensor that can detect whether a person is inhaling an aerosol from mouth piece that is formed by inhalation side of capsule 10, temperature sensors for selectively measuring a temperature of first and second heating elements 72, 74, voltage meter to measure power delivery battery 60, and also configured to detect activation or pressing of any switches, buttons, dials, or other type of manually operated elements on holder 50. The provision of two different power switches 64, 66 permits to selectively provide electric energy to the first and second heating elements 74, 72, so that they can be heated at different temperatures for selective vaporization. Microcontroller 68 can be configured to control power delivery by power switches 64, 66 to control a temperature of each one of the first and second heating elements 74, 72.
FIG. 1B shows capsule 10 in the state where it is connected to the holder 50, by being inserted to capsule accommodating opening 80, and liquid exit port 46 of capsule 10 has been opened by opening device 78, in the variant shown seal 48 has been pierced by cannula 78, thereby allowing vaporizable material EL to egress from reservoir 40 into a fluidic channel, chamber, volume, or space 90 formed between outer side surface 14 of capsule 10, and inner side surface 83 of capsule accommodating opening 80. A wicking element 76 is shown to have a U-shaped cross-section, filling up a portion of fluidic channel, chamber, or space 90, and wicking element 76 being squeezed or compressively pressured by outer side wall 14 and bottom wall 17 of capsule 10 against the corresponding portions of side walls 83 of capsule accommodating opening 80. Side wall 14 and bottom wall 17 of capsule 10 together form a holder-facing section of capsule, having surfaces that will face or are exposed to capsule accommodating opening 80 of holder 50, forming a holder facing surface. The compression of wicking element allows to force all or a substantial part of vaporizable material to flow through wicking element 76, to avoid that there are any empty spaces where vaporizable material EL can avoid wicking element 76. In the variant shown, wicking element 76 forms a cup-like shape with conically shaped or tapered side walls, having an upper edge that lies below input ports 28 so that input ports 28 are not obstructed.
A fluidic path FP is show for vaporizable material and for the vaporized or atomized vaporizable material, leading from reservoir 40 via the liquid exit port 46 and opening device 78 through wicking element 76 arranged inside fluidic chamber 90, towards input ports 28 through lateral tubes 22 to central vapor pipe 23, to be released via inhalation port 24. In the variant shown, fluidic chamber or channel 90 has a conical bowl-like shape, with the lower portion substantially filled with wicking element or structure 76. In the context of this description, the expression downstream is used for parts or portions of the FP that are located closer to inhalation port 24 and the user, or for a fluid flow towards inhalation port 24, while upstream is used for parts or portions of the FP that are located closer to reservoir 40, or for against a fluid flow towards reservoir 40 holding vaporizable material EL. Moreover, venting ducts, holes, channels or openings 84 are formed in the side wall 52 of holder 50, providing for a fluidic connection between an external area of holder and fluidic chamber 90 for air. These venting holes 84 are configured to provide air from the external environment that is pulled into chamber 90 by the suction generated by the user or operator via inhalation port 24. In the variant shown, venting holes 84 are laterally arranged on sides or radially arranged around capsule accommodating opening 80, leading into chamber 90 via wicking element 76, but venting hole or channel 84 can also lead directly into space 92 that is not occupied with wicking element 76.
A user or operator can connect capsule 10 to holder 50, by inserting capsule 10 to capsule accommodating opening 80. This action will open up liquid exit port 46 by opening device 78, for example a cannula. Thereafter, vaporizable material EL will leak out of reservoir 40 to soak wicking element 76. Upon detection of inhalation by a sensor that is operatively connected to processor 68, or by the user or operator pressing an inhalation button, processor 68 can control power devices or switches 62, 64, to heat heating elements 72, 74 of heating device 70. The inhalation will also cause a suction effect from inhalation port 24 along the fluidic pathway FP, with air being fed inside chamber 90 via venting holes 84.
Along fluidic pathway FD, vaporizable material EL can be vaporized or atomized by a two-zone heating process at first and second heating zones HZ1, HZ2. For example, upon vaporizable material exiting liquid exit port 46 deliver port of capsule 10, with first heating element 72 of heating device 70, EL is laterally distributed in the bottom portion of wicking element 76, and is then first partially vaporized or atomized in a first heating zone HZ1 that is adjacent to first heating element 72, at a temperature T1. This heating at HZ1 can render portions or compositions of the liquid state EL that has a lower vaporization temperature to a gaseous state, as compared to other portions or compositions of vaporizable material EL. This allows to perform a first vaporization process within wicking element 76, to vaporize a first amount and composition of vaporizable material that vaporizes at a first temperature that is somewhat below temperature T1. Thereafter, a first amount in gaseous state and a second amount and composition of EL in a liquid state passes through wicking element 76 by capillary action and suction from inhalation of user, to reach a second heating zone HZ2 in side walls of the wicking element 76 that are more downstream than the first heating zone HZ1. In HZ2, a second part of the EL that is in the liquid state can be vaporized or atomized in the second heating zone HZ2, adjacent to the second heating element 74, at a temperature T2 that can be different than temperature T1, preferably a higher temperature than T1, to render portions or compositions of EL that has a higher vaporization temperature to a gaseous or vapor state.
Thereafter, in this example, all or a substantial portion of vaporizable material EL has been rendered gaseous by heating zones HZ1, HZ2 and passes in its gaseous state or vapor state further downstream along FP into the channel or space 92 that is not occupied with wicking element 76, after exiting wicking element 76, and thereafter enters one or more input ports 28 of capsule 10, to continue along FP to vapor pipe 21, towards inhalation port 24 for inhalation by user. In variant, there can be more than two heating zones, for additional selective application of heating temperatures to vaporizable material EL, by having the lower heating temperatures upstream for vaporizing portions of EL with a lower vaporization temperature first, and having the higher heating temperatures further downstream for vaporizing portions of EL with a higher heating temperature later. In a variant, the different heating elements 72, 74 can have the same heating temperature, for a multi-zone heating of vaporizable material spread over a certain distance along a fluidic path FP.
FIG. 1C shows a perspective view of an exemplary capsule 10 having a substantially round cross-section, in a bullet-like shape, having attachment notches 18 for removably fastening capsule 10 to capsule accommodating opening 80 of holder 50 arranged on a cylindrically-shapes side surface of capsule 10, and FIG. 1D shows a transparent perspective view of the capsule receiving side CS of the holder 50 showing two different heating elements 72, 74 of the heating device 70 facing lower section 82 of capsule accommodating opening 80, with the wicking element 76 removed for illustration purposes, and two different power devices or switches 62, 64, and showing engagement grooves 88 for receiving corresponding attachment notches 18 of capsule 10. Different types of fastening mechanism between capsule 10 and holder 50 are possible that allow for a removal connection, for example but not limited to a snap-in ring and corresponding groove partially or entirely surrounding capsule 10 or capsule accommodating opening 80, a bayonet-type lock, a tap, a threading, a clip in mechanism, a loose press-fit engagement for easy removal.
FIG. 1E shows an exemplary cross-sectional view of another variant with capsule 10 and holder 50, where heating device 70 is part of holder 50 and is made of a single heating electrode that has a cup or bowl-like shape to form one heating zone HZ, operatively connected to a power switch 64, to form a lower portion of the side walls 83 and bottom wall 77 of capsule accommodating opening 80. Also, a seal ring 30 is shown that is located in a circular groove formed in side walls of capsule accommodating opening 80, instead of seal ring 30 of capsule 10. In a variant, no seal ring 30 needs to be present, and a gap between capsule 10 and walls of capsule accommodating opening 80 can be used as venting holes 84. Moreover, in the embodiment of FIG. 1E, the wicking element 76 is fixedly or removably attached to capsule 10, for example at the conical or slanted side walls 14, but also at the bottom wall 17 in proximity or surrounding liquid exit port 46. It is also possible that wicking element 76 is formed at least partially inside side wall 14, bottom wall 17, or both. Upon attachment of capsule 10 to holder 50, the attachment mechanism (for example 18, 88, FIGS. 1C and 1D) and capsule accommodating opening 80 are configured such that a compressive force will be applied to wicking element 76, by side wall 14 and bottom wall 17 of capsule 10 and side wall 83 and bottom wall 77 sandwiching the wicking element 76 for improved contact with a heating surface of heater 70. As the capsule 10 can be a disposable part upon consuming all the EL, and as wicking element 76 can accumulate particles and some toxic matter with the vaporization or atomizing of EL, wicking element 76 can also be seen to have a filter function holding such particles inside, that will be replaced with each use of new capsule 10.
In a variant, it is also possible that cavity or opening 80 that is located in capsule or cartridge 10, instead of being located in holder 50 with heater 70. In this respect, holder 50 could have a protrusion having a conical or tapered shape for receiving a cavity 80 that has a corresponding or complemental conical or tapered shape, the cavity 80 located inside capsule 10. Thereby the same features with wicking element 76 that can be squeezed between two conical-formed walls of cavity 80 and protrusion can be preserved. Heating elements of heating device 70 can be arranged on the slanted or conical side walls of the protrusion that will engage with capsule 10 having cavity 80, and vapor channels 22 can be arranged to have their inlet at the slanted or conical side walls that form opening or cavity 80. Venting holes 84 or channels can be still arranged in holder 50, to guide air from the exterior environment to a gap formed between the conical or tapered side walls of protrusion of holder 50, and opening, recess or cavity 80 of capsule 10.
FIGS. 2A to 2C show different exemplary cross-sectional side views of different types of liquid exit ports 146, 246, 346 arranged at a bottom wall 17 of capsule 10, liquid exit ports 146, 246, 346 configured to deliver vaporizable material EL to wicking element 76 in channel or space 90 of holder 50, when capsule 10 is connected or attached to holder 50, and also show different types of opening devices 178, 278, 378 arranged in the capsule receiving cavity or opening 80 of the holder 50 having an area where capsule 50 will be placed. For example, in FIG. 2A, opening device 178 is embodied as a cannula or hollow tube, having an oblique upper edge for piercing a seal membrane layer 148 that forms a closing lid for capsule 10, for example made of metal, having one or more traversing openings 177 at a base portion thereof, so that vaporizable material EL can pass inside cannula to the traversing openings 177 to reach wicking element 76, when capsule 10 connected to holder 50. It is also possible that there is no dedicated seal membrane layer 148, but that opening device 178 pierces through bottom wall 17 of capsule 10. In this variant, liquid exit port 146 remains open once capsule 10 is removed from holder 50, but could be manually closed by an adhesive layer, a plug, or a lid. Also, in this variant, an alternative version of first heating element 72 is shown, having a toroid shape, with an empty space in the middle where opening device 178 is arranged.
Moreover, FIG. 2B shows another variant where a re-closable liquid exit port 246 is presented, having a compressible element such as a spring 242 that is held by a holding structure 245, compressible element 242 pressing or urging against a plug 243 that closes the opening in wall 14 of capsule 10, the holding structure 245 having one or more traversing openings 249, for letting vaporizable material EL pass towards opening. Opening element 278 can be a simple rod, column, or bolt that is smaller in diameter than an opening in bottom wall 17 of capsule 10 to urge or push back plug 243 when capsule 10 is connected to holder 10, or can be a tube or hollow cylinder with upper and lower wall-traversing openings, 279, 277 for improved fluidic connection between reservoir 40 and space or channel 90. Lower opening 277 can laterally lead directly to wicking element 76. Upon removing of capsule 10 from holder 50, plug 243 is pushed down by compressible element 242 as it is not being pushed by opening element 278 anymore.
FIG. 2C shows yet another variant where a re-closable liquid exit port 346 is presented, having a tubular compressible and expandable element 342 such as an elastic tube that is held by a holding structure 345, a lower end of tubular compressible and expandable element 342 holding a plug 343 for closing an opening in bottom wall 17 of capsule 10. Moreover, opening device 378 is embodied as a bolt, rod, pin, column, protrusion that can push against plug 343 Upon insertion and connection of holder 50 to capsule 10, bolt 378 presses against plug 343, and due to its tubular structure and upwardly movement, expandable element 342 will compress to become shorter and will simultaneously expand, so that plug 343 will move upwards. As a diameter of bolt 378 is designed to be smaller than a diameter of opening in bottom wall 17 of capsule 10, vaporizable material EL can flow from reservoir 40 to channel 90 that includes wicking element 76. Upon removing of capsule 10 from holder 50, plug 343 is pushed down by compressible element 342 as it is not being pushed by rod 378 anymore.
FIGS. 3A to 3G depict different views of a capsule 10 and a holder 50 for capsule 10, schematically depicting different arrangements and structures for embodying one or more venting holes 84 to provide for an air intake to capsule accommodating opening 80 or chamber 90. FIG. 3A showing a cross-sectional side view showing a capsule 10 with a conically- and ring-shaped wicking element 76 around a conical wall 14 of capsule 10, and showing a holder 50 having a conically- and ring-shaped heater element 70 with a heating surface that matches an outer surface of wicking element 76 when capsule 10 is inserted and connected to opening 50. Venting holes 84 form channels that lead radially towards opening 80 to provide for air below heating element 70 and wicking element 76, to chamber 90. In this variant, holder 50 includes two separate parts, with upper capsule holding part 51, and lower battery holding part 53. Capsule holding part 51 can be made removable from battery holding part 53, as heater 70 may age and degrade and need replacement. An attachment mechanism can be provided to removably attach capsule 10 to holder 50, such that a compressive force is exerted by surface of heater 70 to wicking element 76 when interconnected, but is not shown here. Moreover, wicking element 76 is formed within a ring-like recess in side wall 14 of capsule 10, such that only a portion of wicking element is protrudes out from recess, for compression by heating element 70 when capsule 10 and holder 50 are interconnected.
FIG. 3B shows another embodiment as a cross-sectional side view with L-shaped vent channels 84 entering from a top face of holder 50 and entering opening 80 through holes that are arranged in heater 70. Moreover, capsule 10 is shown that has a circular ledge 19 that is in parallel to an upper surface of holder 50 when interconnection, such that ledge 19 can press against seal ring or washer 30 for sealing of chamber 90 that is arranged between capsule 10 and holder 50 in capsule accommodating opening 80. When interconnected, entry holes of channels 84 are arranged radially outwardly from axis CA so that they are not obstructed by ledge 19. Walls of heater 70 can include openings or holes that allow for air to pass to chamber 90, but it is also possible that heater 70 is made of two conical rings that are arranged to sandwich channels 84 inbetween.
FIG. 3C shows another variant with a side view and a top view in a direction of axis CA towards holder, showing cut-in recesses 84 at an upper edge of holder 50 serving as venting or air intake holes, and having venting channels 89 along a side surface 83 of opening 90, at least some of the venting channels 89 being in fluidic communication with cut-in recesses 84, in the variant shown a channels leading along a surface of the conically- and ring-shaped inner surface 83 of opening 80. In this variant, a heater 70 is formed having a disk-like shape on bottom surface 77 of capsule accommodating opening 80, and a pin as capsule opening device 78. Air can thereby enter from the exterior environment laterally through cut-in recesses 84 and can then progress and be distributed to chamber 90 via venting channels 89, for example to be lead to a bottom of capsule accommodating opening 80. FIG. 3D showing a side view of a variant where cut-in recesses 84 for air intake are arranged at a lower edge of the capsule 10, and not at the upper edge of holder 50. But in a variant, it is possible that cut-in recesses or holes are arranged at both the capsule 10 and the holder 50.
FIGS. 3E and 3G show a cross-sectional side view and a cross-sectional view of a variant where no seal 30 may be present between capsule 10 and holder 50, and the air intake is made by a gap 584 between capsule 10 and holder 50, when capsule 10 and holder 50 are interconnected to each other. In this respect, upon putting capsule 10 to capsule accommodating opening 80 of holder 50, and the compression of wicking element 76 by heating surface 70, the capsule 10 is dimensioned that a gap 584 is formed having a diameter D1 that is large enough to let air pass into chamber 90. For example, this can be done by a distance D2 between lower surface 17 of capsule 10 and upper surface 77 of opening 80, when capsule 10 and holder 50 are interconnected, is smaller than D1. FIG. 3G shows a cross-sectional view on a direction of axis CA along line CS1 shown in FIG. 3E, where longitudinal grooves 89 are shown within inner surface of heater 70, acting to distribute air entering from gap 584 towards wicking element 76. Grooves 89 can be machined into the metallic element that forms heater 70, and can be distributed around inner surface of heater 70. Moreover, vapor channels 22 are shown that have a slot-like opening or inlet facing the inner side of wicking element 76 to collect the vapor or the atomized liquid from heated wicking element 76, with a plurality of star-like arranged channels 22 leading to vapor pipe 21. In a variant, there can be the same amount of angularly distributed channels 22 and angularly distributed grooves 89. It is also possible that a groove/ridge mechanism is arranged between capsule 10 and opening 80 of holder 50, for example ridges or knobs that engage with grooves 89 of heater 70 or surface 83, so that capsule 10 is always connected to opening 80 with a certain angular orientation to each other. This allows to ascertain that vapor channels 22 and grooves 89 can be arranged to face each other when capsule 10 and holder 50 are interconnected, or arranged not to face each other.
FIG. 3G shows a cross-sectional, exemplary view of different channels at an interface area that forms chamber 90 between capsule 10 and holder 50 when they are interconnected with each other, with surface 17 of capsule 10 and surface 77 of opening 80 facing each other and arranged in parallel, having a wicking element 76 compressed therein, and forming a vapor chamber or channel 90. In this representation, surfaces 17, 77 are shown to be linear, but they could also be curved and arranged concentrically to each other, oval, slanted, depending on the application and form of capsule 10 used. It shows that vapor channels 22 that are in fluidic connection with vapor pipe 21 are arranged with inlets that directly face a surface of wicking element 76, and that a heating surface of heater 70 will be located opposite of inlets of channels 22, to be in contact with the opposite side of wicking element 76, forming the heating zone HZ. This arrangement allows for rapid evacuation of vapor made from vaporizable material EL formed in heating zone HZ towards inlets of channels 22. Exemplarily, three channels 22 are shown, but there can be more or less. On more liquid exit ports 46 can be arranged in the walls of capsule 10, to provide for a fluidic connection between reservoir 40 and chamber 90. In the variant shown, liquid exit ports are arranged to directly lead to the wicking element 76. Preferably, wicking element 76 is attached to wall 17 capsule 10, and not to wall 77 of opening 80. One or more air channels 89 can be present in surface of wall 17, also directly leading to a surface of wicking element 76 to improve aeration of wicking element 76 by air from the exterior environment, arriving via vent openings 84, 584.
FIGS. 4A to 4C show exemplary views of another embodiment of the capsule 410 for an electronic cigarette or vaporizing system 300, with capsule 410 having a closing ring 413 that allows to manually open and close a delivery of vaporizable material EL from reservoir 440 to wicking element 476. In this embodiment, capsule 410 includes an inhalation side or upper part 411 and a holder side or lower part 412, and a rotatable ring 413 inbetween, arranged inside a circular recessed ring. Upper and lower part 411, 412 can be fixed together with different attachment means, for example but not limited to a snap-in mechanism, adhesive, lock, threading. In the variant shown, lower part 412 includes a vapor pipe 421 that is arranged to fully traverse the upper part 411 via a corresponding bore or hole 419, and upper part 411 includes a toroid-shaped inner cavity as the reservoir 440 for the vaporizable material EL. For example, in a removable configuration, corresponding threading can be arranged along outer surface of vapor pipe 421 and inner surface of hole or bore 419, or a threaded nut can be arranged at the vapor exit port 413 to removably attach upper and lower part 411, 421 together. In a variant, a snap-in or ratchet like surface can be arranged on the surfaces of hole or bore 419 and vapor pipe 421.
FIG. 4B shows a cross-sectional view in a viewing direction of axis CA along line CS2 shown in FIG. 4A, showing rotatable ring 413 having a seal layer 430 provided thereon, with openings for each liquid channel 492 that traverses the ring 413, channels 492 shown to be being arranged substantially in parallel with axis CA. In the assembled state, rotatable ring 413 can be turned to different angular positions around axis CA such that positions of liquid exit ports 446 can match with positions of liquid channels 422 that provide for an outlet of vaporizable material EL from reservoir 440 of upper part 411, forming a fluidic pathway from reservoir 440, to liquid exit ports 446, to liquid channel 492 of ring 413, and to wicking element 476 for soaking the wicking element 476, so that the vaporized EL can continue to vapor channels 422 after vaporization with wicking element 476. By turning ring 413 to a different position, all of liquid exit ports 446 can be closed by the angular mismatch of the positions of liquid exit ports 446 relative to liquid channels 492, or the cross-section of a fluidic area for EL can be reduced, by a partial mismatch of positions of liquid exit ports 446 relative to channels 492. As shown in FIG. 4B, ring 413 can be equipped with protruding knobs or ridges 497 to facilitate manual turning by user, and these knobs can be arranged to protrude slightly away from an outer surface of capsule 410. In this embodiment, the fluid chamber 490 is formed by the area that is occupied by wicking element 476.
FIG. 4C shows a cross-sectional view in a viewing direction of axis CA along line CS3 that is shown in FIG. 4A, showing a star-like arrangement of vapor inlets and channels 422 that lead to the centrally-arranged vapor pipe 421. As shown in FIG. 4A, each inlet of channel 422 can have a longitudinal slot-like shape, to face a large surface area of the inner surface of wicking element 476. Also, in the variant shown, upper side surface of wicking element 476 directly face outlet or exit openings of channels 492 of ring 413, so that the EL can directly soak into wicking element 476 from the top. Ring 413 is arranged that it can be turned relative to upper part 411 regardless of whether capsule 410 is connected to holder 450 or not, but in a variant, walls of opening 80 are arranged to cover outer surface of ring 413, so that it cannot be turned in a connected position. Moreover, wicking element 476 slightly protrudes or reaches out over a surface define by wall 414, so that in a connected position with holder 450, heating surfaces of heater 470 will compress wicking element 476 towards capsule 410.
With the present embodiments of the atomizing, vaporization, or electronic cigarette system 100, 300, discussed herein, it is possible to fully dissociate the heating device 70 from the capsule 10 or other type of liquid container element, specifically for the case where the capsule, cartridge, or other container 10 is removable from a holder, to thereby provide for several advantages over the state of the art. For example, this design allows to provide for a more complex but also more reliable heating structure and design, as the heating device 70 can be part and can also be fixedly installed to the holder 50, 450, thereby avoiding electric connection terminals to the capsule 10, and proposing simpler capsule design with no electric elements. In addition, wicking elements 76, 476 are still part of the disposable capsule 10, 410, and are thereby still replaced on a regular basis, as contaminants can accumulate therein. This allows to provide for more complex heating systems with two or more heating zones HZ1, HZ2, to provide for selective heating of a wicking element like mesh layers 76, 476 area where vaporizable material EL is accumulated. As the active heating system is thereby fully placed inside the re-usable holder, and not inside the disposable capsule, the heating system can be made more reliable with more solid and reliable parts and design. The less complex design of capsule 10, 410 allows to make capsules cheaper, using less parts, being less prone to failure and also made entirely of recyclable parts, to reduce its carbon footprint.
While the invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments, and equivalents thereof, are possible without departing from the sphere and scope of the invention. Accordingly, it is intended that the invention not be limited to the described embodiments, and be given the broadest reasonable interpretation in accordance with the language of the appended claims. The features of any one of the above described embodiments may be included in any other embodiment described herein.

Claims

1. An electronic cigarette system comprising:

a liquid capsule including a reservoir for holding vaporizable material, a holder-facing surface, a vapor pipe with an vapor inlet at the holder-facing surface, an inhalation opening, and a liquid exit port arranged at the holder-facing surface;

a capsule holder for removably receiving the liquid capsule, the capsule holder including a capsule accommodating opening, the capsule holder having a heating device; and

a wicking element for being soaked with the vaporizable material,

wherein when the liquid capsule and the capsule holder are interconnected to each other, a fluid chamber is formed between an outer surface of the capsule accommodating opening of the capsule holder and the holder-facing surface of the liquid capsule, and the fluid chamber having the wicking element arranged therein is exposed to a heating surface of the heating device,

wherein when the liquid capsule and the capsule holder are interconnected to each other, a fluidic connection path is formed from the reservoir to the fluid chamber via the liquid exit port, from the fluid chamber to the vapor pipe via the vapor inlet, to reach the inhalation opening, and

wherein the capsule accommodating opening of the capsule holder is formed by a bottom wall and a conically-shaped side wall.

2. The electronic cigarette system of claim 1, wherein the holder facing surface of the liquid capsule comprises:

a bottom wall including the liquid exit port, and

a conically-shaped side wall including an entrance to a vapor channel that leads to the vapor pipe, the conically-shaped side wall of the liquid capsule is shaped complementary to the conically-shaped side wall of the capsule accommodating opening.

3. The electronic cigarette system of claim 1, wherein the heating device includes a first heating element for heating at a temperature T1, a second heating element for heating at a temperature T2, the first heating element arranged upstream along the fluidic connection path as compared to the second heating element-, wherein T2>T1.

4. The electronic cigarette system of claim 3, wherein the first heating element includes a plate-like shaped heater arranged at the bottom wall of the capsule accommodating opening, and the second heating element includes a ring-shaped heater arranged around the conically-shaped side wall of the capsule accommodating opening.

5. The electronic cigarette system of claim 1, wherein the capsule holder includes a valve opening device for opening the liquid exit port when the liquid capsule is connected to the capsule holder.

6. The electronic cigarette system of claim 2, wherein the wicking element is arranged at the second conically-shaped side wall of the liquid capsule,

wherein when the liquid capsule and the capsule holder are interconnected to each other, the conically-shaped side wall of the capsule holder and the conically-shaped side wall of the liquid capsule exert a compressive force to the wicking element.

7. The electronic cigarette system of claim 1, further comprising:

a sealing element arranged between the liquid capsule and the capsule holder.

8. The electronic cigarette system of claim 1, wherein the capsule holder includes an air inlet channel in fluidic communication with an external environment and the fluid chamber.

9. The electronic cigarette system of claim 1, wherein the liquid capsule includes a turnable ring configured to open and close a fluidic communication between liquid exit ports and the fluid chamber.

10. An electronic cigarette system comprising:

a first element having a liquid container for holding vaporizable material, a vapor pipe that is configured to at least partially traverse the liquid container, and a liquid exit port; and

a second element including an opening for receiving the first element, a mechanism for opening the liquid exit port, and a heater; and

a wicking element for being soaked with vaporizable material,

wherein the mechanism for opening the liquid exit port is configured to open the liquid exit port when the first element is placed into the opening of the second element, and

wherein the opening of the second element has a conical surface, and the heater is configured to heat the conical surface of the opening.

11. The electronic cigarette system of claim 10, wherein the heater includes a circular heating device arranged around the conical surface, and the heater is configured to match with a position of the wicking element of the second element.

12. The electronic cigarette system of claim 10, wherein at least one of the first and the second element includes a connection mechanism for removable interconnection of the first element with the opening of the second element.

13. The electronic cigarette system of claim 13, wherein the interconnection of the first and the second element exerts a compressive force on the wicking element by the conical surface.

14. The electronic cigarette system of claim 10, further comprising:

a seal arranged on an inner circumference of the second element or on an outer circumference of the first element.