WO2025195950A1

WO2025195950A1 - An electronic cigarette

Info

Publication number: WO2025195950A1
Application number: PCT/EP2025/057171
Authority: WO
Inventors: Juraj LEHOCKY
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2024-03-22
Filing date: 2025-03-17
Publication date: 2025-09-25
Anticipated expiration: 2026-09-22

Abstract

An electronic cigarette (1) comprising: a tubular casing (10); a battery compartment (20) within the tubular casing, the battery compartment configured to receive a battery (21); a first partition (30) at a first end of the battery compartment and a second partition (40) at a second end of the battery compartment, the first and second partitions configured to provide an airtight seal to the battery compartment. A sodium carbonate layer (41) may be provided on an inner surface of at least one of the partitions (30, 40) to release carbon dioxide for extinguishing a fire in the battery compartment.

Description

AN ELECTRONIC CIGARETTE

FIELD OF THE INVENTION

The present invention relates to an electronic cigarette, in particular an electronic cigarette requiring a power supply unit or battery supply.

BACKGROUND

Electronic cigarettes are an alternative to conventional cigarettes. Instead of generating a combustion smoke, they vaporize a liquid, which can be inhaled by a user. The liquid typically comprises an aerosol-forming substance, such as glycerin or propylene glycol that creates the vapor. Other common substances in the liquid are nicotine and various flavorings.

The electronic cigarette is a hand-held inhaler system, comprising a mouthpiece section, a liquid store and a power supply unit. Vaporization is achieved by a vaporizer or heater unit which typically comprises a heating element in the form of a heating coil and a fluid transfer element, such as a wick, arranged to transfer fluid from the liquid store to the heating element. Vaporisation occurs when the heater heats up the liquid in the fluid transfer element until the liquid is transformed into vapor. The vapor can then be inhaled via an air outlet in the mouthpiece.

The electronic cigarette may comprise a battery section configured to receive a power supply unit or battery and a cartridge comprising the liquid store. The cartridge and the vaporizer are often referred to as “cartomizers”. The power supply unit is connected to the vaporizer of the cartomizer such that electricity can be supplied to the heater of the cartomizer to heat the liquid so as to generate the vapor.

There exists a problem in prior art devices wherein the batteries in the electronic device are susceptible to thermal runaway. The term “thermal runaway” is used to describes a process that accelerates by increasing the temperature and in turn releasing energy that further increases temperature. This phenomenon occurs when an increase in temperature alters the conditions in a way that results in a further increase in temperature.

In the context of a battery, thermal runaway occurs when the temperature inside a battery reaches the point that causes a chemical reaction to occur inside the battery. This chemical reaction produces even more heat, which drives the temperature higher, causing further chemical reactions that create more heat. Furthermore, if oxygen is added a chain reaction is started creating extremely high temperatures (around 400 degrees of Celsius). These temperatures can cause gassing of the battery and a fire that is difficult to extinguish. The batteries required in an electronic cigarette are susceptible to these issues.

Thermal runaway is very dangerous in an electronic cigarette as it may result in a fire within the battery section of the device. It is therefore desirable to provide an electronic cigarette which reduces the risk of thermal runaway and fires, thereby improving the safety and/or reliability of the electronic cigarette.

SUMMARY OF INVENTION

It is an object of the present invention to provide an electronic cigarette which makes progress in solving some of the problems of prior art devices identified above.

According to a first aspect of the present invention, there is provided an electronic cigarette comprising: a tubular casing; a battery compartment within the tubular casing, the battery compartment configured to receive a battery; a first partition at a first end of the battery compartment and a second partition at a second end of the battery compartment, the first and second partitions configured to provide an airtight seal to the battery compartment.

The term “partition” used herein may refer to a physical division disposed at an end of the battery compartment so as to provide a barrier between the battery compartment and rest of the electronic cigarette. The term “airtight seal” as used herein refers to a seal in which air is prevented from escaping or pass through. In this way, the first and second partitions are configured to provide an enclosed space in which there are no gaps or openings allowing air to enter or escape through.

When a battery in a device experiences thermal runaway, it can overheat and catching fire. By including a first and a second partition arranged at respective ends of the battery compartment and provide an airtight seal to the battery compartment, an oxygen supply is restricted into the battery compartment. This prevents the thermal runaway and/or significantly slows it down. This improves the safety and/or reliability of the electronic cigarette. This also provides the customer with additional time to remove the vape from their pocket and prevent injuries.

In some examples, the first partition and second partitions each comprise an outer peripheral edge arranged so as to provide a seal with an inner side wall of the tubular casing.

In this way, there are no gaps or openings between the partition and inner side wall of the tubular casing, such that no air or gases may be exchanged into or out of the battery compartment at this boundary. Therefore, the battery compartment is provided with an effective airtight seal, thereby improving the safety and/or reliability of the electronic device.

In some examples, at least one of the first partition and second partition comprises a flexible material thereby providing an interference fit between the inner side wall of the tube casing and said partition.

Preferably, the first partition and second partition have a slightly larger diameter measurement or cross section to that of the tube casing. Therefore, when the first partition and second partition are situated in the tube casing, the interference between the partitions and the tube casing provide a tight, airtight seal. As such, this example does not require additional adhesives, fasteners or other means for securing parts together, resulting in a simple design. The term “flexible material” may refer to a material that deforms under force without breaking or losing its structural integrity i.e. when the force is removed it returns to its original dimensions. In this way, the partitions help to reduce the pressure in the battery compartment by flexing outwards from the compartment if a pressure builds in the battery compartment.

In some examples, at least one of the first partition and second partition comprises silicon.

Advantageously, silicon is flexible and durable such that it resists wear caused by, for example, an interference fit application. This ensures a secure, airtight seal. Moreover, silicon has a low coefficient of thermal expansion meaning it can withstand temperature changes without significantly changing in dimensions. This is advantageous as the interference fit will not become loose due to a rise in temperature of the electronic cigarette or battery compartment. In some examples, the silicon is HT-RTV 530 Shore A30 or Dowsil 736 High temperature silicone.

Preferably, the silicon is high-temperature food grade silicone. In this way, the silicon will not contain harmful substances which will harm the consumer when using the electronic cigarette.

In some examples, the electronic cigarette further comprises a sodium carbonate layer arranged on an inner surface of at least one of the first partition and second partition.

The sodium carbonate layer may release carbon dioxide. Carbon dioxide smothers fires, depriving them of oxygen and breaking the chemical reaction required for the fire to sustain itself. In particular, sodium carbonate is effective at extinguish chemical fires that may occur when a certain type of battery is used, such as a Nickel metal hydride (NiMH), a Lithium polymer (Li-Pol) or a Lithium ion (Li-Ion) battery. In this way, the sodium carbonate layer can aid in preventing and extinguishing a fire in the battery compartment, thereby further improving the safety and/or reliability of the electronic cigarette. Preferably, the sodium carbonate layer is high-temperature food grade silicone. In this way, the silicon will not contain harmful substances which will harm the consumer when using the electronic cigarette.

In some examples, the second partition is at the distal end of the electronic cigarette, the distal end opposite to a mouthpiece end, wherein the second partition comprises a vent point configured to release gas from the battery compartment if pressure within the battery compartment exceeds a threshold.

Certain types of batteries may experience leaks or degassing events where a fluid, (e.g. a liquid or gas) is produced and released from the battery. For example, Li- ion batteries are known to experience degassing events. These events can be slow or small events that fall within normal behaviour of the battery, and do not necessarily compromise the functionality of the aerosol generation device. However, these events can also be rapid events that cause high pressures. This is particularly concerning when coupled with a thermal runaway event in the battery compartment and may lead to damage to the electronic cigarette or even cause the electronic cigarette to explode. In this way, by providing a vent point configured to release gas from the battery compartment when pressure within the battery compartment exceeds a threshold, the pressure inside the battery compartment may be decreased. Therefore, the vent point helps to release gases from the battery compartment in a controlled way. This further improves the safety and/or reliability of the device. Moreover, in this arrangement, if the thermal runaway is inevitable, controlled gasses release through the bottom part of the device directing them out of the customer’s face.

In some examples, the vent point comprises a thinner part of the second partition so as to provide a preferential rupture point above the threshold. In some examples, the preferential rupture point may be a valve. Since the preferential rupture point is thinner than the rest of the partition, it is less able to withstand to the forces exerted on it by the air pressure inside the battery compartment. In this way, the pressure exerted on the thinner part may result in a rupture and therefore a leak. As such, this preferential rupture point will prevent the tube casing from exploding or the whole partition from blowing up and would open at the preferential rupture point instead. In this way, gas may be released from the battery compartment in a controlled way. This may be considered as a “backup option” only in case there is an oxygen supply into the battery and thermal runaway cannot be prevented.

In some examples, at least one of the first partition and second partitions comprise a flexible material with at least one cable opening configured such that a cable may pass through the cable opening, the cable opening comprising a diameter smaller than the diameter of the cable.

The at least one partition being made of a flexible material allows the diameter of the opening to be widened slightly when inserting the cable. When the material relaxes, it will contract around the cable proving a tight fit. In this way, the at least one of the first partition and second partitions provide a tight seal around the cable, preventing air from entering the battery compartment through the opening. Therefore, the battery compartment is able to supply electricity to other components of the device via the cable, while being situated in an airtight battery compartment. This allows the battery to be isolated from other components of the electronic cigarette while providing its intended functionality. Additionally, the cable is held securely by the cable opening.

In some examples, the diameter of the at least one cable opening is between 20% and 30% smaller than the diameter of the cable.

According to a second aspect of the present invention, there is provided a method of manufacturing an electronic cigarette of any preceding claim, the method comprising: providing a tubular casing for an electronic cigarette; casting a first and second partition within a mould; and securing the first and second partitions within the tubular casing to form a battery compartment with the first partition at a first end of the battery compartment and the second partition at the second end of the battery compartment, such that the first and second partitions provide an airtight seal to the battery compartment.

According to a third aspect of the present invention there is provided a method of manufacturing an electronic cigarette of any of claims 1 to 9, the method comprising: providing a tubular casing for an electronic cigarette; arranging a first support at first end of the battery compartment and pouring a liquid partition former into the tubular casing to form a first partition on the first support at first end of the battery compartment; and providing a second partition at a second end of the battery compartment, such that the first and second partitions provide an airtight seal to the battery compartment.

By pouring a liquid partition former into the tubular casing directly, the first partition is formed directly in the electronic cigarette. In this way, a tight seal is provided between the tube casing and the first partition. In some examples, the liquid partition former comprises silicon.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1a and 1b illustrate an electronic cigarette according to the present invention;

Figure 2 illustrates a first and/or second partition of an electronic cigarette according to the present invention;

Figure 3 illustrates a first and/or second partition of an electronic cigarette according to the present invention;

Figure 4 illustrates a first and/or second partition of an electronic cigarette according to the present invention;

Figure 5a-5d illustrate a method of manufacturing an electronic cigarette according to the present invention;

Figure 6 illustrates a flow diagram of a method of manufacturing an electronic cigarette according to the present invention;

Figure 7 illustrates a flow diagram of a method of manufacturing an electronic cigarette according to the present invention. DETAILED DESCRIPTION

Figures 1a and 1 b schematically illustrate an electronic cigarette 1 according to the present invention. The electronic cigarette 1 comprises a tube casing 10 as an inhaler body. Within the tube casing 10 is a battery compartment 20 that is configured to receive a battery 21. The electronic cigarette 1 further comprises a first partition 30 at a first end of the battery compartment 20 and a second partition 40 at a second end of the battery compartment 20. The first partition 30 and second partition 40 are configured to provide an airtight seal to the battery compartment 20.

As shown in Figure 1a and 1b, the first partition 30 and the second partition 40 each comprise an outer peripheral edge arranged so as to provide a seal with an inner side wall of the tubular casing 10. In this example, the first partition 30 and second partition 40 comprise a flexible material so as to provide an interference fit between the inner side wall of the tube casing 10 and said partition 30 40. In this way, the first partition 30 and second partition 40 are securely held in place within the tube casing 10 without requiring an additional securing means. Although not required, in some examples, it may be advantageous to additionally include other securing means if the electronic cigarette 1 requires a more robust hold between the tube casing 10 and the said partitions 30 40. Silicone glue may be applied to the peripheral edge of the partition 30 40 between the partition 30 40 and the inner wall of the tube casing 10.

The battery 21 is used to supply electricity to one or more other components of the electronic cigarette 1. For example, powerfrom the battery 21 may be required by a heating element additionally included in the electronic cigarette 1 in order to vaporise liquid. As shown in Figure 2, in some examples, the first partition 30 comprises two cable openings 31a 31b configured such that cables 22a 22b may pass through each of the corresponding cable openings 31a 31b. In this example, the first partition 30 comprises a flexible material and the cable openings 31a 31 b comprising a diameter smaller than the diameter of the cables 22a 22b. Both of these characteristics improve the airtight seal between the firth partition 30 and the cables 22a 22b. The flexible material allows the diameter of the openings 31a 31 b to be widened slightly when inserting the cable. When the material relaxes, it will contract around the cable proving a tight fit.

In some examples, the diameter of the cable openings 31a 31 b is between 20% and 30% smaller than the diameter of the cables 22a 22b. In a specific example, the cables 22a 22b may have a diameter of 1 mm, and the diameter of the cable openings 31a 31 b may be in the range of 0.7-0.8mm.

The cable openings 31a 31b may comprise additional components to enhance the tight fit around the cables 22a 22b. The additional component may include a ring seal (e.g. an 0-ring) situated around the cable 22a 22b at the cable opening 31a 31 b so as to improve the airtight seal.

In some examples, both the first partition 30 and second partition 40 may comprise cable openings 31a 31b, depending on where the battery compartment 20 is situated in the tube casing 10 relative to other components which require a power supply from the battery 21 . There may be any number of cable openings 31 a 31 b in the partition 30 40.

In any of the electronic cigarettes 1 described herein, the first partition 30 and second partition 40 may comprise silicon. In some examples, the silicon is HT- RTV 530 Shore A30 or Dowsil 736 High temperature silicone.

Figure 3 illustrates a partition 40 of an electronic cigarette 1 according to the present invention. As shown in Figure 3, the electronic cigarette 1 may further comprise a sodium carbonate layer 41 arranged on an inner surface of at least one of the first partition 30 and second partition 40. The inner surface is the surface of the partition 40 facing the battery 21 of the battery compartment 20.

Figure 4 illustrates a partition 40 of an electronic cigarette 1 according to the present invention wherein the partition 40 comprises two vent points 42a 42b. Specifically Figure 4 shows the second partition 40 intended to be arranged at the distal end of the electronic cigarette 1 , wherein the distal end is opposite to a mouthpiece end. The second partition 40 comprises two vent points 42a 42b configured to release gas from the battery compartment 20 if pressure within the battery compartment exceeds a threshold. In some examples, the vent points 42a 42b comprises a thinner part of the second partition 40 so as to provide a preferential rupture point above the threshold.

The preferential rupture point in Figure 4 is shown to be a cross shaped slit at each of the vent point 42a 42b. In some examples, the preferential rupture point may instead be a single line slit. When the pressure exceeds the threshold, the preferential rupture point may transition from a closed configuration in which air does not enter or leave the battery compartment 20, to an open configuration in which air may pass through the preferential rupture point. When in an open configuration, air leaves the battery compartment 20, resulting in depressurisation of gas in the battery compartment 20. The preferential rupture point may be configured to open passively when the pressure of the air in the battery compartment 20 reaches a threshold, or may instead be configured to actively open when above this threshold. The preferential rupture point may be configured such that only pressure from inside the battery compartment 20 may cause a transition from an open configuration to a closed configuration, pressure from outside the battery compartment 20 may not cause such a transition.

In other examples, both the first and second partition 3040 may comprise at least one vent point, and some examples the first and second partition 30 40 may comprise more or less vent points 42a 42b.

Figures 5a and 5b show a first method 100 of manufacturing an electronic cigarette 1 according to the present invention which includes using a process known as “casting”. This method 100 is also described in Figure 6.

As shown in Figure 5a and described at S101 of Figure 6, the method 100 comprises providing a tubular casing 10 for an electronic cigarette 1. At S 102, a first support 50 is arranged at a first end of the battery compartment 20. The first support 50 may comprise a paper or plastic insert pressed into the tube casing 10. The tube casing 10 may comprise metal. At S103, liquid partition former is poured into the tubular casing 10 to form a partition 40 on the first support 50 at first end of the battery compartment 20.

The liquid partition former may comprise silicon. In this example, silicon is melted at an appropriate temperature before pouring into the tube casing 10. Preferably, the silicon is poured to form a 1 mm layer. To remove trapped air bubbles, the silicon may also be degassed using an appropriate degassing method. The silicon is then cooled and/or cured. In some examples, the support 50 may be removed from the tube casing 10 after casting. The first and/or second partition may be formed using the casting method steps S101-S103.

After forming the partition 40, the battery 21 and any battery fixtures may be inserted into the tube casing 10, as schematically shown in Figure 5c.

In examples where only one partition 30 40 is formed using the casting method in steps S101-S103, the other partition may then be provided. At step S104, a partition 30 at a second end of the battery compartment 20 is provided, such that the first and second partitions 30 40 provide an airtight seal to the battery compartment 20. This is schematically shown in Figure 5d. Any cables protruding from the battery 21 may be feed through cable openings 31a 31 b of the partition 30 as the partition 30 is inserted. The ordering of these steps may vary based on the arrangement of the components of the electronic cigarette 1 and may include additional steps of inserting and/or securing other components.

Figure 7 describes a second method 200 of manufacturing the electronic cigarette 1 according to the present invention, where the first and/or second partition 3040 are cast within a mould.

Step S201 of the method 200 comprises providing a tubular casing for an electronic cigarette 1. Step S202 comprises casting a first and second partition 30 40 within a mould. The mould is shaped so as to produce a partition of desired shape. In some examples, the desired shape may be that of the cross section of the tubing case 10 or it may be shape of slightly bigger dimensions to the cross section of the tubing case, so as to provide a tight seal when secured in the tube casing 10. The casting process using a mould may be similar to that described in relation to Figure 5a and Figure 5b but is instead of pouring a liquid partition former into the tube casing 10 casing directly, the liquid partition former is poured into a mould.

At step S203, the first and second partitions 30 40 are secured within the tubular casing 10 to form a battery compartment 20 with the first partition 30 at a first end of the battery compartment 20 and the second partition 40 at the second end of the battery compartment 20, such that the first and second partitions 3040 provide an airtight seal to the battery compartment 20.

In examples where the electronic cigarette 1 further comprises a sodium carbonate layer 41 arranged on an inner surface of at least one of the first partition and second partition 30 40, the method 100 200 of manufacturing may further comprise inserting the silicon carbonate into the mould/tube casing 10 before liquid partition former is poured. In this way, the liquid former may weld to the sodium carbonate layer as it hardens/cures. Alternatively, the silicon carbonate layer may be added to a semi-cured liquid partition former. Alternatively, the sodium carbonate layer may be formed separate from the partition 30 40 into a rigid layer and glued to the partition 30 40 using an adhesive or welded to the partition 30 40 by appropriate means.

Claims

1 . An electronic cigarette comprising: a tubular casing; a battery compartment within the tubular casing, the battery compartment configured to receive a battery; a first partition at a first end of the battery compartment and a second partition at a second end of the battery compartment, the first and second partitions configured to provide an airtight seal to the battery compartment.

2. An electronic cigarette according to claim 1 , wherein the first partition and second partitions each comprise an outer peripheral edge arranged so as to provide a seal with an inner side wall of the tubular casing.

3. An electronic cigarette according to claim 2, wherein at least one of the first partition and second partition comprises a flexible material thereby providing an interference fit between the inner side wall of the tube casing and said partition.

4. An electronic cigarette according to any preceding claim, wherein at least one of the first partition and second partition comprises silicon.

5. An electronic cigarette according to any preceding claim, further comprising a sodium carbonate layer arranged on an inner surface of at least one of the first partition and second partition.

6. An electronic cigarette according to any preceding claim, wherein the second partition is at the distal end of the electronic cigarette, the distal end opposite to a mouthpiece end, wherein the second partition comprises a vent point configured to release gas from the battery compartment if pressure within the battery compartment exceeds a threshold.

7. The electronic cigarette according to claim 8, wherein the vent point comprises a thinner part of the second partition so as to provide a preferential rupture point above the threshold.

8. An electronic cigarette according to any preceding claim, wherein at least one of the first partition and second partitions comprise a flexible material with at least one cable opening configured such that a cable may pass through the cable opening, the cable opening comprising a diameter smaller than the diameter of the cable.

9. An electronic cigarette according to claim 8, wherein the diameter of the at least one cable opening is between 20% and 30% smaller than the diameter of the cable.

10. A method of manufacturing an electronic cigarette of any preceding claim, the method comprising: providing a tubular casing for an electronic cigarette; casting a first and second partition within a mould; and securing the first and second partitions within the tubular casing to form a battery compartment with the first partition at a first end of the battery compartment and the second partition at the second end of the battery compartment, such that the first and second partitions provide an airtight seal to the battery compartment.

11. A method of manufacturing an electronic cigarette of any of claims 1 to 9, the method comprising: providing a tubular casing for an electronic cigarette; arranging a first support at first end of the battery compartment and pouring a liquid partition former into the tubular casing to form a first partition on the first support at first end of the battery compartment; and providing a second partition at a second end of the battery compartment, such that the first and second partitions provide an airtight seal to the battery compartment.