HEATING CORE, ELECTRONIC CIGARETTE, AND PREPARATION METHODS THEREOF

A heating core includes a conductor and an e-liquid absorber. The conductor includes a cavity and the e-liquid absorber is disposed in the cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. § 119 and the Paris Convention Treaty, this application claims foreign priority to Chinese Patent Application No. 202111015823.8 filed Aug. 31, 2021, to Chinese Patent Application No. 202122104062.5 filed Aug. 31, 2021, to Chinese Patent Application No. 202111109634.7 filed Sep. 22, 2021, and to Chinese Patent Application No. 202122292024.7 filed Sep. 22, 2021. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P. C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, Mass. 02142.

BACKGROUND

The disclosure relates to a heating core, an electronic cigarette, and preparation methods thereof.

A conventional electronic cigarette includes e-liquid absorbent cotton or a ceramic body for absorbing the e-liquid to be atomized. The absorption effect of the ceramic body on thick e-liquid is not good. The cotton is loose and the e-liquid may leak therefrom. In addition, when the atomized e-liquid cools to yield the condensate, the condensate tends to block the air channel of the electronic cigarette. Furthermore, the e-liquid absorbent cotton may burn due to excessive heat. The e-liquid absorbent cotton is usually manually disposed within the conventional electronic cigarette. The manual operation cannot ensure the uniformity of the cotton, thus affecting the taste of the electronic cigarette.

SUMMARY

The first objective of the disclosure is to provide a heating core; the heating core comprises a conductor and an e-liquid absorber with a fixed structure; the conductor comprises a cavity and the e-liquid absorber is disposed in the cavity.

The second objective of the disclosure is to provide an electronic cigarette comprising the heating core.

The third objective of the disclosure is to provide a preparation method for the heating core, and the method comprises: fixing the conductor comprising the cavity in a mold; injecting a solidifiable material into the mold, and guiding the solidifiable material to the cavity; and solidifying the solidifiable material in the cavity to form the e-liquid absorber.

The fourth objective of the disclosure is to provide a preparation method for the electronic cigarette, the method comprises: preparing the heating core; and inserting the heating core into an e-liquid tank to form an electronic cigarette.

DETAILED DESCRIPTION

To further illustrate the disclosure, embodiments detailing a heating core, an electronic cigarette, and preparation methods thereof are described below. It should be noted that the following embodiments are intended to describe and not to limit the disclosure.

A heating core comprises a conductor and an e-liquid absorber with a fixed structure. The conductor comprises a cavity and the e-liquid absorber is disposed in the cavity.

As shown inFIGS.1-2, a heating core comprises the conductor1and an e-liquid absorber2. The conductor1comprises a cavity11disposed in the e-liquid absorber2. The conductor1is wrapped around the e-liquid absorber2to increase the heating area so that the heat can be transferred rapidly between the conductor1and the e-liquid absorber2. The e-liquid absorber2is formed using an injection molding process which offers advantages such as automatic production and consistency in product quality, thus improving the taste of the e-cigarette. The e-liquid absorber2is used to seal the cavity11to prevent leakage of the e-liquid. The temperature of the conductor1reduces the viscosity of the e-liquid to improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity11.

In certain examples, the e-liquid absorber2is obtained by injecting solidifiable material into a mold, and then hardening and sintering the solidifiable material. The e-liquid absorber2is formed using the injection molding process which offers advantages such as automatic production and consistency in product quality, thus improving the taste of the e-cigarette.

The e-liquid absorber2includes, but is not limited to, ceramic, mica, and e-liquid absorbing resin. The conductor1includes, but is not limited to, metal, graphene, and carbon nanomaterials.

The e-liquid absorber2comprises a first side wall and the conductor1comprises an inner wall. An outer surface of the first side wall is tightly attached to the inner wall to eliminate the gap therebetween and prevent the e-liquid from escaping through the gap.

In certain examples, the heating core further comprises a heating element3dispose in the e-liquid absorber2. The heating element3is made of conductive metal. The conductive metal includes, but is not limited to, copper, aluminum, silver, nickel, tungsten, and gold. The conductive metal includes, but is not limited to, a heating wire, a heating sheet, and a heating cylinder. The heating wire and the heating sheet are formed in a spiral or wavy shape. The heating element3is wrapped around the e-liquid absorber2and comprises a conductive pin31extending through the e-liquid absorber2to the outside of the cavity11. The conductive pin31is used to transport electricity from a power supply to the heating element3. In certain examples, the heating element3is wrapped around the e-liquid absorber2spirally to provide uniform heating throughout the e-liquid. In certain examples, the e-liquid absorber2comprises at least one through hole21extending axially through a bottom surface and a top surface of the e-liquid absorber2. As shown inFIG.2, the e-liquid absorber2further comprises a second side wall surrounding the at least one through hole21, and the heating element3is embedded into the second side wall; further, the heating element3is embedded into the second side wall spirally to provide uniform heating throughout the e-liquid.

Optionally, in certain examples, the conductor1is provided with the conductive pin31through which the electricity is directly transported from a power supply to the conductor1for heating.

Optionally, in certain examples, a coil is wrapped around the heating core to produce an electromagnetic field when an electric current is passing through the coil. The heating element3or the conductor1is heated from the electromagnetic field.

In certain examples, the conductor1further comprises at least one e-liquid inlet13communicating with the cavity11and opposite to the e-liquid absorber2. The temperature of the conductor1reduces the viscosity of the e-liquid to improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity11. Preferably, a plurality of e-liquid inlets13is disposed on the conductor1to ensure adequate e-liquid flows to the heating element3, thus preventing the e-liquid absorber2from burning out. The solidifiable material is injected into the mold through the plurality of e-liquid inlets13to ensure the molding process runs smoothly and efficiently.

As shown inFIGS.3-6, in certain examples, the conductor1further comprises a channel12communicating with the cavity11. The temperature of the conductor1reduces chance of vapor being converted into condensate to ensure the channel12is unblocked. In certain examples, the channel12is formed integrally with the cavity11. As shown inFIG.4, the at least one through hole21extends at least into the channel12, so that the heat produced by the heating element3can be conducted into the channel12to reduce chance of vapor being converted into condensate and ensure the channel12is unblocked.

As shown inFIGS.1-2, in certain examples, the conductor1further comprises a first hollow tube101. The cavity11is formed in the first hollow tube101. A plurality of e-liquid inlets13is circumferentially disposed on the first hollow tube101. The at least one through hole21extends axially through the bottom surface and the top surface of the e-liquid absorber2. The heating element3is embedded into the second side wall of the at least one through hole21spirally.

As shown inFIGS.3-4, in certain examples, the conductor1further comprises a second hollow tube102. The first hollow tube101has an elliptical cross section and the second hollow tube102has a round cross section. One end of the first hollow tube101shrinks and extends axially to form the second hollow tube102. The first hollow tube101communicates with the second hollow tube102using integral formation. The cavity11is formed in the first hollow tube101and the channel12is disposed in the second hollow tube102. A plurality of e-liquid inlets13is circumferentially disposed on the first hollow tube101. An electronic cigarette comprises an e-liquid chamber and a mouthpiece. The first hollow tube101and the second hollow tube102are disposed into the e-liquid chamber, and the second hollow tube102communicates with the mouthpiece. The first hollow tube101and the second hollow tube102have exceptional thermal conductivity, which means that the heat is conducted through the first hollow tube101and the second hollow tube102to reduce the viscosity of the e-liquid and improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity11. The e-liquid absorber2comprises two through holes21axially extending through the bottom surface and the top surface of the e-liquid absorber2. The heating core further comprises two heating elements3respectively embedded into the second side walls of the two through holes21spirally. The two through holes21allows a larger amount of smoke to pass through, thus enhancing user experience.

Another example of the heating core is illustrated inFIGS.5-6. It is similar to the example described in connection withFIGS.3-4, except for the following differences.

As shown inFIGS.5-6, the conductor1comprises the first hollow tube101and the second hollow tube102, both of which have a round cross section. One end of the first hollow tube101shrinks and extends axially to form the second hollow tube102. The first hollow tube101communicates with the second hollow tube102using integral formation. The cavity101is formed in the first hollow tube101and the channel12is disposed in the second hollow tube102. Two e-liquid inlets13are circumferentially disposed on the first hollow tube101. An electronic cigarette comprises an e-liquid chamber and a mouthpiece. The first hollow tube101and the second hollow tube102are disposed into the e-liquid chamber, and the second hollow tube102communicates with the mouthpiece. The first hollow tube101and the second hollow tube102have exceptional thermal conductivity, which means that the heat is conducted through the first hollow tube101and the second hollow tube102to reduce the viscosity of the e-liquid and improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity11.

As shown inFIG.6, the e-liquid absorber2only comprises one through hole21. The heating element3is embedded into the second side wall of the e-liquid absorber spirally. The only one through hole21extends into the channel12for heat conduction, and the heat is transferred to the channel, thus reducing the chance of the vapor converting into the condensate, and preventing the blockage of the channel.

As shown inFIG.7, provided is an electronic cigarette100comprising the heating core (shown inFIGS.3-4), an e-liquid tank, a mouthpiece41, and a sealing member. The e-liquid tank comprises an e-liquid chamber4sealed by the sealing member (e.g. a sealing plug). The heating core is disposed into the e-liquid chamber4. The mouthpiece41is disposed on one end of the e-liquid tank. The conductor1comprises the first hollow tube101and the second hollow tube102communicating with the first hollow tube101. The cavity11is disposed in the first hollow tube101. The channel12is disposed in the second hollow tube102to communicate with the cavity11and extend to the mouthpiece41. At least one e-liquid inlet13is disposed on the first hollow tube101. The first hollow tube101and the second hollow tube102extend into the e-liquid chamber4, and the second hollow tube102communicates with the mouthpiece41.

Understandably, the electronic cigarette100may comprise the heating core illustrated inFIGS.1-2orFIGS.5-6.

As shown inFIG.8, a preparation method600for the heating core comprises:

S610. fixing the conductor1comprising the cavity11in a mold;

S620. injecting a solidifiable material into the mold, and guiding the solidifiable material to the cavity11; the solidifiable material includes, but is not limited to, ceramic, mica, and e-liquid absorbing resin; and

S630. solidifying the solidifiable material in the cavity1to form the e-liquid absorber2.

Through the preparation method, the e-liquid absorber2is directly disposed in the conductor thus greatly increasing the contact area therebetween, and the heat can be transferred rapidly between the e-liquid absorber2and the conductor.

As shown inFIG.9, in certain examples, in S610, fixing the conductor1comprising the cavity11in a mold comprises:

S710. fixing the heating element3of the heating core in the mold; and

S720. guiding the heating element3in the cavity11.

The heating element3is directly wrapped around the e-liquid absorber2by S710and S720so that the heating is uniform.

As shown inFIG.10, in certain examples, in S630, solidifying the solidifiable material in the cavity11to form the e-liquid absorber2comprises:

S810. allowing the solidifiable material to stand and solidify in the cavity11to form a precursor; and

S820. sintering the precursor at 600-700° C. for at least 16 hours to obtain the e-liquid absorber2.

In certain examples, the conductor further comprises at least one e-liquid inlet13communicating with the cavity11and opposite to the e-liquid absorber2. The solidifiable material flows through the at least one e-liquid inlet13into the cavity11. Preferably, a plurality of e-liquid inlets13is disposed on the conductor1to ensure adequate e-liquid flows to the heating element3and the molding process runs efficiently.

As shown inFIG.11, a preparation method900for the heating core illustrated inFIGS.3-4comprises:

S910. fixing two spiral-shaped heating elements3on two locating columns of the mold, respectively; and inserting each conductive pin31into a corresponding hole in the mold to prevent the contact of the conductive pin with the solidifiable material;

S920. fixing one end of the first hollow tube101on the two locating columns; disposing two spiral-shaped heating elements3in the cavity11; shaping the mold to define a fixed space having the same shape as the conductor1; fixing the conductor1in the fixed space; and inserting a column body into one end of the second hollow tube102to prevent the solidifiable material from entering the channel12;

S930. injecting the solidifiable material into the mold so that the solidifiable material flows through the plurality of e-liquid inlets13into the cavity11for solidifying; and

S940. taking the heating core from the mold and sintering at 600-700° C. for 16 hours to fix the e-liquid absorber2in the cavity11.

Through the preparation method900, two through holes21are disposed in the e-liquid absorber2; the two spiral-shaped heating elements3are embedded into the second side walls of the two through holes21, respectively; and each conductive pin31extends out of the first hollow tube101.

As shown inFIG.12, a third preparation method1000for the heating core illustrated inFIGS.5-6, the method comprises:

S1010. fixing a spiral-shaped heating element3on a locating column of the mold; and inserting each conductive pin31into a corresponding hole in the mold to prevent the contact of the conductive pin with the solidifiable material;

S1020. fixing one end of the first hollow tube101on the locating column; disposing one heating elements3in the cavity11; shaping the mold to define a fixed space having the same shape as the conductor1; fixedly disposing the conductor1in the fixed space; and inserting a column body into one end of the second hollow tube102to prevent the solidifiable material from entering the channel12;

S1030. injecting the solidifiable material into the mold so that the solidifiable material flows through the plurality of e-liquid inlets13into the cavity11for solidifying; and

S1040. taking the heating core from the mold and sintering at 600-700° C. for 16 hours to fix the e-liquid absorber2in the cavity11.

Depending on the third preparation method1000used, only one through hole21is disposed in the e-liquid absorber2; the spiral-shaped heating element3is embedded into the second side wall of the only one through hole21; and each conductive pin31extends out of the first hollow tube101.

As shown inFIG.13, a fourth preparation method1100for an electronic cigarette, the method comprises:

S1110. preparing the heating core; and

S1120. inserting the heating core into the e-liquid tank4to form an electronic cigarette.