Patent Description:
Aerosol generating devices, such as electronic cigarettes or "e-cigarettes" as they are also known, have gained in popularity over the past ten years as an alternative to traditional smoking articles, like cigarettes, cigars, and cigarillos. Developments in the design and configuration of such aerosol generating devices or vaporizer devices are ongoing to improve their performance and their reliability, as well as their ease of production and their production costs.

Conventional aerosol generating devices usually include a heater powered by an electrical power source and a liquid reservoir containing flavoured liquid (vaporizable material) that can be volatized using the heater and transferred to a user of the aerosol generating device in an airflow, which is preferably guided through a mouthpiece of the device.

In order to provide a convenient way for a user to load the vaporizable material into the aerosol generating device and to avoid the need for the user to handle the vaporizable material (liquid) directly, thereby reducing the likelihood of spillage and waste, conventionally exchangeable capsules are provided. In this way, the integrity, safety and quality of the vaporizable material can also be assured, because it is loaded into the shell or container during manufacture to form a pre-manufactured capsule. Correct dosing of the vaporizable material is also assured.

Moreover, in order to avoid that the heating element is worn out over time, the heating element is often provided within the capsule, thereby forming a so called "cartomizer". As the heating element (heater) is provided with the cartomizer, it is each time the cartomizer (capsule) is replaced, hence, there is no reduction in performance over time.

However, since in general a liquid transport element, in particular a wick, is used to transport the vaporizable material to the heater, in particular a coil that is wound around the wick, it is unavoidable that vaporizable material (liquid) leaks from the reservoir via the liquid transport element into the vaporization chamber and thereby into the air path of the cartomizer. Whilst it is ideal to eliminate leakage, measures should be put in place that contain leaked vaporizable material within the capsule, should leakage occur. Therefore, it is desirable to provide a cartomizer with means that can prevent leaking vaporizable material to affect either the device or consumer.

<CIT> is related to an electronic cigarette comprising from a first, vaping end and a second end distal from the user's mouth, a cartridge, a vaporizer and a battery. It is further disclosed to provide a circular chamber that has direct access to the vaporizing chamber in order to collect leaking vaporizable material. A similar device is shown in <CIT>.

In view of the above, there is the desire to provide a cartomizer for an aerosol generating device, in particular an electronic cigarette or vaporizer, capable of preventing leakage of vaporizable material or liquid from the heater or the liquid transport element (wick) to the outside of the cartomizer, in particular via an air inlet of the cartomizer, thereby ensuring that leaked vaporizable material or liquid affects either the device or consumer.

This aim may be achieved by a cartomizer as defined in claim <NUM>. Embodiments may be found in the dependent claims, the following description and the accompanying drawings.

According to one embodiment of the present invention, there is provided a cartomizer for an aerosol generating device, in particular an electronic cigarette or vaporizer, the cartomizer including: a container for holding at least one reservoir configured to contain a vaporizable material, a vaporizing chamber fluidly connected to a mouth end by a vapor passage, a liquid transport element, in particular a porous capillary member, extending from inside the at least one reservoir to the inside of the vaporizing chamber in order to convey or wick or otherwise transport the vaporizable material from the at least one reservoir to the inside of the vaporizing chamber and an air inlet arranged to supply the vaporizing chamber with air in use, wherein a leakage collecting chamber is arranged, in particular in an airflow direction from the air inlet to the vaporizing chamber, between the vaporizing chamber and the air inlet to collect vaporizable material (leaking) from the vaporizing chamber, and the leakage collecting chamber includes at least one liquid stopping or barrier wall, in particular a first liquid stopping or barrier wall, arranged between the leakage collecting chamber and the air inlet, in particular at least one through-hole of the air inlet, wherein the at least one liquid stopping or barrier wall forms an overflow.

Hence, a cartomizer for an aerosol generating device is provided, capable of reducing the likelihood that vaporizable material or liquid, leaking from the liquid transport element or a heater of the cartomizer reaches the outside of the cartomizer via the air inlet. Thereby, ensuring that leaked vaporizable material or liquid is prevented from affecting the device or a user of the device.

According to a further embodiment of the present invention, the air inlet may comprise or may be formed by an air conduit or chimney that is arranged at the bottom of the container and upstream the through-hole of the air inlet, wherein the air conduit or chimney, in particular a sidewall thereof, forms a second liquid stopping or barrier wall that is arranged between the first liquid stopping or barrier wall and the at least one through-hole.

Moreover, in some embodiments of the present invention, the air conduit or chimney may protrude inside the leakage collecting chamber.

In some embodiments of the present invention, the cartomizer may further include a center leakage collecting chamber that is provided between the air inlet and the leakage collecting chamber, in particular in an airflow direction from the air inlet to the vaporizing chamber, wherein the center leakage collecting chamber is preferably defined or formed by the air conduit or chimney and the first liquid stopping or barrier wall.

Furthermore, the center leakage collecting chamber and the leakage collecting chamber or the leakage collecting chambers, in case two or more collecting chambers are provided, are at least partially separated from each other by the first liquid stopping or barrier wall including at least one connecting hole or groove (fluidly) connecting the center leakage collecting chamber with the leakage collecting chamber or chambers, wherein the connecting hole or groove is preferably arranged with a predetermined axial distance to the bottom of the container.

It is further preferred that the predetermined axial distance from the at least one connecting hole or groove to the bottom of the container is smaller than an axial distance of the at least one through-hole to the bottom of the container.

According to a further embodiment of the present invention, the leakage collecting chamber may further include at least one air outlet arranged at an axial distance relative to the through-hole of the air inlet, wherein the at least one air outlet of the leakage collecting chamber is preferably arranged axially, in particular in an axial direction of the cartomizer, closer to the bottom of the container than the through-hole of the air inlet.

As regards the "axial direction of the cartomizer", said direction defines in the present application in general a longitudinal direction of the cartomizer. However, as the shape of the cartomizer might vary, the "axial direction of the cartomizer" also refers to a direction in which the air flows in general through the cartomizer, namely from the air inlet of the cartomizer to the mouth end of the cartomizer, which is configured to come into contact with the lips of a user during use of the aerosol generating device. Furthermore, the air outlet of the leakage collecting chamber may be transversally distant from the air inlet. In other words, the air outlet might be arranged with a predetermined distance to the air inlet when seen in a plane perpendicular to the axial direction of the cartomizer. Therefore, in use, liquid entering the leakage collecting chamber through the air outlet has no straight path to the air inlet and becomes collected in the collecting chamber instead.

Moreover, in some embodiments, the air outlet of the leakage collecting chamber may protrude by a conduit inside the leakage collecting chamber and/or inside the vaporizing chamber.

Additionally, the leakage collecting chamber may include two air outlets communicating with the vaporizing chamber and arranged on each side of the air inlet.

Furthermore, or alternatively, the cartomizer may be provided with two leakage collecting chambers, which are each arranged on each side of the air inlet and provided with a separate air outlet communicating with the vaporizing chamber.

Moreover, in case of two air outlets, the air outlets may be aligned in a plane of extension of the liquid transport element, which preferably is perpendicular to the axial direction of the device.

According to a further embodiment of the present invention, the leakage collecting chamber is arranged between a first seal arranged or configured for holding the liquid transport element and a wall of the container, preferably a bottom holder of the container arranged for holding electrical connectors.

Furthermore, in some embodiments, the liquid transport element is held by the first seal and a second seal. Both seals may be made of silicone rubber.

Additionally, the second seal may at least partially, in particular completely, separate the at least one reservoir from the vaporizing chamber. Same applies in case the cartomizer is provided with two or more reservoirs.

Moreover, the at least one air outlet may be formed inside the first seal.

In a preferred embodiment, the leakage collection chamber is demarcated by the first seal and the bottom holder of the container.

In some embodiments, the leakage collecting chamber may have a larger transversal cross section than the vaporizing chamber. In other words, in a plane that is perpendicular to the axial direction of the cartomizer, the cross-sectional area of the leakage collecting chamber or collecting chambers is larger than the cross-sectional area of the vaporizing chamber.

Moreover, the first seal may include air channels that fluidly connect the center leakage collecting chamber with the leakage collecting chamber or the leakage collecting chambers.

Additionally, the container, shell or outside casing of the cartomizer may be formed of a rigid material, in particular a rigid thermoplastic material, glass or metal.

A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which:.

Embodiments of the present disclosure will now be explained with reference to the drawings. It will be apparent to those skilled in the field of aerosol generating devices from this disclosure that the following description of the embodiments is provided for illustration only and not for the purpose of limiting the disclosure as defined by the appended claims.

Modifications of features can be combined to form further embodiments. Features described in individual embodiments can be provided in a single embodiment if they are not incompatible. Likewise, features described in a single embodiment can be provided in several embodiments individually or in any suitable sub-combination. As used in the specification and the appended claims, the singular forms "a", "an", "the" and the like include plural referents unless the context clearly dictates otherwise.

The same reference numerals listed in different figures refer to identical, corresponding or functionally similar elements. As described hereinafter, example implementations of the present disclosure relate to cartomizers for aerosol generating devices or aerosol delivery devices. Aerosol generating devices according to the present invention use electrical energy to heat a material (preferably without combusting the material to any significant degree and/or without significant chemical alteration of the material) to form an inhalable substance or vapor; and components of such device have the form of articles that most preferably are sufficiently compact to be considered hand-held devices. That is, use of components of preferred aerosol generating devices does not result in the production of smoke in the sense that aerosol results principally from by-products of combustion or pyrolysis of tobacco, but rather, use of those devices preferably results in the production of vapors resulting from volatilization or vaporization of certain components incorporated therein.

In some example implementations, components of aerosol generating devices may be characterized as electronic cigarettes, and those electronic cigarettes preferably incorporate aerosolisable liquid (e.g. propylene glycol, polyhydric alcohol), tobacco and/or tobacco materials derived at least partially from tobacco, and hence deliver tobacco derived components in aerosol or vapor form to a user. In more detail, aerosol generating devices within the meaning of the present invention may transport the volatilized particles in an airflow through the aerosol generating device, in particular through the cartomizer, to a user of the device, the user of the device being able to activate or deactivate the generation of aerosol and to control the duration, velocity and volume of the airflow by means of puffing or inhaling action.

<FIG> illustrates a known aerosol generating or delivery device <NUM> including a control body <NUM> and a tank <NUM>. As shown in <FIG>, the control body <NUM> can be formed of a control body shell <NUM> that can include a control component <NUM> (e.g., a printed circuit board (PCB), an integrated circuit, a memory component, a microprocessor, individually or as part of a micro-controller, and the like), a flow sensor <NUM>, a battery <NUM>, and one or more light-emitting diodes (LEDs) <NUM>, and such components can be variably aligned. Moreover, the tank <NUM> can be formed of a tank shell <NUM> enclosing a reservoir <NUM> that is in fluid communication with a liquid transport element <NUM> adapted to wick or otherwise transport an aerosol precursor composition stored in the reservoir housing to a heater <NUM> (sometimes referred to as a heating element). A valve may be positioned between the reservoir and heater and configured to control an amount of aerosol precursor composition passed or delivered from the reservoir to the heater. The known device is provided with a mouthpiece <NUM> having an opening defined therein and which may be coupled to the tank shell <NUM> to allow for egress of formed aerosol from the tank <NUM>. The shown device <NUM>, in particular the control body <NUM> and the tank <NUM>, include a coupler <NUM> having a cavity <NUM> therein. A base <NUM> of the tank is adapted to engage the coupler and includes a projection <NUM> to fit within the cavity.

Aerosol generating devices of the present invention generally include a number of components provided within an outer body or shell, which may be referred to as an outside casing or housing. The overall design of the outside casing can vary, and the format or configuration of the outside casing that can define the overall size and shape of the aerosol generating device can vary. For some aerosol generating devices, an elongated body resembling the shape of a cigarette or cigar can be formed from a single, unitary housing, or the elongated housing can be formed of two or more separable bodies. For example, an aerosol generating device can include an elongated shell or body (outside casing) that can be substantially tubular in shape and, as such, resemble the shape of conventional cigarettes or cigars. In one implementation, all of the components of the aerosol generating device are contained within a single housing. Alternatively, an aerosol delivery device can comprise two or more housings that are joined and are separable.

Aerosol generating devices of the present invention can be formed of an outside casing or shell that is not substantially tubular in shape but may be formed to substantially greater transversal dimensions. The outside casing or shell can be configured to include a mouthpiece and/or may be configured to receive a separate shell (e.g. a cartridge, a tank) that can include consumable elements, such as a liquid aerosol former, and can include a vaporizer.

<FIG> shows a schematic sectional view of the interior of a cartomizer <NUM> for an aerosol generating device <NUM> according to a first embodiment of the present invention. As can be taken from <FIG>, the cartomizer <NUM> is generally a container <NUM> or cartridge that can be at least partially inserted into a receiving cavity of an aerosol generating device and that provides the functionalities of generating an aerosol or vapor from a vaporizable material or liquid stored therein. For example, a cartomizer can be a pre-manufactured and pre-filled cartridge that comprises at least one reservoir <NUM> for containing the vaporizable material or liquid from which the aerosol or vapor can be generated. For the purpose of generating said aerosol or vapor, the cartomizer <NUM> may further comprise a heater which is arranged to heat at least a fraction of the vaporizable material or liquid so as to vaporize an amount of it for, in turn, generating the aerosol or vapor. The heater may comprise any one and combination of a wire, a resistive element, a coil, and a susceptor being heatable by induction. The cartomizer <NUM> further comprises an air conduct and/or a mouthpiece (mouth end) <NUM> so as to allow a user to inhale the generated aerosol, preferably as a mixture with air from the environment.

In the shown embodiment the heater is formed by a wire that is wound around a liquid transport element <NUM>, in particular a capillary-type wick, such as bundle of cotton filaments, and located within a vaporizing chamber <NUM>. It should further be mentioned that the vaporizing chamber <NUM> is fluidly connected to the mouth end <NUM>, in particular an opening provided in the mouth end <NUM>, via a vapor passage <NUM>. In other words, vapor generated by the heater can be provided via the vapor passage <NUM> and the opening in the mouth end <NUM> to a user. In the shown embodiment the cartomizer <NUM> is only provided with one reservoir <NUM> which surrounds the vapor passage <NUM>, the heater and the liquid transport element <NUM>. Both ends of the wick <NUM> reach into the reservoir <NUM>, in particular into the vaporizable material stored inside the reservoir <NUM>, on opposing sides and thereby convey, wick or otherwise transport the vaporizable material from the reservoir <NUM> to the heater which is positioned inside the vaporizing chamber <NUM>.

As also can be seen in <FIG>, the cartomizer <NUM> is provided with an air inlet <NUM> which is arranged on the bottom, in particular in a bottom holder <NUM>, of the container <NUM>. The air inlet <NUM> is configured to supply the vaporizing chamber <NUM> with ambient air, which is sucked into the vaporizing chamber <NUM> during use of the aerosol generating device <NUM>.

<FIG> also shows that the cartomizer <NUM> is additionally provided with a leakage collecting chamber <NUM> that is arranged in an airflow direction of the ambient air sucked into the cartomizer, namely from the air inlet <NUM> towards the vaporizing chamber, between the vaporizing chamber <NUM> and the air inlet <NUM> to collect vaporizable material leaking from the vaporizing chamber <NUM>.

Since the air path of the ambient air sucked into the cartomizer <NUM> through the air inlet <NUM> is the only unsealed connection between the environment and the vaporizing chamber <NUM>, besides the vapor passage <NUM>, the air path is the main source of possible leakage.

As indicated in <FIG>, which is a schematic sectional view of a detail of the device <NUM> shown in <FIG>, by the arrows, vaporizable material or liquid leaking from the wick <NUM> drops onto a first sealing <NUM> that is configured to hold or fix the wick <NUM> within the vaporizing chamber <NUM>, in particular together with a second sealing <NUM>, and to form a part, in particular a bottom portion, of the vaporizing chamber <NUM>. Thereby, the leaked vaporizable material or liquid is collected at the bottom of the vaporizing chamber <NUM>. The first sealing <NUM> is provided with two air outlets <NUM> that are formed by two channels or through-holes that go through the first sealing <NUM>, in particular in a direction parallel to the axial direction of the cartomizer <NUM>. It should also be noted that the two air outlets <NUM> are arranged at an axial distance relative to a through-hole 16a of the air inlet <NUM>. Accordingly, the leaked vaporizable material or liquid collected at the bottom of the vaporizing chamber <NUM> flows through one of the air outlets <NUM> to the leakage collecting chamber <NUM> or one of the leakage collecting chambers <NUM>.

As can be taken from <FIG>, the air inlet <NUM> is provided with two through-holes 16a, which are aligned in a direction perpendicular to the axial direction of the cartomizer <NUM>, which extends in <FIG> in view direction, in other words, in a direction into the paper.

<FIG> and <FIG> also show that the two air outlets <NUM> are arranged on each side of the air inlet <NUM>, in particular an air conduit or chimney <NUM> that forms the air inlet <NUM> and is provided at the bottom of the container <NUM>. Moreover, the two air outlets <NUM> are aligned in a vertical plane (in <FIG> and <FIG>) of extension of the liquid transport element <NUM>.

Hence, as indicated by the arrows in <FIG>, the leaked vaporizable material flows through the two air outlets <NUM> and reaches the leakage collecting chambers <NUM>, which are also provided on each side of the air conduit or chimney <NUM> of the air inlet <NUM>. It should also be noted that the second sealing <NUM> separates the reservoir <NUM> from the vaporizing chamber <NUM>, ensuring that the vaporizable material only reaches the heater via the wick <NUM>.

<FIG> shows a vertical and a horizontal schematic sectional view of the cartomizer <NUM> shown in <FIG>, illustrating the air flow through the cartomizer <NUM>. As shown in the right view, the ambient air entering the cartomizer <NUM> through the two through-holes 16a reaches a center leakage collecting chamber <NUM> that is provided in the bottom holder <NUM> of the container <NUM>. In airflow direction, the center leakage collecting chamber <NUM> is arranged between the air inlet <NUM> and the (main) leakage collecting chamber(s) <NUM>. Meaning, the center leakage collecting chamber <NUM> is arranged between a side wall of the chimney <NUM> and a transversal wall of the first seal <NUM>, forcing air to travel to the sides (as indicated by arrows in <FIG>). In other words, as shown in the right view, the air entering the center leakage collecting chamber <NUM> flows through four air channels 30a which are provided in the first seal <NUM> thereby reaching the (main) leakage collecting chamber(s) <NUM>. As shown in the right view of <FIG>, the four air channels 3a are arranged in a double-T form.

<FIG> shows a schematic spatial view of the bottom part of the device shown in <FIG>, in particular of the bottom holder <NUM> of the container <NUM>. It should also be noted that the conduit or chimney <NUM> of the air inlet <NUM> forms part of the bottom holder <NUM>. Moreover, as <FIG> illustrates, the center leakage collecting chamber <NUM> and the two (main) leakage collecting chambers <NUM>, which are arranged on each side of the center leakage collecting chamber <NUM>, are separated from each other by at least one liquid stopping or barrier wall (here a first liquid stopping or barrier wall <NUM>) including four connecting holes <NUM> (in this embodiment formed by cuts or grooves formed in the partition wall) that fluidly connect the center leakage collecting chamber <NUM> with the leakage collecting chambers <NUM>. Since the connecting holes (cuts or grooves) are provided with a predetermined distance to the bottom of the container <NUM>, leaked vaporizable material that is collected inside the (main) leakage collecting chambers <NUM> is prevented from entering the center leakage collecting chamber <NUM>, even in extreme cartomizer orientations. In other words, the two first liquid stopping or barrier walls <NUM>, each provided on one side of the chimney <NUM>, form overflows between the two (main) leakage collecting chambers <NUM> and the center leakage collecting chamber <NUM>. Hence, ensuring that leaked vaporizable material accumulated in the two (main) leakage collecting chambers <NUM> does not or at least only very unlikely reach the center leakage collecting chamber <NUM>.

Moreover, as it is also apparent from <FIG>, <FIG>, the two air outlets <NUM>, in particular bottom or upstream openings of them, are provided closer to the bottom of the container <NUM> than the through-holes 16a of the air inlet <NUM>, thereby ensuring that leaked vaporizable material collected inside the (main) leakage collecting chambers <NUM> does not close the air path, in particular the air path connecting the through-holes 16a of the air inlet <NUM> with the air outlets <NUM> via the leakage collecting chambers <NUM>.

Yet, as shown in <FIG>, even in case leaked vaporizable material would reach the center leakage collecting chamber <NUM>, since the through-holes 16a of the inlet <NUM> are provided on the top of the conduit or chimney, the distance between the bottom of the center leakage collecting chamber <NUM> and the through-holes 16a is maximized, thereby reducing the likelihood of leaked vaporizable material reaching the through-holes 16a. In other words, the air conduit or chimney <NUM>, in particular a side wall thereof, forms a second liquid stopping or barrier wall <NUM> that is arranged between the first liquid stopping or barrier wall <NUM> and the two through-holes 16a of the air inlet <NUM>. Hence, in the unlikely event that a very small amount of leaked vaporizing material reaches the center leakage collecting chamber <NUM>, the second liquid stopping or barrier wall forms a further overflow that ensures that no leaked vaporizing material reaches the air inlet <NUM>.

<FIG> shows a schematic sectional view of a detail of the cartomizer <NUM> shown in <FIG> when inserted into an aerosol generating device <NUM>. It should also be noted that the aerosol generating device <NUM> is provided with electrical contacts <NUM> such as "pogo pins" that are configured to contact the electrical connectors <NUM> of the cartomizer in order to provide the heater of the cartomizer <NUM> with electrical power. As <FIG> also shows, the electrical connectors <NUM> also contact magnets <NUM> which are provided within an inner frame <NUM> of the aerosol generating device <NUM>. Yet, in order to provide the wire of the heater with electrical power, the cartomizer <NUM> is further provided with lead wires <NUM> that electrically connect the wire with the electrical connectors <NUM>.

Claim 1:
A cartomizer (<NUM>) for an aerosol generating device (<NUM>), in particular an electronic cigarette or vaporizer, the cartomizer comprising:
a container (<NUM>) for holding at least one reservoir (<NUM>) configured to contain a vaporizable material;
a vaporizing chamber (<NUM>) fluidly connected to a mouth end (<NUM>) by a vapor passage (<NUM>);
a liquid transport element (<NUM>), in particular a porous capillary member, extending from inside the at least one reservoir (<NUM>) to inside the vaporizing chamber (<NUM>) in order to convey the vaporizable material from the at least one reservoir (<NUM>) to the inside of the vaporizing chamber (<NUM>);
an air inlet (<NUM>) arranged to supply the vaporizing chamber (<NUM>) with air in use;
wherein a leakage collecting chamber (<NUM>) is arranged between the vaporizing chamber (<NUM>) and the air inlet (<NUM>) to collect vaporizable material from the vaporizing chamber (<NUM>), and the leakage collecting chamber (<NUM>) comprises at least one liquid stopping or barrier wall (<NUM>, <NUM>), in particular a first liquid stopping or barrier wall (<NUM>), arranged between the leakage collecting chamber (<NUM>) and the air inlet (<NUM>), in particular at least one through-hole (16a) of the air inlet (<NUM>), forming an overflow, and
the cartomizer (<NUM>) further comprises a center leakage collecting chamber (<NUM>) that is provided between the air inlet (<NUM>) and the leakage collecting chamber (<NUM>).