Patent Description:
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. For example, the device disclosed in <CIT> includes a porous ceramic absorber molded to a conductor; the porous ceramic absorber includes a main body having an outer cylindrical wall and an inner cylindrical wall, and a through hole confined by the inner cylindrical wall; a heating element is disposed in the porous ceramic absorber adjacent to the inner cylindrical wall and is spirally wrapped around the inner cylindrical wall.

<CIT> discloses, in particular in figures <NUM> to <NUM>, two heating elements embedded in a porous body, each around a respective through hole.

The first objective of the invention 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 conductor comprises a cylindrical wall having an inner cylindrical surface, and the cavity is confined by the inner cylindrical surface. The conductor further comprises a channel communicating with the cavity, a plurality of e-liquid inlets communicating with the cavity and opposite to the e-liquid absorber, a first hollow tube, and a second hollow tube. The first hollow tube and the second hollow tube are integrally formed; the first hollow tube has an elliptical cross section, and the second hollow tube has a round cross section. One end of the first hollow tube shrinks and extends axially to form the second hollow tube. The cavity is formed in the first hollow tube; and the plurality of e-liquid inlets is circumferentially disposed on the first hollow tube. The channel is disposed in the second hollow tube and communicates with the cavity. The e-liquid absorber is molded to the conductor. The e-liquid absorber comprises an outer cylindrical wall, two inner cylindrical walls, and two through holes each confined by one of the two inner cylindrical walls. The outer cylindrical wall of the e-liquid absorber is attached to the inner cylindrical surface of the conductor, and the heating core is free of a gap between the outer cylindrical wall of the e-liquid absorber and the inner cylindrical surface of the conductor. Two heating elements are embedded in the e-liquid absorber adjacent to the two inner cylindrical walls, respectively; and the two heating elements are spirally wrapped around the two inner cylindrical walls, respectively.

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

There is also provided 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.

There is also provided 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.

In the drawings, the following reference numbers are used: <NUM>. Conductor; <NUM>. E-liquid absorber; <NUM>. Heating element; <NUM>. Cavity; <NUM>. Channel; <NUM>. E-liquid inlet; <NUM>. Through hole; <NUM>. Conductive pin; <NUM>. Mouthpiece; <NUM>. Electronic cigarette; <NUM>. First hollow tube; <NUM>. Second hollow tube; <NUM>. Second preparation method; <NUM>. Third preparation method; and <NUM>. Fourth preparation method.

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.

The invention provides a heating core as shown in <FIG>, obtained by a preparation method as shown in <FIG>. The invention also provides an electronic cigarette as shown in <FIG>, obtained by a preparation method as shown in <FIG>. The embodiments of <FIG>, <FIG>, <FIG> and <FIG> are useful for understanding the invention.

As shown in <FIG>, a heating core comprises the conductor <NUM> and an e-liquid absorber <NUM>. The conductor <NUM> comprises a cavity <NUM> wherein the e-liquid absorber <NUM> is disposed. The conductor <NUM> is wrapped around the e-liquid absorber <NUM> to increase the heating area so that the heat can be transferred rapidly between the conductor <NUM> and the e-liquid absorber <NUM>. The e-liquid absorber <NUM> is 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 absorber <NUM> is used to seal the cavity <NUM> to prevent leakage of the e-liquid. The temperature of the conductor <NUM> reduces the viscosity of the e-liquid to improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity <NUM>.

In certain examples, the e-liquid absorber <NUM> is obtained by injecting solidifiable material into a mold, and then hardening and sintering the solidifiable material. The e-liquid absorber <NUM> is 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 absorber <NUM> includes, but is not limited to, ceramic, mica, and e-liquid absorbing resin. The conductor <NUM> includes, but is not limited to, metal, graphene, and carbon nanomaterials.

The e-liquid absorber <NUM> comprises a first side wall and the conductor <NUM> comprises 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 element <NUM> dispose in the e-liquid absorber <NUM>. The heating element <NUM> is 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 element <NUM> is wrapped around the inner wall of the e-liquid absorber <NUM> that confines the through hole <NUM> and comprises a conductive pin <NUM> extending through the e-liquid absorber <NUM> to the outside of the cavity <NUM>. The conductive pin <NUM> is used to transport electricity from a power supply to the heating element <NUM>. In certain examples, the heating element <NUM> is wrapped around the inner wall of the e-liquid absorber <NUM> that confines the through hole <NUM> spirally to provide uniform heating throughout the e-liquid. In certain examples, the e-liquid absorber <NUM> comprises at least one through hole <NUM> extending axially through a bottom surface and a top surface of the e-liquid absorber <NUM>. As shown in <FIG>, the e-liquid absorber <NUM> further comprises a second side wall surrounding the at least one through hole <NUM>, and the heating element <NUM> is embedded into the second side wall; further, the heating element <NUM> is embedded into the second side wall spirally to provide uniform heating throughout the e-liquid.

Optionally, in certain examples, the conductor <NUM> is provided with the conductive pin <NUM> through which the electricity is directly transported from a power supply to the conductor <NUM> for 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 element <NUM> or the conductor <NUM> is heated from the electromagnetic field.

In certain examples, the conductor <NUM> further comprises at least one e-liquid inlet <NUM> communicating with the cavity <NUM> and opposite to the e-liquid absorber <NUM>. The temperature of the conductor <NUM> reduces the viscosity of the e-liquid to improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity <NUM>. Preferably, a plurality of e-liquid inlets <NUM> is disposed on the conductor <NUM> to ensure adequate e-liquid flows to the heating element <NUM>, thus preventing the e-liquid absorber <NUM> from burning out. The solidifiable material is injected into the mold through the plurality of e-liquid inlets <NUM> to ensure the molding process runs smoothly and efficiently.

As shown in <FIG>, in certain examples, the conductor <NUM> further comprises a channel <NUM> communicating with the cavity <NUM>. The temperature of the conductor <NUM> reduces chance of vapor being converted into condensate to ensure the channel <NUM> is unblocked. In certain examples, the channel <NUM> is formed integrally with the cavity <NUM>. As shown in <FIG>, the at least one through hole <NUM> extends at least into the channel <NUM>, so that the heat produced by the heating element <NUM> can be conducted into the channel <NUM> to reduce chance of vapor being converted into condensate and ensure the channel <NUM> is unblocked.

As shown in <FIG>, in certain examples, the conductor <NUM> further comprises a first hollow tube <NUM>. The cavity <NUM> is formed in the first hollow tube <NUM>. A plurality of e-liquid inlets <NUM> is circumferentially disposed on the first hollow tube <NUM>. The at least one through hole <NUM> extends axially through the bottom surface and the top surface of the e-liquid absorber <NUM>. The heating element <NUM> is embedded into the second side wall of the at least one through hole <NUM> spirally.

As shown in <FIG>, according to the invention, the conductor <NUM> further comprises a second hollow tube <NUM>. The first hollow tube <NUM> has an elliptical cross section and the second hollow tube <NUM> has a round cross section. One end of the first hollow tube <NUM> shrinks and extends axially to form the second hollow tube <NUM>. The first hollow tube <NUM> communicates with the second hollow tube <NUM> using integral formation. The cavity <NUM> is formed in the first hollow tube <NUM> and the channel <NUM> is disposed in the second hollow tube <NUM>. A plurality of e-liquid inlets <NUM> is circumferentially disposed on the first hollow tube <NUM>. An electronic cigarette comprises an e-liquid chamber and a mouthpiece. The first hollow tube <NUM> and the second hollow tube <NUM> are disposed into the e-liquid chamber, and the second hollow tube <NUM> communicates with the mouthpiece. The first hollow tube <NUM> and the second hollow tube <NUM> have exceptional thermal conductivity, which means that the heat is conducted through the first hollow tube <NUM> and the second hollow tube <NUM> to reduce the viscosity of the e-liquid and improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity <NUM>. The e-liquid absorber <NUM> comprises two through holes <NUM> axially extending through the bottom surface and the top surface of the e-liquid absorber <NUM>. The heating core further comprises two heating elements <NUM> respectively embedded into the second side walls of the two through holes <NUM> spirally. The two through holes <NUM> allows a larger amount of smoke to pass through, thus enhancing user experience.

Another example of the heating core is illustrated in <FIG>. It is similar to the example described in connection with <FIG>, except for the following differences.

As shown in <FIG>, the conductor <NUM> comprises the first hollow tube <NUM> and the second hollow tube <NUM>, both of which have a round cross section. One end of the first hollow tube <NUM> shrinks and extends axially to form the second hollow tube <NUM>. The first hollow tube <NUM> communicates with the second hollow tube <NUM> using integral formation. The cavity <NUM> is formed in the first hollow tube <NUM> and the channel <NUM> is disposed in the second hollow tube <NUM>. Two e-liquid inlets <NUM> are circumferentially disposed on the first hollow tube <NUM>. An electronic cigarette comprises an e-liquid chamber and a mouthpiece. The first hollow tube <NUM> and the second hollow tube <NUM> are disposed into the e-liquid chamber, and the second hollow tube <NUM> communicates with the mouthpiece. The first hollow tube <NUM> and the second hollow tube <NUM> have exceptional thermal conductivity, which means that the heat is conducted through the first hollow tube <NUM> and the second hollow tube <NUM> to reduce the viscosity of the e-liquid and improve the degree of atomization, thus providing a smooth flow of e-liquid into the cavity <NUM>.

As shown in <FIG>, the e-liquid absorber <NUM> only comprises one through hole <NUM>. The heating element <NUM> is embedded into the second side wall of the e-liquid absorber spirally. The only one through hole <NUM> extends into the channel <NUM> for 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 in <FIG>, provided is an electronic cigarette <NUM> comprising the heating core (shown in <FIG>), an e-liquid tank, a mouthpiece <NUM>, and a sealing member. The e-liquid tank comprises an e-liquid chamber <NUM> sealed by the sealing member (e.g. a sealing plug). The heating core is disposed into the e-liquid chamber <NUM>. The mouthpiece <NUM> is disposed on one end of the e-liquid tank. The conductor <NUM> comprises the first hollow tube <NUM> and the second hollow tube <NUM> communicating with the first hollow tube <NUM>. The cavity <NUM> is disposed in the first hollow tube <NUM>. The channel <NUM> is disposed in the second hollow tube <NUM> to communicate with the cavity <NUM> and extend to the mouthpiece <NUM>. At least one e-liquid inlet <NUM> is disposed on the first hollow tube <NUM>. The first hollow tube <NUM> and the second hollow tube <NUM> extend into the e-liquid chamber <NUM>, and the second hollow tube <NUM> communicates with the mouthpiece <NUM>.

Understandably, the electronic cigarette <NUM> may comprise the heating core illustrated in <FIG> or <FIG>.

As shown in <FIG>, a preparation method <NUM> for the heating core comprises:.

Through the preparation method, the e-liquid absorber <NUM> is directly disposed in the conductor thus greatly increasing the contact area therebetween, and the heat can be transferred rapidly between the e-liquid absorber <NUM> and the conductor.

As shown in <FIG>, in certain examples, in S<NUM>, fixing the conductor <NUM> comprising the cavity <NUM> in a mold comprises:.

The heating element <NUM> is directly wrapped around the inner wall of the e-liquid absorber <NUM> that confines the through hole <NUM> by S710 and S720 so that the heating is uniform.

As shown in <FIG>, in certain examples, in S630, solidifying the solidifiable material in the cavity <NUM> to form the e-liquid absorber <NUM> comprises:.

In certain examples, the conductor further comprises at least one e-liquid inlet <NUM> communicating with the cavity <NUM> and opposite to the e-liquid absorber <NUM>. The solidifiable material flows through the at least one e-liquid inlet <NUM> into the cavity <NUM>. Preferably, a plurality of e-liquid inlets <NUM> is disposed on the conductor <NUM> to ensure adequate e-liquid flows to the heating element <NUM> and the molding process runs efficiently.

As shown in <FIG>, a preparation method <NUM> for the heating core illustrated in <FIG> comprises:.

Through the preparation method <NUM>, two through holes <NUM> are disposed in the e-liquid absorber <NUM>; the two spiral-shaped heating elements <NUM> are embedded into the second side walls of the two through holes <NUM>, respectively; and each conductive pin <NUM> extends out of the first hollow tube <NUM>.

As shown in <FIG>, a third preparation method <NUM> for the heating core illustrated in <FIG>, the method comprises:.

Depending on the third preparation method <NUM> used, only one through hole <NUM> is disposed in the e-liquid absorber <NUM>; the spiral-shaped heating element <NUM> is embedded into the second side wall of the only one through hole <NUM>; and each conductive pin <NUM> extends out of the first hollow tube <NUM>.

Claim 1:
A heating core, comprising a conductor (<NUM>) and an e-liquid absorber (<NUM>);wherein:
the conductor (<NUM>) comprises a cylindrical wall having an inner cylindrical surface, and a cavity (<NUM>) confined by the inner cylindrical surface; and the e-liquid absorber (<NUM>) is disposed in the cavity (<NUM>);
the conductor (<NUM>) further comprises a channel (<NUM>) communicating with the cavity (<NUM>), a plurality of e-liquid inlets (<NUM>) communicating with the cavity (<NUM>) and opposite to the e-liquid absorber (<NUM>), a first hollow tube (<NUM>), and a second hollow tube (<NUM>);
the first hollow tube (<NUM>) and the second hollow tube (<NUM>) are integrally formed; the first hollow tube (<NUM>) has an elliptical cross section, and the second hollow tube (<NUM>) has a round cross section;
one end of the first hollow tube (<NUM>) shrinks and extends axially to form the second hollow tube (<NUM>);
the cavity (<NUM>) is formed in the first hollow tube (<NUM>); and the plurality of e-liquid inlets (<NUM>) is circumferentially disposed on the first hollow tube (<NUM>);
the channel (<NUM>) is disposed in the second hollow tube (<NUM>) and communicates with the cavity (<NUM>);
the e-liquid absorber (<NUM>) is molded to the conductor (<NUM>);
the e-liquid absorber (<NUM>) comprises an outer cylindrical wall, two inner cylindrical walls, and two through holes (<NUM>) each confined by one of the two inner cylindrical walls;
the outer cylindrical wall of the e-liquid absorber (<NUM>) is attached to the inner cylindrical surface of the conductor (<NUM>), and the heating core is free of a gap between the outer cylindrical wall of the e-liquid absorber (<NUM>) and the inner cylindrical surface of the conductor (<NUM>); and
two heating elements (<NUM>) are embedded in the e-liquid absorber (<NUM>) adjacent to the two inner cylindrical walls, respectively; and the two heating elements (<NUM>) are spirally wrapped around the two inner cylindrical walls, respectively.