US20170027225A1 - Aerosol-forming member - Google Patents

Abstract

An aerosol-forming member for an aerosol delivery device is disclosed. The aerosol-forming member comprises a sheet of material configured to heat and wick a solution. The sheet of material comprises at least one corrugation.

Description

RELATED APPLICATIONS
• The present application is a National Phase entry of PCT Application No. PCT/GB2015/050195, filed on 28 Jan. 2015, which claims priority to GB Patent Application No. 1401520.2, filed on 29 Jan. 2014, which are hereby fully incorporated herein by reference.
TECHNICAL FIELD
• The disclosure relates to an aerosol-forming member for an aerosol delivery device. The disclosure also relates to an aerosol delivery device component comprising the aerosol-forming member, and an aerosol delivery device comprising said aerosol delivery device component.
BACKGROUND
• An aerosol delivery device is a device used for delivering substances into the body via the lungs. One type of aerosol delivery device forms a vapor of a solution in which the substances are dissolved. This vapor condenses within the aerosol delivery device as it mixes with air so as to form droplets or aerosol which is suitable for inhalation. These aerosol delivery devices may comprise a heating element that is configured to evaporate the solution held within the aerosol delivery device so as to form said aerosol. Alternatively, some aerosol delivery devices may utilize piezo atomizers to generate the aerosol.
SUMMARY
• According to the disclosure, there is provided an aerosol-forming member comprising a sheet of material configured to heat and wick a solution, wherein the sheet of material comprises at least one corrugation.
• In one embodiment, the sheet of material may comprise a capillary structure configured to wick a solution.
• The capillary structure may be exposed on both sides of the sheet of material. The capillary structure may extend throughout the whole sheet of material. The sheet of material may be heatable. The capillary structure may be made of an (electrically) heatable material.
• In an alternative embodiment, the sheet of material may comprise a first layer that is heatable and a second layer comprising a capillary structure.
• The sheet of material may comprise a peak and a trough, with said peaks/troughs being either rounded or pointed, i.e. where the sheet of material includes corrugations forming vertices.
• Alternatively, the sheet of material may have a wave form.
• According to another aspect, there is provided an aerosol delivery device component comprising an air inlet and an air outlet fluidly communicating via an aerosol chamber defined by chamber walls, and an aerosol-forming member as described above, the aerosol forming member being located at least partially within the aerosol chamber.
• In one embodiment, the aerosol delivery device component may further comprise an aerosol-forming member located completely in the aerosol chamber.
• In one embodiment, the sheet of material may comprise two opposing major surfaces that are aligned with a direction of flow of air through the aerosol chamber.
• In another embodiment, the sheet of material may comprise two opposing ends that are attached to the aerosol delivery device component such that the sheet of material is suspended across the aerosol chamber.
• The aerosol forming member may be attached to at least one of the chamber walls.
• In one embodiment, one of the chamber walls is a printed circuit board and the aerosol-forming member is attached to the printed circuit board.
• In one embodiment, the at least one corrugation of the sheet of material may be in close proximity to at least one of the chamber walls.
• In one embodiment, the at least one corrugation of the sheet of material may be in contact with at least one of the chamber walls.
• At least one of the chamber walls may comprise a heat shield.
• According to yet another aspect, there is provided an aerosol delivery device component comprising an air inlet and an air outlet fluidly communicating via an aerosol chamber defined by chamber walls, wherein at least one of the chamber walls comprises a liquid reservoir matrix.
• The liquid reservoir matrix may comprise a capillary structure.
• In one embodiment, the liquid reservoir matrix may comprise a heat resistant layer and a resilient layer.
• In another embodiment, two opposing chamber walls may each comprise a liquid reservoir matrix, and the heat resistant layer of each liquid reservoir matrix is innermost relative to the aerosol chamber such that the resilient layer urges the heat resistant layers towards one another.
• The aerosol delivery device component may further comprise an aerosol-forming member located at least partially within the aerosol chamber. In one embodiment, the aerosol delivery device component may further comprise an aerosol-forming member located completely within the aerosol chamber.
• In one embodiment, the aerosol-forming member may comprise any of the features described above.
• The at least one corrugation of the sheet of material may be in contact with the liquid reservoir matrix.
• According to a further aspect, there is provided an aerosol delivery device comprising an aerosol delivery device component and/or aerosol forming member as described above.
• According to another aspect, there is provided an aerosol-forming member comprising a sheet of material configured to heat and wick a solution, wherein the sheet of material has a cross-sectional profile having at least one point of inflection.
BRIEF DESCRIPTION OF THE DRAWINGS
• Embodiments will now be described, by way of example only, with reference to the accompanying drawings in which:
• FIG. 1ashows a cross-sectional side view of an aerosol delivery device comprising an aerosol-forming member according to an embodiment.
• FIG. 1bshows a cross-sectional side view of an alternative aerosol delivery device comprising an aerosol-forming member according to an embodiment.
• FIG. 2ashows a cross-sectional side view of a detachable component, which may be used in the device ofFIG. 1a, comprising an aerosol-forming member according to an embodiment.
• FIG. 2bshows a cross-sectional view of the aerosol delivery device along the line X-X ofFIG. 2a.
• FIG. 2cshows a cross-sectional view of the aerosol delivery device along the line X-X ofFIG. 1b.
• FIG. 3ashows a cross-sectional view of another embodiment of the aerosol delivery device.
• FIG. 3bshows a cross-sectional view of another embodiment of the aerosol delivery device.
DETAILED DESCRIPTION
• Referring now toFIG. 1a, anaerosol delivery device1 according to an embodiment is disclosed. The aerosol delivery device comprises an aerosoldelivery device component1′, and anenergy store component1″. The aerosoldelivery device component1′ is removably attachable to theenergy store component1″, however it is envisaged that in an alternative embodiment, the aerosoldelivery device component1′ and theenergy store component1″ are inseparable such that they form a single component.
• The aerosoldelivery device component1′ may be disposable and theenergy store component1″ may be reusable. However, it is envisaged that when the two components are formed as a single component then the aerosol delivery device may be disposable or reusable.
• Theenergy source component1″ comprises a housing holding abattery30 and anelectric circuitry31 as shown inFIG. 1a. It should be appreciated that an alternative power source to a battery may be used.
• The aerosoldelivery device component1′ is shown in greater detail inFIG. 2aand it comprises ahousing2 formed with amouthpiece3 at one end and an attachment end formed with a connectingpassage35 at the opposite end. The connectingpassage35 electrically connects components held in the aerosoldelivery device component1′ with thebattery15 disposed in theenergy store component1″ via the electric circuitry31 (not shown).
• Thehousing2 is further formed with an air passage extending through the aerosoldelivery device component1′. The air passage comprises anair inlet5,plenum chamber4,chamber inlet33,aerosol chamber6,chamber outlet28 andoutlet aperture7. In use air is drawn in through theair inlet5, into theplenum chamber4, then to thechamber inlet33 which supplies the air into theaerosol chamber6, the air then exits theaerosol chamber6 viachamber outlet28 and leaves the aerosoldelivery device component1′ via theoutlet aperture7 formed in themouthpiece3.
• FIG. 2billustrates a cross-sectional view of the aerosoldelivery device component1′ along line X-X shown inFIG. 2a. As can be seen inFIG. 2b, theaerosol chamber6 is located in the center of the housing and is defined by chamber walls. The chamber walls comprise twopartitioning walls8, achamber side wall32 and asupport plate20′ as explained in more detail below. An aerosol-forming member10A according to an embodiment is located in theaerosol chamber6. On opposite sides of eachpartitioning walls8 relative to theaerosol chamber6, are twosolution reservoirs9 configured to contain a solution. In one embodiment thesupport plate20′ is the PCB. In an alternative embodiment, thesupport plate20′ is integrated with thehousing2 such that a capillary gap is formed between the housing and thepartitioning wall8.
• According to one embodiment, the aerosol-forming member10A may comprise a sheet of material having a single layer that is configured to wick and heat a solution. Thus, the sheet of material can absorb solution from thesolution reservoirs9 and thereafter heat it up so that it evaporates and forms a vapor. The sheet of material is sheet-like in nature. The sheet of material may comprise an open-pored structure, foam structure, mesh structure or interconnecting network of pores, all of which form a capillary structure. The capillary structure enables the aerosol-forming member10A to wick or absorb a solution. The term “capillary structure” used herein is to be understood as a structure through which liquid or a solution can travel as a result of capillary action.
• An embodiment of an alternativeaerosol delivery device1 is shown inFIG. 1band it comprises ahousing2 with amouthpiece3. Apassage4 is provided in thehousing2 and is open to atmosphere via anair inlet5. Thepassage4 is in fluid communication with anaerosol chamber6 which in turn is in fluid communication with anoutlet aperture7 formed in themouthpiece3. Therefore, in use, air may be drawn through theair inlet5 and into theaerosol chamber6, via thepassage4, and then through theoutlet aperture7 as is indicated by the arrows inFIG. 1.
• Referring now toFIG. 2cwhich shows a cross-sectional view of theaerosol delivery device1 ofFIG. 1b, a space is provided inside thehousing2 which is divided by apartitioning wall8 into theaerosol chamber6 and aliquid reservoir9 that contains a solution. Theaerosol chamber6 is defined by thepartitioning wall8, asupport plate19 and aheat shield26. Thepartitioning wall8,support plate19 andheat shield26 act as chamber walls. Twocapillary gaps17,18 are formed between theends20,21 of thepartitioning wall8 and thesupport plate19. For the avoidance of doubt, the device shown inFIG. 1 may also include a similar heat shield as necessary. In one embodiment thesupport plate19 is the PCB. In an alternative embodiment, thesupport plate19 is integrated with thehousing2 such that a capillary gap is formed between the housing and thepartitioning wall8.
• An aerosol-formingmember10aaccording to an embodiment is located in theaerosol chamber6 as seen inFIG. 2bor2c. The aerosol-formingmember10acomprises a sheet of configured to havecorrugations10bsuch that it comprises peaks and troughs. In the present application, a corrugation is to be understood as two bends, or a peak and a trough, or a ridge and a groove. The sheet of material may also be described as having a cross-sectional profile comprising at least one point of inflection.
• The corrugations of the aerosol-formingmembers10amay follow a meandering or oscillating path, or a sine curve or any other similar pattern. The aerosol-formingmember10amay comprise regular corrugations such that it comprises a repetition of identical corrugations as seen inFIG. 2. However, in an alternative un-illustrated embodiment the aerosol-forming member may comprise irregular corrugations wherein the shape of the peaks and troughs differ from one another. AlthoughFIGS. 2aand 2bshow an aerosol-formingmember10acomprisingrounded corrugations10b, i.e. rounded peaks and troughs, it should be understood that the disclosure is not limited thereto, but also includes corrugations forming vertices (forming zig-zag like corrugations). These vertices may have obtuse, acute and/or right angles. Such an arrangement is shown in the embodiment ofFIG. 3b(the description of the corresponding reference numerals for the embodiment ofFIG. 3aapplying also to the embodiment ofFIG. 3b).
• The sheet of material may comprise a single layer that is sheet-like in nature and comprises two major opposingsurfaces13,14 and two opposing ends15,16. The two opposing ends15,16 are attached to a support plate19 (according to the device ofFIG. 1b) orsupport plate20′ (according to the device ofFIG. 1a) such that they locate in correspondingcapillary gaps17,18 formed between thesupport plate19,20′ and theends21,20 (according to the device of FIG.1b) of thepartitioning wall8. In an embodiment the two opposing ends15,16 are also electrically connected to thesupport plate19. Thesupport plate19 may be a printed circuit board (PCB). The sheet of material is configured to extend in a contact-free manner across theaerosol chamber6 such that the aerosol-formingmember10ais suspended across theaerosol chamber6 and only theends15,16 of the aerosol-formingmember10aare in contact with the chamber walls of theaerosol chamber6. This configuration reduces undesired loss in heat conduction of the aerosol-formingmember10a. As a result, the aerosol-formingmember10acan heat up faster to a sufficient temperature wherein a solution held in the aerosol-forming member evaporates than if the aerosol-forming member was in continuous contact with the chamber walls. It should be understood that the sheet of material does not have to be a single layer, but can be a sheet of multiple layers of the same or different material that are layered/laminated/attached so as to form the final sheet-like material.
• In one embodiment, the aerosol-formingmember10ahas corrugations such that it extends substantially across the entire cross-section of theaerosol chamber6 as seen inFIGS. 2b,cand3a,b. More specifically, the aerosol-formingmember10adoes not only extend in a direction between thecapillary gaps17,18, but also extends across substantially the whole distance between thesupport plate19 and thepartitioning wall8/heat shield26 (according to the embodiment ofFIG. 2c), and across substantially the whole distance between thesupport plate20′ and thechamber wall32/heat shield26 (according to the embodiment ofFIG. 2b). Thus, in these embodiments, thecorrugations10bare adjacent or in close proximity to the chamber walls, or more specifically thewall8,32, theheat shield26 and thesupport plate19,20′. In another embodiment, the aerosol-formingmember10aextends across theaerosol chamber6 to such an extent that thecorrugations10bcontact or engage with the chamber walls (as shown inFIGS. 3aand 3b). In yet another embodiment, the depth of thecorrugations10bis shorter such that the aerosol-formingmember10adoes not extend across the whole distance between thesupport plate19 and thepartitioning wall8/heat shield26 (according to the embodiment ofFIG. 2c), or the aerosol-formingmember10adoes not extend across the whole distance between thesupport plate20′ and thewall32/heat shield26 (according to the embodiment ofFIG. 2b). It is not necessary that each of thecorrugations10bcontact or be in close proximity with the chamber walls. Where there are multiple corrugations, each corrugation may be independently configured to either be in contact with the chamber walls, be in close proximity with the chamber walls, or to be distanced from the chamber walls.
• The sheet of material, which may comprise a single layer, is configured to wick and heat a solution such that the sheet of material can absorb solution and thereafter heat it up such that it evaporates and forms a vapor. The sheet of material may comprise an open-pored structure, foam structure or interconnecting network of pores, all of which form a capillary structure. The capillary structure enables the aerosol-formingmember10ato wick or absorb a solution. The term “capillary structure” used herein is to be understood as a structure through which liquid or a solution can travel as a result of capillary action.
• The aerosol-formingmember10amay be made of a porous granular, fibrous or flocculent sintered metal(s) so as to form said capillary structure. In another embodiment, the aerosol-formingmember10acomprises an open-pored metallic foam or a group of layers of wire mesh or calendered wire mesh or wire fabric which also forms a capillary structure. The aerosol-formingmember10amay be formed from stainless steel, e.g. AISI 304 or 316, or from a heating conductor alloy, like nickel chromium alloys.
• Furthermore, theaerosol forming member10amay be formed with a capillary structure that extends throughout the whole aerosol-formingmember10asuch that it is exposed on the twomajor surfaces13,14 of the sheet of material. In this embodiment each of the major surfaces would be exposed to thechamber6. Alternatively, one of themajor surfaces13,14 may optionally be sealed with a metallic foil or cover that is sintered or attached to said major surface such that said surface is vapor impermeable. Alternatively, a region of one or both of themajor surfaces13,14 may be sealed so as to be vapor impermeable. In another embodiment, the aerosol-formingmember10ais configured such that the capillary structure does not extend throughout the whole aerosol-forming member. For example, in one embodiment the capillary structure does not extend to one of themajor surfaces13,14 such that there is no exposed capillary structure in this area. Alternatively the capillary structure is exposed on a region of one or bothmajor surfaces13,14. In the context of the present disclosure, reference to “exposure” of the capillary surface does so with reference to thechamber6 and it is possible that there are areas of the capillary surface that extend to themajor surfaces13,14 but that are covered by other components of the device.
• In yet another un-illustrated embodiment, a thin support layer may be attached to one or both of themajor surfaces13,14. Such a support layer provides stability to the sheet of material. The support layer may be formed from a wire mesh or from individual wires and may be made of stainless steel.
• The material from which the aerosol-formingmember10ais formed is heatable in that it comprises sufficient electrical resistivity so that when current is passed through, the aerosol-formingmember10aheats up to a temperature sufficient to cause the solution held in the capillary structure to evaporate or vaporize. In these embodiments, the aerosol-formingmember10acan be considered to comprise a heating element formed with a capillary structure such that the heating element and the capillary structure are integrated and form a single entity or unit.
• In the above described embodiments wherein the sheet of material comprises a single layer configured to wick and heat a solution, the sheet of material can be described as comprising a heating element and a wick that are arranged in the same surface.
• In an alternative un-illustrated embodiment, the sheet of material may comprise a plurality of layers, for example it may comprise any combination of the aforementioned structures and materials, e.g. by providing multiple layers of different structures/materials, the layers being joined together, e.g. by sintering. One such alternative un-illustrated embodiment will now be described in more detail.
• This un-illustrated alternative aerosol-forming member comprises a sheet of material that is sheet-like in nature and formed from a plurality of layers. For example, the aerosol-formingmember10amay comprise a first heatable layer acting as a heating element. The first layer is formed from a material that is configured to be heated up and may comprise a metal wire mesh, it may be made of stainless steel or nickel chromium alloys. The aerosol-formingmember10amay further comprise a second layer formed with an open-pored structure, foam structure or interconnecting network of pores, all of which form a capillary structure. The capillary structure enables the aerosol-formingmember10ato wick or absorb a solution. This second layer may comprise a fiber web or fabric made of glass fibers, glass fiber yarns or any other non-conductive and inert, thus relatively non-heatable (electrically non-heatable) fiber materials. In this embodiment the sheet of material can be described as comprising a heating element and a wick that are arranged in parallel surfaces and are connected to each other. The second layer acts as a wick.
• The first layer (heating element) and the second layer (wick formed with a capillary structure) are laid on top of each other so as to form a sheet of material having two opposing major surfaces, wherein the capillary structure is exposed on one or both major surfaces (depending on the configuration of the heating element).
• In an alternative un-illustrated embodiment, the sheet of material comprises a third layer that is similar to the second layer in that it comprises a capillary structure. The second and the third layer sandwich the first layer such that the capillary structure is exposed on both major surfaces of the sheet of material.
• In the embodiments wherein the sheet of material is formed from a plurality of layers as described above, the first layer forming the heating element and the second and/or third layer(s) forming the wick are parallel and connected to each other. The layers may be connected to each other by mechanical, chemical or thermal means. In one embodiment, the layers are sintered or fritted to one another.
• It should be understood that the present disclosure wherein the sheet of material comprises a plurality of layers is not limited to the examples described above. For example, in an alternative embodiment both the first and the second layers may be made of a heatable material. For instance, the first layer may comprise a metal foil, and the second layer may be made of a porous granular, fibrous or flocculent sintered metal(s) or comprise an open-pored metallic foam or a wire mesh structure all of which form said capillary structure. The first and second layers may be formed from stainless steel and may be sintered together. In this embodiment the sheet of material can be described as comprising a heating element and a wick that are arranged in the same surface and in parallel surfaces, the capillary structure being only exposed on one of the major surfaces of the sheet of material.
• In another embodiment, the first and second layers may be made of porous heatable material(s), such that both layers are configured to heat and wick a solution. In this embodiment the sheet of material can be described as comprising a heating element and a wick that are arranged in the same surface and in parallel surfaces.
• In a further alternative un-illustrated embodiment, the sheet of material comprises a porous first layer having small sized pores and a second porous layer having larger sized pores than the first layer, thus both layers are formed with a capillary structure however the second layer forming the inner major surface can emit more vapor than the first layer forming the outer major surface. At least one of the two layers is formed from a heatable material as described above. Both layers may be formed with a structure and material as discussed above in relation to the capillary structure.
• The sheet of material according to any of the above described embodiments has a thickness or depth that falls within the range of 20-500 μm. Alternatively, the thickness falls within the range of 50 to 200 μm. The thickness or depth should be understood as meaning the distance between the twomajor surfaces13,14 of the sheet of material.
• The ends21,20 of the partitioning wall8 (according to the embodiment ofFIG. 2c) are formed with twosupply passages22 such that thereservoir9 andcapillary gaps17,18 are in fluid communication. The supply passages are of a width sufficient to achieve a capillary effect. Therefore, in use, a solution held in thereservoir9 moves by capillary action from thefluid reservoir9 into thesupply passages22 towards thecapillary gaps17,18, and then from thecapillary gaps17,18 to the capillary structure at theends15,16 of the aerosol-formingmember10a. The capillary structure of the aerosol-formingmember10aprovides a capillary effect similar to a wick, thus the capillary structure enables the aerosol-formingmember10ato absorb the solution provided to thecapillary gaps17,18 such that the solution is distributed throughout the whole capillary structure of the sheet of material.
• The embodiment ofFIG. 2boperates in a similar manner, except the aerosol-formingmember10ais fed fromreservoir9 viacapillary gaps17,18.
• It should be understood that the present disclosure is not limited to twocapillary gaps17,18, but may comprise only a single capillary gap feeding only one of theends15,16 of the aerosol-formingmember10a.
• Abattery30 controlled by a controller forming part of a printed circuit board (PCB) is disposed in thehousing2 as seen inFIG. 1, and theends15,16 of the aerosol-formingmember10aare electrically connected, e.g. via circuitry, to the positive and negative terminals of thebattery30 respectively. When current is drawn from thebattery30 and through the sheet of material, the resistance of the sheet of material causes it to increase in temperature. In the embodiment wherein the sheet of material comprises a non-porous heatable first layer, for instance a metal foil, and where the outer major surface is formed from said first layer, the resistance of said first layer causes the first layer acting as a heating element to increase in temperature, the first layer in turn heating up adjacent second and/or third layers including the solution contained/stored in the pores/void of the capillary structure of said second and/or third layers. The current drawn by thebattery30, and thus the temperature of the sheet of material may be controlled by a switching circuit, e.g. a Power-MOSFET switching circuit, within thehousing2. The switching circuit may provide automatic control of the temperature, for example, by using temperature sensors (not shown), or may be controlled by a button or dial (not shown) provided on thehousing2 that may be manipulated by the user.
• In one embodiment thepartitioning wall8 may be provided with aheat shield26 on a surface facing the aerosol-formingmember10a. Theheat shield26 is shown inFIG. 2band it protects thepartitioning wall8 from overheating as the temperature of the aerosol-formingmember10ais increased. Theheat shield26 may be formed from a thin non-conductive material like oxidized stainless steel wire mesh or inert fabrics like glass or carbon fabrics. It should be understood that theheat shield26 is optional.
• Operation of the aerosol delivery device will now be described with reference toFIGS. 1 and 2. In use, the user may manually activate theaerosol delivery device1 or theaerosol delivery device1 may be activated automatically as the user starts puffing on theaerosol delivery device1. This may be achieved by a pressure sensor (not shown) included in theelectric circuitry31 and communicating with the inlet passage/plenum chamber4 via a connecting passage. In either embodiment, thebattery30 provides a potential difference between the opposing ends15,16 of the aerosol-formingmember10aas the aerosol delivery device is activated, causing current to flow though the sheet of material such that themember10aincreases in temperature. This increase in temperature causes the solution held in the capillary structure of the sheet of material to evaporate so as to form a vapor. The evaporated solution mixes with the air drawn into the aerosol delivery device viapassage4 by the user. The evaporated solution mixes with air in theaerosol chamber6, and as this occurs the vapor condenses and forms droplets such that an inhalable aerosol is produced.
• The aerosol-forming member according to any of the above described embodiments is located in thehousing2 such that the planes of themajor surfaces13,14 are parallel to or substantially aligned with the direction of the airflow through theaerosol chamber6. Thus, when a solution is held in the aerosol-formingmember10aand it is heated up such that the solution evaporates, the solution evaporates in a direction transverse to the direction of the airflow. In the embodiments wherein the capillary structure is exposed on both sides of the sheet of material, the solution is evaporated from both sides in opposite directions. Thecorrugations10bof the sheet ofmaterial form channels25 through which air flows and also in which a solution is evaporated such that when it mixes with airflow aerosol is formed. Thus, thecorrugations10borchannels25 direct the flow of aerosol through the aerosol delivery device towards the user. Furthermore, as a result of thecorrugations10b, solution is evaporated from themajor surfaces13,14 in a direction towards another region of themajor surfaces13,14 which results in reduced levels of aerosol condensing on the chamber walls and other internal components. Furthermore, as vapor is emitted from themajor surfaces13,14 towards another region of the same major surface, vapor density is increased. Additionally, as the aerosol-forming member cools down aerosol and vapor remaining in theaerosol chamber6 that condenses onto one of themajor surfaces13,14 will be reabsorbed into the capillary structure of the aerosol-forming member and re-evaporated as the aerosol-forming member heats up again. Condensate formed on the chamber walls may at least partially be reabsorbed into the capillary structure via thecorrugations10b.
• As previously described, the corrugated configuration reduces condensation from forming and accumulating on the chamber walls, internal components and/or inner walls of thehousing2. Thus, sponges or other means for absorbing condensation not inhaled by the user that are used in some conventional aerosol delivery devices may be omitted. This results in a more compactaerosol delivery device1, as well as a simplified manufacturing process and reduced costs. Furthermore, by reducing the amount of aerosol and vapor from condensing onto inner walls of thehousing2, the transfer of condensation heat to thehousing2 may be reduced, making theaerosol delivery device1 more comfortable for the user to hold.
• After the aerosol-formingmember10ahas been activated and aerosol has formed in thechannels25, the aerosol is drawn through thechannels25 as the user continues to inhale. The aerosol then exits theaerosol chamber6 through achamber outlet31 provided in thehousing2 as seen inFIG. 1b. The aerosol then passes through an optionalaerosol refining member32 provided in thehousing2, causing the aerosol to be cooled. The refiningmember32 may also contain flavoring agents like menthol that are released into the flow of aerosol before entering the user's mouth via theoutlet7 provided in themouthpiece3. Meanwhile, the solution that has evaporated from the capillary structure of the sheet of material is replaced by fresh solution from thereservoir9 due to the capillary effect of thecapillary gaps17,18 and the capillary structure of the aerosol-formingmember10aas described above and fresh air enters thechannels25 via theair inlet5 andpassage4. In one embodiment, a pressure drop element/flow resistor33 is positioned in thepassage4 so that the flow of air into theaerosol chamber6 can be controlled. Theflow resistor33 may consist of a simple aperture or hole and may be identical with theair inlet5 in thehousing2. Alternatively, theflow resistor33 may consist of a porous body similar to a cigarette filter providing the flow resistance of a conventional cigarette.
• Thevalve33 may be controlled by the PCB or manually, for example, by adjusting a switch or dial (not shown) on thehousing2 of theaerosol delivery device1.
• The degree of corrugation can be varied by varying the number of corrugations per distance unit. For example, in one embodiment the sheet of material comprises three corrugations per distance unit. In another embodiment the sheet of material comprises 6 corrugations per distance unit. The greater the degree of corrugation the more aerosol is generated by the aerosol-forming member per inhalation.
• It should be understood that due to the corrugations of the above described embodiments, the aerosol-forming member has larger surface area compared to a flat aerosol-forming member. Advantageously, this increases the efficiency of theaerosol forming member10ain that it can produce more aerosol per inhalation. Furthermore, due to the corrugation of the aerosol-formingmember10a, theaerosol delivery device1 can be made more compact.
• Referring now toFIG. 3a, another embodiment of anaerosol delivery device51 is disclosed.FIG. 3ashows a cross-section of anaerosol delivery device51 similar to theaerosol delivery device1 shown inFIG. 1a. Theaerosol delivery device51 comprises ahousing52 with a mouthpiece (not shown). A passage (not shown) is provided in thehousing52 and is open to atmosphere via an air inlet (not shown). The passage is in fluid communication with anaerosol chamber56 which in turn is in fluid communication with an outlet aperture (not shown) formed in the mouthpiece. Therefore, in use, air may be drawn through the passage and into theaerosol chamber56, via the passage, and then through the outlet aperture similar to the airflow of the aerosol delivery device shown inFIG. 1a.
• An aerosol-formingmember60ais located in theaerosol chamber56 as seen inFIG. 3a. The aerosol-formingmember60acomprises a sheet ofmaterial having corrugations60bsuch that it forms peaks and troughs. A corrugation is to be understood as two bends, or a peak and a trough, or a ridge and a groove. The sheet of material may also be described as having a cross-sectional profile comprising at least one point of inflection.
• The corrugations may follow a meandering or oscillating path, or a sine curve, or a zigzag-like configuration, or any other similar pattern. The aerosol-formingmember60amay comprise regular corrugations such that it comprises a repetition of identical corrugations as seen inFIG. 3a. However, in an alternative un-illustrated embodiment the aerosol-forming member may comprise irregular corrugations wherein the shape of peaks and troughs differ from one another. AlthoughFIG. 3ashows an aerosol-formingmember60acomprisingrounded corrugations60b, i.e. rounded peaks and troughs, it should be understood that the disclosure is not limited thereto, but also includes corrugations forming vertices. These vertices may have obtuse, acute and/or right angles. This embodiment is shown inFIG. 3band the reference numerals ofFIG. 3aapply correspondingly to the components ofFIG. 3b.
• The aerosol-formingmember60ais similar to the embodiments of the aerosol-formingmember10adescribed above with reference toFIGS. 1 and 2 and so a detailed description will be omitted. However, it should be understood that the aerosol-formingmember60acomprises a sheet material having two opposingmajor surfaces66,67. The aerosol-formingmember60ahas an open-pored structure, foam structure or interconnecting network of pores, all of which form a capillary structure. The capillary structure enables the aerosol-formingmember60ato wick or absorb a solution. The sheet of material may comprise a single or a plurality of layers according to the various embodiments described with reference toFIG. 2.
• Theaerosol chamber56 is defined by chamber walls comprising two opposingchamber side walls53,54 and two opposing chambermain walls57a,57b. The chambermain walls57a,57bcomprise aliquid reservoir matrix58,59. Theliquid reservoir matrix58,59 comprises a capillary structure, for example an interconnecting porous or open-porous structure, such that it can hold a solution or liquid. Theliquid reservoir matrix58,59 comprises a heatresistant layer62 and aresilient layer63. The heatresistant layer62 of each chambermain wall57a,57bis exposed to the space of theaerosol chamber56 and the resilient layer of eachmain wall57a,57bis sandwiched between the heatresistant layer62 and thehousing52.
• The heatresistant layer62 is sheet-like in nature and comprises one or a plurality of layers that may have a structure of fabric, mesh, woven fiber web, non-woven fiber web or foam. The heatresistant layer62 is made of a heat resistant material, for example, glass, metal, carbon-based materials, ceramic, cotton or heat resistant plastic. If the heatresistant layer62 is made of metal, the metal may be coated or oxidized so as to prevent short circuits. The heatresistant layer62 is configured to resist heat so that it can withstand heat emitted by theaerosol forming member60aand thereby protect theresilient layer63.
• Theresilient layer63 may comprise various structures, for example, its structure may be formed from woven fibers, non-woven fibers, foam or sponge. Theresilient layer63 may be made of plastic.
• Theresilient layer63 provides a spring force such that it urges or biases the heatresistant layer62 towards thecorrugations60b, i.e. the peaks, troughs or vertices, such that the heatresistant layer62 of eachliquid reservoir matrix58,59 is in contact with the corrugations, i.e. the peaks, troughs or vertices. This enables theliquid reservoir matrices58,59 to supply solution held therein to the aerosol-formingmember60asuch that the solution spreads throughout the capillary structure of the aerosol-formingmember60a.
• The capillarity of the aerosol-formingmember60amay be greater than the capillarity of thereservoir matrices58,59, but at least greater than the capillarity of theresilient layer63 so as to induce a flow of solution from theliquid reservoir matrices58,59 towards the aerosol-formingmember60a. The capillarity is defined by the pore size and the wetting conditions of the respective capillary structures.
• It should be understood that the present disclosure is not limited to comprising twoliquid reservoir matrices58,59. It may comprise more than two liquid reservoir matrices. For example, each peak and trough of a corrugation may be in contact with discrete liquid reservoir matrices. In an alternative embodiment, only one chambermain wall57acomprises a liquid reservoir matrix and the other chambermain wall57bis made of a non-porous material (vice versa).
• Ends64,65 of the aerosol-formingmember60aare attached to thechamber side walls53,54. In an embodiment both ends64,65 of the aerosol-formingmember60aare attached and can be electrically connected to a support plate, which may be a printed circuit board (PCB). Alternatively, ends of the aerosol-formingmember60amay be attached to one of the heatresistant layers62 of the chambermain walls57a,57bas seen inFIG. 3. In each embodiment, the aerosol-formingmember60ais suspended across theaerosol chamber56.
• The aerosol-delivery device51 further comprises a battery (not shown) and a printed circuit board (PCB) (not shown) as described with reference toFIGS. 1 and 2, and the aerosol-delivery device51 is configured similar to theaerosol delivery device1 described with reference toFIGS. 1 and 2 such that the ends64,65 of the aerosol-formingmember60a, are electrically connected to the positive and negative terminals of the battery respectively. When current is drawn from the battery through the sheet of material of the aerosol-formingmember60a, the resistance of the sheet of material causes it to increase in temperature.
• Operation of the aerosol-formingmember60awill now be described with reference toFIG. 3. Similar to the aerosol-delivery device1 described with reference toFIG. 2, the user may manually activates theaerosol delivery device51 or theaerosol delivery device51 may be activated automatically as the user starts puffing on theaerosol delivery device51. This may be achieved by a pressure sensor (not shown) located in the passage extending between the air inlet and aerosol chamber. In either embodiment, the battery provides a potential difference between theends64,65 of the aerosol-formingmember60aas theaerosol delivery device51 is activated, causing current to flow between theends64,65 such that the sheet of material increases in temperature. This increase in temperature causes the solution held in the capillary structure of the sheet of material to evaporate so as to form a vapor. The vapor mixes with air drawn into the aerosol delivery device via passage by the user. The vapor mixes with air in theaerosol chamber56, and as this occurs the vapor condenses and forms droplets such that an inhalable aerosol is produced.
• The aerosol-forming member according to any of the above described embodiments with reference toFIG. 3 is located in thehousing52 such that the planes of themajor surfaces66,67 are substantially parallel or aligned with the direction of the airflow. Thus, when a solution is held in the aerosol-formingmember60aand it is heated up such that the solution evaporates, the solution evaporates in a direction transverse to the direction of the airflow. In the embodiments wherein the capillary structure is exposed on both sides of the sheet of material, the solution is evaporated from both sides in opposite directions. Thecorrugations60bof the sheet ofmaterial form channels68 through which air flows. Furthermore, evaporated solution or vapor mixes with the airflow in thechannels68 such that aerosol is formed. Thus, thecorrugations60borchannels68 direct the flow of aerosol through theaerosol delivery device51 towards the user. Furthermore, as the sheet of material comprises corrugations solution is evaporated from themajor surfaces66,67 in a direction towards another region of the major surfaces which results in reduced levels of aerosol condensing on the chamber walls and other internal components. Furthermore, as the aerosol-formingmember60acools down aerosol and vapor remaining in theaerosol chamber56 that condenses onto one of themajor surfaces66,67 will be reabsorbed into the capillary structure of the aerosol-formingmember60aand re-evaporated as the aerosol-formingmember60aheats up again. Condensate formed on the chamber walls may at least partially be reabsorbed into the capillary structure of the heatresistant layer62 and that way resupplied to the capillary structure of the aerosol-formingmember60a.
• Similar to the aerosol-formingmember10adescribed with reference toFIG. 2, the corrugated configuration of the aerosol-formingmember60bshown inFIG. 3 also reduces condensation from forming on the chamber walls, internal components and/or inner walls of thehousing52. Thus, separate sponges other than theliquid reservoir matrices58,59 or other extra means for absorbing condensation not inhaled by the user that are used in some conventional aerosol delivery devices may be omitted. This results in a more compactaerosol delivery device51, as well as a simplified manufacturing process and reduced costs. Furthermore, by reducing the amount of aerosol from condensing onto the inner walls of thehousing52, the transfer of condensation heat to thehousing52 may be reduced, making theaerosol delivery device51 more comfortable for the user to hold.
• After the aerosol-formingmember60ahas been activated and aerosol has formed in thechannels68, the aerosol is drawn through thechannels68 as the user continues to inhale. The aerosol then exits theaerosol chamber56 through a chamber outlet provided in thehousing52. The aerosol then passes through an optional filter sponge provided in thehousing52, causing any large particulate in the flow to condense and be removed from the air flow before entering the user's mouth via the outlet provided in the mouthpiece. Meanwhile, the solution that has evaporated from the capillary structure of the sheet of material is replaced by fresh solution from theliquid reservoir matrices58,59 due to the capillary effect of the capillary structure and the peaks, troughs and/or vertices being in contact with theliquid reservoir matrices58,59. Fresh air enters thechannel68 via the air inlet and passage. In one embodiment, a flow resistor (as described above) is positioned in the passage so that the flow of air into theaerosol chamber56 can be controlled. The valve may be controlled by the PCB or manually, for example, by adjusting a switch or dial (not shown) on thehousing52 of theaerosol delivery device51.
• It should be understood that due to the corrugation of the above described embodiments, the aerosol-forming member has larger surface area compared to a flat aerosol-forming member. Advantageously, this increases the efficiency of theaerosol forming member10ain that it can produce more aerosol per inhalation. Furthermore, due to the corrugation of the aerosol-formingmember60a, theaerosol delivery device51 can be made more compact.
• Furthermore, the degree of corrugation of the aerosol-formingmember60acan be changed as described with reference toFIG. 2.
• In any of the above mentioned embodiments of the aerosol-forming member, one or both of theends15,16,64,65 may be located in line with or off-set from the peaks, troughs or vertices of thecorrugations10b,60b.
• In any of the above mentioned embodiments of the aerosol-forming component or device, there may be multiple aerosol-forming members, e.g. two, three, four, five or six aerosol-forming members. Where there are multiple aerosol-forming members, the number and configuration of the corrugations on each of the aerosol forming members may be the same or different. Where the number and configuration of the corrugations are the same, the aerosol-forming members may be positioned in the aerosol-forming component or device such that the corrugations are aligned. Where the multiple aerosol-forming members contain a different number and/or configuration of corrugations, the corrugations that are present may still be aligned. For example, two corrugations a first aerosol-forming member may be aligned with three corrugations of a second aerosol forming member. Such a configuration would result in thechannels25,68 being maintained throughout the aerosol chamber. Alternatively, the multiple aerosol-forming members may be positioned in the aerosol-forming component or device such that the corrugations are offset. This may result in better mixing conditions between the vapor and the air and increased aerosol yields. The multiple aerosol forming members may be electrically connected in series or in parallel. Furthermore, the multiple aerosol forming members may be controlled differently, e.g. heated up sequentially.
• The above described embodiments of the aerosol-forming member of theaerosol delivery device1 are described for use with a solution. It should be understood that this solution may comprise certain constituents or substances that may have a stimulatory effect on the user. These constituents or substances may be of any kind that is suitable for being delivered via inhalation. The solution in which the constituents or substances are held or dissolved may primarily consist of water, ethanol, glycerol, propylene glycol or mixtures of the aforementioned solvents. By means of a sufficiently high degree of dilution in an easily volatile solvent, such as ethanol and/or water, even substances which are otherwise difficult to evaporate can evaporate in a substantially residue-free manner, and thermal decomposition of the liquid material can be avoided or significantly reduced.
• In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which that which is claimed may be practiced and provide for superior aerosol-forming member, aerosol delivery device component and aerosol delivery device. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims (28)

1. An aerosol-forming member comprising:

a sheet of material configured to heat and wick a solution, wherein the sheet of material comprises at least one corrugation, so as to provide the sheet a material with a cross-sectional profile comprising at least one point of inflection.

2. An aerosol-forming member according toclaim 1, wherein the sheet of material comprises a capillary structure configured to wick a solution.

3. An aerosol-forming member according toclaim 1, wherein the capillary structure is exposed on both sides of the sheet of material.

4. An aerosol-forming member according toclaim 1, wherein the capillary structure extends throughout the whole sheet of material.

5. An aerosol-forming member according toclaim 1, wherein the sheet of material comprises a first layer that is heatable and a second layer comprising a capillary structure.

6. An aerosol-forming member according toclaim 1, wherein the sheet of material comprises a peak and a trough.

7. An aerosol-forming member according toclaim 1, wherein the at least one corrugation forms vertices.

8. An aerosol-forming member according toclaim 1, wherein the at least one corrugation is rounded.

9. An aerosol delivery device component comprising:

an air inlet and an air outlet fluidly communicating via an aerosol chamber defined by chamber walls; and

an aerosol-forming member according toclaim 1, the aerosol forming member being located at least partially within the aerosol chamber.

10. An aerosol delivery device component according toclaim 9, wherein the sheet of material comprises two opposing major surfaces that are aligned with a direction of flow of air through the aerosol chamber.

11. An aerosol delivery device component according toclaim 9, wherein the sheet of material comprises two opposing ends that are attached to the aerosol delivery device component such that the sheet of material is suspended across the aerosol chamber.

12. An aerosol delivery device component according toclaim 9, wherein the aerosol forming member is attached to at least one of the chamber walls.

13. An aerosol delivery device component according toclaim 9, wherein the at least one corrugation of the sheet of material is in close proximity to at least one of the chamber walls.

14. An aerosol delivery device component according toclaim 9, wherein the at least one corrugation of the sheet of material is in contact with at least one of the chamber walls.

15. An aerosol delivery device component according toclaim 9, wherein at least one of the chamber walls comprises a heat shield.

16. An aerosol delivery device component comprising:

an air inlet and an air outlet fluidly communicating via an aerosol chamber defined by chamber walls, wherein at least one of the chamber walls comprises a liquid reservoir matrix.

17. An aerosol delivery device component according toclaim 16, wherein the liquid reservoir matrix comprises a capillary structure.

18. An aerosol delivery device component according toclaim 16, wherein the liquid reservoir matrix comprises a heat resistant layer and a resilient layer.

19. An aerosol delivery device component according toclaim 18, wherein two opposing chamber walls each comprise a liquid reservoir matrix, and the heat resistant layer of each liquid reservoir matrix is innermost relative to the aerosol chamber such that the resilient layer urges the heat resistant layers towards one another.

20. An aerosol delivery device component according toclaim 16, further comprising an aerosol-forming member at least partially located within the aerosol chamber.

21. (canceled)

22. An aerosol delivery device component according toclaim 20, wherein the at least one corrugation of the sheet of material is in contact with the liquid reservoir matrix.

23. An aerosol delivery device comprising an aerosol-forming member as claimed inclaim 1.

24. An aerosol delivery device according toclaim 23 comprising multiple aerosol-forming members.

25. An aerosol delivery device according toclaim 24 comprising multiple aerosol-forming members positioned in the aerosol delivery device such that the corrugations are aligned with respect to a direction of airflow through the device.

26. An aerosol delivery device according toclaim 24 comprising multiple aerosol-forming members positioned in the aerosol delivery device such that the corrugations are off-set with respect to a direction of airflow through the device.

27. An aerosol delivery device comprising an aerosol delivery device component as claimed inclaim 9.

28. An aerosol delivery device comprising an aerosol delivery device component as claimed inclaim 16.

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