Electronic cigarette

Abstract

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

Description

Technical Field

[0001] This invention relates to an electronic cigarette, specifically to an electronic cigarette that requires a power supply unit or battery power. Background Technology

[0002] Electronic cigarettes are an alternative to regular cigarettes. Instead of producing burning smoke, electronic cigarettes vaporize a liquid that can be inhaled by the user. The liquid typically includes aerosol-forming substances, such as glycerin or propylene glycol, which produce vapor. Other common substances in the liquid are nicotine and various flavorings.

[0003] Electronic cigarettes are handheld inhaler systems that include a mouthpiece section, a liquid reservoir, and a power supply unit. Vaporization is achieved through a vaporizer or heater unit, which typically includes a heating element in the form of a heating coil and a fluid delivery element, such as a wick, arranged to transfer fluid from the liquid reservoir to the heating element. Vaporization occurs when the heater heats the liquid in the fluid delivery element until the liquid is converted into vapor. The vapor can then be inhaled through an air outlet in the mouthpiece.

[0004] Electronic cigarettes may include a battery section and a cartridge, the battery section being configured to receive a power supply unit or battery, and the cartridge including a liquid reservoir. The cartridge and vaporizer are commonly referred to as a "cartomizer." The power supply unit is connected to the cartomizer of the cartomizer, allowing power to be supplied to the cartomizer's heater to heat the liquid and produce vapor.

[0005] Problems exist in existing technology devices, where batteries in electronic devices are prone to thermal runaway. The term "thermal runaway" is used to describe a process accelerated by an increase in temperature and the subsequent release of energy that further increases the temperature. This phenomenon occurs when conditions change in a way that leads to a further increase in temperature.

[0006] In the context of batteries, thermal runaway occurs when the internal temperature reaches a point that triggers a chemical reaction within the battery. This chemical reaction generates even more heat, driving the temperature even higher and initiating further chemical reactions that generate even more heat. Furthermore, if oxygen is added, a chain reaction begins, producing extremely high temperatures (around 400 degrees Celsius). These temperatures can cause battery gas release and fires that are difficult to extinguish. The batteries used in e-cigarettes are prone to these problems.

[0007] Thermal runaway is extremely dangerous in e-cigarettes because it can cause a fire within the device's battery section. Therefore, it is desirable to provide an e-cigarette that reduces the risk of thermal runaway and fire, thereby improving the safety and / or reliability of the e-cigarette. Summary of the Invention

[0008] The purpose of this invention is to provide an electronic cigarette that makes progress in solving some of the problems of the aforementioned prior art devices.

[0009] According to a first aspect of the present invention, an electronic cigarette is provided, comprising: a tubular housing; a battery compartment located within the tubular housing and configured to receive a battery; a first partition located at a first end of the battery compartment and a second partition located at a second end of the battery compartment, the first partition and the second partition being configured to provide an airtight seal to the battery compartment.

[0010] As used herein, the term "separator" can refer to a physical separator located at the end of the battery compartment to provide a barrier between the battery compartment and the rest of the e-cigarette. As used herein, the term "airtight seal" refers to a seal that prevents air from escaping or passing through. In this way, the first and second separators are configured to provide an enclosed space in which there are no gaps or openings that allow air to enter or escape.

[0011] When the battery in the device experiences thermal runaway, it may overheat and ignite. By including a first and second separator disposed at the respective ends of the battery compartment and providing an airtight seal to the battery compartment, the oxygen supply to the battery compartment is restricted. This prevents thermal runaway and / or significantly slows it down. This improves the safety and / or reliability of the e-cigarette. It also gives the customer additional time to remove the e-cigarette from their pocket and prevent injury.

[0012] In some examples, both the first and second partitions include an outer peripheral edge that is arranged to provide a seal with the inner wall of the tubular housing.

[0013] In this way, there are no gaps or openings between the separator and the inner wall of the tubular housing, ensuring that no air or gas can be exchanged into or out of the battery compartment at this boundary. Therefore, the battery compartment is provided with an effective hermetic seal, thereby improving the safety and / or reliability of the electronic device.

[0014] In some examples, at least one of the first and second separators comprises a flexible material, thereby providing an interference fit between the inner wall of the tube housing and the separator.

[0015] Preferably, the diameter or cross-section of the first and second separators is slightly larger than the diameter or cross-section of the outer casing. Therefore, when the first and second separators are located within the outer casing, the interference between the separators and the outer casing provides a tight, hermetic seal. Thus, this example eliminates the need for additional adhesives, fasteners, or other devices to hold the parts together, resulting in a simple design.

[0016] The term "flexible material" can refer to a material that deforms under force without breaking or losing its structural integrity; that is, it returns to its original size when the force is removed. In this way, if pressure builds up in the battery compartment, the separator helps reduce the pressure in the battery compartment by flexing outward from the battery compartment.

[0017] In some examples, at least one of the first and second separators comprises silicone.

[0018] Advantageously, silicone is flexible and durable, making it resistant to wear caused by applications such as interference fits. This ensures a robust hermetic seal. Furthermore, silicone has a low coefficient of thermal expansion, meaning it can withstand temperature variations without significant dimensional changes. This is advantageous because the interference fit will not loosen due to increased temperatures in the e-cigarette or battery compartment. In some examples, the silicone is HT-RTV 530 Shore A30 or Dowsil 736 high-temperature silicone.

[0019] Preferably, the silicone is high-temperature food-grade silicone. In this way, the silicone will not contain harmful substances that could harm the user when using the e-cigarette.

[0020] In some examples, the electronic cigarette further includes a layer of sodium carbonate disposed on the inner surface of at least one of the first and second separators.

[0021] The sodium carbonate layer releases carbon dioxide. Carbon dioxide retards fires, deprives them of oxygen, and disrupts the chemical reactions necessary for a fire to sustain itself. In particular, sodium carbonate is effective in extinguishing chemical fires that may occur when certain types of batteries are used, such as nickel-metal hydride (NiMH), lithium polymer (Li-Pol), or lithium-ion (Li-Ion) batteries. In this way, the sodium carbonate layer can help prevent and extinguish fires in the battery compartment, thereby further improving the safety and / or reliability of e-cigarettes.

[0022] Preferably, the sodium carbonate layer is high-temperature food-grade silicone. In this way, the silicone will not contain harmful substances that could harm the user when using the e-cigarette.

[0023] In some examples, the second separator is located at the distal end of the electronic cigarette, opposite to the mouthpiece end, wherein the second separator includes a vent point configured to release gas from the battery compartment if the pressure inside the battery compartment exceeds a threshold.

[0024] Certain types of batteries may experience leakage or degassing events, in which fluids (e.g., liquids or gases) are generated and released from the battery. For example, degassing events are known to occur in lithium-ion batteries. These events may be slow or minor events within the normal behavior of the battery and may not necessarily impair the function of the aerosol generating device. However, these events can also be rapid events leading to high pressure. This is particularly concerning when coupled with thermal runaway events in the battery compartment and can potentially damage the e-cigarette or even cause it to explode. In this way, the pressure inside the battery compartment can be reduced by providing venting points configured to release gas from the battery compartment when the pressure exceeds a threshold. Therefore, the venting points facilitate the controlled release of gas from the battery compartment. This further improves the safety and / or reliability of the device. Furthermore, in this arrangement, if thermal runaway is unavoidable, the controlled gas is released through the bottom portion of the device, thus guiding it away from the customer's face.

[0025] In some examples, the venting point includes a thinner portion of the second separator to provide a preferential rupture point above a threshold. In some examples, the preferential rupture point can be a valve. Because the preferential rupture point is thinner than the rest of the separator, it is less likely to withstand the force exerted on it by the air pressure inside the battery compartment. In this way, the pressure exerted on the thinner portion may cause rupture and thus leakage. Thus, the preferential rupture point will prevent the casing from exploding or the entire separator from bursting, and will instead open at the preferential rupture point. In this way, gas can be released from the battery compartment in a controlled manner. This can only be considered a "backup option" if there is an oxygen supply in the battery and thermal runaway cannot be prevented.

[0026] In some examples, at least one of the first and second separators includes a flexible material having at least one cable opening configured to allow a cable to pass through the opening, the cable opening having a diameter smaller than the diameter of the cable.

[0027] At least one separator made of a flexible material allows for a slight widening of the opening diameter when the cable is inserted. As the material relaxes, it contracts around the cable, ensuring a tight fit. In this way, at least one of the first and second separators provides a tight seal around the cable, preventing air from entering the battery compartment through the opening. Therefore, the battery compartment can supply power to other components of the device via the cable while remaining within the airtight battery compartment. This allows the battery to be isolated from other components of the e-cigarette while providing its intended function. Additionally, the cable is securely held in place by the cable opening.

[0028] In some examples, the diameter of at least one cable opening is between 20% and 30% smaller than the diameter of the cable.

[0029] According to a second aspect of the invention, a method of manufacturing an electronic cigarette as described in any of the preceding claims is provided, the method comprising: providing a tubular housing for the electronic cigarette; casting a first separator and a second separator in a mold; and fixing the first separator and the second separator within the tubular housing to form a battery compartment, wherein the first separator is located at a first end of the battery compartment and the second separator is located at a second end of the battery compartment, such that the first separator and the second separator provide an airtight seal for the battery compartment.

[0030] According to a third aspect of the present invention, a method of manufacturing an electronic cigarette as claimed in any one of claims 1 to 9 is provided, the method comprising: providing a tubular housing for the electronic cigarette; disposing a first support member at a first end of the battery compartment and pouring a liquid separator forming agent into the tubular housing to form a first separator at the first end of the battery compartment and on the first support member; and providing a second separator at a second end of the battery compartment such that the first separator and the second separator provide an airtight seal to the battery compartment.

[0031] The first separator is formed directly within the electronic cigarette by pouring a liquid separator forming agent directly into the tubular housing. This provides a tight seal between the tubular housing and the first separator. In some examples, the liquid separator forming agent includes silicone. Attached Figure Description

[0032] Figure 1a and Figure 1b An electronic cigarette according to the present invention is shown; Figure 2 A first separator and / or a second separator of an electronic cigarette according to the present invention are shown; Figure 3 A first separator and / or a second separator of an electronic cigarette according to the present invention are shown; Figure 4 A first separator and / or a second separator of an electronic cigarette according to the present invention are shown; Figures 5a to 5d A method for manufacturing an electronic cigarette according to the present invention is shown; Figure 6 A flowchart illustrating a method for manufacturing an electronic cigarette according to the present invention is shown; Figure 7 A flowchart illustrating a method for manufacturing an electronic cigarette according to the present invention is shown. Detailed Implementation

[0033] Figure 1a and Figure 1bAn electronic cigarette 1 according to the present invention is schematically shown. The electronic cigarette 1 includes a tube housing 10 serving as the inhaler body. Inside the tube housing 10 is a battery compartment 20 configured to receive a battery 21. The electronic cigarette 1 further includes a first partition 30 at a first end of the battery compartment 20 and a second partition 40 at a second end of the battery compartment 20. The first partition 30 and the second partition 40 are configured to provide an airtight seal to the battery compartment 20.

[0034] like Figure 1a and Figure 1b As shown, both the first separator 30 and the second separator 40 include an outer peripheral edge arranged to provide a seal with the inner wall of the tubular housing 10. In this example, the first separator 30 and the second separator 40 comprise a flexible material to provide an interference fit between the inner wall of the tubular housing 10 and the separators 30, 40. In this way, the first separator 30 and the second separator 40 are securely held in place within the tubular housing 10 without the need for additional securing devices. While not essential, in some examples, it may be advantageous to additionally include other securing devices if the electronic cigarette 1 requires a more secure hold between the tubular housing 10 and the separators 30, 40. Silicone may be applied to the outer peripheral edges of the separators 30, 40 between the separators 30, 40 and the inner wall of the tubular housing 10.

[0035] Battery 21 powers one or more other components of the electronic cigarette 1. For example, a heating element additionally included in the electronic cigarette 1 may require power from battery 21 to vaporize the liquid. Figure 2 As shown, in some examples, the first separator 30 includes two cable openings 31a, 31b, configured such that cables 22a, 22b can pass through each of the corresponding cable openings 31a, 31b. In this example, the first separator 30 comprises a flexible material, and the cable openings 31a, 31b have diameters smaller than the diameters of the cables 22a, 22b. Both of these characteristics improve the airtight seal between the first separator 30 and the cables 22a, 22b. The flexible material allows the diameters of the openings 31a, 31b to widen slightly when the cable is inserted. When the material relaxes, it will contract around the cable, ensuring a tight fit.

[0036] In some examples, the diameters of cable openings 31a and 31b are between 20% and 30% smaller than the diameters of cables 22a and 22b. In specific examples, cables 22a and 22b may have a diameter of 1 mm, and the diameters of cable openings 31a and 31b may be in the range of 0.7 mm to 0.8 mm.

[0037] Cable openings 31a and 31b may include additional components to enhance the tight fit around cables 22a and 22b. These additional components may include sealing rings (e.g., O-rings) positioned around cables 22a and 22b at cable openings 31a and 31b to improve airtight sealing.

[0038] In some examples, both the first separator 30 and the second separator 40 may include cable openings 31a, 31b, depending on the location of the battery compartment 20 within the housing 10 relative to other components that require a power supply from the battery 21. Any number of cable openings 31a, 31b may be present in the separators 30, 40.

[0039] In any electronic cigarette 1 described herein, the first separator 30 and the second separator 40 may comprise silicone. In some examples, the silicone is HT-RTV 530 Shore A30 or Dowsil 736 high-temperature silicone.

[0040] Figure 3 A separator 40 of the electronic cigarette 1 according to the present invention is shown. Figure 3 As shown, the electronic cigarette 1 may further include a sodium carbonate layer 41 disposed on the inner surface of at least one of the first separator 30 and the second separator 40. The inner surface is the surface of the separator 40 facing the battery 21 of the battery compartment 20.

[0041] Figure 4 A separator 40 of an electronic cigarette 1 according to the present invention is shown, wherein the separator 40 includes two ventilation points 42a, 42b. Specifically, Figure 4 A second separator 40 is shown, intended to be disposed at the distal end of the electronic cigarette 1, opposite to the mouthpiece end. The second separator 40 includes two venting points 42a, 42b, configured to release gas from the battery compartment 20 if the pressure within the battery compartment exceeds a threshold. In some examples, venting points 42a, 42b include a thinner portion of the second separator 40 to provide a preferential rupture point above the threshold.

[0042] Figure 4The preferred rupture point is shown as a cross-shaped slit at each of the vent points 42a, 42b. In some examples, the preferred rupture point may alternatively be a single-line slit. When the pressure exceeds a threshold, the preferred rupture point can transition from a closed configuration where air neither enters nor leaves the battery compartment 20 to an open configuration where air can pass through the preferred rupture point. In the open configuration, air leaves the battery compartment 20, resulting in depressurization of the gas in the battery compartment 20. The preferred rupture point can be configured to passively open when the air pressure in the battery compartment 20 reaches the threshold, or alternatively, can be configured to actively open when it exceeds the threshold. The preferred rupture point can be configured such that only pressure from inside the battery compartment 20 can cause a transition from the open to the closed configuration, while pressure from outside the battery compartment 20 may not cause such a transition.

[0043] In other examples, both the first partition 30 and the second partition 40 may include at least one venting point, while in some examples, the first partition 30 and the second partition 40 may include more or fewer venting points 42a, 42b.

[0044] Figure 5a and Figure 5b A first method 100 for manufacturing an electronic cigarette 1 according to the invention is shown, the method comprising using a process known as “casting”. Figure 6 The method is also described in the text 100.

[0045] like Figure 5a As shown and in Figure 6 As described at S101, method 100 includes providing a tubular housing 10 for an electronic cigarette 1. At S102, a first support 50 is arranged at a first end of a battery compartment 20. The first support 50 may include a paper or plastic insert pressed into the tubular housing 10. The tubular housing 10 may include metal. At S103, a liquid separator forming agent is poured into the tubular housing 10 to form a separator 40 at the first end of the battery compartment 20, on the first support 50.

[0046] The liquid separator forming agent may include silicone. In this example, the silicone is melted at a suitable temperature before being poured into the tube housing 10. Preferably, the silicone is poured to form a 1 mm layer. To remove trapped air bubbles, the silicone may also be degassed using a suitable degassing method. The silicone is then cooled and / or cured. In some examples, the support 50 may be removed from the tube housing 10 after casting. The first separator and / or the second separator may be formed using casting process steps S101 to S103.

[0047] After the separator 40 is formed, the battery 21 and any battery retainer can be inserted into the tube housing 10, such as... Figure 5c As shown schematically.

[0048] In the example where only one separator 30, 40 is formed using the casting method in steps S101 to S103, another separator can then be provided. In step S104, a separator 30 is provided at the second end of the battery compartment 20, such that the first separator 30 and the second separator 40 provide an airtight seal to the battery compartment 20. This... Figure 5d The diagram is schematically shown. When the separator 30 is inserted, any cable protruding from the battery 21 can be fed through the cable openings 31a, 31b of the separator 30. The order of these steps can vary based on the arrangement of the components of the electronic cigarette 1 and may include additional steps for inserting and / or securing other components.

[0049] Figure 7 A second method 200 for manufacturing an electronic cigarette 1 according to the invention is described, wherein a first separator 30 and / or a second separator 40 are cast in a mold.

[0050] Step S201 of method 200 includes providing a tubular housing for an electronic cigarette 1. Step S202 includes casting a first separator 30 and a second separator 40 within a mold. The mold is shaped to produce separators of a desired shape. In some examples, the desired shape may be the shape of a cross-section of the tubular housing 10, or it may be a shape slightly larger than the cross-section of the tubular housing to provide a tight seal when fixed within the tubular housing 10. The casting process using a mold can be similar to that described above. Figure 5a and Figure 5b The described casting process, however, instead of pouring the liquid separator forming agent directly into the outer casing 10, involves pouring the liquid separator forming agent into the mold.

[0051] In step S203, the first separator 30 and the second separator 40 are fixed inside the tubular housing 10 to form a battery compartment 20, wherein the first separator 30 is located at a first end of the battery compartment 20 and the second separator 40 is located at a second end of the battery compartment 20, such that the first separator 30 and the second separator 40 provide an airtight seal to the battery compartment 20.

[0052] In an example where the electronic cigarette 1 further includes a sodium carbonate layer 41 disposed on the inner surface of at least one of the first separator 30 and the second separator 40, the manufacturing methods 100, 200 may further include inserting silicon carbonate into the mold / tube housing 10 before pouring the liquid separator forming agent. In this way, the liquid forming agent can be welded to the sodium carbonate layer as it hardens / cures. Alternatively, the silicon carbonate layer can be added to the semi-cured liquid separator forming agent. Alternatively, the sodium carbonate layer can be formed separately from the separators 30, 40 as a rigid layer and glued to the separators 30, 40 using an adhesive or welded to the separators 30, 40 by suitable means.

Claims

1. An electronic cigarette, comprising: Tubular outer shell; A battery compartment located within the tubular housing, the battery compartment being configured to receive a battery; A first partition located at a first end of the battery compartment and a second partition located at a second end of the battery compartment are configured to provide an airtight seal to the battery compartment.

2. The electronic cigarette according to claim 1, wherein, Both the first and second partitions include an outer peripheral edge arranged to provide a seal with the inner wall of the tubular housing.

3. The electronic cigarette according to claim 2, wherein, At least one of the first and second separators comprises a flexible material, thereby providing an interference fit between the inner wall of the tube housing and the separator.

4. The electronic cigarette according to any of the preceding claims, wherein, At least one of the first separator and the second separator comprises silicone.

5. The electronic cigarette according to any of the preceding claims, further comprising a sodium carbonate layer disposed on the inner surface of at least one of the first separator and the second separator.

6. The electronic cigarette according to any of the preceding claims, wherein, The second separator is located at the distal end of the electronic cigarette, opposite to the mouthpiece end, wherein the second separator includes a vent point configured to release gas from the battery compartment if the pressure inside the battery compartment exceeds a threshold.

7. The electronic cigarette according to claim 8, wherein, The venting point includes a thinner portion of the second separator to provide a preferred rupture point above the threshold.

8. The electronic cigarette according to any of the preceding claims, wherein, At least one of the first and second partitions includes a flexible material having at least one cable opening configured to allow a cable to pass through, the cable opening having a diameter smaller than the diameter of the cable.

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

10. A method of manufacturing an electronic cigarette according to any preceding claim, the method comprising: Provides a tubular casing for electronic cigarettes; The first and second separators are cast into the mold; as well as The first separator and the second separator are fixed inside the tubular housing to form a battery compartment, wherein the first separator is located at a first end of the battery compartment and the second separator is located at a second end of the battery compartment, such that the first separator and the second separator provide an airtight seal to the battery compartment.

11. A method for manufacturing an electronic cigarette according to any one of claims 1 to 9, the method comprising: Provides a tubular casing for electronic cigarettes; A first support member is arranged at the first end of the battery compartment, and a liquid separator forming agent is poured into the tubular housing to form a first separator at the first end of the battery compartment on the first support member; as well as A second separator is provided at the second end of the battery compartment, such that the first separator and the second separator provide an airtight seal for the battery compartment.

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