EVAPORATIVE DEVICE FOR AN INHALATOR AND METHOD FOR MANUFACTURING AN INHALATOR

Description

[0001] The present invention relates to a vaporizer device. Furthermore, the invention relates to a method for manufacturing a vaporizer device. It is well known to use vaporizer heads based on the wick-coil principle in electronic cigarettes. In addition to the widely used wick-coil e-cigarettes, other approaches include the surface vaporization of liquid directly on the liquid surface; this principle is known, for example, from patent application DE 10 2016 120 803.

[0002] Furthermore, it is known from DE 10 2017 130 501 A1 to use a so-called film evaporator. This involves a carrier consisting of a layered system with a polymer film and at least one metal film that makes contact with the polymer film over its entire surface. The polymer film has at least one fluid-permeable first opening, and the metal film has at least one fluid-permeable second opening that communicates with the first opening. The metal film forms the heating elements, and the heating elements are arranged to delimit the second opening.

[0003] Furthermore, a film evaporator is also known from WO 2016 / 166670 A1, which comprises a flexible film with an electrically conductive network having resistance zones that define the heating element. A flexible film is also provided on which sections containing an aromatic substance are arranged opposite the heating element, so that this substance can be evaporated. A very similar principle is also known from EP 3 282 872 B1.

[0004] From EP 3 099 190 B1 a sinusoidal evaporator film is known with a material surface area designed for heating and absorbing a solution and comprising a corrugation.

[0005] WO 2019 / 211311 A1 discloses a heating arrangement for forming an aerosol. A liquid is conveyed from a liquid storage section to an electric heater by means of a capillary body. The electric heater is arranged on an outer surface of the capillary body and comprises a heating layer that includes a porous film made of electrically conductive material.

[0006] In previously known solutions, a common problem is that sufficient quantities of liquid cannot be vaporized. Since the vaporization rate is essentially dependent on the surface area of ​​the vaporizing foil, increasing the vaporization rate in previously known solutions inevitably requires more space. However, compactness is a key quality characteristic of electronic cigarette products and medical inhalers.

[0007] The object of the invention is to provide an improved vaporizer device for an inhaler, an improved inhaler, and an improved cartridge. Furthermore, it is an object of the invention to provide an improved method for operating and manufacturing a vaporizer device.

[0008] The invention solves the problem with the features of the independent claims. Further preferred embodiments of the invention can be found in the dependent claims, the figures, and the accompanying description.

[0009] A medical inhaler within the meaning of the invention is a device suitable for making medications or homeopathic remedies inhalable or available for inhalation by a patient. Examples of substances that can be vaporized by such a medical inhaler include, for example, cannabinoids, such as cannabidiol or tetrahydrocannabinol, analgesics, or agents effective in connection with the treatment of asthma, COPD, or other lung diseases, or other illnesses or conditions.

[0010] An electronic cigarette product within the meaning of the invention is a device suitable for making liquids or liquid mixtures, e.g. comprising polyglycol, glycerin and optionally nicotine and optionally flavorings and / or flavourings, inhalable or available for inhalation by a user.

[0011] According to the invention, it is proposed that the evaporator film forms at least one supply channel through which the at least one first receiving opening can be supplied with liquid from the wick structure.

[0012] For the purposes of this application, a supply channel is understood to be a channel for conveying a liquid, wherein the liquid is conveyed within the channel through at least two opposing surfaces of the channel.

[0013] The supply channel allows the first receiving opening of the evaporator foil to be spatially separated from the wick structure, so that the evaporator foil can be thermally decoupled from the wick structure and the liquid reservoir in the sections where it forms the at least one supply channel. The invention recognizes that this significantly improves the energy efficiency of the evaporator device because the energy supplied by the metal foil, which acts as a heating element, can be used specifically for the evaporation of the liquid. This reduces the unwanted transfer of heat energy via the wick structure to the liquid reservoir or to the liquid contained within it. As a result, an evaporator device can operate for a longer period without recharging, given the same battery charge.

[0014] Furthermore, the at least one supply channel allows the usable surface area of ​​the vaporizer foil for evaporation to be increased without increasing the base area, i.e., without requiring more space. This allows the amount of vaporization per inhalation to be increased without the need for additional wicking material.

[0015] It has proven advantageous to use a nonwoven fabric, for example a fiberglass nonwoven fabric, as the wick structure.

[0016] Furthermore, it has proven advantageous to use the existing evaporator film itself to form the supply channel. The evaporator film rests against the wick structure across its base, allowing the liquid transferred from the wick structure to the evaporator film to be introduced into the supply channel efficiently and reliably. For the purposes of this application, the base is the area over which the evaporator film is in contact with the wick structure.

[0017] The supply channel can, for example, be designed to supply liquid to several of the first receiving openings of the evaporator film.

[0018] A first intake port can, for example, be fluidically connected to exactly one or more discharge ports. Similarly, it is also possible, for example, for several first intake ports to be fluidically connected to exactly one or more discharge ports.

[0019] By forming at least one supply channel using the evaporator film, the existing polymer film can be used to create the supply channel. Thus, even when at least one supply channel is formed, the metal film is protected from the liquid within the supply channel.

[0020] Preferably, the evaporator film is designed such that the metal foil is completely embedded in the polymer film. The metal foil, which preferably has a meandering structure, is embedded in the polymer film in such a way that sections with and without metal foil alternate within the polymer film. The through-holes are then provided in the areas where no metal foil is embedded. This design of the evaporator film ensures that the liquid cannot come into contact with the metal foil, even during operation. This improves the system reliability, particularly the service life and fail-safe operation, of the evaporator device. Furthermore, it prevents the metal foil and the fluid from reacting chemically to form a harmful substance.

[0021] In the embodiments shown below, any combination of two or more embodiments is also possible.

[0022] According to a further embodiment, the at least one supply channel is formed by a fold in the evaporator film. Folding the evaporator film allows for the creation of a supply channel using simple manufacturing techniques. This makes the evaporator film cost-effective to produce.

[0023] Furthermore, it is advantageous if the fold comprises two opposing fold surfaces connected to each other via at least one fold edge, wherein at least 20%, preferably at least 30%, and more preferably at least 50% of the opposing fold surfaces are aligned parallel to each other. The at least partially parallel arrangement of the two fold surfaces ensures suitable dimensioning of the supply channel. Furthermore, this allows the capillary action to be predefined as effectively as possible.

[0024] For example, the extent of the fold, viewed along a direction orthogonal to an adjacent base surface of the evaporator film, is at least 5 times the height of the evaporator film, further, for example, 10 times, and more preferably, for example, 20 times. The spatial configuration of the evaporator film thus achieved creates, with a constant base area, an increased surface area that can be used for evaporating the liquid. The height of the evaporator film is preferably between 25 µm and 50 µm, and further preferably between 30 µm and 40 µm.

[0025] The fold is preferably oriented such that it encloses an angle between 30° and 150° with respect to the adjacent base surface of the evaporator film or the top surface of the support element, more preferably between 80° and 100° and in particular an angle of 90°.

[0026] Since the first receiving openings are preferably provided on the fold surfaces, the fluid-permeable passage opening is traversed in a direction parallel to the base surface when the fold is oriented orthogonally to the base surface.

[0027] Furthermore, it is proposed that several folds be provided, with the folds spaced apart by an intermediate section of the evaporator film. The multiple folds further enhance the positive effect associated with the supply channel or the fold itself. The intermediate section between two folds ensures that the folds are sufficiently spaced apart to allow the evaporated liquid to flow freely from the dispensing openings provided in the folds. The evaporator device can thus be designed to be more energy-efficient, and the evaporation rate can be increased. Preferably, the fold edges of the multiple folds are arranged parallel to each other.

[0028] According to a further embodiment, at least one second receiving opening is provided, arranged on the base surface, wherein the at least one second receiving opening can be supplied with liquid directly via the wick structure. The second receiving opening is provided in addition to the at least one first receiving opening, so that the amount of vapor that can be generated can be increased. Preferably, several second receiving openings are provided on the base surface. By combining the at least one second receiving opening, which is located on the base surface, and the at least one first receiving opening, which is supplied with liquid via the at least one supply channel, the amount of vaporized liquid and simultaneously the energy efficiency of the vaporizer device can be increased.Preferably, the second receiving openings and the discharge openings connected to them in terms of flow are arranged on both sides with respect to the fold, so that evaporation of liquid can take place on both sides of the fold, both on the top of the evaporator film and on the outer surfaces of the fold.

[0029] The aforementioned intermediate section between two adjacent folds is particularly advantageous if the intermediate section includes at least one of the second receiving openings. This intermediate section preferably also includes the base area, so that, in addition, the release of evaporated liquid between two folds is possible via one or more release openings, which are supplied with liquid via one or more of the second receiving openings. The release openings provided in the intermediate section allow the evaporation rate to be increased even further.

[0030] It is further proposed that at least 20%, for example at least 30%, or further, for example at least 50% of the surface area of ​​the evaporator film should serve to form the supply channel.

[0031] For the purposes of this application, the term "flat area" of the evaporator film refers to the maximum area that the evaporator film can occupy in its fully extended state, i.e., without any folds, bends, or other deformations. Typically, the evaporator film is in such a maximally extended state before being installed in the evaporator device.

[0032] The proposed ratio between the planar extent of the evaporator film and the planar proportion for the formation of at least one supply channel ensures that the technical effect associated with the supply channels, namely thermal insulation, is particularly advantageous and that at the same time a sufficient quantity of liquid to be evaporated can be supplied via the supply channels of the evaporator film.

[0033] Typically, in the areas of the evaporator film where it forms the supply channel, contact with the wick structure will not be possible. Therefore, it is further proposed that, for example, at least 10% of the evaporator film's surface area should form the base, or at least 20%, and particularly at least 30%. Having the base area in contact with the wick structure is advantageous for efficiently directing the liquid into the at least one supply channel, as the base area transitions directly into the supply channel. Furthermore, a sufficiently large base area ensures that any second receiving opening that may be provided on the base area can be adequately supplied with liquid.

[0034] According to a further embodiment, it is proposed that the at least one supply channel is configured to guide the liquid from the wick structure along a main flow direction to the at least one first receiving opening, wherein the main flow direction forms an angle between 30° and 150°, in particular an angle between 80° and 100°, with the adjacent base surface. This orientation of the flow channel allows the at least one first receiving opening to be arranged in a different plane than the base surface. This provides not only thermal decoupling but also the possibility of making the geometry of the evaporator film more flexible. The evaporator film can thus have a spatial geometry that extends beyond the usual planar extent of film structures. In this way, the area usable for evaporating liquid can be increased without having to increase the base surface area.

[0035] If the base is a flat plane, the angle between the base and the main flow direction is determined automatically. If the base is curved, the surface directly adjacent to the supply channel is chosen as the reference surface. If several curved surfaces border the supply channel, the angle between the main flow direction and a hypothetical base, determined by averaging the orientations of the adjacent bases, is used.

[0036] It is further proposed that the orthogonal extension of at least one supply channel with respect to the adjacent base area should be at least five times, and preferably ten times, the height of the evaporator film. This orthogonal extension of the supply channel has been shown to offer an ideal compromise between sufficient thermal insulation and a satisfactory supply of liquid to the first receiving opening. This further improves the overall energy efficiency of the evaporator device.

[0037] The through-openings associated with the fold preferably have a distance from the top surface of the evaporator film, which is orthogonal to the top surface, that corresponds to more than 50% of the fold's orthogonal extent relative to the base surface, and more preferably more than 60%, and particularly more preferably more than 70%. This creates a sufficiently large liquid column in the supply channel, enabling thermal decoupling of the metal foil, which serves as the heating element, from the wick structure and the liquid reservoir.

[0038] It is further proposed that at least one supply channel be dimensioned such that the liquid travels from the wick structure to at least one initial receiving opening under the influence of capillary forces. Utilizing capillary forces ensures a more reliable supply of the liquid to be evaporated to at least one supply channel.

[0039] According to the invention, a support element is provided, on the upper side of which the evaporator film is arranged, and on the lower side of which the liquid reservoir is arranged, wherein an opening is provided for receiving the wick structure, the opening connecting the upper side to the lower side in a fluid-conducting manner. Preferably, the evaporator film, or a metal foil encompassed therein which can be operated as a heating element, is attached to the upper side of the support element by means of a connecting element in the form of a soldered or sintered connection. For example, several liquid reservoirs, such as exactly two liquid reservoirs, can also be provided, which are connected by a common wick structure. The liquid reservoirs are preferably arranged on the lower side of the support element. Of course, each liquid reservoir can also be assigned its own wick structure.This ensures a homogeneous supply of liquid to the wick structure. For example, a single liquid reservoir can be provided, featuring a bridge so that the wick structure is clamped between the reservoir and the evaporator film; this improves the liquid supply to the evaporator film via the wick structure. The corresponding arrangement of the components relative to the support element enables a stable construction that can withstand vibrations, while simultaneously ensuring a reliable supply of the liquid to be evaporated to the evaporator film via the wick structure inserted into the opening.

[0040] According to a further embodiment, it is proposed that the base be a flat surface. Alternatively, the base is the partial surface of a cylinder. Such a design of the base, which is in contact with the wick structure, allows for advantageous wetting of the evaporator film with liquid, so that the at least one supply channel adjacent to the base can be adequately supplied with liquid.

[0041] If the base surface is designed in the form of a cylindrical surface, it is advantageous for the wick structure to have a cylindrical shape with a longitudinal axis, wherein the wick structure is surrounded by the base surface of the evaporator film, and wherein a main flow direction of the at least one supply channel extends radially with respect to the longitudinal axis of the wick structure. The surface of the evaporator film opposite the wick structure thus corresponds to the geometry of the wick structure, so that the evaporator film can be sufficiently wetted with the liquid to be evaporated.

[0042] In the case of a wick structure with a cylindrical base shape, it is further proposed that the evaporator film be surrounded by an outer ring, so that a flow channel is formed between the evaporator film and the outer ring. The outer ring and the wick structure preferably share a common longitudinal axis. To form the flow channel, the outer ring then has an inner radius that corresponds at least to the maximum radial extent of the evaporator film. The flow channel thus formed allows the discharge openings to be particularly favorably surrounded by flow, thereby further increasing the evaporation rate.

[0043] The aforementioned problem is also solved by an inhaler and a cartridge comprising a vaporizer device according to any one of claims 1 to 13.

[0044] Furthermore, the aforementioned problem is solved by a method for operating an evaporator device according to one of claims 1 to 13, wherein the evaporator film is subjected to an electrical heating voltage to generate the liquid vapor.

[0045] Finally, the aforementioned problem is solved by a method for manufacturing an evaporator device, wherein the evaporator device comprises an evaporator film arranged on a support element, wherein the evaporator film forms at least one supply channel by which the evaporator film can be supplied with liquid to be evaporated from a liquid reservoir via a dock structure, wherein the supply channel is formed by a fold of the evaporator film, wherein the method comprises the following steps: a) Providing a base material for the production of the evaporator film comprising a polyimide substrate with a copper lamination applied to one side; b) Structuring the copper lamination by an etching process so that a copper structure is formed on the substrate; c) Applying a polyimide top layer to the side of the substrate with the copper structure; d) Creating a through-hole by means of a laser, through which a top side of the evaporator film can be fluidically connected to a bottom side of the evaporator film; e) Cutting a fold line by means of a laser, so that an incision is created; f) Folding the evaporator film along the incised fold line; g) Connecting the folded evaporator film to the support element.

[0046] The proposed method allows for the simple production of an evaporator film with a fold, the fold forming the supply channel. This manufacturing process enables the production of a very thin evaporator film and also allows for the creation of a fold with a very tight bending radius thanks to the cut fold edge. This increases the surface area of ​​the evaporator film through which the evaporated liquid can be released, thus improving the overall evaporation performance. For example, Pyralux®<HT or Pyralux®<AP from DuPont can be used as the polyimide substrate. The substrate thickness is preferably between 5 and 50 µm, further examples between 20 and 30 µm, and particularly preferably 25 µm.The thickness of the copper lamination is preferably between 1 and 10 µm, more preferably between 2 and 8 µm, and particularly preferably 5 µm. The evaporator film produced in this way offers the advantage that the fold forms a supply channel through which the openings of the evaporator film can then be supplied with the liquid to be evaporated.

[0047] It is further proposed that the following sub-steps be carried out in procedural step b): b 1 ) Applying a photoresist to the copper lamination; b 2 ) Exposing the photoresist in predefined areas; b 3 ) Developing the photoresist so that the remaining photoresist forms a protective layer for the copper lamination in the predefined areas; b 4 ) Applying an etching agent to the side with the developed photoresist so that the copper lamination remains on the substrate only in the predefined areas; b 5 ) Removing the remaining photoresist.

[0048] The photoresist, also known as photoresist, can be laminated onto the copper. Subsequent exposure can be achieved, for example, through direct illumination, where only predefined areas are selectively lit, or through mask exposure. In mask exposure, a mask is applied to the photoresist; this mask is partially transparent, allowing the areas to be selectively illuminated by a light source. After developing the photoresist, only the predefined areas remain on the copper lamination, thus protecting the copper in these areas. Applying an etching agent to the side with the copper lamination and the developed photoresist then etches away the copper in the areas where the developed photoresist does not provide protection.The copper lamination thus remains only at predefined locations on the substrate, creating a copper structure. In a subsequent step, the photoresist is removed again—a process known as stripping—leaving only the substrate with the copper structure. What remains of the full-surface copper lamination is therefore a copper structure.

[0049] Preferably, in process step c), a polyimide top layer is applied by lamination in a vacuum press. The polyimide top layer applied in this way allows the substrate with the copper structure to be prestressed, such that the substrate exhibits a concave bend on the side with the polyimide top layer. The concave bend has proven advantageous because it enables a fold with a particularly sharply tapered fold edge. To ensure simple further processing despite the curvature, the substrate with the copper structure and polyimide top layer is preferably fixed in the prestressed state on a flat surface of a carrier for further processing. For example, Pyralux® < HT0100 from DuPont can be used as the material for the polyimide top layer.

[0050] It is further proposed that in process step e), contact points for supplying the evaporator film with an electrical heating voltage are additionally exposed using the laser. Exposing the contact points means removing the polyimide top layer at the corresponding locations. This provides a particularly cost-effective way to supply the evaporator film with the appropriate heating voltage.

[0051] It is further proposed that in process step e), the evaporator film be additionally cut to size for connection with the support element. This makes it possible, for example, to produce a large-area layered system from which a plurality of evaporator films can be cut. In this way, the evaporator film can be manufactured cost-effectively in large quantities. By cutting, an evaporator film can then be formed from the large-area layered system, the dimensions of which are such that it can be connected to a support element of the evaporator device. This is preferably done in such a way that the supply channel formed by the fold directly contacts the wick structure, which is inserted into an opening of the support element.

[0052] The invention is explained below with reference to preferred embodiments and the accompanying figures. Fig. 1 a schematic sectional view of an evaporator device with one supply channel; Fig. 2 a schematic sectional view of an evaporator film; Fig. 3 a schematic sectional view of an evaporator device with two supply channels; Fig. 4 a sectional view of an evaporator device with a cylindrical wick structure; Fig. 5 a schematic sectional view of a fold of an evaporator film; Fig. 6 steps a) and b) of a manufacturing process for an evaporator device; Fig. 7 steps c) to e) of a manufacturing process for an evaporator device; Fig. 8 an evaporator film after carrying out process step f) from a first perspective; Fig. 9 an evaporator film after carrying out process step f) from a second perspective; Fig. 10 an evaporator device after carrying out process step g) from a perspective view.

[0053] Figure 1shows an evaporator device 1 comprising an evaporator film 2 which is attached via a connecting means 25 to a top surface 19 of a support element 18, a liquid reservoir 6 which is arranged on a bottom surface 20 of the support element 18, and a wick structure 7 which is configured to supply the evaporator film 2 with liquid to be evaporated from the liquid reservoir 6.

[0054] Of course, it is also possible in principle to provide two or more liquid storage tanks 6.

[0055] The support element 18 has an opening 21 into which the wick structure 7 is inserted. This allows the liquid to be evaporated from the liquid reservoir 6 to be conveyed by means of the wick structure 7 through the opening 21 to the evaporator film 2. Furthermore, the liquid reservoir 6 has a web 41 over which the wick structure 7 can be pressed between the liquid reservoir 6 and the evaporator film 2. In the illustrated embodiments, the wick structure 7 is a nonwoven fabric, for example, a glass fiber nonwoven fabric.

[0056] The evaporator foil 2, or a metal foil 5 contained therein, which can be operated as a heating element, is preferably connected to the carrier element 18 via a connecting element 25 in the form of a soldered or sintered connection.

[0057] An exemplary representation of the evaporator film 2 is shown in Figure 2schematically represented. The evaporator film 2 comprises a layer system 3, which in turn comprises a polymer film 4 and at least one metal film 5 that makes contact with the polymer film 4 over its entire surface. Preferably, the polymer film 4 is laminated onto the metal film 5. In the embodiment according to Figure 2 The metal foil 5 is completely surrounded by the polymer film 4. The metal foil 5 is thus entirely encased in the polymer film 4. This ensures that the liquid cannot come into contact with the metal foil, even during operation. The polymer film 4 is preferably a polyimide film.

[0058] The evaporator film 2 is perforated so that a first intake opening 8 on a lower surface 40 can be fluidically connected to a discharge opening 9 on a top surface 27. The first intake opening 8 and the discharge opening 9 together each form a fluid-permeable passage 26.

[0059] The in Figure 1 The illustrated wick structure 7 preferably consists of a porous and / or capillary material which, due to capillary forces, is able to passively replenish sufficient quantities of liquid evaporated from the evaporator film 2 from the liquid reservoir 6 to the evaporator film 2 in order to prevent the through-hole 26 from running dry and the problems arising therefrom.

[0060] The metal foil 5 according to Figure 2 It is designed as a heating element, for example in the form of an ohmic heater. When using the evaporator foil 2 made of Figure 2 as part of the evaporator device 1 from Figure 1The liquid within the through-holes 26 evaporates, and the liquid is replenished from the liquid reservoir 6, for example by capillary action via the wick structure 7. During operation, the metal foil 5 is activated in certain phases, for example when an inhalation is detected by a user, by applying a heating voltage to two contact points 38 (see Figures 7 to 10The metal foil 5 is heated by the flow of an electric current through it. This heats up, resulting in heat generation in the fluid-permeable opening 26. As the fluid flows through the opening 26 from the first receiving opening 8, it is heated to such an extent that it reaches the vaporous state and exits the discharge openings 9 as vapor. This evaporation creates additional volume within the opening 26, into which liquid can creep due to capillary action. The supply of liquid is further increased via the supply channel 11 and the wick structure 7 from the liquid tank 6. During the evaporation process in the opening 26, liquid is continuously supplied from the liquid reservoirs 6 via the wick structure 7.

[0061] As from Figure 1As can be seen, the first two intake openings 8 are not supplied with liquid directly via the wick structure 7. The supply is provided via a supply channel 11, which is fluidically connected between the first intake opening 8 and the wick structure 7 and is formed by the evaporator film 2 itself.

[0062] The supply channel 11 is formed by a fold 14 of the evaporator film 2, which is in Figure 5The image is shown enlarged in a sectional view. The fold 14 of the evaporator film 2 forms two opposing fold surfaces 15, which are connected to each other via a fold edge 16. The opposing fold surfaces 15 of a fold 14 can be irregularly shaped, but are aligned parallel to each other, for example, in sections or areas where the proportion of the total area of ​​the fold surfaces 15 exceeds 20%. A parallel alignment of the opposing fold surfaces 15 is advantageous because it allows the effect of the capillary forces to be predefined as effectively as possible.

[0063] Preferably, the extent b of the fold 14 in a direction orthogonal to an adjacent base surface 10 of the evaporator film 2 is at least 5 times the height a of the evaporator film 2. This results in a more spatially pronounced design of the evaporator film 2 compared to the evaporator films 2 otherwise laid flat in the prior art.

[0064] The fold 14 is designed in such a way that it is oriented perpendicularly with respect to the base surface 10 or to a top surface 19 of the support element 18, cf. Figure 1 . A perpendicular orientation of the fold 14 means that its fold surfaces 15 are aligned orthogonally to the adjacent base surface 10.

[0065] The supply channel 11 formed by the fold 14 is thus also oriented perpendicularly with respect to the base surface 10. This design of the fold 14 results in a main flow direction 13 of the liquid within the supply channel 11. The main flow direction 13 is the direction in which the majority of the liquid flows from the wick structure 7 to a first receiving opening 8 within the at least one supply channel 11. Accordingly, the main flow direction 13 is also oriented orthogonally with respect to the base surface 10 adjacent to the fold 14.

[0066] The first two receiving openings 8 are provided on the folding surfaces 15, so that the fluid-permeable passage openings 26 are oriented in a direction parallel to the base surface 10.

[0067] Furthermore, fold 14 in Figure 5exactly two of the fluid-permeable openings 26. Of course, the fold 14 can also have only one of the openings 26 or more than two. If several openings 26 are provided, these can also be arranged one after the other with respect to an axis perpendicular to the plane of the drawing. Figure 5 The passage openings 26 can also be arranged one above the other with respect to an axis orthogonal to the base surface 10.

[0068] The in the Figure 5The illustrated through-openings 26 have a distance c from the top surface 27 of the evaporator foil 2, which is located opposite the base surface 10, in the orthogonal direction. This distance c corresponds to more than 50% of the extent b in the orthogonal direction of the fold 14, preferably more than 60%, and more preferably more than 70%. This spacing of the through-openings 26, and thus also of the first receiving openings 14, from the top surface 27 ensures a sufficient liquid column in the supply channel 11, thus enabling thermal decoupling of the metal foil 5, which serves as the heating element. The liquid column located in the fold 14 insulates the metal foil 5, which emits heat energy during operation, from the wick structure 7 and the two liquid reservoirs 6, thereby increasing the energy efficiency of the evaporator device 1.

[0069] When operating the evaporator device 1 from Figure 1 The heat generated in the fluid-permeable opening 26 draws the liquid to be evaporated from the liquid reservoirs 6 into the opening 26 via the wick structure 7 and the supply channel 11. There, the liquid is heated at least to its boiling point, causing it to evaporate and escape in a gaseous state from the discharge opening 9. During this process, i.e., while the metal foil 5 is activated (heating), liquid is continuously drawn from the liquid reservoirs 6 via the wick structure 7 and the supply channel 11, ensuring continuous evaporation.

[0070] Furthermore, the Figure 1It can be seen that the vapor is not only released via the discharge openings 9, which are assigned to an outer surface 28 perpendicular to the base surface 10 of the fold 14. Additional discharge openings 9 are also arranged on the upper surface 27 of the evaporator film 2, opposite the base surface 10. These discharge openings 9 are fluidically connected to second receiving openings 12, which can be supplied with liquid directly via the wick structure 7. The second receiving openings 12 are therefore not supplied with liquid via the supply channel 11. However, the through-openings 26, which are assigned to the second receiving openings 12, can be designed in the same way as those that are supplied with liquid via the supply channel 11; in this regard, please refer to the explanations in [reference to be added]. Figure 2 referred.

[0071] By combining first intake openings 8, supplied via the supply channel 11, and second intake openings 12, supplied directly via the wick structure 7, vaporized liquid can be released in different directions, thus increasing the overall surface area of ​​the vaporizer film 2 available for vaporization via the delivery openings 9. This allows for an increase in the overall vaporization rate per inhalation.

[0072] Figure 3 shows an evaporator device 1 with the same basic structure as the evaporator device 1 from Figure 1 , however with the difference that in addition to the first fold 14a a second fold 14b is provided, which is separated from the first fold 14a by an intermediate section 17.

[0073] Each of the two folds 14a and 14b has two first receiving openings 8 and corresponding discharge openings 9. Naturally, the number of receiving openings 8 and the corresponding number of through openings 26 can be varied, as already described in the embodiment shown. Figure 1 As explained, it can be changed at will.

[0074] Furthermore, the intermediate section 17 also includes at least one second receiving opening 12, which is supplied with liquid directly via the wick structure 7. Additionally, a further second receiving opening 12 is provided to the left of the first fold 14a and to the right of the second fold 14b. This arrangement has proven advantageous because each of the folds 14a and 14b can be surrounded by a flow of vaporized liquid from both sides, starting from the second receiving opening 12, and simultaneously, an additional flow around the folds 14a and 14b is enabled from the first receiving openings 8, which are assigned to the folds 14a and 14b themselves. In this way, the amount of vaporization per inhalation can be significantly increased, and at the same time, the insulating effect of the liquid column present in the supply channels 11 of the first and second folds 14a and 14b ensures the thermal decoupling of the metal foil 5 from the wick structure 7.the two fluid reservoirs 6 are increased.

[0075] Of course, more than two folds 14a and 14b can also be provided, which can further enhance the effect. If several folds 14a and 14b are provided, they are preferably aligned parallel to each other, i.e., the fold edges 16 of the multiple folds 14a and 14b are aligned parallel to each other. Furthermore, for example, all main flow directions 13 in the supply channels 11 formed by the folds 14 are aligned orthogonally to the base surface 10 adjacent to the respective fold 14.

[0076] Figure 4Figure 1 shows an embodiment of the evaporator device 1 with a cylindrical wick structure 7 having a longitudinal axis 24 of the wick structure 7 that is oriented perpendicular to the plane of the drawing. It can be seen that the evaporator film 2 surrounds the lateral surface of the cylindrical wick structure 7, with a plurality of folds 14 being provided that extend radially with respect to the longitudinal axis 24. This means that the fold edge 16, see also Figure 1, is formed by the fold. Figure 5 , in the radial direction with respect to the longitudinal axis 24, is furthest away from the longitudinal axis 24. The fold edge 16 is then, for example, aligned parallel to the longitudinal axis 24.

[0077] In the embodiment according to Figure 4Supply channels 11 are formed by a multitude of folds 14. In this embodiment, the liquid evaporates exclusively through through-openings 26, which are supplied with liquid via a supply channel 11 through first receiving openings 8.

[0078] Of course, in addition to the through-openings 26 associated with the folds 14, through-openings 26 can also be provided that are supplied with liquid directly via the wick structure 7, i.e., via a second receiving opening 12. For example, at least one through-opening 26 can be provided between each fold 14, which is supplied with liquid via a second receiving opening 12.

[0079] In a cylindrical wick structure 7, the base surface 10 is not flat, but curved. If, in this case, the main flow direction 13 in the supply channel 2 is oriented orthogonally to the adjacent base surface 10, then this refers to the Figure 4 The section shown is a tangent 29 through the point on the base 10 that is directly adjacent to the fold 14.

[0080] The corresponding liquid reservoir 6, which supplies the wick structure 7 with liquid, is located in the Figure 4not shown. However, this can, for example, be arranged axially behind and / or in front of the wick structure 7 with respect to the longitudinal axis 24. Accordingly, the liquid to be evaporated is conveyed axially from the liquid reservoir 6 by the wick structure 7 and then deflected radially with respect to the longitudinal axis 24 in order to deliver the liquid to be evaporated to the evaporator film 2 or to the supply channel 11 formed by the evaporator film 2.

[0081] The evaporator film 2 is in the embodiment according to Figure 4 surrounded by an outer ring 22, such that a plurality of flow channels 23 are formed between the vaporizer film 2 and the outer ring 22. When a user inhales, the multiple flow channels 23 are then traversed in the direction of the longitudinal axis 24.

[0082] The Figure 6Figure 1 shows process steps a) and b) of a process 30 for manufacturing the evaporator device 1. In a first process step a), a base material 31 comprising a substrate 32 and a copper cladding 33 applied thereto is provided.

[0083] The subsequent process step b), in which the copper lamination 34 is structured to create a copper structure 42, is subdivided into process steps b1) to b5). In process step b1), a photoresist 34 is laminated onto the copper lamination 33, which is exposed in predefined areas in process step b2). This can be done, for example, by direct illumination or by means of a mask. In process step b3), the photoresist 34 is developed, i.e., only a resist mask resulting from the exposure remains on the copper lamination 33; the remaining photoresist 34 is removed. In process step b4), an etching agent is applied to the side with the developed photoresist 34, so that the copper lamination is etched away in the areas where there is no protection from the resist mask formed by the photoresist 34. The full-surface copper lamination 33 thus forms a copper structure 42.In process step b 5), the remaining photoresist 34 is then removed, so that only the copper structure 42 remains on the substrate 32. Preferably, the copper structure 42 has a meandering shape. The result of process step b), namely the copper structure 42 applied to the substrate 32, is shown in . Figure 6 schematically depicted below.

[0084] Figure 7 Figure 30 shows process steps c) to e). In process step c), a polyimide top layer 36 is applied to the side of the substrate 32 with the copper structure 42, so that the metal foil 5 (see Figure 5) is covered with the copper structure 42. Figure 2The copper structure 42 is completely embedded in layers of polyimide, namely the polyimide substrate 32 and the polyimide top layer 36. The polyimide top layer 36 is laminated on one side in a vacuum press, which causes the resulting intermediate product to curvature such that the top surface 27, i.e., the side with the polyimide top layer 36, is concave; see illustration in Figure 7 c) below.

[0085] In process step d), the intermediate product now available, comprising the substrate 32, the copper structure 42, and the polyimide top layer 36, is then perforated by means of a laser, so that flow connections between the top surface 27 and the bottom surface 12 are created. This forms the through-holes 26, which connect the first and second receiving openings 8 and 12, respectively, with the discharge openings 9; see also Figures 1 to 5 As in Figure 7As can be clearly seen, the perforation takes place exclusively in areas where there is no copper structure 42, i.e. between two areas with a copper structure 42.

[0086] In process step e 1), a folded edge 16 is additionally cut using a laser, the resulting incision 37 preferably penetrating the polyimide cover layer 36 completely, while the substrate 32 is preferably only partially cut. In process step e 2), several contact points 38 are exposed using the laser, i.e., the polyimide cover layer 36 is removed by the laser at the corresponding location until part of the copper structure 42 is exposed.

[0087] If necessary, the evaporator film 2 can be cut or trimmed as an intermediate step so that it has the correct size for connection with the carrier element 18.

[0088] The Figures 8 and 9Figure 2 shows the evaporator film 2 in a folded state, and thus the result of process step f). The folding is carried out along the cut fold edges 16, so that sharp fold edges 16 can be achieved. Figure 8 Figure 2 shows the evaporator film 2 from a perspective looking at the top surface 27. It is clearly visible how the folded surfaces 15 are curved due to the prestress generated in process step c). Furthermore, the contact points 38 and the meandering copper structure 42 visible through the polyimide top layer 36 can be seen.

[0089] Figure 9 Figure 2 shows the evaporator foil 2 from a perspective looking at the underside 40. Furthermore, a curvature 39 of the evaporator foil 2 is indicated.

[0090] Figure 10 Figure 2 shows the evaporator film 2 in a state connected to the support element 18, i.e. after completion of process step g).

[0091] Figure 10Figure 1 shows a perspective view of an evaporator device 1 with a similar basic structure to the one in Figure 2. Figure 1 The illustrated embodiment of the evaporator device 1. It can be seen that the fold 14 protrudes like a fin from the plane formed by the top surface 27 of the evaporator film 2.

[0092] Due to the curvature 39 of the evaporator film 2 produced in process step c), the fold 14 exhibits a prestress in the state connected to the support element 18. This prestress results in the fold 14 having a more stable structure and allows the sharp fold edge 16 to be maintained permanently, for example, during operation, transport, or improper handling. It can also be seen that the evaporator film 2 is connected to the top surface 19 of the support element 18. The evaporator film 2 has four through-openings 26a, 26b (not visible back side of the fold 14), 26c, and 26d, with two through-openings 26a and 26b each having a first receiving opening 8 (see figure). Figure 1 ) and two further through-openings 26c and 26d each through a second receiving opening 12 (see Figure 1) are supplied with liquid to be evaporated. Accordingly, the evaporated liquid is released on both sides of the fold 14, both on a top surface 27 of the evaporator film 2 and simultaneously on the outer surfaces 28 of the fold 14.

[0093] As described above, the metal foil 5 formed by the copper structure 42 within the polymer film 4, which is formed from the substrate 32 and the polyimide cover layer 36, has meandering structures, with the meandering structures having separately controllable sections. Separately controllable means that the corresponding section has separate contact points 38 and thus the heating voltage applied to the respective section can be individually adjusted. For this purpose, the respective section is electrically isolated from the other sections of the copper structure 42. A separately controllable section of the copper structure 42 is referred to as a controllable channel. Each of these sections forms an ohmic heater, and it has proven advantageous if each separately controllable section of the metal foil 5 or metal structure 42 has a resistance between 1 and 3 Ω, for example, approximately 2 Ω.Preferably, the embodiment features in . Figure 10 four separately controllable channels, wherein the through-holes 26a, 26b, 26c and 26d are each assigned to one of these four channels, so that the through-holes 26a to 26d can be controlled separately via the channels.

[0094] By attaching the evaporator foil 2 to the carrier element 18 and / or to the wick structure 7 by means of the connecting agent 25, the evaporator foil 2 can be reliably held in the formed position.

[0095] With the evaporator device 1 according to Figure 10 For example, it is possible to vaporize 7.4 mg of liquid during a three-second inhalation; at the same time, an energy efficiency of 60% and more can be achieved under normal room conditions.

Claims

1. Vaporizer device (1) for an inhaler, in particular for an electronic cigarette product or a medical inhaler, comprising - a vaporizer film (2), - a fluid storage reservoir (6), and - a wick structure (7) which is configured to supply the vaporizer film (2) with liquid from the liquid reservoir (6), - the vaporizer film (2) having at least one first receiving opening (8) for receiving liquid and at least one discharge opening (9) for discharging vaporized liquid, - the vaporizer film (2) being in contact with the wick structure (7) via a base surface (10), - the vaporizer film (2) forming at least one supply channel (11) via which the at least one first receiving opening (8) can be supplied with liquid from the wick structure (7), characterized in that - the vaporizer film (2) comprises a layer system (3) having a polymer film (4) and at least one metal foil (5) which is designed as a heating element and which makes surface contact with the polymer film (4), - a support element (18) being provided, on the top face (19) of which the vaporizer film (2) is arranged, and on the bottom face (20) of which the liquid reservoir (6) is arranged, - an opening (21) for receiving the wick structure (7) being provided, - the opening (21) fluidically connecting the top face (19) to the bottom face (20).

2. Vaporizer device (1) according to claim 1, characterized in that - the at least one supply channel (11) is formed by a fold (14) of the vaporizer film (2).

3. Vaporizer device (1) according to claim 2, characterized in that - the fold (14) comprises two opposing fold surfaces (15) which are connected to each other via at least one fold edge (16), - at least 20% of the opposing fold surfaces (15) being aligned in parallel with one another.

4. Vaporizer device (1) according to any of claims 2 or 3, characterized in that - a plurality of the folds (14) are provided, the folds (14) being spaced apart from one another by an intermediate portion (17) of the vaporizer film (2).

5. Vaporizer device (1) according to any of the preceding claims, characterized in that - at least one second receiving opening (12) is provided which is arranged on the base surface (10), - it being possible for the at least one second receiving opening (12) to be supplied with liquid directly via the wick structure (7).

6. Vaporizer device (1) according to any of the preceding claims, characterized in that - at least 20% of the planar extent of the vaporizer film (2) forms at least one supply channel (11).

7. Vaporizer device (1) according to any of the preceding claims, characterized in that - the at least one supply channel (11) is configured to direct the liquid from the wick structure (7) in a main flow direction (13) to the at least one first receiving opening (8), - the main flow direction (13) forming, together with the adjacent base surface (10), an angle between 30° and 150°, in particular an angle between 80° and 100°.

8. Vaporizer device (1) according to any of the preceding claims, characterized in that - an extent (b) of the at least one supply channel (11) in the orthogonal direction with respect to the adjacent base surface (10) corresponds to at least 5 times the height (a) of the vaporizer film (2).

9. Vaporizer device (1) according to any of the preceding claims, characterized in that - the at least one supply channel (11) is designed such that the liquid is from the wick structure (7) to the at least one first receiving opening (8) under the influence of capillary forces.

10. Vaporizer device (1) according to any of the preceding claims, characterized in that - the base surface (10) is a flat surface.

11. Vaporizer device (10) according to any of claims 1 to 9, characterized in that - the base surface (10) is the partial lateral surface area of a cylinder.

12. Vaporizer device (1) according to claim 11, characterized in that - the wick structure (7) has a cylindrical shape with a longitudinal axis (24), - the wick structure (7) being surrounded by the base surface (10) of the vaporizer film (2), - a main flow direction (13) of the at least one supply channel (11) extending in a radial direction with respect to the longitudinal axis (24) of the wick structure (7).

13. Vaporizer device (1) according to claim 12, characterized in that - the vaporizer film (2) is surrounded by an outer ring (22) so that a flow channel (23) is formed between the vaporizer film (2) and the outer ring (22).

14. Inhaler comprising a vaporizer device (1) according to any of the preceding claims.

15. Cartridge for an inhaler comprising a vaporizer device (1) according to any of claims 1 to 13.

16. Method for operating a vaporizer device (1) according to any of claims 1 to 13, wherein an electrical heating voltage is applied to the vaporizer film (1) in order to generate the liquid vapor.

17. Method (30) for manufacturing a vaporizer device (1), wherein the vaporizer device (1) comprises a vaporizer film (2) arranged on a support element (18), wherein the vaporizer film (2) forms at least one supply channel (11), by means of which the vaporizer film (2) can be supplied with liquid to be vaporized from a liquid reservoir (6) via a wick structure (7), wherein the supply channel (11) is formed by a fold (14) of the vaporizer film (2), wherein the method (30) comprises the following steps: a) providing a base material (31) for manufacturing the vaporizer film (2), the base material comprising a substrate (32) made of polyimide having a copper lamination (33) applied to one face thereof; b) structuring the copper lamination (33) by an etching process so that a copper structure (42) is formed on the substrate (32); c) applying a polyimide top layer (36) to the face of the substrate (32) that has the copper structure (42); d) creating a through-opening (26), using a laser, via which through-opening a top face (27) of the vaporizer film (2) can be fluidically connected to a bottom face (40) of the vaporizer film (2); e) cutting a fold edge (16) using a laser so that a notch (37) is created; f) folding the vaporizer film (2) along the notched fold edge (16); g) connecting the folded vaporizer film (2) to the support element (18).

18. Method (30) according to claim 17, characterized in that the following sub-steps are carried out in method step b): b1) applying a photoresist (34) to the copper lamination (33); b2) exposing the photoresist (34) in predefined areas; b3) developing the photoresist (34) so that the remaining photoresist (34) forms a protective layer for the copper lamination (33) in the predefined areas; b4) applying an etching agent to the face having the developed photoresist (34) so that the copper lamination (33) remains only in the predefined areas on the substrate (32); b5) removing the remaining photoresist (34).

19. Method (30) according to claim 17 or 18, characterized in that, in method step c), a polyimide top layer (36) is applied by laminating in a vacuum press.

20. Method (30) according to any of claims 17 to 19, characterized in that, additionally, in process step e), contact points (38) for supplying the vaporizer film (2) with an electrical heating voltage are exposed by means of the laser.

21. Method (30) according to any of claims 17 to 20, characterized in that, additionally, in process step e), the vaporizer film (2) is cut to size for connection to the support element (18).