Leak-reduced aerosol generator

Abstract

Leak-reduced aerosol generator The aerosol generating device (10) comprises a housing (12) having a first end defining a mouthpiece (18), a second end (14), and a cavity (25) defined between the first and second ends. The device (10) further comprises a reservoir (22) within the cavity for storing a liquid aerosol-forming substrate. The device (10) further comprises an atomizer (24) and a valve (26) within the mouthpiece (18) of the housing, the valve having a downstream side and an upstream side, the upstream side of the valve including one or more of a hydrophilic coating, a hydrophobic coating, or a liquid-absorbent coating.

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating device for heating an aerosol-forming substrate to form an inhalable aerosol. In particular, the present invention relates to an aerosol-generating device configured to minimize leakage of liquid aerosol-forming substrate or condensate. [Background technology]

[0002] Devices for generating aerosols for inhalation by a user are well known in the art and typically include a device that heats a liquid to vaporize the liquid and generate an aerosol. Such devices typically include a liquid reservoir or reservoir for holding a quantity of liquid aerosol-forming substrate or "e-liquid" and a heater for heating the e-liquid to generate the aerosol. Such devices also include an airflow path in communication with the heater so that the aerosol can be carried along the airflow path and delivered to the user.

[0003] The quality of the aerosol generated by known devices can be evaluated using a number of different factors. These factors may include the amount of aerosol generated, the density of the droplets in the aerosol, the temperature of the aerosol, and the rate of delivery of the aerosol. The quality of the user experience provided by known devices can be evaluated using several different factors. These factors may include the quality of the aerosol generated, as well as the frequency of liquid leakage from the device.

[0004] Liquid leakage from the aerosol generating device can be e-liquid leakage from the reservoir itself. Liquid leakage from the device can be e-liquid that impinges on the heater but is not vaporized by the heater. Liquid vaporized by the heater condenses within the device to form large droplets that can then leak from the device. In particular, large droplets can form when hot air and vapor from the heater meet the cooler interior surfaces of the device housing.

[0005] It would be desirable to provide an aerosol generation system that minimizes liquid leakage. Liquid leakage during use can provide a poor taste or unpleasant experience to the user. Liquid leakage between uses can damage items such as clothing or can give the impression of a low quality device. It would be desirable to minimize liquid leakage to improve the user experience. Summary of the Invention

[0006] According to a first aspect of the present invention, there is provided an aerosol generating device comprising a housing having a first end defining a mouthpiece, a second end, and a cavity defined between the first and second ends. The device also comprises a reservoir within the cavity for storing a liquid aerosol-forming substrate and an atomizer. The device further comprises a valve within the mouthpiece of the housing, the valve having a downstream side and an upstream side, the upstream side of the valve including one or more of a hydrophilic coating, a hydrophobic coating, or a liquid-absorbent coating.

[0007] The device may include an air inlet in the housing and an airflow channel extending from the air inlet through the recess to the mouthpiece. The valve may be in the airflow channel. The airflow channel may pass through an atomizer. The atomized liquid may be entrained in the airflow passing through the airflow channel.

[0008] As used herein, "aerosol-generating device" refers to a device that interacts with an aerosol-forming substrate or an aerosol-generating article to generate an aerosol. The aerosol-generating device may comprise one or more components that are used to provide energy from a power source to the aerosol-forming substrate or the aerosol-generating article to generate an aerosol. The aerosol-generating device may comprise a power source, which may be an external power source or an on-board power source that forms part of the aerosol-generating device. The aerosol-generating device may interact with the aerosol-forming substrate or the aerosol-generating article to generate an aerosol that can be directly inhaled by a user.

[0009] The term "aerosol-forming substrate," as used herein, relates to a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be adsorbed, coated, impregnated, or otherwise loaded onto a carrier or support. Suitable aerosol-forming substrates may comprise nicotine, plant-derived material, homogenized plant-derived material, at least one aerosol former, or other additives or ingredients (such as flavorings).

[0010] As used herein, "downstream" is used to describe the relative positioning of a component or portion of a component of an aerosol-generating device with respect to the direction of airflow through the device during use. The downstream side of the valve may be closest to the user's mouth in the direction of airflow, and the upstream side of the valve may be closest to the atomizer in the direction of airflow. In other words, air from the atomizer may enter the upstream side of the valve during use, and air from the downstream side of the valve may be drawn into the user's mouth during use. The aerosol-generating article may have a proximal end through which the generated aerosol exits the aerosol-generating device and is delivered to the user. The proximal end may also be referred to as a mouthpiece. During use, a user may suck on the proximal end or mouthpiece end to inhale the generated aerosol. The aerosol-generating device may be an elongated device with a distal end opposite the proximal or mouth end. In such embodiments, the proximal end may be referred to as the downstream end. Similarly, as used herein, "upstream" is used to describe the relative position of a component or portion of a component of an aerosol-generating device at the distal end of the aerosol-generating device.

[0011] As used herein, "length" refers to the greatest longitudinal dimension between the upstream end of the device (in this case the proximal or closed end) and the downstream end or mouthpiece of the device.

[0012] The reservoir may be fixed within the housing of the aerosol generating device. The reservoir may be refillable to allow repeated use of the aerosol generating device. In embodiments of the invention including a refillable reservoir, the housing of the aerosol generating device may include an opening configured to allow a liquid aerosol-forming substrate to be inserted into the reservoir through the opening. Alternatively, the reservoir may be removable from the housing of the aerosol generating device. A removable reservoir may be refilled once removed from the housing. Alternatively, a removable reservoir may be a single-use reservoir that is discarded after use. A new reservoir may then be inserted into the aerosol generating device.

[0013] The reservoir is preferably in fluid communication with the atomizer. A liquid aerosol-forming substrate can be transported from the reservoir to the atomizer for atomization. Liquid transport can be provided by a wick or capillary element extending between the reservoir and the atomizer. The atomizer liquid can be entrained in the airflow of the airflow channel to form the aerosol.

[0014] The valve may control the flow of fluid out of the aerosol generating device. Preferably, the valve prevents liquid from exiting the aerosol generating device while allowing the generated aerosol to be inhaled by a user through the mouthpiece.

[0015] A coating on the valve may further reduce the flow of large droplets of liquid through the valve. A coating may additionally or alternatively be provided downstream of the valve at the proximal end of the aerosol generating device. The coating may be a hydrophilic coating, a hydrophobic coating, or a liquid-absorbent coating.

[0016] Liquid incident on the hydrophobic coating can be repelled. Having a hydrophobic coating upstream of the valve can repel liquid from the valve, and the liquid can be retained within the housing of the aerosol generating device. In this way, liquid condensation and the formation of large droplets within the housing can be prevented from leaking through the valve. The hydrophobic coating can be formed at least in part from either polyurethane (PU) or a superhydrophobic metal layer, such as a microporous or mesh metal, such as copper or aluminum, functionalized with carbon chains to make it superhydrophobic.

[0017] Liquid incident on the hydrophilic coating can be attracted to the coating. The coating can be either upstream or downstream of the valve. The hydrophilic coating can attract liquid near the valve and prevent large droplets of liquid from flowing through the valve or into the user's mouth. The hydrophilic coating can be at least partially formed of three polyamides, polyvinyl acetate, cellulose acetate, or cotton.

[0018] Liquid incident on the liquid-absorbent covering can be absorbed by the covering. The covering can be either upstream or downstream of the valve. Absorbing the liquid into the covering can store the liquid within the covering and prevent large droplets of liquid from flowing out of the valve. The liquid-absorbent covering can be at least partially formed of nylon (polyamide), cellulose acetate, or cotton cellulose.

[0019] Any combination of hydrophobic, hydrophilic and liquid absorbent coatings may be used.

[0020] The valve is preferably a one-way valve configured to inhibit the flow of large droplets of liquid from the upstream side of the valve to the downstream side of the valve. The one-way valve may be configured in conjunction with one or more coatings to prevent large droplets of liquid from flowing out of the aerosol generating device while allowing the aerosol to be inhaled through the valve.

[0021] In some embodiments, the valve includes a hydrophobic coating, and the aerosol generating device further includes a storage tank. The storage tank may be configured to receive liquid repelled by the hydrophobic coating. In these embodiments, the liquid repelled by the hydrophobic coating may be stored in the storage tank. The aerosol generating device may further include a wick or capillary element for conducting the liquid from the hydrophobic coating to the storage tank. The storage tank may be positioned within the housing of the aerosol generating device. The storage tank may be fixed within the housing of the aerosol generating device, and the housing may include an opening through which the storage tank can be emptied. Alternatively, the storage tank may be removable from the housing of the aerosol generating device. A removable storage tank may be emptied once removed from the housing so that it can be reinserted into the housing and reused. Alternatively, a removable storage tank may be disposable once removed from the housing. A new storage tank may then be inserted into the housing. The storage tank may be in fluid communication with the reservoir to allow the liquid in the storage tank to return to the reservoir for re-atomization.

[0022] The valve may be a ball valve. Alternatively, the valve may be a duckbill valve. Alternatively, the valve may be a diaphragm valve. Alternatively, the valve may be an umbrella valve. Alternatively, the valve may be a hinged flap. The valve of the present invention may be any suitable one-way valve, although the valve is advantageously of simple construction and easily actuated. A duckbill valve or an umbrella valve are good options.

[0023] The valve is preferably actuated by a user inhaling on the mouthpiece of the aerosol generating device. Actuation of the valve may result in the valve opening, allowing fluid to flow from inside the housing of the aerosol generating device through the mouthpiece of the aerosol generating device. Actuation as a result of inhalation may provide an easily operable device, as no additional action is required by the user. Actuation as a result of inhalation may ensure that aerosol can pass through the valve when the user inhales on the aerosol generating device. Actuation as a result of inhalation may ensure that the valve remains in a closed position when the aerosol generating device is not in use, so that liquid cannot escape through the valve when the aerosol generating device is not in use.

[0024] Alternatively, or additionally, the valve may be actuated via a button on the housing. In this alternative embodiment, the valve is mechanically actuated. A mechanically actuated valve may provide the user with a greater sense of control when using the aerosol generating device. A mechanically actuated valve may require manual actuation while the user inhales into the aerosol generating device for the generated aerosol to flow out of the device. The button may be located on the side of the aerosol generating device housing or on the end of the aerosol generating device housing. The user may simultaneously press the button to actuate the valve and inhale into the mouthpiece of the aerosol generating device.

[0025] Alternatively, or additionally, the valve may be actuated by an electrical signal. The electrical signal may be generated by a flow sensor located within the housing of the device and configured to detect a user sucking on the mouthpiece of the device. The flow sensor may be located downstream of the valve. The housing may include a bypass flow channel in which the flow sensor is located.

[0026] The valve is preferably located at or near the proximal end of the housing. The valve is preferably located within the mouthpiece. Providing a valve in the mouthpiece of the aerosol generating device may allow the valve to minimize leakage of both liquid leaking from the reservoir and liquid produced by condensation upstream of the atomizer within the aerosol generating device housing. Minimizing the length of the housing located downstream of the valve may also minimize the space within which the aerosol can further condense to form liquid.

[0027] The atomizer may include a heater. The heater may vaporize the liquid aerosol-forming substrate to form a vapor. The vapor may cool to form droplets of the liquid that condense into the airflow, forming the aerosol. Alternatively, the atomizer may be a mechanical atomizer including a piezoelectric element. In this alternative embodiment, the piezoelectric element may vibrate in response to an alternating current passing through the piezoelectric element. The vibration of the piezoelectric element may force the liquid aerosol-forming substrate through the nozzle assembly such that droplets of the liquid aerosol-forming substrate are formed. The droplets are entrained in the airflow in the airflow channel, forming the aerosol.

[0028] The heater may include one or more heating elements. The heating element may be a planar heating element, a heater rod, a heater coil, or any other suitable heating element configuration. The heating element may be formed of an electrically resistive material so that an electric current is passed through the heating element to cause it to generate heat. The heating element may be directly electrically coupled to a heat source. Suitable electrically resistive materials include semiconductors such as doped ceramics (e.g., doped silicon carbide), "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, alloys, and composites of ceramic and metallic materials. Alternatively, or additionally, the heating element may include a susceptor, and the heater may further include an inductor positioned to induce an electric current to heat the susceptor. For example, the inductor may include a coil disposed outside or surrounding the heating chamber, which acts to induce a heating current in the susceptor.

[0029] The heater may include a wick that directs the liquid from the reservoir to the heater. The wick may direct the liquid aerosol-forming substrate from the reservoir to the heater. The wick may be at least partially formed of a material that can absorb the liquid aerosol-forming substrate. Such a material may be a porous material, a fibrous material, a spongy material, a foam material, or a capillary material. The wick may include a bundle of capillaries. The wick may include a plurality of fibers. The wick may include fine tubes. The wick may include a combination of fibers, threads, and fine tubes. The fibers, threads, and fine tubes may generally be aligned to transport the liquid to the electric heater. Such a material may have a predetermined capillary action. Examples of suitable materials for absorbing the liquid aerosol-forming substrate include ceramic- or graphite-based materials in the form of fibers or sintered powders. Examples of suitable materials also include sponge or foam materials, foamed metal or plastic materials, fibrous materials such as spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene, or polypropylene fibers, nylon fibers, or ceramics).

[0030] Wicks of different porosities can be used to accommodate different liquid physical properties (viscosity, surface tension, vapor pressure, etc.). The wick can have a first end positioned within the reservoir and a second end terminating in a heater. Alternatively, the second end of the wick can be surrounded by the heater. For example, if the heating element is a coil heating element, the coil can be wrapped around the second end of the wick. The second end of the wick is typically positioned within an airflow path within the housing of the aerosol generating device so that air is drawn through the wick and entrains the vapor. The vapor then cools to form the aerosol.

[0031] The aerosol generating system may also preferably include a directing means configured to direct liquid resulting from condensation of the aerosolized liquid aerosol-forming substrate to the heater. The directing means may be located within the housing of the device. The directing means may be located external to each of the reservoir and the atomizer. The directing means may be a wick member or capillary element, or any means capable of transporting liquid to the atomizer. Directing the liquid to the atomizer may allow the liquid to be aerosolized or re-aerosolized, thereby preventing the liquid from accumulating within the housing.

[0032] The reservoir of the aerosol generating device preferably includes an outer wall having a first surface exposed to the airflow channel in the housing and formed of a hydrophobic material. The reservoir may further include a second surface opposite the first surface and formed of a hydrophilic material. The outer wall of the reservoir may be positioned adjacent to the airflow channel downstream of the atomizer. This arrangement allows liquid condensed on the outer wall to be transported through the outer wall into the reservoir, but prevents liquid in the reservoir from leaking out through the outer wall.

[0033] The airflow channel downstream of the atomizer may have a wall that contacts the aerosol in the airflow channel and has a first layer comprising a hydrophobic material and a second layer underlying the first layer and comprising a hydrophilic material.

[0034] The aerosol generating system may preferably further comprise a power supply and a control unit. The power supply provides power to the heater. The heater is preferably configured to heat the aerosol-forming substrate. This arrangement may generate an aerosol for inhalation by a user. The control unit may control the supply of power from the power supply to the heater. The control unit may control the temperature generated and the duration of heating. The control unit may control other features of the heater.

[0035] Specific embodiments will now be discussed in detail and are shown by way of example only in the following figures: [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 1 shows a perspective view of an aerosol generating device according to the present invention. [Figure 2a] FIG. 2a shows a diagram of an aerosol generating device according to the present invention including a duckbill valve. [Figure 2b] FIG. 2b shows a diagram of an aerosol generating device according to the present invention including a duckbill valve. [Figure 2c] FIG. 2c shows a diagram of an aerosol generating device according to the present invention including a duckbill valve. [Figure 2d] FIG. 2d shows a diagram of an aerosol generating device according to the present invention including a duckbill valve. [Figure 2e] FIG. 2e shows a diagram of an aerosol generating device according to the present invention including a duckbill valve. [Figure 3a] FIG. 3a shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3b] FIG. 3b shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3c] FIG. 3c shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3d] FIG. 3d shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3e] FIG. 3e shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3f] Figure 3f shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 3g] FIG. 3g shows a diagram of an aerosol generating device according to the present invention including an umbrella valve. [Figure 4a] FIG. 4a shows a diagram of an aerosol generating device according to the present invention including a ball valve. [Figure 4b]FIG. 4b shows a diagram of an aerosol generating device according to the present invention including a ball valve. [Figure 4c] FIG. 4c shows a diagram of an aerosol generating device according to the present invention including a ball valve. [Figure 4d] FIG. 4d shows a diagram of an aerosol generating device according to the invention including a ball valve. [Figure 4e] FIG. 4e shows a diagram of an aerosol generating device according to the invention including a ball valve. [Figure 5a] Figure 5a shows a layer applied to the walls of an airflow passage in an aerosol generating device according to the invention. [Figure 5b] Figure 5b shows a layer applied to the walls of an airflow passage in an aerosol generating device according to the invention. [Figure 5c] FIG. 5c shows a layer applied to the walls of an airflow passage in an aerosol generating device according to the invention. DETAILED DESCRIPTION OF THE INVENTION

[0037] FIG. 1 shows a schematic diagram of an aerosol generating device 10. The aerosol generating device 10 comprises a housing 12 having a distal end 14 and a proximal end 16. The housing 12 at the proximal end 16 narrows to define a mouthpiece 18. Within the housing 12 are a power source 21 and control unit 20, a reservoir of liquid aerosol-forming substrate 22, an atomizer 24, and a valve 26. An airflow channel 25 is defined within the housing 12 so that air can be drawn through the housing 12 from an air inlet 23 to the mouthpiece 18 through the valve 26. A user draws on the mouthpiece 18, drawing air from the air inlet 23 through or past the atomizer 24, such that aerosolized droplets of the liquid aerosol-forming substrate 22 are entrained in the airflow. The airflow then exits the valve 26 to the user, who inhales it.

[0038] The power supply 21 and control unit 20 are typically contained in the reusable portion of the device, and the atomizer 24, liquid reservoir 22 and mouthpiece 18 are part of the consumable portion of the device that is attached to the reusable portion during use.

[0039] 2a-2e show various views of a first embodiment of an aerosol generating device 10 according to the present invention. The valve 26 in this first embodiment is a duckbill valve. In this first embodiment, the proximal end 16 of the mouthpiece 18 of the housing 12 is covered by a valve connector 28. The valve connector 28 has a distal open end 30 and a proximal closed end 32. The open end 30 is configured to slide over and be held in position over the proximal end 16 of the housing 12. The closed end 32 includes an opening 34. The duckbill valve 26 is positioned within the opening 34 of the valve connector 28.

[0040] FIG. 2c shows only duckbill valve 26. Duckbill valve 26 includes valve seat 36 and nozzle 38. Channel 42, shown in FIG. 2d, extends through nozzle 38 and is defined by the nozzle's interior wall 50. Channel 42 extends from opening 44 in valve seat 36 to opening 46 in nozzle 38, defined by opposing sides 40 and 40′. When in place, channel 42 in duckbill valve 26 aligns with airflow channel 25 of device 10, as shown in the cross-sectional views of FIGS. 2d and 2e.

[0041] Nozzle 38 is formed of a rubber or elastomeric material to allow nozzle 38 to deform. Nozzle 38 is shaped so that when no force is applied to nozzle 38, opposing sides 40 and 40' of nozzle 38 touch and nozzle opening 46 is in a closed position. In the closed position, opposing sides 40 and 40' of nozzle 38 prevent liquid, such as e-liquid or condensed aerosol, from leaking through valve 26 when the user is not inhaling the device. When air is drawn from valve seat 36 through channel 42 into nozzle 38, air pressure inside nozzle 38 forces opposing sides 40 and 40' apart, allowing air to escape through opening 44.

[0042] The duckbill valve 26 includes an inner coating 48, shown in FIG. 2e. The inner coating 48 is a hydrophobic coating. The coating 48 covers substantially the entire inner wall 50 of the nozzle 38. The coating 48 repels liquids, such as e-liquids or condensed aerosols. When a user inhales on the device 10 and the nozzle 38 is in the open position, the coating 48 repels the liquid so that the liquid cannot pass through the nozzle 38, thereby preventing the liquid from leaking out through the opening 46. In this manner, the coating 48 prevents liquid from leaking from the mouthpiece 18 during use.

[0043] 3a-3g show various views of a second embodiment of an aerosol generating device 10 according to the present invention. The valve 26 in this second embodiment is an umbrella valve. In the second embodiment, as in the first embodiment, the proximal end 16 of the mouthpiece 18 of the housing 12 is covered by a valve connector 28. Again, as in the first embodiment, the valve connector 28 of the second embodiment has a distal open end 30 and a proximal closed end 32. The open end 30 is configured to slide over the proximal end 16 of the mouthpiece 18 and be held in place over the proximal end 16. In the second embodiment, the closed end 32 includes a central opening 54 and two side openings 56 and 56'. The side openings 56 and 56' are coaxial with the air channel 25 of the device 10, as shown in the cross-sectional views of FIGS. 3d and 3e.

[0044] 3c shows only the umbrella valve 52. The umbrella valve 52 includes a valve body 58, a valve neck 60, and an umbrella portion 62. The valve neck 60 extends between the valve body 58 and the umbrella portion 62. The valve neck 56 is positioned within the central opening 54 of the closed end 32 of the valve connector 28. The valve body 58 is located upstream of the closed end 32. The umbrella portion 62 is located downstream of the closed end 32, opposite the valve body 58. The umbrella portion 62 is a concave, circular portion that extends downward from the end of the valve neck 60 toward the valve body 58.

[0045] The valve disc 58 has an outer periphery that is larger than the inner periphery of the central opening 54. Thus, the valve disc 58 is prevented from passing through the central opening 54.

[0046] The umbrella portion 62 has an outer periphery such that it extends over each of the side openings 56 and 56' in the closed position, as shown in FIG. 3f. In the closed position, liquid is prevented from leaking through the valve 26 when the user is not inhaling on the device 10. The umbrella portion 62 is formed of a rubber or elastomeric material so that the umbrella portion 62 is deformable. When air is drawn through the device 10, air pressure against the upstream side of the umbrella portion 62 from the air passing through the side openings 56 and 56' causes the umbrella portion 62 to deform and invert so that it no longer covers the side openings 56 and 56' and allows air to pass through the valve 26, as shown in FIG. 3g.

[0047] The umbrella valve 52 includes an inner coating 64, shown in FIGS. 3f and 3g. The inner coating 64 is a hydrophobic coating. The coating 64 is located both upstream of the closed end 32 and upstream of the umbrella portion 62. The coating 64 repels liquids, such as e-liquids or condensed aerosols. When a user inhales on the device 10 and the umbrella portion 62 is inverted so that the side openings 56 and 56' are uncovered, the coating 64 repels the liquid, preventing it from leaking through the side openings 56 and 56'. In this manner, the coating 64 prevents liquid from leaking from the mouthpiece 18 during use.

[0048] 4a-4e show various views of a third embodiment of an aerosol generating device 10 according to the present invention. The valve 26 in this third embodiment is a ball valve. In the third embodiment, as in the first embodiment, the proximal end 16 of the mouthpiece 18 of the housing 12 is covered by a valve connector 28. Again, as in the first embodiment, the valve connector 28 in the third embodiment has a distal open end 30 and a proximal closed end 32. The open end 30 is configured to slide over the proximal end 16 of the mouthpiece 18 and be held in place over the proximal end 16.

[0049] In a third embodiment, closed end 32 includes an opening 66. Opening 66 is aligned with air channel 25 of device 10, as shown in the cross-sectional views of Figures 4d and 4e. Figure 4b shows a perspective front view of valve portion 68 positioned over closed end 32 of valve connector 28. Figure 4c shows a side view of valve portion 68 only.

[0050] Valve portion 68 includes a central ball element 70. Ball element 70 has a rounded upstream side 72. Ball element 68 has a flattened downstream side 74. Extending radially outward from opposite sides of downstream side 74 of ball element 70 are wing portions 76 and 76'. Wing portions 76 and 76' are each formed from a curved, planar sheet. The sheet is bent to form a "zigzag" shape when viewed from the side in FIG. 4c.

[0051] In position, wing portions 76 and 76' are adjacent closed end 32 of valve connector 28, and ball element 70 is positioned within opening 66. Ball element 70 blocks opening 66, preventing liquid, such as e-liquid or condensed aerosol, from leaking through valve 26 when the user is not inhaling device 10.

[0052] Wing portions 76 and 76' are formed of a resilient material, such as rubber or an elastomeric material, so that wing portions 76 and 76' are deformable. The "zigzag" shape of wing portions 76 and 76' allows wing portions 76 and 76' to act like a spring. If wing portions 76 and 76' are deformed by an applied force, they return to their original position when the force is removed. When air is drawn through device 10, air pressure on upstream side 72 of ball element 70 pushes ball element 70 away from opening 66, causing wing portions 76 and 76' to deform. Ball element 70 no longer covers opening 66, allowing air to pass through valve 26.

[0053] Ball valve 52 includes an inner coating 78, shown in FIG. 4e. Inner coating 64 is a hydrophobic coating. Coating 78 is located on upstream side 72 of ball element 70. Coating 78 repels liquids, such as e-liquids or condensed aerosols. When a user inhales on device 10 and ball element 70 is pulled away from opening 66, coating 78 repels the liquid, preventing it from leaking through opening 66. In this manner, coating 78 prevents liquid from leaking from mouthpiece 18 during use.

[0054] Figures 5a, 5b, and 5c illustrate the airflow channel through the consumable portion of an aerosol-generating device of the type shown in Figure 1. The consumable portion comprises an outer housing 86 and an inner housing 85. Within the inner housing is a liquid reservoir having an outer wall 82. The liquid reservoir holds a liquid aerosol-forming substrate 80. A mesh heater 84 is provided at the base of the reservoir, which vaporizes liquid from the reservoir during operation. The vapor can escape into airflow channel 90. Airflow channel 90 extends from the inlet through the housing to the mouthpiece and includes a valve as described.

[0055] The walls of the airflow channel 90 are provided with two distinct membranes in a layered structure, as illustrated in Figures 5b and 5c. Figure 5c is an enlarged view of a portion of Figure 5b, where the two layers are most clearly visible. The underlying layer 94 is hydrophilic. The overlying layer 92, which contacts the aerosol in the airflow channel 90, is hydrophobic. This combination of layers creates a diode for liquid flow, whereby liquid condensed on the hydrophobic layer is efficiently transported to the hydrophilic layer, but liquid does not return from the hydrophobic layer to the hydrophilic layer. If the outer walls of the reservoir are made fluid-permeable below these layers (e.g., by forming openings through the outer walls) or are completely replaced by these layers, liquid condensing in the airflow channel downstream of the heater can effectively return to the reservoir.

Claims

1. An aerosol generating device, comprising: a housing having a first end defining a mouthpiece, a second end, and a recess defined between the first end and the second end; a reservoir within said well for storing a liquid aerosol-forming substrate; Atomizer and a valve within the mouthpiece of the housing, the valve having a downstream side and an upstream side, the upstream side of the valve including a hydrophobic coating.

2. 2. The aerosol generating device of claim 1, comprising an air inlet in the housing and an airflow channel extending from the air inlet through the recess to the mouthpiece, the valve being located within the airflow channel.

3. 3. The aerosol generating device of claim 2, wherein the airflow channel passes through the atomizer.

4. 4. An aerosol generating device according to claim 1, wherein the valve is a one-way valve configured to prevent liquid from passing from the upstream side of the valve to the downstream side of the valve.

5. 5. The aerosol generating device according to claim 1, further comprising a storage tank configured to receive liquid repelled by the material of the hydrophobic coating.

6. 6. The aerosol generating device according to claim 1, wherein the valve is one of a ball valve, a duckbill valve, a diaphragm valve, an umbrella valve, and a hinged flap.

7. 7. An aerosol generating device according to claim 1, wherein the valve is activated by a user inhaling into the mouthpiece of the aerosol generating device.

8. 7. An aerosol generating device according to any one of claims 1 to 6, wherein the valve is actuated via a button on the housing.

9. An aerosol generating device according to any one of claims 1 to 8, wherein the valve is positioned within the mouthpiece at or near the first end of the housing.

10. 10. The aerosol generating device according to claim 1, wherein the atomizer is equipped with a heater.

11. 11. The aerosol generating device of claim 10, wherein the heater comprises one or more heating elements.

12. 12. The aerosol generating device of claim 11, wherein the heater comprises a wick or capillary element for directing liquid from the reservoir to one or more heating elements.

13. 13. An aerosol generating device according to claim 11 or 12, further comprising directing means configured to direct liquid resulting from condensation of an aerosolized liquid aerosol-forming substrate towards the heater.

14. 14. An aerosol generating device according to any one of claims 1 to 13, wherein the reservoir comprises an outer wall exposed to an airflow channel in the housing and having a first surface formed of a hydrophobic material.

15. 15. The aerosol generating device of claim 14, wherein the outer wall is positioned within the airflow channel downstream of the atomizer.

Images