An aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material

Abstract

An aerosol generating device (100) includes a cartridge (106) including a storage chamber (108) having a primary reservoir (110), a secondary reservoir (112), and at least one channel (217, 116). The primary reservoir (110) stores an aerosol generating substrate and the at least one channel (217, 116) is defined between the primary and secondary reservoirs (110, 112) to convey the aerosol generating substrate from the primary reservoir (110) to the secondary reservoir (112). When a first end of the aerosol generating device (100) is oriented in an angular position above 0 to 90 degrees with respect to a horizontal plane (HH), a fluid communication between the primary and secondary reservoirs (110, 112) is established, and thereafter a fluid communication between the secondary reservoir (112) and a capillary material (122) of an atomizer is established in a direction substantially orthogonal to a longitudinal axis (C-C) of the aerosol generating device (100).

Description

AN AEROSOL GENERATING DEVICE WITH AN IMPROVED CARTRIDGE TO REDUCE OVERSATURATION OF A CAPILLARY MATERIALTECHNICAL FIELD

[0001] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to a simple and improved aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material.BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced as prior art.

[0003] Aerosol generating devices (AGDs) typically operate using a rechargeable battery to heat an aerosol generating substrate to produce an aerosol for inhalation. The aerosol generating devices, specifically closed-type aerosol generating device include a cartridge having a storage compartment to stockpile the aerosol generating substrate, an atomizer unit consisting of a capillary material (also referred as “wick” herein) and a heater to draw and aerosolize the aerosol generating substrate, and a condensation chamber configured to carry the aerosol generated to the mouthpiece end of the aerosol generating device (also referred as device).

[0004] The storage compartment of the existing aerosol generating device is directly coupled to the capillary material. The aerosol generating substrate (also referred to as aerosol generating liquid) is drawn on to the heater through the capillary material’s capillary action. Since, the aerosol generating liquid is always in direct contact with the capillary material, and there is no medium or mechanism to regulate the liquid flow to the capillary material, there is always excess liquid available causing the capillary material to get oversaturated. The capillary material oversaturation effects the volumetric efficiency and energy efficiency of the device. The aerosol generating liquid from the oversaturated capillary material may dribble (leak) into the airflow path of the aerosol generating device and other parts of the atomizer unit. The liquid leakage caused due to the oversaturation of the capillary material in the manner described above reduces the device’s volumetric efficiency. Further, the leaked liquid may eventually block the airflow path and may result in reduced Total Particulate Matter (TPM) delivery to the user. Also, the liquid leakage into the airflow path can reach theuser’s mouth end, causing an unpleasant experience to the user. Further, the power required for aerosolizing the aerosol generating liquid increases due to the oversaturated capillary material thereby effecting the energy efficiency of the device. Thus, the oversaturated capillary material always demands more power to aerosolize the aerosol generating liquid to deliver the desired total particulate matter (TPM) to the user.

[0005] Efforts are underway to address this issue through innovative design solutions. These include designing capillary tubes to collect excess aerosol generating substrate (or aerosol generating liquid).

[0006] A patent document W02020176902A2 titled, “Cartridge for a vaporizer device” describes a vaporizer device includes a vaporizer cartridge. The vaporizer cartridge includes a cartridge housing; a storage chamber disposed within the cartridge housing and configured to contain a liquid vaporizable material, an inlet configured to allow air to enter an internal airflow path within the cartridge housing; an atomizer configured to cause conversion of at least some of the liquid vaporizable material to an inhalable state; and a collector. The collector includes a capillary structure configured to retain a volume of the liquid vaporizable material in fluid contact with a storage chamber of the vaporizer cartridge. The capillary structure includes a microfluidic gate configured to prevent air and liquid from bypassing each other during filling and emptying of the collector. Further, the microfluidic gate includes a plurality of openings connecting the storage chamber and the collector. The plurality of openings have a first channel and a second channel, where the first channel has a higher capillary drive than the second channel. Further, the microfluidic gate includes a pinch-off point between the plurality of openings.

[0007] However, the referred document describes about creation of the collector comprising a capillary structure within the vaporizer cartridge to collect the excessive liquid due to increased pressure in the cartridge relative to the ambient pressure, and travel back when the pressure drops in the cartridge relative to ambient pressure.

[0008] Another patent document US2014000638A1 titled, “Reservoir and heater system for controllable delivery of multiple aerosolisable materials in an electronic smoking article” describes a smoking article including an aerosolization zone including a resistive heating element; an aerosol precursor composition in liquid form comprising a first component and a second component; a first reservoir comprising a porous material that is at least partially saturated with the first component of the aerosol precursor composition; a second reservoir comprising the second component of the aerosol precursor composition; a first transport element providing fluid communication between the first reservoir and theaerosolization zone; and a second transport element providing fluid communication between the second reservoir and the aerosolization zone. However, the referred document describes the plurality of reservoir structures which are used to transport the individual aerosol precursor from their respective reservoir to a heating element, Further, the referred document falls short in addressing the excess liquid flow leading to capillary material oversaturation.

[0009] Thus, the above referred documents are insufficient in providing solution to reduce oversaturation of the capillary material. Thus, there arises a need for modification in design of the cartridge to address the problems associated with oversaturation of the capillary material.

[0010] There is therefore a need in the art to develop a cost effective, compact and portable aerosol generating device with an improved cartridge design to reduce oversaturation of the capillary material.OBJECTS OF THE PRESENT DISCLOSURE

[0011] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as listed herein below.

[0012] It is an object of the present disclosure to provide a simple, compact and portable aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material.

[0013] It is an object of the present disclosure to provide an improved design of a cartridge which avoid liquid leakage due to the oversaturation of the capillary material, thereby improving the volumetric efficiency of the aerosol generating device.

[0014] It is an object of the present disclosure to provide an improved design of a cartridge which avoid issue of leakage of the aerosol generating liquid into an airflow path and reaching the user’s mouth end.

[0015] It is another object of the present disclosure to provide an improved aerosol generating device which helps in preventing leakage of the aerosol generating substrate into the airflow path and blockage in the airflow path caused by the oversaturation of the capillary material with an improved design of a cartridge.

[0016] It is another object of the present disclosure to provide an aerosol generating device with an improved cartridge that can reduce the power requirement to generate the desired aerosol by the way of controlling the excess liquid supply to the capillary material, thereby improving the energy efficiency of the aerosol generating device.

[0017] It is yet another object of the present disclosure to provide an aerosol generating device that can be cost-effective.SUMMARY

[0018] Aspects of the present disclosure relate generally to the field of aerosol generating devices. In particular, the present disclosure pertains to a simple and improved aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material.

[0019] According to an aspect of the present disclosure, the disclosed aerosol generating device (also referred to simply as device) includes a cartridge including a storage chamber and an atomizer. The storage chamber includes a primary reservoir, a secondary reservoir, and at least one channel. The primary reservoir is configured to store an aerosol generating substrate and the at least one channel is defined between the primary reservoir and the secondary reservoir to convey the aerosol generating substrate from the primary reservoir to the secondary reservoir.

[0020] In addition, when a first end of the aerosol generating device is oriented in an angular position above 0 degrees to 90 degrees with respect to a horizontal plane (HH), a fluid communication between the primary reservoir and the secondary reservoir is established, and thereafter a fluid communication between the secondary reservoir and a capillary material of the atomizer is established in a direction substantially orthogonal to a longitudinal axis of the aerosol generating device.

[0021] In one or more embodiments, the first end of the aerosol generating device may be a mouthpiece end of the aerosol generating device. A second end of the aerosol generating device may be a charging end of the aerosol generating device.

[0022] In one or more embodiments, when the first end of the aerosol generating device may be oriented in the angular position above 0 degree to 90 degrees with respect to the horizontal plane (HH), the fluid communication between the primary reservoir and the secondary reservoir may be established and the aerosol generating substrate may flow from the primary reservoir to the secondary reservoir.

[0023] In one or more embodiments, the secondary reservoir may have a reserve capacity to hold a volume of the aerosol generating substrate sufficient for 1 to 10 inhalations required during operation of the aerosol generating device.

[0024] In one or more embodiments, when the aerosol generating device is orientated horizontally with respect to the horizontal plane (HH), the fluid communication between the primary reservoir and the secondary reservoir may be stopped.

[0025] In one or more embodiments, the at least one channel may include a single communication channel configured to directly convey the aerosol generating substrate from the primary reservoir to the secondary reservoir.

[0026] In one or more embodiments, the at least one channel may include a first peripheral channel, a second peripheral channel, and a central channel. A width of each of the first and second peripheral channels may be smaller than a width of the central channel, to allow the aerosol generating substrate to enter the first and second peripheral channels descending down with an advancing meniscus, and air in the secondary reservoir to escape through the central channel.

[0027] In one or more embodiments, a volume of the secondary reservoir may be smaller than a volume of the primary reservoir to store less amount of aerosol generating substrate.

[0028] In one or more embodiments, the secondary reservoir may include an inlet section, and an outlet section. The inlet section may be fluidically coupled to the primary reservoir. The inlet section is in an elevated position relative to the horizontal plane (HH), and the outlet section may be fluidically coupled with the capillary material.

[0029] In one or more embodiments, the primary reservoir may include an outlet section, wherein a width of the inlet section of the secondary reservoir may be either smaller or same to a width of the outlet section of the primary reservoir: to displace air in the secondary reservoir with the aerosol generating substrate in the primary reservoir, in case of absence of the channels.

[0030] In one or more embodiments, the capillary material may be in direct contact with the secondary reservoir through a plurality of vents. The plurality of vents may facilitate the aerosol generating substrate to be seeped into the capillary material for aerosolization.

[0031] In one or more embodiments, the secondary reservoir may include a plurality of micro-channels configured to communicate the aerosol generating substrate from the secondary reservoir towards the plurality of vents and thereafter through the outlet section, the aerosol generating substrate may be seeped into the capillary material.

[0032] In one or more embodiments, the secondary reservoir may include an array of bubbles configured between a wall of the secondary reservoir, and a wall of the capillary material, to enhance uniform absorbance of the aerosol generating substrate by the capillary material.

[0033] In one or more embodiments, the aerosol generating device may include a control unit communicably coupled to the atomizer. Upon detection of airflow by at least one sensor, the control unit may actuate the atomizer to heat-up the aerosol generating substrate to generate the aerosol to be inhaled by the user.

[0034] In one or more embodiments, the atomizer may be positioned horizontally below the secondary reservoir to heat-up the aerosol generating substrate to generate the aerosol.

[0035] In one or more embodiments, the atomizer may include the capillary material and at least one heater. The capillary material may absorb the aerosol generating substrate to be aerosolized and thereafter the at least one heater having heater pins may heat-up the aerosol generating substrate to generate the aerosol.

[0036] In one or more embodiments, the cartridge may include a condensation chamber configured to carry the aerosol generated to a mouthpiece of the aerosol generating device.

[0037] In another aspect, the present disclosure pertains to a cartridge for an aerosol generating device. The cartridge includes a storage chamber, and an atomizer including a capillary material, and at least one heater. The storage chamber includes a primary reservoir, a secondary reservoir, and at least one channel. The primary reservoir is configured to store aerosol generating substrate. The at least one channel is defined between the primary reservoir and the secondary reservoir to convey the aerosol generating substrate from the primary reservoir to the secondary reservoir.

[0038] In addition, the secondary reservoir having an elevated inlet section, and the secondary reservoir is positioned horizontally above a first surface of the capillary material.

[0039] In one or more embodiments, the first surface of the capillary material may be in direct contact with the secondary reservoir through a plurality of vents. The plurality of vents may facilitate the aerosol generating substrate to be seeped into the capillary material for aerosolization.

[0040] In one or more embodiments, the at least one heater may be positioned horizontally below a second surface of the capillary material.

[0041] In one or more embodiments, when the cartridge is positioned in the aerosol generating device, such that a first end of the aerosol generating device may be oriented in an angular position above 0 degree to 90 degrees with respect to a horizontal plane (HH), the aerosol generating substrate may flow from the primary reservoir to the secondary reservoir, and thereafter the aerosol generating substrate may flow from the secondary reservoir to the capillary material.

[0042] In one or more embodiments, the first end of the aerosol generating device may be a mouthpiece end of the aerosol generating device. A second end of the aerosol generating device may be a charging end of the aerosol generating device.

[0043] In one or more embodiments, the secondary reservoir may have a reserve capacity to hold a volume of aerosol generating liquid sufficient for 1 to 10 inhalations required during operation of the aerosol generating device.

[0044] In one or more embodiments, the at least one channel may include a single communication channel configured to directly convey the aerosol generating substrate from the primary reservoir to the secondary reservoir.

[0045] In one or more embodiments, the at least one channel may include a first peripheral channel, a second peripheral channel, and a central channel. A width of each of the first and second peripheral channels may be smaller than a width of the central channel, to allow the aerosol generating substrate to enter the first and second peripheral channels descending down with an advancing meniscus, and air in the secondary reservoir to escape through the central channel.

[0046] In one or more embodiments, a volume of the secondary reservoir may be smaller than a volume of the primary reservoir to store less amount of aerosol generating substrate.

[0047] In one or more embodiments, the secondary reservoir may include the elevated inlet section, and an outlet section. The elevated inlet section may be in an elevated position relative to the horizontal plane (HH). The elevated inlet section may be fluidically coupled to the primary reservoir, and the outlet section may be fluidically coupled with the capillary material.

[0048] In one or more embodiments, the primary reservoir may include an outlet section, wherein a width of the inlet section of the secondary reservoir may be either smaller or same to a width of the outlet section of the primary reservoir: to displace air in the secondary reservoir with the aerosol generating substrate in the primary reservoir, in case of absence of the channels.

[0049] In one or more embodiments, the capillary material may absorb the aerosol generating substrate to be aerosolized and thereafter the at least one heater having heater pins may be configured to heat-up the aerosol generating substrate to generate the aerosol.

[0050] In one or more embodiments, the cartridge may include a condensation chamber to carry the aerosol generated to a mouthpiece of the aerosol generating device.BRIEF DESCRIPTION OF DRAWINGS

[0051] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together withthe description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0052] FIG. 1A illustrates an exemplary architecture representing the proposed aerosol generating device with an improved cartridge, in accordance with embodiments of the present disclosure.

[0053] FIG. IB illustrates a sectional view of a cartridge of an aerosol generating device of FIG. 1A showing a storage chamber, in accordance with embodiments of the present disclosure.

[0054] FIG. 2A illustrates a detailed side sectional view of a cartridge of an aerosol generating device of FIG 1A, in accordance with embodiments of the present disclosure.

[0055] FIG. 2B illustrates a detailed view of the secondary reservoir and a capillary material connection of the cartridge, in accordance with embodiments of the present disclosure.

[0056] FIG. 2C illustrates a detailed view of an array of bubbles of the secondary reservoir and at least one channel, in accordance with embodiments of the present disclosure.

[0057] FIG. 2D illustrates a detailed view of an elevated inlet section of the secondary reservoir, in accordance with embodiments of the present disclosure.

[0058] FIG. 2E illustrates a detailed view of bubble structure of the secondary reservoir, in accordance with embodiments of the present disclosure.

[0059] FIGs. 3A and 3B illustrate detailed views of orientation of the aerosol generating device which enables movement of aerosol generating liquid from the primary to the secondary reservoir, in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0060] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the disclosure.

[0061] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0062] If the specification states that a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0063] As used in the description herein and throughout the description that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0064] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein does not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0065] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the description herein.

[0066] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skilled in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0067] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to a simple and improved aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material.

[0068] Existing aerosol generating devices have the storage compartment coupled directly to the capillary material. The capillary material therefore draws the aerosol generating substrate or aerosol generating liquid as a consequence of capillary action. When there is no medium or mechanism to regulate the liquid flow to the capillary material, there is always excess liquid available causing the capillary material to oversaturate. The oversaturation of the capillary material effects the volumetric efficiency and the energy efficiency of the device. The aerosol generating liquid from the oversaturated capillary material may dribble (leak) into the airflow path and other parts of the atomizer region. The liquid leakage caused in the manner described above due to the oversaturation of the capillary material reduces the device’s volumetric efficiency. Further, the leaked liquid may eventually block the airflow path and may result in reduced Total Particulate Matter (TPM) delivery to the user. Also, the liquid leakage in to the airflow path can reach the user’s mouth end, thereby causing an unpleasant experience to the user. Further, the power required for aerosolizing the aerosol generating liquid increases due to the oversaturated capillary material thereby effecting the energy efficiency of the device. Thus, the oversaturated capillary material always demands more power to aerosolize the aerosol generating liquid and deliver the desired total particulate matter (TPM).

[0069] To address the aforesaid issues, the proposed aerosol generating device has been developed with an improved cartridge design, aiming to reduce oversaturation of a capillary material due to excess aerosol generating substrate.

[0070] As illustrated, in an embodiment, referring to FIG. 1A, IB and 2A, the proposed aerosol generating device 100 (also referred as device 100 herein) includes a mouthpiece 102, a cartridge 106 including a cartridge bottom 201, and a control unit 104. The cartridge 106 includes a storage chamber 108 configured to store an aerosol generating substrate to be aerosolized, an atomizer 120 configured to draw and aerosolize the aerosol generating substrate, and a condensation chamber 118 configured to carry the aerosol generated to the mouthpiece 102.

[0071] In an embodiment and referring to FIG. IB, the cartridge 106 includes the storage chamber 108 which further includes a primary reservoir 110, a secondary reservoir 112, and at least one channel 217, 116. The primary reservoir 110 and the secondary reservoir 112 are coupled through the at least one channel 217, 116. The at least one channel 217,116 is defined between the primary reservoir 110 and the secondary reservoir 112 to convey the aerosol generating substrate from the primary reservoir 110 to the secondary reservoir 112. When the first end of the aerosol generating device 100 is oriented in an angular positionabove 0 degree to 90 degrees with respect to a horizontal plane (HH), a fluid communication between the primary reservoir 110 and the secondary reservoir 112 is established, and thereafter a fluid communication between the secondary reservoir 112 and a capillary material 122 of the atomizer 120 is established in a direction substantially orthogonal to a longitudinal axis C-C of the aerosol generating device 100. The longitudinal axis C-C is an axis along a length of the aerosol generating device 100. Here, the first end of the aerosol generating device 100 can be a mouthpiece end of the aerosol generating device 100, and a second end of the aerosol generating device 100 can be a charging end of the aerosol generating device 100.

[0072] Further, as shown in FIG, 2B, the secondary reservoir 112 includes an inlet section 208 and an outlet section 209, where the inlet section 208 can be fluidically coupled to the primary reservoir 110. The inlet section 208 is in an elevated position relative to the horizontal plane (HH). The outlet section 209 can be fluidically coupled with a capillary material (also referred herein as absorbent material) 122. The primary reservoir 110 is configured to store the aerosol generating substrate and is not in direct contact with the capillary material 122 of the atomizer 120. The secondary reservoir 112 is in communication with the primary reservoir 110 via the at least one channel 217, 116 and stores less amount of the aerosol generating substrate to reduce oversaturation of the capillary material 122. As mentioned above, the secondary reservoir 112 comprises the inlet section 208. In an embodiment, the inlet section 208 is in the elevated position, the elevated position having a higher elevation with respect to the horizontal plane HH when the aerosol generating device 100 is oriented at 0 degree and thus can be an elevated inlet section 208 as shown in FIG. 2D.

[0073] In an implementation, wherein during operation of the aerosol generating device 100 (when the device 100 is in an operating range above 0 degree to 90 degrees)the aerosol generating substrate flows from the primary reservoir 110 to the secondary reservoir 112 to seep the aerosol generating substrate into the capillary material 122.

[0074] In an embodiment, the secondary reservoir 112 can have a reserve capacity to hold a volume of the aerosol generating substrate sufficient for 1 to 10 inhalations required during operation of the aerosol generating device 100. Further, a volume of the secondary reservoir 112 is smaller than a volume of the primary reservoir 110 to store less amount of the aerosol generating substrate.

[0075] Referring to FIG. 3 A, the improved design of the cartridge 106 of the present invention suspends or stops the fluid communication between the primary and secondaryreservoirs 110, 112, when the aerosol generating device 100 is aligned horizontally with respect to the horizontal plane HH.

[0076] Furthermore, referring to FIG. 3B, in one of exemplary embodiments, the fluid communication between the primary and secondary reservoirs 110, 112 can be established, when device 100 is tilted to 10 degrees with respect to a horizontal plane HH such as ground. That is, when an angle between a central axis CC of the aerosol generating device 100 and the horizontal plane HH such as ground equal to 10 degrees, the fluid communication between the primary and secondary reservoirs 110, 112 can be established.

[0077] In an embodiment, there can be only single communication channel 217 (single fluid communication channel) and the aerosol generating substrate can directly enter from the primary reservoir 110 to the secondary reservoir 112 through the single communication channel 217.

[0078] In an embodiment, as shown in FIG. 2 A, the primary reservoir 110 can include an outlet section 208, wherein a width of the inlet section 208 of the secondary reservoir 112 can either be smaller or equal to a width of the outlet section 208 of the primary reservoir 110: to displace air in the secondary reservoir 112 with the aerosol generating substrate in the primary reservoir 110, in case of absence of the channels 116. In some embodiments, the outlet section 208 of the primary reservoir 110 can be same as the inlet section 208 of the secondary reservoir 112.

[0079] In an embodiment, the cartridge 106 can include the at least one channel 116 (also referred as fluid communication channels 116) configured to convey the aerosol generating substrate from the primary reservoir 110 to the secondary reservoir 112. In some embodiments, as shown in FIG. 2C, the at least one channel 116 can include a first peripheral channel 210, a second peripheral channel 211, and a central channel 212, where the first peripheral channel 210 and the second peripheral channel 211 can be smaller in width as that of the central channel 212. In an example embodiment, the aerosol generating substrate can enter the first peripheral channel 210 and the second peripheral channel 211 descending down with an advancing meniscus and the air in the secondary reservoir 112 escaping through the central channel 212. Based on orientation of the device 100, air can be displaced through at least one of the channels 116 and the aerosol generating substrate can enter or advance through the remaining channels.

[0080] In an embodiment, the secondary reservoir 112 can include an array of bubbles 215 to form a bubble structure as shown in FIGs. 2C and 2E. The bubbles 215 can be formed either by protrusion or depression in the secondary reservoir 112, volume created between a wall214 of the capillary material 122, and a wall 213 of the secondary reservoir 112 to enhance the filling time of the aerosol substrate. These bubbles 215 can create impression on the capillary material (absorbent material) 122 which can enhance the uniform absorbance of the aerosol generating substrate through capillary actions.

[0081] In an embodiment, the secondary reservoir 112 may not have the array of bubbles 215 or the bubble structure and the aerosol generating substrate can directly enter from the secondary reservoir 112 to the capillary material 122.

[0082] In an embodiment, the capillary material 122 can be in direct contact with the secondary reservoir 112 through a plurality of vents 114 (simply referred as “vents 114” hereinafter). The vents 114 can facilitate the aerosol generating substrate to be seeped into the capillary material 122 for aerosolization. The vents 114 can be selected from but not limited to round or circular shaped vents, slotted vents, funnel-shaped vents, and the like. In another embodiment, the secondary reservoir 112 can include a plurality of micro-channels 114A configured to communicate the aerosol generating substrate from the secondary reservoir 112 towards the vents 114 and thereafter through the outlet section 209, the aerosol generating substrate can be seeped into the capillary material 122. Further, material used for the capillary material 122 may depend upon the aerosol generating substrate to be aerosolized. The material for the capillary material 122 can be selected from but not limited to Silica, Cotton, Ceramic, Stainless Steel mesh, Ekowool, Bamboo Fiber, and the like.

[0083] In an embodiment, the atomizer 120 can include the capillary material 122 and at least one heater 124 (simply referred as “heater 124” herein) configured near the secondary reservoir 112 to heat-up the aerosol generating substrate to generate the aerosol. In an embodiment, referring to FIG. 2E, the atomizer 120 can be positioned horizontally below the secondary reservoir 112 to heat-up the aerosol generating substrate. The heater 124 having heater pins 202 heat-up the aerosol generating substrate to generate the aerosol. The capillary material 122 absorbs the aerosol generating substrate to be aerosolized and thereafter the heater 124 can aerosolize the aerosol generating substrate to generate the aerosol. The heater 124 can include one or more heating elements that can be selected from but not limited to a ceramic heating element, a stainless-steel coil, a mesh heating element, an induction heating element, a Nichrome wire, and the like.

[0084] In an embodiment, the aerosol generating substrate flows from the primary reservoir 110 to the secondary reservoir 112 when the aerosol generating device 100 is oriented in an angular position ranging above 0 degree to 90 degrees.

[0085] In an embodiment, when a user starts using the aerosol generating device 100, the aerosol generating substrate (aerosol generating liquid) enters from the primary reservoir 110 to the secondary reservoir 112 as shown in FIG. 2A. That is, the aerosol generating liquid flows from the primary reservoir 110 to the secondary reservoir 112 through the single fluid communication channel 217 and then through the inlet section 208 of the secondary reservoir 112. Further, through the vents 114 and then through the outlet section 209 of the secondary reservoir 112, the aerosol generating substrate can be seeped into the capillary material 122. In some embodiments, the secondary reservoir 112 may have the bubbles 215. In some embodiments, the secondary reservoir 112 may not have the bubbles 215. In some embodiments, there can be a plurality of micro-channels 114A in the secondary reservoir 112 to communicate the aerosol forming substrate towards the vents 114 and further, through the outlet section 209, the aerosol generating substrate is seeped into the capillary material 122.

[0086] In an embodiment, the improved cartridge 106 of the present invention can include the at least one channel 116 such as the first peripheral channel 210, the second peripheral channel 211, and the central channel 212 as shown in FIG. 2C. When the user starts using the aerosol generating device 100, the aerosol generating substrate (aerosol generating liquid) flows from the primary reservoir 110 to the secondary reservoir 112 through the first peripheral channel 210, the second peripheral channel 211 and then through the inlet section 208 of the secondary reservoir 112. Further, through the vents 114 and then through the outlet section 209 of the secondary reservoir 112, the aerosol generating substrate can be seeped into the capillary material 122. In some embodiments, the secondary reservoir 112 can have bubbles 215. In some embodiments, the secondary reservoir 112 cannot have bubbles 215. In some embodiments, the plurality of micro-channels 114A in the secondary reservoir 112 can communicate the aerosol forming substrate towards the vents 114 and further, through the outlet section 209, the aerosol generating substrate is seeped into the capillary material 122.

[0087] In some embodiments, the cartridge 106 can be a refillable tank in the aerosol generating device 100, while in some embodiments, the cartridge 106 can be a disposable cartridge. The cartridge 106 holds the aerosol generating substrate, which can include, but are not limited to: a mixture of propylene glycol (PG), a vegetable glycerin (VG), flavorings, and active compounds.

[0088] In general, the design of the mouthpiece 102 can vary depending on the style and design of the aerosol generating device 100. The design of the mouthpiece 102 can include, but not limited to: a narrow and tube-like structure, a wider structure, a flat structure, and the like. In some embodiments, the mouthpiece 102 can be detachably attached to the cartridge106 through an attachment mechanism, thus facilitating easy detachment for cleaning or replacement. The attachment mechanism can be any one of but not limited to threaded connection, snap-fit connection, bayonet connection, magnetic connection, press-fit connection, and the like. In one or more embodiments, the mouthpiece 102 can be made of materials which include, but are not limited to a plastic, a metal, a silicone, medical-grade materials, and the like, which are safe for oral contact with the mouth of the user and easy to clean. In some embodiments, the mouthpiece 102 can also include filters or screens to trap particles or contaminations coming with the airflow.

[0089] In an embodiment, the aerosol generating device 100 can include at least one sensor 126 which automatically actuates the atomizer 120 of the aerosol generating device 100, when the user inhales. In some embodiments, the at least one sensor 126, can be replaced by a manual button which is pressed by the user to actuate the aerosol generating device 100.

[0090] The control unit 104 may include one or more processors (interchangeably referred to as processor, hereinafter). The processor may be implemented as one or more microprocessors, microcomputers, microcontrollers, edge or fog microcontrollers, digital signal processors, central processing units, logic circuitries, and / or any devices that process data based on operational instructions. Among other capabilities, the processor may be configured to fetch and execute computer-readable instructions stored in a memory of the control unit 104. The memory may be configured to store one or more computer-readable instructions or routines in a non-transitory computer readable storage medium, which may be fetched and executed to actuate the atomizer 120, upon detection of airflow by the at least one sensor 126, thereby generating the aerosol for inhalation by the user.

[0091] In an embodiment, the memory may comprise any non-transitory storage device including, for example, volatile memory such as Random-Access Memory (RAM), or nonvolatile memory such as Erasable Programmable Read-Only Memory (EPROM), flash memory, and the like.

[0092] In an embodiment, the control unit 104 can be configured to actuate the atomizer 120, upon detection of airflow by the at least one sensor 126, thereby generating the aerosol for inhalation by the user. In another embodiment, the control unit 104 of the aerosol generating device 100 can include a power source 128. The power source 128 can be a battery, including, without limitation, a rechargeable lithium-ion battery, a lithium polymer battery, Nickel-metal Hydride (NiMH) battery, and the like. The battery provides an electric current required to heat-up the heater 124 and aerosolize the aerosol generating substrate. In another embodiment, the atomizer 120 can be connected to the power source 128. Upon actuation ofthe aerosol generating device 100, the power source 128 can transmit the electric current through the atomizer 120, which results in heating-up of the heater 124.

[0093] According to another aspect of the present disclosure, the disclosed cartridge 106 to reduce oversaturation of a capillary material 122, includes a storage chamber 108 configured to store an aerosol generating substrate to be aerosolized. The cartridge 106 includes an atomizer 120 including the capillary material 122, and at least one heater 124. The storage chamber 108 includes a primary reservoir 110, a secondary reservoir 112 fluidically coupled to the primary reservoir 110, and at least one channel 217, 116. The primary reservoir 110 is configured to store the aerosol generating substrate and is not in direct contact with the capillary material 122. The at least one channel 217, 116 is defined between the primary reservoir 110 and the secondary reservoir 112 to convey the aerosol generating substrate from the primary reservoir 110 to the secondary reservoir 112. In addition, the secondary reservoir 112 has an elevated inlet section 208 and referring to FIG. 2E, the secondary reservoir 112 is positioned horizontally above a first surface of the capillary material 122. The elevated inlet section 208 is in an elevated position relative to the horizontal plane (HH), which elevated inlet section 208 can be fluidically coupled to the primary reservoir 110. The secondary reservoir 112 can also include an outlet section 209 fluidically coupled with the capillary material 122.

[0094] In an embodiment, the first surface of the capillary material 122 can be in direct contact with the secondary reservoir 112 through a plurality of vents 114. The vents 114 can facilitate the aerosol generating substrate to be seeped into the capillary material 122 for aerosolization.

[0095] In an embodiment, when the cartridge 106 is positioned in the aerosol generating device 100, such that a first end of the aerosol generating device 100 can be oriented in an angular position above 0 degree to 90 degrees with respect to a horizontal plane HH, the aerosol generating substrate flows from the primary reservoir 110 to the secondary reservoir 112 and thereafter the aerosol generating substrate can flow from the secondary reservoir 112 to the capillary material 122. Here, the first end of the aerosol generating device 100 can be a mouthpiece end of the aerosol generating device 100. A second end of the aerosol generating device 100 can be a charging end of the aerosol generating device 100.

[0096] Further, the capillary material 122 can absorb the aerosol generating substrate to be aerosolized and thereafter the heater 124 having heater pins 202 can heat-up the aerosol generating substrate to generate the aerosol. In an embodiment, the heater 124 can be positioned horizontally below a second surface of the capillary material 122. In addition, thecartridge 106 can include a condensation chamber 118 configured to carry the aerosol generated to a mouthpiece 102 of the aerosol generating device 100.

[0097] In an embodiment, the at least one channel 217 can include a single communication channel 217 (single fluid communication channel) to directly convey the aerosol generating substrate from the primary reservoir 110 to the secondary reservoir 112. In some embodiments, the at least one channel 116 can include a first peripheral channel 210, a second peripheral channel 211, and a central channel 212. A width of each of the first and second peripheral channels 210, 211 can be smaller than a width of the central channel 212, to allow the aerosol generating substrate to enter the first and second peripheral channels 210, 211 descending down with an advancing meniscus, and air in the secondary reservoir 112 to escape through the central channel 212.

[0098] In an embodiment, as shown in FIG. 2A, the primary reservoir 110 can include an outlet section 208, wherein a width of the inlet section 208 of the secondary reservoir 112 can be either smaller or equal to a width of the outlet section 208 of the primary reservoir 110: to displace air in the secondary reservoir 112 with the aerosol generating substrate in the primary reservoir 110, in case of absence of the channels 116. In some embodiments, the outlet section 208 of the primary reservoir 110 can be same as the inlet section 208 of the secondary reservoir 112.

[0099] In an embodiment, the capillary material 122 can be in direct contact with the secondary reservoir 112 through the vents 114. The vents 114 can facilitate the aerosol generating substrate to be seeped into the capillary material 122 for aerosolization.

[0100] In another aspect, the cartridge 106 of the present invention suspends or stops the fluid communication between the primary and secondary reservoirs 110, 112, when the device 100 is aligned horizontally. Further, a volume of the secondary reservoir 112 is smaller than a volume of the primary reservoir 110 to store less amount of the aerosol generating substrate. The secondary reservoir 112 can have a reserve capacity to hold a volume of the aerosol generating substrate sufficient for 1-10 inhalations required during operation of the aerosol generating device 100.

[0101] In one or more embodiments, the aerosol generating substrate flows from the primary reservoir 110 to the secondary reservoir 112, when the aerosol generating device 100 is oriented in an angular position ranging from 0 degrees to 90 degrees.

[0102] As can be appreciated, the proposed cartridge 106 includes a primary reservoir 110 and a secondary reservoir 112 to reduce oversaturation of the capillary material 122 andreduce leakage of the aerosol generating substrate, since the capillary material 122 is in direct contact with the secondary reservoir 112 and not with the primary reservoir 110.

[0103] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.ADVANTAGES OF THE INVENTION

[0104] The present invention provides a simple, compact and portable aerosol generating device with an improved cartridge to reduce oversaturation of a capillary material.

[0105] The present invention provides an improved design of a cartridge which improves the volumetric efficiency of the aerosol generating device by preventing liquid leakage due to the oversaturation of the capillary material.

[0106] The present invention provides an improved design of a cartridge which improves the user experience when using the aerosol generating device by preventing the leakage of the aerosol generating liquid into an airflow path and reaching the user’s mouth end.

[0107] The present invention provides an improved design of a cartridge which ensures reliable delivery of Total Particulate Matter (TPM) by preventing leakage of the aerosol generating substrate into airflow path and blockage in the airflow path caused by oversaturation of the capillary material.

[0108] The present invention provides an aerosol generating device with an improved cartridge design that improve the energy efficiency of the aerosol generating device by reducing the power requirement to generate the desired TPM which otherwise would demand excess power for the oversaturated capillary material.

[0109] The present invention provides an aerosol generating device that is cost- effective.

Claims

We Claim:

1. An aerosol generating device (100) comprising: a cartridge (106) comprising a storage chamber (108) and an atomizer (120); wherein the storage chamber (108) comprising a primary reservoir (110), a secondary reservoir (112) and at least one channel (217, 116), the primary reservoir (110) is configured to store an aerosol generating substrate and the at least one channel (217, 116) is defined between the primary reservoir (110) and the secondary reservoir (112) to convey the aerosol generating substrate from the primary reservoir (110) to the secondary reservoir (112); wherein when a first end of the aerosol generating device (100) is oriented in an angular position above 0 degree to 90 degrees with respect to a horizontal plane (HH), a fluid communication between the primary reservoir (110) and the secondary reservoir (112) is established; and thereafter a fluid communication between the secondary reservoir (112) and a capillary material (122) of the atomizer (120) is established in a direction substantially orthogonal to a longitudinal axis (C-C) of the aerosol generating device (100).

2. The aerosol generating device (100) as claimed in claim 1, wherein the first end of the aerosol generating device (100) is a mouthpiece end of the aerosol generating device (100) and a second end of the aerosol generating device (100) is a charging end of the aerosol generating device (100).

3. The aerosol generating device (100) as claimed in claim 1, wherein when the first end of the aerosol generating device (100) is oriented in the angular position above 0 degree to 90 degrees with respect to the horizontal plane (HH), the fluid communication between the primary reservoir (110) and the secondary reservoir (112) is established and the aerosol generating substrate flows from the primary reservoir (110) to the secondary reservoir (112).

4. The aerosol generating device (100) as claimed in claim 1, wherein the secondary reservoir (112) has a reserve capacity to hold a volume of the aerosol generating substrate sufficient for 1 to 10 inhalations required during operation of the aerosol generating device (100).

5. The aerosol generating device (100) as claimed in claim 1, wherein when the aerosol generating device (100) is orientated horizontally with respect to the horizontal plane(HH), the fluid communication between the primary reservoir (110) and the secondary reservoir (112) is stopped.

6. The aerosol generating device (100) as claimed in claim 1, wherein the at least one channel (217) comprises a single communication channel (217) configured to directly convey the aerosol generating substrate from the primary reservoir (110) to the secondary reservoir (112).

7. The aerosol generating device (100) as claimed in claim 1, wherein the at least one channel (116) comprises a first peripheral channel (210), a second peripheral channel (211), and a central channel (212), wherein a width of each of the first and second peripheral channels (210, 211) is smaller than a width of the central channel (212), to allow the aerosol generating substrate to enter the first and second peripheral channels (210, 211) descending down with an advancing meniscus, and air in the secondary reservoir (112) to escape through the central channel (212).

8. The aerosol generating device (100) as claimed in claim 1, wherein a volume of the secondary reservoir (112) is smaller than a volume of the primary reservoir (110) to store less amount of aerosol generating substrate.

9. The aerosol generating device (100) as claimed in claim 1, wherein the secondary reservoir (112) comprises an inlet section (208), and an outlet section (209), wherein the inlet section (208) is fluidically coupled to the primary reservoir (110), which inlet section (208) is in an elevated position relative to the horizontal plane (HH), and the outlet section (209) is fluidically coupled with the capillary material (122).

10. The aerosol generating device (100) as claimed in claims 1 and 9, wherein the primary reservoir (110) comprises an outlet section (208), wherein a width of the inlet section (208) of the secondary reservoir (112) is either smaller or equal to a width of the outlet section (208) of the primary reservoir (110): to displace air in the secondary reservoir (112) with the aerosol generating substrate in the primary reservoir (110), in case of absence of the channels (116).

11. The aerosol generating device (100) as claimed in claim 9, wherein the capillary material (122) is in direct contact with the secondary reservoir (112) through a plurality of vents (114), wherein the plurality of vents (114) facilitates the aerosol generating substrate to be seeped into the capillary material (122) for aerosolization.

12. The aerosol generating device (100) as claimed in claim 11, wherein the secondary reservoir (112) comprises a plurality of micro-channels (114A) configured to communicate the aerosol generating substrate from the secondary reservoir (112)towards the plurality of vents (114) and thereafter through the outlet section (209), the aerosol generating substrate is seeped into the capillary material (122).

13. The aerosol generating device (100) as claimed in claim 1, wherein the secondary reservoir (112) comprises an array of bubbles (215) configured between a wall (213) of the secondary reservoir (112), and a wall (214) of the capillary material (122), to enhance uniform absorbance of the aerosol generating substrate by the capillary material (122).

14. The aerosol generating device (100) as claimed in claim 1, comprising a control unit (104) communicably coupled to the atomizer (120), wherein upon detection of airflow by at least one sensor (126), the control unit (104) actuates the atomizer (120) to heatup the aerosol generating substrate to generate the aerosol to be inhaled by the user.

15. The aerosol generating device (100) as claimed in claim 1, wherein the atomizer (120) is positioned horizontally below the secondary reservoir (112) to heat-up the aerosol generating substrate to generate the aerosol.

16. The aerosol generating device (100) as claimed in claim 1, wherein the atomizer (120) comprises the capillary material (122) and at least one heater (124), wherein the capillary material (122) absorbs the aerosol generating substrate to be aerosolized and thereafter the at least one heater (124) having heater pins (202) is configured to heatup the aerosol generating substrate to generate the aerosol.

17. The aerosol generating device (100) as claimed in claims 1 and 16, wherein the cartridge (106) comprises a condensation chamber (118) configured to carry the aerosol generated to a mouthpiece (102) of the aerosol generating device (100).

18. A cartridge (106) for an aerosol generating device (100), the cartridge (106) comprising: a storage chamber (108); and an atomizer (120) comprising a capillary material (122) and at least one heater (124); wherein the storage chamber (108) comprising a primary reservoir (110), a secondary reservoir (112) and at least one channel (217, 116), the primary reservoir (110) is configured to store aerosol generating substrate and the at least one channel (217, 116) is defined between the primary reservoir (110) and the secondary reservoir (112) to convey the aerosol generating substrate from the primary reservoir (110) to the secondary reservoir (112); andwherein the secondary reservoir (112) having an elevated inlet section (208) and the secondary reservoir (112) is positioned horizontally above a first surface of the capillary material (122).

19. The cartridge (106) as claimed in claim 18, wherein the first surface of the capillary material (122) is in direct contact with the secondary reservoir (112) through a plurality of vents (114), wherein the plurality of vents (114) facilitate the aerosol generating substrate to be seeped into the capillary material (122) for aerosolization.

20. The cartridge (106) as claimed in claim 18, wherein the at least one heater (124) is positioned horizontally below a second surface of the capillary material (122).

21. The cartridge (106) as claimed in claim 18, wherein when the cartridge (106) is positioned in the aerosol generating device (100), such that a first end of the aerosol generating device (100) is oriented in an angular position above 0 degree to 90 degrees with respect to a horizontal plane (HH), the aerosol generating substrate flows from the primary reservoir (110) to the secondary reservoir (112) and thereafter the aerosol generating substrate flows from the secondary reservoir (112) to the capillary material (122).

22. The cartridge (106) as claimed in claim 21, wherein the first end of the aerosol generating device (100) is a mouthpiece end of the aerosol generating device (100) and a second end of the aerosol generating device (100) is a charging end of the aerosol generating device (100).

23. The cartridge (106) as claimed in claim 18, wherein the secondary reservoir (112) has a reserve capacity to hold a volume of aerosol generating liquid sufficient for 1 to 10 inhalations required during operation of the aerosol generating device (100).

24. The cartridge (106) as claimed in claim 18, wherein the at least one channel (217) comprises a single communication channel (217) configured to directly convey the aerosol generating substrate from the primary reservoir (110) to the secondary reservoir (112).

25. The cartridge (106) as claimed in claim 18, wherein the at least one channel (116) comprises a first peripheral channel (210), a second peripheral channel (211), and a central channel (212), wherein a width of each of the first and second peripheral channels (210, 211) is smaller than a width of the central channel (212), to allow the aerosol generating substrate to enter the first and second peripheral channels (210, 211) descending down with an advancing meniscus, and air in the secondary reservoir (112) to escape through the central channel (212).

26. The cartridge (106) as claimed in claim 18, wherein a volume of the secondary reservoir (112) is smaller than a volume of the primary reservoir (110) to store less amount of aerosol generating substrate.

27. The cartridge (106) as claimed in claim 18, wherein the secondary reservoir (112) comprises the elevated inlet section (208), and an outlet section (209), wherein the elevated inlet section (208) is in an elevated position relative to the horizontal plane (HH), which elevated inlet section (208) is fluidically coupled to the primary reservoir (110), and the outlet section (209) is fluidically coupled with the capillary material (122).

28. The cartridge (106) as claimed in claims 18 and 27, wherein the primary reservoir (110) comprises an outlet section (208), wherein a width of the inlet section (208) of the secondary reservoir (112) is either smaller or equal to a width of the outlet section (208) of the primary reservoir (110): to displace air in the secondary reservoir (112) with the aerosol generating substrate in the primary reservoir (110), in case of absence of the channels (116).

29. The cartridge (106) as claimed in claims 18 and 20, wherein the capillary material (122) absorbs the aerosol generating substrate to be aerosolized and thereafter the at least one heater (124) having heater pins (202) is configured to heat-up the aerosol generating substrate to generate the aerosol.

30. The cartridge (106) as claimed in claims 18 and 29, comprising a condensation chamber (118) to carry the aerosol generated to a mouthpiece (102) of the aerosol generating device (100).

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