CARTOMISER

Abstract

A cartomizer for an aerosol-generating device, the cartomizer including an aerosol-generating device interface configured to interface with an aerosol-generating device; and a vaporizer for generating aerosol from aerosol-generating material held in a reservoir of the cartomizer. The aerosol-generating device interface further includes one or more through holes, each through hole sized so as to receive a power-supply pin of the aerosol generating device, and the vaporizer is arranged in the cartridge such that the vaporizer is adjacent the one or more through holes so that, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device electrically couple to the vaporizer. Also described is an aerosol-generating device including the abovementioned cartomizer.

Description

RELATED APPLICATIONS

The present application is a National Phase entry of PCT Application No. PCT/GB2022/053342 filed Dec. 21, 2022, which claims priority to GB Application No. 2118793.5 filed Dec. 22, 2021 and GB Application No. 2206239.2 filed Apr. 28, 2022, each of which is hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a cartomizer for an aerosol-generating device such as a vaping device.

BACKGROUND

A vaping device may comprise a main housing which contains a power source and control electronics and a replaceable or refillable cartomizer which plugs in to the top end of the main housing.

A cartomizer is used to heat a liquid to produce an aerosol. The liquid may be stored in a reservoir of the cartomizer and a vaporizer with a combined wicking and heating function may be used to wick liquid from the reservoir and to heat the wicked liquid to produce the aerosol, which exits via a mouthpiece at the top end of the cartomizer. The vaporizer may be powered by the power source (e.g. a battery) of the main housing via electrical connections which are made across the interface between the top end of the main housing and the bottom end of the cartomizer. When the liquid in the reservoir has been used up, the cartomizer may be refilled by refilling the reservoir of the cartomizer, and this typically involves unplugging the cartomizer from the main housing, filling the reservoir with new liquid, and then plugging the cartomizer back in to the top end of the main housing. Alternatively, the old (empty) cartomizer may be unplugged and be disposed of or recycled, and a new (full) cartomizer may be plugged in to the main housing.

In either scenario, it is likely the main housing will be used with multiple cartomizers (even in the case of a refillable cartomizer, cross contamination of liquids or fouling of the vaporizer may lead to users replacing these refillable cartomizers after a period of use). Accordingly, there can be a high level of material waste when cartomizers are disposed of or unable to be recycled. Various approaches are described which seek to help address some of these issues.

SUMMARY

According to a first aspect of certain embodiments there is provided a cartomizer for an aerosol-generating device, the cartomizer including an aerosol-generating device interface configured to interface with an aerosol-generating device; and a vaporizer for generating aerosol from aerosol-generating material held in a reservoir of the cartomizer. The aerosol-generating device interface further comprises one or more through holes, each through hole sized so as to receive a power-supply pin of the aerosol generating device. The vaporizer is arranged in the cartridge such that the vaporizer is adjacent the one or more through holes so that, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device electrically couple to the vaporizer.

According to a second aspect of certain embodiments there is provided an aerosol-generating device comprising a cartomizer according to the first aspect.

It will be appreciated that features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to, and may be combined with, embodiments of the invention according to other aspects of the invention as appropriate, and not just in the specific combinations described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which:

FIG. 1 is a perspective view of a vaping device.

FIG. 2 is an exploded perspective view of an example cartomizer suitable for use in the vaping device of FIG. 1.

FIGS. 3 and 4 are overhead and underneath perspective views of the example cartomizer, with some components omitted for clarity of depiction.

FIGS. 5 and 6 are vertical sectional and perspective sectional views of the example cartomizer.

FIGS. 7A, 7B and 7C are respectively side, upper perspective and lower perspective views of an upper clamping unit of the example cartomizer.

FIGS. 8A, 8B and 8C are respectively an upper perspective view (with the block shown as being transparent, so as to illustrate some hidden features), an upper perspective view (without transparency) and a lower perspective view of a lower support unit of the example cartomizer.

FIG. 9 is an exploded perspective view of an embodiment of a cartomizer in accordance with the present disclosure suitable for use in the vaping device of FIG. 1.

FIGS. 10A, 10B and 10C are respectively a vertical sectional view, an enlarged sectional view portion and a side view of the embodiment of the cartomizer.

FIG. 11 is a diagrammatic depiction of some dimensions of components of a variant of the embodiment of the cartomizer.

FIG. 12 is a diagrammatic depiction of air flow paths in a variant of the embodiment of the cartomizer.

FIG. 13 is an exploded perspective view of an embodiment of a second embodiment of a cartomizer in accordance with the present disclosure, one that is suitable for use in a vaping device similar to the vaping device of FIG. 1.

FIG. 14 is a perspective view of a microfluidic vaporizer suitable for use in the second embodiment of the cartomizer, in accordance with a first example.

FIG. 15 is a perspective view of a microfluidic vaporizer suitable for use in the second embodiment of the cartomizer, in accordance with a second example.

FIG. 16 is a perspective view of a microfluidic vaporizer, in accordance with a third example.

DETAILED DESCRIPTION

In some embodiments, the aerosol-generating device is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating liquid is not a requirement.

In some embodiments, the aerosol-generating device is a hybrid system to generate aerosol using a combination of aerosol-generating materials. Each of the aerosol-generating materials may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

In some embodiments, the or each aerosol-generating material may comprise one or more active constituents, one or more flavors, one or more aerosol-former materials, and/or one or more other functional materials.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

FIG. 1 shows a vaping device 1 comprising a main housing 2 and a cartomizer 3. The main housing 2 is in the form of a power pack because it contains a rechargeable battery, as well as control electronics. The cartomizer 3 plugs in to a top end 21 of the main housing 2 and may be unplugged therefrom when the cartomizer 3 needs to be re-filled with liquid or replaced with a new cartomizer upon depletion of the liquid in the original cartomizer. This plugging and unplugging occurs along a longitudinal axis L1 of the vaping device 1.

FIGS. 2 to 8 show an example of a first type of cartomizer 3A suitable for use in the vaping device of FIG. 1. From the exploded view of FIG. 2, it may be seen that the cartomizer 3A is assembled from a stack of components: an outer housing 4, an upper clamping unit 5, a planar vaporizer 6, a lower support unit 7 and an end cap 8.

In the exploded views of FIGS. 3 and 4, the planar vaporizer 6 and the end cap 8 are omitted to improve the clarity of depiction of the components that are shown.

All of the components are shown assembled together in FIGS. 5 and 6.

The cartomizer 3A has a top end 31 and a bottom end 32 which are spaced apart along the longitudinal axis L1, which is the longitudinal axis of the cartomizer as well as being the longitudinal axis of the vaping device 1. The top end 31 of the cartomizer defines a mouthpiece end of the vaping device, and the mouthpiece 33 includes a mouthpiece orifice 41 which is provided at the top end 42 of the outer housing 4 in the center of a top face 43.

The outer housing 4 includes a circumferential side wall 44 which leads down from the top end 42 to a bottom end 45 of the outer housing 4 and which defines an internal reservoir 46. Prior to assembly of the cartomizer 3A, the bottom end 45 of the outer housing is open, but upon assembly the bottom end 45 is closed by a plug formed by the upper clamping unit 5 and the lower support unit 7 which are stacked together with the planar vaporizer 6 sandwiched therebetween.

The upper clamping unit 5 is an intermediate component of the stack of components and is shown in detail in FIGS. 7A to 7C. The upper clamping unit 5 includes a foot 51 in the form of a block and an upwardly extending air tube 52. On each side of the air tube 52, the foot 51 includes a well 53 which descends from a flat top surface 54 to a flat bottom surface 55 of the foot 51. At the bottom surface 55, each well 53 is open (see FIG. 7C) and, specifically, opens into an elongate recess 56 formed in the bottom surface 55, with the depth of the recess 56 matching the thickness of the planar vaporizer 6. The foot 51 includes two circumferential capillary breaks 57 for reducing or preventing leakage of liquid from the reservoir 46. The air tube 52 extends up from the bottom of the wells 53 and an internal air passage 58 of the air tube 52 has a bottom end 581 at a central portion of the recess 56 and a top end 582 at the top of the air tube 52. From FIG. 5, it may be seen that the top of the air tube 52 fits onto the bottom end 471 of an air tube 47 which extends downwards from the mouthpiece orifice 41 in the top face 43 of the outer housing 4. Thus, the air passage 58 is connected to an air passage 48 of the air tube 47.

The lower support unit 7 is shown in detail in FIGS. 8A to 8C and is in the form of a block having a flat top surface 71 and a flat bottom surface 72. A central air passage 73 extends upwardly from the bottom surface 72 to the top surface 71. On each side of the air passage 73, the block of the lower support unit 7 includes a through hole 74 which is shown empty in FIGS. 8A to 8C, but which in practice (see, for example, FIGS. 5 and 6) includes a co-molded contact pad 75 in the form of a pin. Each contact pad 75 is a press fit in its respective through hole 74. Each contact pad 75 provides an electrical connection path from the bottom surface 72 to a respective end portion of the planar vaporizer 6 when the planar vaporizer 6 is sandwiched between the top surface 71 of the lower support unit 7 and the recess 56 of the bottom surface 55 of the upper clamping unit 5 (see, for example, FIG. 5).

The block of the lower support unit 7 includes two circumferential capillary breaks 76 for reducing or preventing leakage of liquid from the reservoir 46. The foot 51 of the upper clamping unit 5 and the lower support unit 7 (with its block-like form) combine together to form a plug which seals the bottom end of the reservoir 46 (see FIG. 5) and in total four circumferential capillary breaks 57, 76 are present for reducing or preventing leakage of liquid from the reservoir 46.

When the components of the cartomizer 3A have been assembled together, an overall air passage 34 exists from the bottom end 32 to the top end 31 of the cartomizer 3A and it is formed by the air passage 73 leading to the air passage 58 which, in turn, leads to the air passage 48 and the mouthpiece orifice 41. Where the air passage 73 meets the air passage 58, the air flow bifurcates as it passes around the side edges of the planar vaporizer 6.

The version of the vaporizer 6 used in the cartomizer 3A is planar and is in the form of a plate and is elongate in the direction of a longitudinal axis. The planar vaporizer 6 has the shape of a strip and has parallel sides. The planar vaporizer 6 has parallel upper and lower major (planar) surfaces and parallel side surfaces and parallel end surfaces. The length of the planar vaporizer 6 is 10 mm. Its width is 1 mm, and its thickness is 0.12 mm. The planar vaporizer has a resistance of 0.5 to 0.6 Ohms. The small size of the planar vaporizer 6 enables it to take less time to reach a desired operating temperature compared with a large-size vaporizer, and less energy is used in doing so. The small size of the planar vaporizer 6 enables the overall size of the cartomizer to be reduced and the overall mass of the components of the cartomizer to be reduced.

Along the longitudinal axis, the vaporizer 6 has a central portion 67 and first and second end portions 68, 69 (shown in FIG. 2). When the vaporizer is in situ in the cartomizer, the central portion 67 is positioned in the air passage 34 as is shown in, for example, FIGS. 5 and 6. The central portion 67 extends across the top end of the air passage 73 of the lower support unit 7, and across the bottom end 581 of the air passage 58 of the upper clamping unit 5. The end portions 68, 69 are clamped between the upper clamping unit 5 and the lower support unit 4.

The end portions 68, 69 are connected in to a heater current circuit from below, by virtue of being seated on the contact pads 75. The end portions 68, 69 are also configured to receive liquid from the reservoir 46 from above, by virtue of being positioned beneath the wells 53 of the upper clamping unit 5. Relative to the longitudinal axis L1, the wells 53 are inboard of the contact pads 75, as may be seen in FIGS. 5 and 6.

The vaporizer 6 is made of a porous and electrically conductive material. For example, it is formed from sintered metal fibers having a mean diameter of 12 microns or less. The material may be a 316 L stainless steel non-woven sintered mesh. The density of fibers may be between 100 g/m² and 500 g/m². The mesh thickness may be 0.10 mm to 1 mm. The sintering temperature range may be 850° C. to 1400° C. under a weighted mass of between 0.5 kg and 25 kg. A vacuum and an inert gas such as nitrogen may be used, with a cycle time ranging from 2 hours to 16 hours. The resultant mesh is then compressed to the required thickness using a powered press. The mesh is then cut through to the required shape using mechanical cutting or laser cutting. Other metals may be used, such as Hastalloy or nickel chrome.

When the planar vaporizer 6 is clamped in position inside the cartomizer 3A, the longitudinal axis L2 of the planar vaporizer 6 is transverse to the longitudinal axis L1 of the cartomizer 3A. The plane of the plate-like planar vaporizer 6 is perpendicular to the longitudinal axis L1. The end portions 68, 69 of the vaporizer sit flat on top of the lower support unit 7 on the top surface 71 thereof. The thickness dimension of the planar vaporizer is typically small (e.g. the thickness of 0.12 mm already mentioned) and the orientation of the planar vaporizer is such that the planar vaporizer barely contributes to the overall height of the components making up the cartomizer compared with a cartomizer in which the planar vaporizer is upright (with the planar vaporizer extending in the longitudinal direction of the cartomizer). Also, the liquid storage volume of the reservoir 46 does not have to be reduced as a result of the planar vaporizer projecting up into the reservoir.

Because the planar vaporizer 6 is seated in the recess 56, it may be considered that the presence of the planar vaporizer does not itself contribute any height at all to the overall height of the stack of internal components of the cartomizer (the lower support unit, the vaporizer and the upper clamping unit).

The top end 21 of the main housing 2 includes an air inlet hole 22 on each side of the main housing 2 (with one of the two air inlet holes 22 being visible in FIG. 1). Air can enter the air inlet holes 22 and flow transversely inwards to the longitudinal axis L1 so as to enter the bottom end of the air passage 73 of the lower support unit 7 and to start to flow in the direction of the longitudinal axis L1 towards the mouthpiece 33. The main housing 2 has two power supply pins (not shown) which make contact with the bottom ends of the contact pads 75. The top ends of the contact pads 75 are in electrical contact with the end portions 68, 69 of the planar vaporizer 6. The end portions 68, 69 of the planar vaporizer 6 are exposed at the bottom of the wells 53 to the liquid in the reservoir 46, and the wicking characteristic of the porous planar vaporizer 6 transports a supply of the liquid to the central portion 67 of the planar vaporizer 6 which is exposed to the air flow along the air passage 34 (the air passage 73, the air passage 58 and the air passage 48). The current supplied by the contact pads 75 from the power source (e.g. the battery) of the main housing 2 causes the central portion 67 of the planar vaporizer 6 to heat up. The wicked liquid in the planar vaporizer 6 at the central portion 67 thereof becomes an aerosol and becomes entrained in the air flow along the air passage 34. The aerosol travels up the air passage 34 and out of the mouthpiece orifice 41 and is breathed in by the user of the vaping device 1.

As shown in FIG. 2, the cartomizer 3A includes an end cap 8 at its bottom end. The end cap 8 is made of metal and serves to assist with retaining the cartomizer 3A in the main housing 2 when the cartomizer 3A is plugged in to the top end of the main housing 2, because the main housing 2 is provided with magnets which are attracted to the metal of the end cap 8. The end cap 8 has a bottom wall 81 with a central opening 82 (see FIG. 5) which conforms to the shape of the raised central portion of the bottom surface 72 of the lower support unit 7. The end cap 8 also has a circumferential side wall 83 which has two opposed cut-outs 84 which latch onto corresponding projections 49 on the outer surface of the bottom end of the side wall 44 of the outer housing 4, so that the end cap 8 has a snap-fit type connection onto the bottom end of the outer housing 4. When the end cap 8 has been fitted in position, it holds in position the lower support unit 7, the upper clamping unit 5 and the planar vaporizer 6 which is sandwiched between the lower support unit 7 and the upper clamping unit 5.

It would be possible to omit the end cap 8 (in order to reduce the component count) by arranging for the lower support unit 7 to form a snap-fit type connection with the bottom end of the side wall 44 of the outer housing 4. Additionally, the cartomizer 3A could be provided with indentations which engage with projections at the top end 21 of the main housing 2, so that a releasable connection is provided between the cartomizer and the main housing.

In any case, the cartomizer 3A is provided with what may more generally be referred to as a device interface which is a part of the cartomizer 3A that interfaces with the main housing 2 (or aerosol-generating device). In the above example, the device interface may include the metal cap 8 including the bottom wall 81 and circumferential side wall 83 and/or the lower support unit 7 including the bottom surface 72. More generally, the device interface of the cartomizer 3A may encompass any part or parts of the cartomizer 3A that contact, abut, engage or otherwise couple to the main housing 2.

In accordance with aspects of the present disclosure, FIGS. 9 to 12 show an embodiment of a cartomizer 3B suitable for use in the vaping device of FIG. 1. The cartomizer 3B is generally the same as the cartomizer 3A; however, as will be discussed below, the cartomizer 3B is configured in such a way as to provide an electrical contact between the vaporizer 6 and the battery in the main housing 2 of the vaping device 1 which reduces the number of components, particularly in the cartomizer 3B itself. In this regard, noting that the vaping device 1 is configured such that multiple cartomizers 3, 3A, 3B are to be used with the main housing 2 (e.g., when the cartomizer is depleted), reducing the number of components in the cartomizer 3B can be beneficial for reducing waste when the cartomizer is disposed of and/or of reducing costs when the cartomizer is produced.

The cartomizer 3B is substantially the same as the example cartomizer 3A described above. Like components are represented with like reference signs, and a detailed description thereof will be omitted for conciseness; Only the differences relative thereto will be discussed herein.

The cartomizer 3B omits the two contact pads 75 of the cartomizer 3A. Instead, in the cartomizer 3B, the through holes 74 of the of the lower support unit 7 are designed to receive power-supply pins 23 of the main housing 2 which are longer than the power-supply pins of the main housing that would be used with the cartomizer 3A. The additional length corresponds approximately to the height of the lower support unit 7. Hence, when the cartomizer 3A is engaged with the main housing 2, the power-supply pins 23 protruding from a part of the main housing 2, enter the cartomizer 3B and pass through the through holes 74. The power-supply pins are spring-loaded (also known as pogo pins). However, in other implementations, the power-supply pins may not be spring-loaded.

In accordance with the principles of the present disclosure, the device interface comprises one or more through holes (e.g., the two through holes 74 through the lower support unit 7) which are configured to permit power-supply pins 23 of the main housing 2 to be received in the one or more through holes (as shown in FIG. 3B, this may encompass one power-supply pin 23 received in a first through hole and another power-supply pin 23 received in a second through hole). That is to say, the through holes 74 form part of the device interface that allow the power-supply pins 23 of the main housing 2 to interface with the cartridge 3B. As shown in FIGS. 10A and 10B, the top end 231 of each power-supply pin 23 is shown as touching the undersurface (the lower surface 62) of a respective one of the end portions 68, 69 of the planar vaporizer 6 so as to form an electrical connection therewith. Accordingly, the power supply pins 23 interface with/contact the planar vaporizer 6 of the cartomizer 3B to form an electric circuit therewith. It should also be appreciated that the planar vaporizer 6 is arranged in the cartridge 3B such that the vaporizer is adjacent the through holes 74 (specifically, the end portions 68, 69 each spatially overlap a respective through hole 74).

There is also shown an annular gap between the top end 231 and the side wall of the through hole 74. This annular gap may be omitted if, for example, the through hole 74 is given a taper and the top end 231 of the power-supply pin 23 is given a corresponding taper so that, when the power-supply pin 23 is fully inserted, the top end 231 seals against the side wall of the through hole 74.

This can assist with preventing leakage of liquid down the two through holes 74. In relation to the tapering of each through hole 74, it involves the hole having a slightly wider width at the bottom surface 72 of the lower support unit 7 and a slightly narrower width at the top surface 71 of the lower support unit 7. In other implementations, additional or alternative mechanisms may be employed to help reduce or prevent leakage, such as a flexible member made, e.g., from silicone (such as an O-ring) against which the power-supply pin 23 (or top end 231 thereof) forms a corresponding seal. However, more generally, each through hole 74 is sized and/or shaped to receive a corresponding power-supply pin 23 (or the top end 231 thereof) from the main housing 2.

Therefore, in accordance with the principles of the present disclosure, the planar vaporizer 6 is arranged such that the planar vaporizer 6 is adjacent the one or more through holes 74 of the lower support unit 7 so that, when the cartomizer 3B is engaged with the main housing 2 (or more generally, the aerosol-generating device), the respective power-supply pins 23 of the main housing 2 electrically couple to the planar vaporizer 6.

FIG. 11 is a diagrammatic depiction of some dimensions of components of a variant of the cartomizer 3B. In this variant, the height of the upper clamping unit 5 and the height of the lower support unit 7 have been reduced, compared to the cartomizer 3B. Also, the end cap 8 of cartomizer 3B has been omitted. In FIG. 11, a friction fit and/or an adhesive and/or a weld may be used to secure the upper clamping unit 5 and the lower support unit 7 in the bottom end 45 of the outer housing 4.

FIG. 12 is a diagrammatic depiction of the air flow paths in said variant of the cartomizer 3B. The arrows A1 represent air flow that has entered the vaping device 1 through the air inlet holes 22 of the main housing 2 and is travelling transversely towards the central (longitudinal) axis of the vaping device. The arrows A2 represent air flow that is turning from the horizontal to the vertical ready to enter the air passage 73 of the lower support unit 7. The arrow A3 represents air flow that is approaching the lower surface 62 of the planar vaporizer 6 and is getting ready to bifurcate ready to pass around the sides of the planar vaporizer. The arrow A4 represents air flow that has entrained the aerosol produced by the heating of the planar vaporizer 6 by the electric current passing therealong.

In the implementations described above, the orientation of the vaporizer means that the contribution of the vaporizer to the height of the components making up the cartomizer is reduced compared with a cartomizer in which the vaporizer is upright (with the elongate vaporizer extending in the longitudinal direction of the cartomizer).

The height of the lower support unit and the vaporizer is less than for a lower support unit which has an elongate vaporizer which extends upright from (is perpendicular to) the lower support unit.

In relation to the reservoir which is positioned above the vaporizer, the liquid storage volume of the reservoir does not have to be reduced as a result of the vaporizer projecting up into the reservoir.

Corrugations of the central portion of the vaporizer increase an effective length of the central portion that is exposed to an air flow of the air passage, and this may provide an increased rate of evaporation from the central portion. When the central portion is rotated (twisted), this may reduce the air flow resistance imparted by the presence of the central portion in the air passage, whilst still maintaining the surface area of evaporation provided by the central portion.

This arrangement of the upper clamping unit so it sits on top of the lower support unit may securely hold the (planar) vaporizer in position, and the orientation of the vaporizer minimises the contribution of the vaporizer to the overall height of the stack of components (lower support unit, vaporizer and upper clamping unit).

The provision of the recess may assist with assembling the components of the cartomizer, because the recesss provides a destination location in which the vaporizer is to be positioned. If the depth of the recess is the same as or greater than the thickness of the end portions of the vaporizer, the vaporizer does not itself contribute any height to the overall height of the stack of components (lower support unit, vaporizer and upper clamping unit).

The plug (formed by the lower support unit and the upper clamping unit) which closes the bottom end of the outer housing also serves a second purpose of closing the reservoir which is defined inside the outer housing.

The first and second through holes of the lower support unit enable power supply pins, of the main housing, when the cartomizer is plugged into the main housing, to directly contact the end portions of the vaporizer.

The tapering of the holes may enable the holes to seal against correspondingly tapered power supply pins, which may help with reducing leakage of liquid from the reservoir of the cartomizer.

The co-molded contact pads may be used as an alternative to the through holes. The co-molded contact pads may provide a more-secure means of reducing leakage of liquid from the reservoir of the cartomizer, compared with sealing the tapered through holes with tapered power supply pins which are repeatedly inserted into and removed from the tapered through holes as the cartomizer is plugged into and unplugged from the main housing.

By positioning the wells inboard of the first and second through holes of the lower support unit or the first and second co-molded contact pads of the lower support unit, it is ensured that, in use, the reservoir liquid is wicked along heated portions of the vaporizer as the wicked liquid migrates to the central portion of the vaporizer.

A small size of the vaporizer enables it to take less time to reach a desired operating temperature compared with a large-size vaporizer, and less energy is used in doing so. A small size of the vaporizer enables the overall size of the cartomizer to be reduced and the overall mass of the components of the cartomizer to be reduced.

By having a narrow central part instead of a uniform width along the length of a planar vaporizer, the rate of aerosol generation may be increased, and the aerosol particle size may be reduced, for example to an average of about 0.5 microns.

By using the lower support unit to provide the bottom surface of the cartomizer, the component count of the cartomizer may be reduced. For example, there is no need to provide a bottom end cap (e.g. a metal end cap) which clips onto the other components at the bottom end of the cartomizer. If the number of components of the cartomizer is reduced, the cost of the cartomizer is reduced.

FIG. 13 is an exploded perspective view of a further cartomizer 3C in accordance with aspects of the present disclosure. The cartomizer 3C is suitable for use in a vaping device similar to the vaping device of FIG. 1. The differences relative to the cartomizer 3B will be discussed in more detail below.

In cartomizer 3C, the vaporizer 6′ is different to the vaporizer 6 described above. For example, the vaporizer 6 described above is made of a porous and electrically conductive material. However, the vaporizer 6′ in cartomizer 3C is a microfluidic vaporizer 6′.

The microfluidic vaporizer 6′ is shown, highly schematically, in FIG. 14. The microfluidic vaporizer 6′ is formed from a non-conductive substrate material 162 (such as silicon dioxide) and an electrically resistive layer 164 provided on a surface of the substrate material 162. The electrically resistive layer 164 may be formed from any suitable electrically conductive material, for example a metal or metal alloy, such as nickel chromium (NiCr) or titanium. The electrically resistive layer 164 is capable of heating when a suitable electrical current is passed through the electrically resistive layer 164 (for example, as supplied by main housing 2).

The microfluidic vaporizer 6′ comprises three sections or parts; a central part 167 and two end parts 168, 169 adjacent the central part 167. As seen in FIG. 14, microfluidic vaporizer 6′ also includes a plurality of capillary tubes 166 in the central part 167. The capillary tubes 166 extend through the microfluidic vaporizer 6′. More specifically, the capillary tubes 166 extend from a first surface of the substrate material 162 opposite the surface on which the electrically resistive layer 164 is disposed (not shown in FIG. 14), through the substrate material 162 and through the electrically resistive layer 164. That is, the capillary tubes 166 extend from a first side of the vaporizer 6′, through the vaporizer 6′ and to a second side of the vaporizer 6′. The side of the substrate material 162 opposite the electrically resistive layer 164 is arranged in the cartomizer 3C so as to receive fluid from the reservoir 46 (explained in more detail below). The capillary tubes 166 are configured so as to facilitate the transfer of liquid aerosol-generating material from one side of the substrate material 162 to the electrically resistive layer 164 via capillary action/capillary forces. Hence, the capillary tubes 166 provide liquid aerosol-generating material to the electrically resistive layer 164 which, when energised, vaporizes the liquid aerosol-generating material.

The capillary tubes 166 are formed in the vaporizer 6′ via a manufacturing process. That is to say, the capillary tubes 166 do not naturally exist in the substrate material 162, e.g., as a result of the selection of the substrate material, such as a porous material, but rather, the capillary tubes 166 are formed in the substrate material 162 and/or electrically resistive layer 164 through a suitable process. A suitable process is laser drilling, however any other suitable technique may be employed in order to generate the capillary tubes 166. The capillary tubes 166 may have a diameter on the order to tens of microns, e.g., 10 μm to 100 μm. However, the exact size of the capillary tubes 166 may depend on the properties of the liquid aerosol-generating material (e.g., viscosity) that is intended to pass along the capillary tubes 166 (that is, the properties of the liquid in the reservoir 46 of the cartomizer 3C). In addition, because the capillary tubes 166 are engineered in the vaporizer 6′, the capillary tubes 166 follow a substantially linear (straight) path from one side of the vaporizer 6′ to the other side of the vaporizer 6′. Put another way, the engineered capillary tubes 166 span the shortest distance between points on different sides of the vaporizer 6′. Providing engineered capillary tubes 166 enables not only more flexibility in the choice of material to use as the substrate material 162 but also allows for the capillary tubes 166 to be engineered to provide optimal capillary action for the specific liquid aerosol-generating material to be used with the vaporizer 6′.

Turning back to FIG. 13, the microfluidic vaporizer 6′ is located in a similar position between a lower support unit 7′ and upper clamping unit 5′ as discussed in respect of the vaporizer 6 in cartomizer 3B. More specifically, the microfluidic vaporizer 6′ is orientated such that the electrically resistive layer 164 faces towards the lower support unit 7′ while the opposite side of the substrate material 162 (i.e., the lower surface not shown in FIG. 14) is orientated towards the upper clamping unit 5′.

The upper clamping unit 5′ and lower support unit 7′ are substantially similar to their counterparts described in cartomizer 3B. However, owing in part to the differences in the vaporizers 6, 6′, the airflow is different in cartomizer 3C as compared to cartomizer 3B. In particular, with the vaporizer 6 of cartomizer 3B, liquid is able to wick in the direction along the longitudinal axis of the vaporizer 6 towards the central portion 67 of the vaporizer 6 where it is subsequently vaporized and is entrained in airflow flowing through the central air passage 73 and along the air tube 52.

Conversely, the vaporizer 6′ is less adapt at transporting liquid along the longitudinal axis of the vaporizer 6′; predominantly because the capillary tubes 166 extend in a relatively vertical orientation. Accordingly, in the example cartomizer 3B shown in FIG. 13, the upper clamping unit 5′ is provided with a central well/opening (not shown in FIG. 13) that substantially aligns with a central portion of the vaporizer 6′. Liquid held in the reservoir 46 is able to flow to the central portion of the vaporizer 6′ (and more specifically the capillary tubes 166) via the central opening of the upper clamping unit 5′. Instead of an airflow channel that passes through the center of the upper clamping unit 5′, an airflow channel 52′ is provided by an indentation in the foot 51 of the upper clamping unit 5′.

In order to complete the airflow pathway, the lower support unit 7′ is provided with a substantially larger opening forming the central air passage 73′. Compared to FIG. 9, the central air passage 73′ is show as being square and has a width dimension substantially larger than the width dimension of the vaporizer 6′. That is to say, the vaporizer 6′ (or a central portion thereof) extends across a part of the opening of air passage 73′ but the air passage 73′ extends either side of the vaporizer 6′. When the cartomizer 3C is assembled, the indentation overlaps one side of the opening of air passage 73′ such that the indentation allows for air to pass through the air passage 73′ and along the airflow channel 52′. Accordingly, air that enters the lower support unit 7′ and passes along air passage 73′ is able to pass across the surface of the vaporizer 6′, thereby entraining vaporized liquid in the airflow, and subsequently pass around a side of the vaporizer 6′ and up through the airflow channel 52′.

Additionally, the outer housing 4′ is correspondingly adapted to accommodate the different air flow. In this regard, outer housing 4 of cartomizer 3B is configured to couple to the central air channel 52 of the upper clamping unit 5. Conversely, in cartomizer 3C, the outer housing 4′ is provided with a side channel (not shown) providing a tubular passageway extending from the bottom end 45 of the housing 4′ to the mouthpiece orifice 41. The end of the side channel at the bottom end 45 of housing 4′ is configured to engage with the indentation of the foot 51 of the upper clamping unit 5′. That is, a wall of the side channel of housing 4′ may be pressed into engagement with the upper clamping unit 5′ at the location of the indentation to provide a fluid tight coupling between the two. In some implementations, the side channel may comprise a wall which extends along, or part way along, the indentation when the housing 4′ and upper clamping unit 5′ are coupled together, such that the indentation/foot 51 surrounds the wall of the side channel. The coupling between the housing 4′ and upper clamping unit 5′ is configured to be fluid tight, such that liquid from the reservoir 46 may not leak into the air channel 52′/side channel of housing 4′, while air/aerosol from the air channel 52′/side channel of housing 4′ is unable to pass into the reservoir 46. Any suitable coupling may be employed.

It should be appreciated that upper clamping unit 5′ shown in FIG. 13 comprises one indentation. In this example, the opposite side of the opening of air passage 73′ is blocked off by the upper clamping unit 5′, such that air is only permitted to flow past one side of the vaporizer 6′. However, in other implementations, a second indentation may be provided on the opposite side of the upper clamping unit 5′, forming a corresponding air channel, Subsequently, air may be permitted to flow past both sides of the vaporizer 6′ in such implementations.

Further, as seen in FIG. 13, the vaporizer 6′ is arranged such that it is adjacent the through holes 74 in lower support unit 7′. More specifically, the vaporizer 6′ extends over/overlaps the through holes 74. With reference to FIG. 11, the vaporizer 6′ in this example has a longitudinal extent (i.e., an extent in the longitudinal direction) of approximately 9 to 10 mm. However, in other implementations, the vaporizer 6′ may have a longitudinal extent that is equal to or greater than 4 mm, equal to or greater than 3 mm or equal to or greater than 2 mm. Both aerosol generation performance of the vaporizer 6′ and the separation distance of the power-supply pins 23 may dictate the overall size/footprint of the vaporizer 6′.

As should be appreciated with reference to FIG. 14, the two end portions 168 and 169 of the vaporizer 6′ each overlap a respective through hole 74. The end portions 168 and 169 do not comprise any capillary tubes 166 but are provided with the electrically resistive layer 164. Accordingly, much like with cartomizer 3B, it should be understood that power-supply pins 23 (and top ends 231) of the main housing 2 are capable of extending through the through holes 74 and contacting respective ends of the vaporizer 6′ when the cartomizer 3C is coupled to the main housing 2. In this way, similarly, an electrical circuit is capable of being formed with the rechargeable battery of the main housing 2. Electrical power is able to be supplied to the vaporizer 6′ from the rechargeable battery via the power-supply pins 23 to cause heating of the electrically resistive layer 164 and subsequently any liquid brought into contact/proximity of the electrically resistive layer 164.

In the cartomizer 3C described above, it should be appreciated that the reservoir 46 is effectively a sealed volume defined by the inner surface of the outer housing 4′, the upper clamping unit 5′ and lower support unit 7′, and at least the central portion 167 of the vaporizer 6′ which is positioned to abut against the central well (not shown) of the upper clamping unit 5′. Owing to the construction of the vaporizer 6′, namely that the capillary tubes 166 are substantially the only the designed fluid passage into/out of the reservoir 46, when the capillary tubes 166 are filled with liquid, then air may be unable to pass into the reservoir 46. In some implementations, as the liquid in the reservoir 46 depletes, the pressure within the reservoir 46 may change if air is unable to enter the reservoir 46 to help balance out this pressure change. The change in pressure may impact the ability of the vaporizer/capillary tubes 166 to transport liquid to the electrically resistive layer 164. In such cases, the cartomizer 3C is designed to have an air inlet in fluid communication with the reservoir 46 that allows air to enter the reservoir 46 to counteract the pressure change. The air inlet may be liquid impermeable to prevent or reduce liquid exiting the reservoir 46 through the air inlet. In some implementations, the air inlet may be an opening (e.g., towards the top end 31 of the cartomizer 3C), having a small diameter such that any liquid is unable to escape the reservoir through the opening due to surface tension, or the opening may be provided with a liquid impermeable, air permeable layer to allow air to enter the reservoir 46 but prevent liquid escaping.

In other implementations, the upper clamping unit 5′ and/or lower support unit 7′ may be designed with a weakness in the seal formed by the outer circumferential surface of the foot 51 or the outer circumferential surface of the lower support unit 7′. Such weakness may be provided via a thinning of the wall of the upper clamping unit 5′/lower support unit 7′ which may temporarily deform or marginally separate from the outer housing 4′ when exposed to a change in pressure, to thereby produce a temporary gap that allows air to enter into the reservoir 46. Thus, broadly, there may be provided a cartomizer for an aerosol-generating device, the cartomizer comprising: a vaporizer for generating aerosol from aerosol-generating material held in a reservoir of the cartomizer, wherein the vaporizer comprises a substrate and an electrically resistive layer disposed on a first surface of the substrate, wherein one or more capillary tubes extend from another surface of the substrate and through the electrically resistive layer disposed on the first surface of the substrate, and the cartomizer comprises an air inlet configured to allow air to enter the reservoir of the cartomizer. The air inlet may optionally be configured to reduce or prevent liquid escaping the reservoir through the air inlet. The air inlet may optionally be provided via a weakened region in one or more liquid sealing elements of the cartomizer.

Above is described an example of a cartomizer 3C employing a microfluidic vaporizer 6′. However, it should be appreciated that the example cartomizer 3C is one example of a cartomizer 3C employing a microfluidic vaporizer 6′ in which power-supply pins 23 are provided to pass through though holes 74 in a device interface of the cartomizer 3C, with the power supply-pins 23 subsequently forming an electric circuit with the vaporizer 6′. Other configurations of cartomizers including the microfluidic vaporizer 6′ may be realised (for example, having different shapes, different components, different configurations, different airflow paths, etc.).

However, in accordance with the principles of the present disclosure, there is provided a cartomizer 3C that comprises a microfluidic vaporizer 6′ for generating aerosol from aerosol-generating material held in the cartomizer. The cartomizer 3C includes an aerosol-generating device interface configured to interface with an aerosol-generating device/main housing 2 (whereby the device interface may include the metal cap 8 including the bottom wall 81 and circumferential side wall 83 and/or the lower support unit 7′ including the bottom surface 72). More generally, the device interface of the cartomizer 3C may encompass any part or parts of the cartomizer 3C that contact, abut, engage or otherwise couple to the main housing 2. The aerosol-generating device interface further comprises one or more through holes 74, with each through hole 74 sized so as to receive a power-supply pin 23 of the aerosol generating device/main housing 2. Furthermore, the vaporizer 6′ is arranged in the cartomizer 3C such that the vaporizer 6′ is adjacent the one or more through holes 74 so that, when the cartomizer 3C is engaged with the aerosol-generating device/main housing 2, the respective power-supply pins 23 of the aerosol-generating device/electrically couple to the vaporizer 6′.

In the example shown above, the end portions 168, 169 of the vaporizer 6′ do not comprise capillary tubes 166. However, in some implementations, the end portions 168, 169 may comprise capillary tubes 166. Depending on the specific configuration, the capillary tubes 166 in the end portions 168, 169 may be redundant in that the ends of capillary tubes 166 of the end portions 168, 169 do not contact the central opening of the upper clamping unit 5′ and thus are not in fluid communication with the reservoir 46.

The microfluidic vaporizer 6′ may, in some implementations, be formed to have a relatively small footprint. Because the capillary tubes 166 are engineered to provide suitable capillary action for the liquid aerosol-generating material stored in the cartomizer 3C, the microfluidic vaporizer 6′ may be effective at supplying liquid to the electrically resistive layer 164 and thus a smaller footprint for the vaporizer 6′ having suitable performance characteristics for the given application at hand may be achievable. For example, in some instances, the vaporizer 6′ may have a footprint of 4×4 mm (16 mm²) or less, 3 mm×3 mm (9 mm²) or less, or 2×2 mm (4 mm²) or less. Regardless of the exact footprint, the significant quantity is the longitudinal extent. Hence, in some implementations, the vaporizer 6′ may have a longitudinal extent of less than or equal to 4 mm, 3 mm, or 2 mm. While such smaller footprint/longitudinal extent vaporizers 6′ may be achievable, the process of electrically coupling the vaporizer 6′ to the power-supply pins 23 may require further adaptation of the cartomizer 3C.

For instance, with reference to FIG. 11, it can be seen that the power-supply pins 23 are spaced apart a distance of 8.5 mm, and each power-supply pin 23 may have a diameter on the order of one millimetre or so. In some implementations, the spacing of the power-supply pins 23 on the main housing 2, along with the corresponding through holes 74, may be decreased (to a distance comparable to the length of the vaporizer 6′). However, bringing the power-supply pins closer together may necessitate a variation in the airflow through the cartomizer 3C (for example, for a 3×3 mm vaporizer 6′, the pins 23 may be spaced around 2-3 mm apart which may restrict the size of the air channel 52′). In other implementations, the vaporizer 6′ may be coupled to electrically conductive contact elements at end portions thereof, so as to facilitate the electrical coupling of the microfluidic vaporizer 6′.

FIG. 15 depicts, highly schematically, such an example of the microfluidic vaporizer 6″ coupled to electrically conductive contact elements. As can be seen in FIG. 15, the substrate material 162 has a different (i.e., smaller) dimension in the longitudinal direction than the substrate material of FIG. 14. More specifically, the substrate material 162 is approximately the same size as the central portion 167 comprising the plurality of capillary tubes 166. The electrically resistive layer 164 is provided in the central portion 167 of the vaporizer 6″. Instead of the end portions shown in FIG. 14, the vaporizer 6″ is shown as being coupled to electrically conductive contact elements 168″ and 169″. The electrically conductive contact elements may be formed from any suitable conductive material (e.g., the same or different material that electrically resistive layer 164 is formed from). The electrically conductive contact elements 168″, 169″ may be in the form of contact pads. The electrically conductive contact elements 168″, 169″ are electrically connected to the electrically resistive layer 164, e.g., via suitable wiring or soldering, etc. It should be appreciated that the electrically conductive contact elements 168″, 169″ are provided at a position relative to the vaporizer 6″ so as to electrically couple the power-supply pins 23 to the electrically resistive layer 164 of the vaporizer 6″. Accordingly, it should be appreciated that even when the vaporizer itself does not have an adequate footprint that overlaps with the through holes 74, electrically conductive contact elements 168″, 169″ can be provided to the vaporizer 6″ to take account of the spacing stipulated by the placement of the power-supply pins 23 of the main housing 2 (e.g., when the length of the substrate material 162 is different (i.e., smaller) than the distance between the power-supply pins 23). In these implementations, the vaporizer 6″ is provided adjacent the through holes 74; however, it is the electrically conductive contact elements that overlap the through holes 74.

Further, it should be appreciated that while FIG. 15 shows a vaporizer 6″ in which electrically conductive contact elements 168″, 169″ are provided at opposing longitudinal ends of the vaporizer 6″, in other implementations, the electrically conductive contact elements may be formed by extensions of the electrically resistive layer 164. That is to say, rather than providing separate electrically conductive contact elements 168″, 169″ that are subsequently electrically coupled to the vaporizer 6″, the electrically resistive layer 164 may have a greater dimension in the longitudinal direction than the substrate material 162. Put another way, the electrically resistive layer 164 may overhang the ends of the substrate material 162. In these implementations, the extended ends of the electrically resistive layer 164 overlap the through holes 74 and provide contact with the power-supply pins 23.

Broadly speaking, in some implementations, when the footprint of the substrate material 162 of the vaporizer 6′, 6″ is chosen so as to have a length that is less than twice the diameter of the power supply pins 23, then the vaporizer 6′, 6″ is provided either with an extension of the resistive layer 164, or with separate electrically conductive contact elements as shown in FIG. 15. Moreover, in implementations where the footprint of the substrate material 162 of the vaporizer 6′, 6″ is chosen so as to have a length that is greater than twice the diameter of the power supply pins 23, the vaporizer 6′, 6″ may still be provided either with an extension of the resistive layer 164 or with separate electrically conductive contact elements as shown in FIG. 15, depending on the configuration of the power-supply pins 23 of the main housing 2.

In the example shown in FIG. 13, the power-supply pins 23 directly contact the vaporizer 6′ (specifically the electrically resistive layer 164). This is achievable in part due to the orientation of the vaporizer 6′ such that the electrically resistive layer 164 faces towards the bottom of the cartomizer 3C (device interface) and subsequently the power supply pins 23 of the main housing 2 when the main housing couples to the cartomizer 3C. However, the orientation of the vaporizer 6′ is not limited to this and, in other implementations, the vaporizer 6′ may be provided in alternative implementations, for example, where the electrically resistive layer faces away from the bottom of the cartomizer 3C (device interface).

In such implementations, the vaporizer may be provided with electrically conductive elements that facilitate the electrical coupling of the power-supply pins 23 to the electrically resistive layer 164.

FIG. 16 depicts, highly schematically, such an example of the microfluidic vaporizer 6′″. The microfluidic vaporizer 6′″ is similar to microfluidic vaporizer 6′; however, the microfluidic vaporizer 6′″ includes vias 168a and 169a at respective end portions 168, 169 of the vaporizer 6′″, shown in phantom in FIG. 16. The vias 168a, 169a extend from one side of the substrate material 162 to the other side of the substrate material 162 and may or may not also extend through the electrically resistive layer 164. In any case, the vias 168a, 169a are configured to provide an electrically conductive path between the underside (i.e., the side not visible in FIG. 16) of the substrate material 162 and the electrically resistive layer 164. In such an example, the vaporizer 6′″ is orientated in the cartomizer 3C such that the electrically resistive layer 164 faces away from the device interface. Accordingly, when the power-supply pins 23 pass through the through holes 74 of the lower support unit 7′, the power-supply pins 23 make electrical contact with the surface of the vias 168a, 169a opposite the electrically resistive layer 164. An electrical circuit may nonetheless be formed but, in this implementation, the current supplied by the power-supply pins 23 additionally passes through the vias 168a, 169a.

It should also be appreciated that the vias 168a, 169a shown in FIG. 16 are one example of an electrically conductive element designed to electrically connect the electrically resistive layer 164 when the electrically resistive layer 164 is unable to directly contact the power-supply pins 23. In other implementations, the end portions 168, 169 of the vaporizer may be coated in an electrically resistive material and/or electrical tracks may be provided on the outer surfaces of the substrate material 162 such that an electrical path is formed around the outside surfaces of the substrate material 162 and coupled to the electrically resistive layer 164. In other implementations, the substrate material 162 itself may include, locally at the end portions 168, 169 or entirely throughout the substrate material 162, conductive elements (e.g., fibers/wires) that permit current to be applied to the underside of the vaporizer and pass to the electrically resistive layer 164.

It should also be appreciated that when the vaporizer 6′″ is orientated such that the electrically resistive layer 164 faces away from the device interface, the cartomizer may be adapted in order to supply liquid to the underside of the vaporizer 6′″. In some implementations, the reservoir 46 may be moved so as to sit beneath the vaporizer 6′″. However, this has some drawbacks including separating the vaporizer 6′″ from the device interface by a greater margin. In other implementations, a wicking element (or more generally a liquid transport element) may be provided to transport liquid from the reservoir 46 (which may be located above the vaporizer 6′″, e.g., as in cartomizers 3B and 3C), to the underside of the vaporizer 6′″.

Thus, there has been described a cartomizer for an aerosol-generating device, the cartomizer including an aerosol-generating device interface configured to interface with an aerosol-generating device; and a vaporizer for generating aerosol from aerosol-generating material held in a reservoir of the cartomizer. The aerosol-generating device interface further comprises one or more through holes, each through hole sized so as to receive a power-supply pin of the aerosol generating device, and the vaporizer is arranged in the cartridge such that the vaporizer is adjacent the one or more through holes so that, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device electrically couple to the vaporizer. Also described is an aerosol-generating device comprising the abovementioned cartomizer.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. A cartomizer for an aerosol-generating device, the cartomizer comprising:

an aerosol-generating device interface configured to interface with an aerosol-generating device; and

a vaporizer for generating aerosol from aerosol-generating material held in a reservoir of the cartomizer, wherein

the aerosol-generating device interface further comprises one or more through holes, each through hole sized so as to receive a power-supply pin of the aerosol generating device, and

the vaporizer is arranged in the cartridge such that the vaporizer is adjacent the one or more through holes so that, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device electrically couple to the vaporizer.

2. The cartomizer of claim 1, wherein the vaporizer is arranged such that the vaporizer extends over the one or more through holes, and wherein, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device directly contact the vaporizer.

3. The cartomizer of claim 2, wherein the vaporizer has a longitudinal extent of greater than 2 mm, or greater than 3 mm, or greater than 4 mm.

4. The cartomizer of claim 1, wherein the cartomizer further comprises one or more electrically conductive contact elements arranged to electrically couple to ends of the vaporizer, and wherein the electrically conductive contact elements are arranged to extend over the one or more through holes, and wherein, when the cartomizer is engaged with the aerosol-generating device, the respective power-supply pins of the aerosol-generating device directly contact the electrically conductive contact elements.

5. The cartomizer of claim 4, wherein the vaporizer has a longitudinal extent of less than or equal to 4 mm, 3 mm, or 2 mm.

6. The cartomizer of claim 1, wherein the vaporizer is elongate along a longitudinal axis and has a central portion and first and second end portions.

7. The cartomizer of claim 6, wherein at least the central portion of the vaporizer is configured to wick liquid aerosol-generating material.

8. The cartomizer of claim 1, wherein the vaporizer comprises a substrate and an electrically resistive layer disposed on a first surface of the substrate, wherein one or more capillary tubes extend from another surface of the substrate and through the electrically resistive layer disposed on the first surface of the substrate.

9. The cartomizer of claim 8, wherein the another surface of the vaporizer is provided in fluid communication with the reservoir of the cartomizer.

10. The cartomizer of claim 8, wherein the one or more capillary tubes have a diameter such that a liquid aerosol-generating material held in the reservoir of the cartomizer is able to move, via capillary forces, along the one or more capillary tubes.

11. The cartomizer of claim 10, wherein the capillary tubes are configured move liquid aerosol-generating material held in the reservoir of the cartomizer to the electrically resistive layer of the vaporizer.

12. The cartomizer of claim 8, wherein the one or more capillary tubes are formed by a laser drilling process.

13. The cartomizer of claim 8, wherein the substrate of the vaporizer is formed from a non-conductive material, such as silicon dioxide.

14. The cartomizer of claim 8, wherein the electrically resistive layer of the vaporizer is formed from an electrically conductive material, such as titanium.

15. The cartomizer of claim 1, wherein:

the cartomizer has a top end and a bottom end which are spaced apart along a longitudinal axis of the cartomizer; and

the vaporizer is positioned below the reservoir of the cartomizer and vaporizer sits flat on top of a lower support unit such that the longitudinal axis of the vaporizer is positioned transverse to the longitudinal axis of the cartomizer.

16. The cartomizer according to claim 15, wherein the central portion of the vaporizer is planar with the end portions of the vaporizer and extends across an air passage of the lower support unit.

17. The cartomizer according to claim 15, wherein the plane of the vaporizer is perpendicular to the longitudinal axis of the cartomizer.

18. The cartomizer according to claim 15, wherein the cartomizer includes an upper clamping unit which sits on top of the lower support unit with the vaporizer sandwiched between the lower support unit and the upper clamping unit.

19. The cartomizer according to claim 15, wherein:

the cartomizer includes an outer housing and at the top end of the cartomizer the outer housing includes a mouthpiece;

the vaporizer is positioned inside the outer housing at the bottom end of the cartomizer; and

the reservoir is positioned inside the outer housing between the mouthpiece and the vaporizer.

20. The cartomizer according to claim 18, wherein the lower support unit and the upper clamping unit form a plug which closes a bottom end of the outer housing and a bottom end of the reservoir.

21. The cartomizer according to claim 15, wherein the lower support unit comprises the one or more through holes, wherein each through hole leads from a bottom surface of the lower support unit to the vaporizer.

22. The cartomizer according to claim 15, wherein each through hole is tapered from having a wider width at the bottom surface of the lower support unit to having a narrower width at the top surface of the lower support unit.

23. An aerosol-generating device comprising a cartomizer according to claim 1.