Note: Descriptions are shown in the official language in which they were submitted.
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1
Vapour Generation Device Vaporisation Component
Field of Invention
The present invention relates to vapour generation devices, and more
specifically
heaters for vapour generation devices.
Background
Vapour generating devices, such as electronic cigarettes, are becoming
increasingly popular consumer products.
Heating devices for vaporisation or aerosolisation are known in the art. Such
devices typically include a heater arranged to heat a vaporisable product. In
operation, the vaporisable product is heated with the heater to vaporise the
constituents of the product for the consumer to inhale. In some examples, the
product may comprise tobacco in a capsule or may be similar to a traditional
cigarette, in other examples the product may be a liquid, or liquid contents
in a
capsule.
There is a need to improve the experience of the consumer of such products; an
object of the present invention is to address this need by improving the
quality of
the vapour flow. There is also a need to improve evaporator operation; another
object of the invention is to address this.
Summary
In a first aspect, there is provided a vaporisation component of a vapour
generation device, wherein the vaporisation component comprises:
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an evaporator component configured to generate a vapour flow by
vaporising a vaporisable substance, the evaporator component having a first
surface over which air flows in an airflow channel of a vapour generation
device
in a direction toward a mouthpiece, wherein at least a portion of the first
surface
is non-flat with respect to the airflow channel so as to interfere with an
airflow in
the airflow channel and affect a distribution of droplets in the generated
vapour
flow.
In this way, the interference with the airflow due to the non-flat first
surface of the
evaporator component increases the mixing of the airflow with the droplets.
Consequently, a more even distribution of droplets in the airflow can be
achieved.
This homogenises the output combination of air, vapour and droplets from a
mouthpiece of a vapour generation device comprising the vaporisation
component. This increased mixing of hot droplets with the cool airflow also
reduces overall vapour temperature, which can improve the user experience. The
non-flat surface also allows for the airflow to be directed toward the
surface, rather
than across the surface; this increases the probability of removing droplets
from
the region around the surface earlier in their formation. As such, an
increased
mixing of the airflow with the droplets is achieved: this also limits the
growth of
droplets and reduces the likelihood of coalescence between droplets thereby
inhibiting the formation of droplets that are undesirably large. Furthermore,
the
non-flat surface causes air to flow across the surface at differing velocities
at
different locations compared to a flat surface; this causes different forces
to be
applied to droplets proximal to the surface as they are carried away from the
surface by the airflow. These differing forces applied to different droplets
can
cause a beneficial variation in droplet size. Smaller droplets aid in nicotine
delivery to the lungs, and large droplets improve flavour delivery to the
mouth.
These technical advantages combine to improve the experience of a user of a
vapour generation device that incorporates the vaporisation component.
Preferably, the evaporator component further comprises one or more evaporator
channels arranged therethrough to connect the first surface to a reservoir
configured to store the vaporisable substance, and wherein the evaporator
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channels are configured to transport the vaporisable substance from the
reservoir
to openings in the first surface.
In this way, the interference with the airflow due to the non-flat first
surface
increases the probability of removing droplets from the region around the
first
surface earlier in their formation. This firstly helps to inhibit droplets
from blocking
the evaporator channels, and secondly helps to inhibit droplets coalescing to
form
larger droplets that may cause greater blockages to one or more of the
evaporator
channels. Inhibiting the blockage of the one or more evaporator channels by
droplets improves the operation of the evaporator component.
Preferably, the evaporator component is a block with one or more through-holes
passing through the block to form the one or more evaporator channels arranged
through the block.
Preferably, the evaporator component is a heater and the one or more
evaporator
channels are arranged through the heater.
Preferably, the non-flat portion of the first surface has a curved profile.
Preferably, the non-flat portion of the first surface comprises a plurality of
curved
profiles.
Preferably, the curved profile is curved in at least one dimension of the
first
surface.
Preferably, the curved profile is curved in two dimensions of the first
surface.
Preferably, the curved profile is substantially concave.
Preferably, the curved profile is substantially convex.
Preferably, the curved profile comprises convex and concave portions.
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Preferably, the non-flat portion of the first surface linearly tapers inward
to the
airflow channel in the direction of airflow, or wherein the first surface
linearly tapers
inward to the airflow channel in a direction opposite to the direction of
airflow.
Preferably, the first surface further comprises a plurality of recessed
portions
configured to interfere with an airflow in the airflow channel and affect a
distribution
of droplets in the vapour flow.
In this way, the recessed portions can control micro-scale airflow over the
first
surface. This can further contribute to the interference with the airflow in
the
airflow channel and affect the distribution of droplets in the generated
vapour flow
as the recessed portions change the airflow over the first surface.
Preferably, the first surface has hydrophobic properties.
In this way, the hydrophobic properties help to inhibit the build-up of
droplets on
the surface of the evaporator component. The repulsion of the droplets due to
the
hydrophobicity aids in removing the droplets from the surface of the
evaporator
component when combined with the airflow in the airflow channel. The build-up
of droplets on the surface of the evaporator component can negatively impact
the
operation of the evaporator component; the removal of the droplets, aided by
the
hydrophobic properties, helps to negate this issue thereby improving the
performance of the evaporator component.
Preferably, the vaporisation component further comprises a reservoir
configured
to house the vaporisable substance, the reservoir in connection with a second
surface of the evaporator component, wherein the second surface is distinct
from
the first surface.
In a second aspect, there is provided a cartridge for use with a vapour
generating
device, the cartridge comprising the vaporisation component of the first
aspect.
In this way, the vaporisation component can form part of a consumable
cartridge
and can be replaceable in a vapour generation device. In particular, this can
be
beneficial when changing to a vaporisable substance of a different flavour, in
a
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new cartridge, as a new evaporator component would be used and the generated
vapour would not be contaminated with residual flavouring from the previous
vaporisable substance.
In a third aspect, there is provided a vapour generating device comprising the
5 vaporisation component of the first aspect or the cartridge of the second
aspect.
In a fourth aspect, there is provided a vaporisation component of a vapour
generation device, wherein the vaporisation component comprises:
an evaporator component configured to generate a vapour flow by
vaporising a vaporisable substance, the evaporator component having a first
surface over which air flows in an airflow channel of a vapour generation
device
in a direction toward a mouthpiece, wherein the first surface comprises a
plurality
of recessed portions configured to interfere with an airflow in the airflow
channel
and affect a distribution of droplets in the generated vapour flow.
In this way, the recessed portions in the first surface of the evaporator
component
can control micro-scale airflow over the first surface. This interference with
the
airflow in the airflow channel affects the distribution of droplets in the
generated
vapour flow as the recessed portions change the airflow over the first
surface.
This provides a more homogenous output from a mouthpiece of an vapour
generation device incorporating the vaporisation component. The interference
with the airflow provided by the recessed portions also reduces coalescence of
droplets, thereby inhibiting the formation of undesirably large droplets, as
the
droplets a carried away from the first surface before such coalescence can
occur.
The interference with the airflow provided by the recessed portions is also
advantageous in that it increases the mixing of hot droplets with the cool air
in the
airflow so as to reduce the overall vapour temperature. Each of these
advantages
can contribute to improving the quality of the vapour output that is inhaled
by the
user of a vapour generation device incorporating a vaporisation component
having
an evaporator component with recessed portions.
Preferably, the evaporator component further comprises one or more evaporator
channels arranged therethrough to connect the first surface to a reservoir
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configured to store the vaporisable substance, and wherein the evaporator
channels are configured to transport the vaporisable substance from the
reservoir
to openings in the first surface.
In this way, the interference with the airflow due to the recessed portions in
the
first surface increases the probability of removing droplets from the region
around
the first surface earlier in their formation. This firstly helps to inhibit
droplets from
blocking the evaporator channels, and secondly helps to inhibit droplets
coalescing to form larger droplets that may cause greater blockages to one or
more of the evaporator channels. Inhibiting the blockage of the one or more
evaporator channels by droplets improves the operation of the evaporator
component.
Preferably, the evaporator component is a block with one or more through-holes
passing through the block to form the one or more evaporator channels arranged
through the block.
Preferably, the evaporator component is a heater and the one or more
evaporator
channels are arranged through the heater.
Preferably, openings of the one or more evaporator channels are alternately
arranged with the plurality of recessed portions in the first surface.
In this way, droplets formed at each of the one or more evaporator channels
have
recessed portions in close proximity that will interfere with the airflow to
draw the
droplets away from the evaporator channels.
Preferably, the plurality of recessed portions are a plurality of dimples in
the first
surface.
Preferably, the recessed portions are hemispherical or substantially
hemispherical
in shape.
Preferably, a recessed portion is arranged to provide a circular airflow in
the
proximity of the recessed portion when air flows over the first surface.
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Preferably, a recessed portion has a depth of 1 to 10 mm.
Preferably, at least a portion of the first surface is non-flat with respect
to the
airflow channel so as to interfere with an airflow in the airflow channel and
affect
a distribution of droplets in the generated vapour flow.
In this way, the interference with the airflow due to the non-flat first
surface
increases the mixing of the airflow with the droplets. This can further
contribute
to the interference with the airflow in the airflow channel and affect the
distribution
of droplets in the generated vapour flow as the non-flat shape changes the
airflow
over the first surface.
Preferably, the plurality of recessed portions are arranged in the non-flat
portion
of the first surface.
In this way, the combined effect of the recessed portions and non-flat shape
on
the airflow over the first surface can be emphasised.
Preferably, the non-flat portion of the first surface has a curved profile.
Preferably, the first surface has hydrophobic properties.
In this way, the hydrophobic properties help to inhibit the build-up of
droplets on
the surface of the evaporator component. The repulsion of the droplets due to
the
hydrophobicity aids in removing the droplets from the surface of the
evaporator
component when combined with the airflow in the airflow channel. The build-up
of droplets on the surface of the evaporator component can negatively impact
the
operation of the evaporator component; the removal of the droplets, aided by
the
hydrophobic properties, helps to negate this issue thereby improving the
performance of the evaporator component.
Preferably, the hydrophobic properties are provided by a hydrophobic layer.
Preferably, the vaporisation component further comprises a reservoir
configured
to house the vaporisable substance, the reservoir in connection with a second
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surface of the evaporator component, wherein the second surface is distinct
from
the first surface.
In a fifth aspect, there is provided a cartridge for use with a vapour
generating
device, the cartridge comprising the vaporisation component of the fourth
aspect.
In this way, the vaporisation component can form part of a consumable
cartridge
and can be replaceable in a vapour generation device. In particular, this can
be
beneficial when changing to a vaporisable substance of a different flavour, in
a
new cartridge, as a new evaporator component would be used and the generated
vapour would not be contaminated with residual flavouring from the previous
vaporisable substance.
In a sixth aspect, there is provided a vapour generating device comprising the
vaporisation component of the fourth aspect or the cartridge of the fifth
aspect.
In a seventh aspect, there is provided a vaporisation component of a vapour
generation device, wherein the vaporisation component comprises:
an evaporator component configured to generate a vapour flow by
vaporising a vaporisable substance, the evaporator component having a first
surface over which air flows in a vapour generation device, wherein the first
surface comprises hydrophobic properties configured to repel droplets from the
vapour flow.
In this way, the hydrophobic properties help to inhibit the build-up of
droplets on
the surface of the evaporator component. The repulsion of the droplets aids in
removing the droplets from the first surface when combined with an airflow
over
the first surface. The build-up of droplets on the surface of the evaporator
component can negatively impact the operation of the evaporator component; the
removal of the droplets, brought about by the hydrophobic properties, helps to
negate this issue thereby improving the operation of the evaporator component.
Preferably, the evaporator component further comprises one or more evaporator
channels arranged therethrough to connect the first surface to a reservoir
configured to store the vaporisable substance, and wherein the evaporator
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channels are configured to transport the vaporisable substance from the
reservoir
to openings in the first surface.
In this way, the hydrophobic properties provide for repelling droplets so as
to inhibit
the pooling of droplets on the first surface of the evaporator component;
pooled
droplets can block the one or more evaporator channels. Inhibiting the build-
up
or pooling of such droplets improves the operation of the evaporator
component.
Preferably, the evaporator component is a block with one or more through-holes
passing through the block to form the one or more evaporator channels arranged
through the block.
Preferably, the evaporator component is a heater and the one or more
evaporator
channels are arranged through the heater.
Preferably, the first surface comprises a structured surface configured to
provide
hydrophobic properties.
Preferably, the structured surface is a micro-structured and/or nano-
structured
surface.
Preferably, the structured surface comprises a hierarchical structured surface
comprising a micro-scale roughness covered by a nano-scale roughness.
Preferably, the first surface further comprises a hydrophobic layer at least
partially
coating the structured surface.
Preferably, the evaporator component comprises a hydrophobic layer at least
partially forming the first surface.
Preferably, the hydrophobic layer comprises at least one of a high temperature
polymer, a ceramic, a rare earth oxide, grafted organic molecules or polymers.
Preferably, the hydrophobic properties are provided by a chemical coating
added
to the first surface of the evaporator. Alternatively, the hydrophobic
properties are
provided by a physical treatment applied to the first surface of the
evaporator.
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Alternatively, the hydrophobic properties are provided by a combination of a
chemical coating added to the first surface of the evaporator and a physical
treatment applied to the first surface of the evaporator.
Preferably, the hydrophobic properties are configured to provide a contact
angle
5 for a droplet of greater than or equal to 1500.
In this way, the hydrophobic properties can exhibit superhydrophobicity aiding
in
the removal of droplets from the first surface of the evaporator component.
Preferably, the vaporisation component further comprises a reservoir
configured
to house the vaporisable substance, the reservoir in connection with a second
10 surface of the evaporator component, wherein the second surface is
distinct from
the first surface.
In an eighth aspect, there is provided a cartridge for use with a vapour
generating
device, the cartridge comprising the vaporisation component of the seventh
aspect.
In this way, the vaporisation component can form part of a consumable
cartridge
and can be replaceable in a vapour generation device. In particular, this can
be
beneficial when changing to a vaporisable substance of a different flavour, in
a
new cartridge, as a new evaporator component would be used and the generated
vapour would not be contaminated with residual flavouring from the previous
vaporisable substance.
In a ninth aspect, there is provided a vapour generating device comprising the
vaporisation component of the seventh aspect or the cartridge of the eighth
aspect.
In a tenth aspect, there is provided a method of fabricating a vaporisation
component of a vapour generation device, wherein the vaporisation component
comprises an evaporator component configured to generate a vapour flow by
vaporising a vaporisable substance, the evaporator component having a first
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surface over which air flows in a vapour generation device, the method
comprising:
modifying the first surface to provide hydrophobic properties configured to
repel droplets from the vapour flow.
In this way, a vaporisation component having an evaporator component with
hydrophobic properties is provided. These hydrophobic properties help to
inhibit
the build-up of droplets on the surface of the evaporator component. The
repulsion of the droplets aids in removing the droplets from the first surface
when
combined with an airflow over the first surface. The build-up of droplets on
the
surface of the evaporator component can negatively impact the operation of the
evaporator component; the removal of the droplets, brought about by the
hydrophobic properties, helps to negate this issue thereby improving the
operation
of the evaporator component.
Preferably, modifying the first surface comprises patterning the first surface
such
that first surface comprises a structured surface configured to provide
hydrophobic
properties.
Preferably, modifying the first surface comprises applying a hydrophobic layer
to
the first surface.
Brief Description of the Drawings
Embodiments of the invention are now described, by way of example, with
reference to the drawings, in which:
Figure 1A is a conceptual cross-sectional view of a portion of a vaporisation
component for a vapour generation device;
Figure 1B is a conceptual cross-sectional view of a vaporisation component
integrated into a portion of a vapour generation device;
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Figure 2A is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 2B is a conceptual cross-sectional view of a vaporisation component
integrated into a portion of a vapour generation device;
Figure 3 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 4 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 5 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 6 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 7 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 8 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 9 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface;
Figure 10A is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a plurality of recessed portions
in a surface;
Figure 10B is a conceptual plan view of a portion of a vaporisation component
with
an evaporator component having a plurality of recessed portions in a surface;
Figure 10C is a conceptual cross-sectional view of a vaporisation component
integrated into a portion of a vapour generation device;
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Figure 11 is a conceptual cross-sectional view of a portion of a vaporisation
component with an evaporator component having a non-flat surface with a
plurality
of recessed portions;
Figure 12A is a conceptual cross-sectional view of an vaporisation component
with
a hydrophobic layer arranged on the first surface of the evaporator component;
Figure 12B is a conceptual cross-sectional view of a vaporisation component
having a structured first surface with a hydrophobic layer arranged on the
structured first surface of the evaporator component; and
Figure 120 is conceptual perspective view of the vaporisation component of
Figure 12A.
Detailed Description
A vapour generation device is a device arranged to heat a vapour generating
product to produce a vapour for inhalation by a consumer. In a specific
example,
a vapour generating product can be a liquid which forms a vapour when heated
by the vapour generation device. A vapour generation device can also be
considered an electronic cigarette, or aerosol generation device. In context
of the
present disclosure, the terms vapour and aerosol can be used interchangeably.
A
vapour generating product, or aerosol generating product, can be a liquid or a
solid such as a fibrous material, or a combination thereof, that when heated
generates a vapour or aerosol.
Figure 1A shows a cross-sectional diagram of a portion of a vaporisation
component 100 for a vapour generation device.
The vaporisation component 100 comprises an evaporator component 102 and a
reservoir 116. The reservoir 116 is arranged to store a liquid vapour
generating
product. The evaporator component 102 (hereinafter referred to as the
evaporator) can be considered as an evaporator block or heater, and in an
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example can be formed from silicon. Figure 1B shows a conceptual cross-
sectional diagram of the evaporator 102 integrated into a portion 180 of a
vapour
generation device.
The evaporator 102 has a first surface 104 that faces toward the airflow
channel
128 of the vapour generation device. The airflow channel 128 of the vapour
generation device is a channel through which air flows substantially in a
direction
118 toward a mouthpiece 120 when a consumer draws upon the mouthpiece 120;
that is, the airflow channel 128 connects air inlets (not shown) to the
mouthpiece
120 for the passage of air through the device. The airflow channel 128 is
arranged
to transport generated vapour to the mouthpiece 120 through which the vapour
is
inhaled. The first surface 104 of the evaporator 102 can be arranged in the
airflow
channel 128, and in the example of Figures 1A and 1B can form a portion of an
internal sidewall of the airflow channel 128. The cross-section of Figures 1A
and
1B are viewed along a direction perpendicular to the direction along the
airflow
channel 128 toward the mouthpiece 120.
In an example, the evaporator can be a micro-electro-mechanical system (M EMS)
evaporator; this evaporator can be silicon-based at least in part.
The evaporator 102 has a second surface 106 on a separate face to the first
surface 104. In the example of Figures 1A and 1B the second surface 106 is on
an opposing face to the first surface 104. The second surface 106 of the of
the
evaporator 102 is arranged to be in connection with the reservoir 116.
A plurality of channels 108 are arranged through the evaporator 102 to connect
a
set of first openings 110 in the first surface 104 to a corresponding set of
second
openings 112 in the second surface 106. That is, each of these evaporator
channels 108 is a through-hole that passes through the evaporator 102 with one
end of each evaporator channel 108 forming a first opening 110 in the first
surface
104 and the other end of each evaporator channel 108 forming a second opening
112 in the second surface 106. These evaporator channels 108 can be in an
array
type arrangement and of micrometre scale.
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The evaporator channels 108 are arranged to draw liquid from the reservoir 116
through the second openings 112, through the evaporator channels 108, and to
the first openings 110 by capillary force.
Any suitable number of evaporator channels 108, with corresponding numbers of
5 first 110 and second openings 112, can be arranged in the evaporator 102.
In
some examples there may be one evaporator channel 108, in other examples
there may be a plurality of evaporator channels 108.
In some examples, an optional wicking material 114 can be incorporated into
the
vaporisation component 100, and in particular can be arranged between the
10 second surface 106 of the evaporator 102 and the reservoir 116. The
wicking
material 114 can aid in the transfer of liquid from the reservoir 116 to the
second
openings 112 in the second surface 106. In this way, the reservoir 116 can
either
be in direct connection with the second surface 106 of the evaporator 102, or
in
connection connected with the second surface 106 by way of the wicking
material
15 114.
For clarity, only the evaporator 102 of the vaporisation component 100 is
shown
in Figure 1B; the reservoir 116 and optional wicking material 114 are not
shown
but can readily be included.
In operation, liquid is drawn from the reservoir 116 into the second openings
112
in the second surface 106 of the evaporator 102 and into and through the
evaporator channels 108 by capillary action. A potential is applied to the
evaporator 102 by a heater control circuit (not shown) so as to heat the
evaporator
102. In turn the evaporator 102 heats the liquid, through the sidewalls of the
evaporator channels 108, as the liquid is drawn through the evaporator
channels
108 to create a vapour. The vapour then exits the evaporator channels 108 as a
vapour flow through the first openings 110 in the first surface 104 and enters
the
airflow channel 128 of the vapour generation device. This vapour flow can also
include liquid droplets 124 from the evaporator channels 108.
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In the example of Figure 1B, the first surface 104 of the evaporator 102
partially
defines an internal wall of the airflow channel 128. The airflow channel 128
can
be considered as a tube or passageway, defined by internal walls, through
which
the air and vapour travels to the mouthpiece 120. An opposing internal wall
122
of the airflow channel is also shown in Figure 1B; the opposing internal wall
122
at least partially forms part of the internal wall of the airflow channel 128
opposite
to the first surface 104 of the evaporator 102. Further internal walls, that
complete
the definition of the airflow channel 128, connect the first surface 104 of
the
evaporator and the opposing wall 122. For clarity, these further internal
walls are
not shown in the cut-away section in Figure 1B.
When a consumer draws on the mouthpiece 120, air is brought into the airflow
channel 128 through air inlets (not shown) connected to the airflow channel
128
and distal from the mouthpiece 120 so as to create a pressure change that
draws
the generated vapour flow to the mouthpiece 120, in the airflow 118 as it
passes
over the first surface 104, for inhalation by the consumer.
For clarity, sections of the body of the vapour generation device are not
shown in
Figure 1B, including portions containing control electronics, a power source
such
as a battery, and the electronics connecting the evaporator to the control
electronics and power source.
The vaporisation component 100 of Figure 1, including the evaporator 102,
reservoir 116 and optional wicking material 114, can be a single component. In
some examples, the vaporisation component 100 is a component of the vapour
generation device, with the reservoir 116 being refillable. In other examples,
the
vaporisation component 100 of Figure 1 (including the evaporator 102,
reservoir
116 and optionally the wicking material 114) can be comprised in a removable
cartridge for the vapour generation device that can be detached from the
vapour
generation device (such as when the reservoir 116 is empty of liquid). In this
example, the vaporisation component 100 can be a replaceable consumable,
alternatively the reservoir 116 can be refilled.
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In other examples, the evaporator 102 can be a component of the vapour
generation device, and the reservoir 116 (and optionally the wicking material
114)
can form a removable component that can be detached from the vapour
generation device (such as when the reservoir 116 is empty of liquid).
The shape of at least a portion of the first surface 104 of the evaporator 102
described with reference to Figures 1A and 1B can be modified so as to
interfere
with and perturb the airflow 118 within the airflow channel 128 as it flows
substantially toward the mouthpiece 120. This interference with the airflow
affects
the distribution of liquid droplets 124 in the generated vapour flow. Figures
2 to 9,
present various examples of vaporisation components 200, 300, 400, 500, 600,
700, 800, 900 with non-flat first surfaces of the evaporator, with respect to
the
airflow channel 128, which provide such an interference with the airflow. The
vaporisation components of Figures 2 to 9 comprise the features described with
reference to the vaporisation component 100 of Figures 1A and 1B (as in some
cases denoted by the common reference numerals), but with a non-flat first
surface for the evaporator. The vaporisation components of Figures 2 to 9 can
be
integrated into a vaporisation device as described with reference to Figures
1A
and 1R A non-flat evaporator surface causes the cross-section of the airflow
channel 128 to be non-consistent in shape along its length when travelling
toward
the mouthpiece 120. A non-flat evaporator surface can increase the amount of
airflow that hits the surface compared to a flat evaporator surface.
Figure 2A shows a cross-sectional diagram of a portion of a vaporisation
component 200 for a vapour generation device viewed along a direction
perpendicular to the direction along the airflow channel 128 toward the
mouthpiece 120. The first surface 204 of the evaporator 202 is non-flat in
that it
is concavely shaped relative to the airflow channel 128 to provide the first
surface
204 with a curved profile. That is, the evaporator 202 has a concavely curved
portion 230 extending inward to evaporator 202 in the first surface 204. Along
the
direction toward the mouthpiece 120, the first surface 204 follows a curved
profile
that first curves away from the centre of the airflow channel 128, and then
back
toward the centre of the airflow channel 128. This concavely curved profile
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interferes with the airflow 218 as the airflow 218 moves over the first
surface 204
such that the air no longer flows in a direct or unperturbed manner when
substantially flowing toward the mouthpiece 120 through the airflow channel
128,
as indicated the arrow 118 depicting the effect on the airflow 218. That is,
the
concavely curved first surface 204 perturbs the airflow 218 as it flows
substantially
toward the mouthpiece 120.
Figure 2B presents a conceptual cross-sectional diagram of a portion 280 of a
vapour generation device with a similar arrangement to that described with
reference to Figure 1B, but including the evaporator 202 described with
reference
to Figure 2A (for clarity the reservoir 116 and optional wicking material 114
are not
shown). The concavely curved first surface 204 of the evaporator 202
interferes
with the airflow 218 as it passes through the airflow channel 128 over the
first
surface 204. This increases the Reynolds number of the
airflow 218.
Consequently, the distribution of the liquid droplets 124 included in the
vapour flow
from the first openings 110 of the evaporator channels 108 is affected by this
interference to the airflow 218.
The interference with the airflow 218 due to the non-flat first surface 204
increases
the mixing of the airflow 218 with the droplets 124. Consequently, a more even
distribution of droplets 124 in the airflow 218 can be achieved. This
homogenises
the output combination of air, vapour and droplets from the mouthpiece 120
thereby improving the experience for the user of the device. Furthermore, this
increased mixing of hot droplets 214 with the cool airflow 218 reduces overall
vapour temperature, which can improve the user experience.
The non-flat first surface 204 allows for the airflow 218 to be directed
toward the
first surface 204, rather than only across the surface as in Figure 1. This,
therefore, increases the probability of removing droplets 124 from the region
around the first surface 204 earlier in their formation. That is, the an
increased
mixing of the airflow 218 with the droplets 124 is achieved that allows for
the
droplets 124 to be more readily moved away from the first openings 110 in the
first
surface 204 of the evaporator 202; this limits the growth of droplets 124 and
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reduces the likelihood of coalescence between droplets 124 thereby inhibiting
the
formation of droplets 124 that are undesirably large.
Another advantage of the non-flat first surface 204 is realised in that the
non-flat
first surface 204 causes the air to flow across the surface 204 at differing
velocities
at different locations compared to a flat first surface. This causes different
forces
to be applied to droplets 124 in the vapour flow as they are carried away from
the
first surface 204. These differing forces applied to different droplets 124
can cause
a beneficial variation in droplet size. Smaller droplets aid in nicotine
delivery to
the lungs, and large droplets improve flavour delivery to the mouth. By
providing
droplets 124 of varying sizes, in the output to the user of the device, the
user
experience is improved.
Figures 3 to 9 present other examples of vaporisation components with non-flat
surfaces that also provide these advantageous effects.
Figure 3 provides an example of a vaporisation component 300 with an
alternative
curved profile to Figure 2, and shows a cross-sectional diagram of a portion
of the
vaporisation component 300 for a vapour generation device viewed along a
direction perpendicular to the direction along the airflow channel 128 toward
the
mouthpiece 120. The first surface 304 of the evaporator 302 is non-flat in
that it
is convexly shaped relative to the airflow channel 128 to provide the first
surface
304 with a curved profile. That is, the evaporator 302 has a convexly curved
portion 330 extending inward to the airflow channel 128. Along the direction
toward the mouthpiece 120, the first surface 304 follows a curved profile that
first
curves inward toward the centre of the airflow channel 128, and then curves
outward away from the centre of the airflow channel 128. This convexly curved
profile interferes with the airflow 318 as the airflow 318 moves over the
first surface
304 such that the air no longer flows in a direct or unperturbed manner when
substantially flowing toward the mouthpiece 120 in the airflow channel 128, as
indicated arrow 318 depicting the effect on the airflow. That is, the convexly
curved first surface 304 perturbs the airflow 118 as it flows substantially
toward
the mouthpiece 120.
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Figure 4 provides an example of a vaporisation component 400 with an
alternative
curved profile to Figures 2 and 3, and shows a cross-sectional diagram of a
portion
of the vaporisation component 400 for a vapour generation device viewed along
a direction perpendicular to the direction along the airflow channel 128
toward the
5 mouthpiece 120. The first surface 404 of the evaporator 402 is non-flat
in that it
comprises a plurality of concavely shaped regions 430 relative to the airflow
channel 128 to provide the first surface 404 with a curved profile. That is,
the
evaporator 402 has a plurality of concavely curved portions 430 extending
inward
to evaporator 402 in the first surface 404. In Figure 4 two concavely shaped
10 regions 430 are present, the skilled person will however understand that
the
plurality of concavely shaped regions 430 can comprise more than two concavely
shaped regions. Along direction toward the mouthpiece 120, the first surface
404
follows a curved profile that first curves away from the centre of the airflow
channel
128, then back toward the centre of the airflow channel 128, then away from
the
15 centre of the airflow channel 128, and then back toward the centre of
the airflow
channel 128 again. The plurality of concavely shaped regions 430 interfere
with
the airflow 418 as the airflow 418 moves over the first surface 404 such that
the
air no longer flows in a direct or unperturbed manner when substantially
flowing
toward the mouthpiece 120 in the airflow channel 128, as indicated arrow 418
20 depicting the effect on the airflow. That is, the plurality of concavely
shaped
regions 430 in the first surface 404 perturb the airflow 418 as it flows
substantially
toward the mouthpiece 120. In related examples, the first surface can
alternatively
comprise a plurality of convexly curved portions, or a combination of at least
one
concavely curved portion and at least one convexly curved portion in the
direction
along the airflow channel 128 toward the mouthpiece 120.
Figure 5 provides an example of a vaporisation component 500 with a sloped non-
flat first surface 504 of the evaporator 502, and shows a cross-sectional
diagram
of a portion of the vaporisation component 500 for a vapour generation device
viewed along a direction perpendicular to the direction along the airflow
channel
128 toward the mouthpiece 120. The sloped non-flat first surface 504 linearly
tapers inwardly to the airflow channel 128 in the direction along the airflow
channel
128 toward the mouthpiece 120, i.a the first surface linearly tapers inward
toward
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the centre of airflow channel 128 in the substantial direction of the airflow
518.
This tapering of the first surface 504 interferes with the airflow 518 as the
airflow
518 moves over the first surface 504 such that the air no longer flows in a
direct
or unperturbed manner when substantially flowing toward the mouthpiece 120 in
the airflow channel 128, rather the airflow 518 is partially guided inwardly
to the
centre of the airflow channel 128 as indicated arrow 518 depicting the effect
on
the airflow. That is, the linearly tapering first surface 504 perturbs the
airflow 518
as it flows substantially toward the mouthpiece 120.
Figure 6 provides an example of a vaporisation component 600 with a sloped non-
flat first surface 604 of the evaporator 602, and shows a cross-sectional
diagram
of a portion of the vaporisation component 600 for a vapour generation device
viewed along a direction perpendicular to the direction along the airflow
channel
128 toward the mouthpiece 120. The sloped non-flat first surface 604 linearly
tapers inwardly toward the centre of the airflow channel 128 in a direction
along
the airflow channel 128 away from the mouthpiece 120, i.e. the first surface
linearly tapers inward toward to the centre of the airflow channel 128
opposite to
the substantial direction of the airflow 618. This tapering of the first
surface 604
interferes with the airflow 618 as the airflow 618 moves over the first
surface 604
such that the air no longer flows in a direct or unperturbed manner when
substantially flowing toward the mouthpiece 120 in the airflow channel 128,
rather
the airflow 618 is partially guided outwardly from the centre of the airflow
channel
as indicated arrow 618 depicting the effect on the airflow. That is, the
linearly
tapering first surface 604 perturbs the airflow 118 as it flows substantially
toward
the mouthpiece 120.
In alternatives to Figures 5 and 6 the tapering can be curved rather than
linear.
The examples described with reference to Figures 2 to 6 comprise first
surfaces
that are non-flat in a direction toward the mouthpiece 120 along the airflow
channel
128. Figures 7 to 9 present various examples of non-flat
first surfaces of the
evaporator in a direction perpendicular to the direction toward the mouthpiece
120
along the airflow channel 128, which can also provide such an interference
with
the airflow.
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When the first surface is non-flat only in one direction, it can be considered
as
non-flat in one dimension. The non-flat first surfaces of any of Figures 2 to
6,
which are non-flat in the direction toward the mouthpiece 120 along the
airflow
channel 128, can be combined with the non-flat first surfaces of any of
Figures 7
to 9, which are non-flat in the direction perpendicular to the direction
toward the
mouthpiece 120 along the airflow channel 128. In this way, the first surface
can
be non-flat in two dimensions.
Figure 7 provides an example of a vaporisation component 700 with a convexly
shaped non-flat first surface 704 of the evaporator 702, and shows a cross-
sectional diagram of a portion of a vaporisation component 700 for a vapour
generation device viewed in a direction along the airflow channel 128 toward
the
mouthpiece 128. The first surface 704 of the evaporator 702 is convexly shaped
relative to the airflow channel 128 to provide the first surface 704 with a
curved
profile. That is, the evaporator 702 has a convexly curved portion 730
extending
inward toward the centre of the airflow channel 128. In a direction across the
airflow channel 128, perpendicular to the direction toward the mouthpiece 120,
the first surface 704 follows a curved profile that it first curves inward
toward the
centre of the airflow channel 128, and then outward away from the centre of
the
airflow channel 128. This convexly curved profile 730 interferes with the
airflow
as the airflow moves over the first surface 704 such that the air no longer
flows in
a direct or unperturbed manner when substantially flowing toward the
mouthpiece
120 in the airflow channel 128. That is, the convexly curved first surface 704
perturbs the airflow as it flows substantially toward the mouthpiece 120.
Figure 8 provides an example of a vaporisation component 800 with a concavely
shaped non-flat first surface 804 of the evaporator 802, and shows a cross-
sectional diagram of a portion of a vaporisation component 800 for a vapour
generation device viewed in a direction along the airflow channel 128 toward
the
mouthpiece 120. The first surface 804 of the evaporator 802 is concavely
shaped
relative to the airflow channel 128 to provide the first surface 804 with a
curved
profile. That is, the evaporator 802 has a concavely curved portion 830
extending
inward to the evaporator 802. In a direction across the airflow channel 128,
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perpendicular to the direction toward the mouthpiece 120, the first surface
804
follows a curved profile that it first curves outward away from centre of the
airflow
channel 128, and then back inward toward the centre of the airflow channel
128.
This concavely curved profile 830 interferes with the air flow as the airflow
moves
over the first surface 804 such that the air no longer flows in a direct or
unperturbed
manner when substantially flowing toward the mouthpiece 120 in the airflow
channel 128. That is, the concavely curved first surface 804 perturbs the
airflow
as it flows substantially toward the mouthpiece 120.
Figure 9 provides an example of a vaporisation component 900 with a non-flat
first
surface defined by a plurality of concavely shaped regions 930. Figure 9 shows
a cross-sectional diagram of a portion of a vaporisation component 900 for a
vapour generation device viewed in a direction along the airflow channel 128
toward the mouthpiece 120. The first surface 904 of the evaporator 902 is non-
flat in that it comprises a plurality of concavely shaped regions 930 relative
to the
airflow channel 128 to provide the first surface 904 with a curved profile.
That is,
the evaporator 902 has a plurality of concavely curved portions 930 extending
inward to evaporator 902 in the first surface 904. In Figure 9 two concavely
shaped regions 930 are present, the skilled person will however understand
that
the plurality of concavely shaped regions 930 can comprise more than two
concavely shaped regions. In a direction across the airflow channel 128,
perpendicular to the direction toward the mouthpiece 120, the first surface
904
follows a curved profile that first curves away from the centre of the airflow
channel
128, then back toward the centre of the airflow channel 128, then away from
the
centre of the airflow channel 128, and then back toward the centre of the
airflow
channel 128 again. The plurality of concavely shaped regions 930 interfere
with
the airflow as the airflow moves over the first surface 904 such that the air
no
longer flows in a direct or unperturbed manner when substantially flowing
toward
the mouthpiece 120 in the airflow channel 128. That is, the plurality of
concavely
shaped regions 930 in the first surface 904 perturb the airflow as it flows
substantially toward the mouthpiece 120. In related examples, the first
surface
can alternatively comprise a plurality of convexly curved portions, or a
combination
of at least one concavely curved portion and at least one convexly curved
portion
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in the direction across the airflow channel perpendicular to the direction
toward
the mouthpiece.
In some examples, only a portion of the first surface of the evaporator may be
non-flat in the manner described with reference to Figures 2 to 9, in other
example
the entire first surface of the evaporator may be non-flat in the manner
described
with reference to Figures 2 to 9. In some examples, the first surface of the
evaporator can include multiple non-flat regions by comprising any combination
of
one or more of the non-flat profiles described with references to Figures 2 to
9 in
such multiple non-flat regions.
Alternatively or additionally to the features of the vaporisation components
described with reference to Figures 1 to 9, the first surface of the
evaporator of
the vaporisation component can be modified so as to interfere with and perturb
the airflow within the airflow channel as it flows substantially toward the
mouthpiece by arranging a plurality of recessed portions in the first surface.
The
vaporisation component of Figures 10A-C comprises the features described with
reference to the vaporisation component 100 of Figures 1A and 1B (as in some
cases denoted by the common reference numerals), but with recessed portions
1050 in the first surface 1004 of the evaporator 1002. The vaporisation
components of Figure 10 can be integrated into a vaporisation device as
described
with reference to Figures 1A and 1B. The recessed portions 1050, or dimples,
can control micro-scale airflow 1018' over the first surface 1004 of the
evaporator
1002. This interference with the airflow 1018 in the airflow channel 128
affects
the distribution of droplets 124 in the generated vapour flow as the recessed
portions 1050 change the airflow 1018 over the first surface 1004.
Figure 10A shows a cross-sectional diagram of a portion of a vaporisation
component 1000 for a vapour generation device viewed along a direction
perpendicular to the direction along the airflow channel 128 toward the
mouthpiece 120. Figure 10B shows a corresponding top down plan view of a
portion of the vaporisation component 1000.
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The first surface 1004 of the evaporator 1002 has a plurality of recessed
portions
1050. These recessed portions 1050 are configured to interfere with the
airflow
1018 in the airflow channel 128 as it flows toward the mouthpiece 120. The
recessed portions 1050 can be considered as dimples in the first surface 1004.
5 The recessed portions 1050 in Figures 10A-C are hemispherical or
substantially
hemispherical shaped recesses 1050 in the first surface 1004. These recessed
portions 1050 are configured to create an array of regions in which the
airflow
1018 over the first surface 1004 is perturbed to form at least partially
circular
pockets, or vortexes, of airflow 1018'. The airflow 1018 across the first
surface
10 1004 flows downward into the recessed portions 1050, and is ejected from
the
recessed portions 1050 in a circular or vortex-like manner 1018' such that
this
perturbed airflow 1018' is directed substantially toward the centre of the
airflow
channel 128.
Whilst the recessed portions 1050 are described as being hemispherical in
shape,
15 with reference to Figure 10, it will be understood that the recessed
portions 1050
may alternatively be shaped as any portion of a sphere or spheroid, or any
other
suitable shape that perturbs the airflow 1018 over the first surface 1004 such
that
the perturbed airflow is directed substantially toward the centre of the
airflow
channel 128.
20 Figure 10B shows the recessed portions 1050 arranged in a uniform, grid-
like
manner in the first surface 1004. In some examples, the recessed portions 1050
can be arranged in such a uniform manner across the entire first surface 1004
of
the evaporator 1002. In other examples, the recessed portions 1050 can be
arranged in an unordered manner across the entire first surface 1004. In
further
25 examples, the recessed portions 1050 may be arranged in one or more
regions of
the first surface 1002 in either an ordered or unordered manner. In yet
another
example, the first surface 1004 may comprise recessed portions 1050 arranged
in combinations of ordered and unordered regions.
Figure 100 presents a conceptual cross-sectional diagram of a portion 1080 of
a
vapour generation device with a similar arrangement to that described with
reference to Figure 1B, but including the evaporator 1002 described with
reference
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to Figures 10A and 10B (for clarity the reservoir and optional wicking
material are
not shown). As is shown, the airflow 118 over the first surface 1004 of the
evaporator 1002 is perturbed to create vortex-like or circular regions of
airflow
1018' due to shape of the recessed portions 1050. These regions of circular
airflow 1018' cause liquid droplets 124 in vapour flow to be carried away from
the
first surface 1004 when they are ejected from the first openings 110 of the
evaporator channels 108.
The recessed portions 1050 provide similar advantages to the non-flat first
surfaces described with references to Figures 2 to 9. The interference with
the
airflow 1018 provided by the recessed portions 1050, creating the circular
regions
of airflow 1018', improves the mixing of the droplets 124 in the airflow 1018
thereby providing a more homogenous output from the mouthpiece 120 for the
consumer. This interference with the airflow 1018 provided by the recessed
portions 1050 also reduces coalescence of droplets 124, thereby inhibiting the
formation of undesirably large droplets, as the droplets 124 are carried away
from
the first surface 1004 before such coalescence can occur. The interference
with
the airflow 1018 provided by the recessed portions 1050 is also advantageous
in
that it increases the mixing of hot droplets 124 with the cool air in the
airflow 1018
so as to reduce the overall vapour temperature. Each of these advantages can
contribute to improving the quality of the vapour output that is inhaled by
the user
of a vapour generation device comprising a vaporisation component having an
evaporator 1002 with recessed portions 1050.
The recessed portions 1050 are arranged in close proximity to the first
openings
110 of the evaporator channels 108. More specifically, in the example of
Figures
10A-C, the recessed portions 1050 and the first openings 110 are alternately
arranged in the first surface 1004. In other examples, the recessed portions
1050
and first openings 110 may be arranged in any other suitable pattern such that
droplets in the vapour are suitably carried away from the first surface 1004
of the
evaporator 1002.
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In an examples, the recessed portions 1050 can have depths ranging from 1 to
10
mm. The recessed portions 1050 could, however, have other suitable depths for
perturbing the airflow 1018 across the first surface 1004.
Whilst Figures 10A-C depict the recessed portions 1050 in a flat first surface
1004,
similar to that of Figure 1, in other examples the recessed portions 1050 can
be
arranged in a non-flat first surface, or a non-flat portion of the first
surface, such
as the non-flat first surfaces (or non-flat portions of first surfaces)
described with
reference to Figures 2 to 9. In this way, the combination of the non-flat
surface
and the recessed portions can be used to interfere with the airflow in the
airflow
channel 128.
A particular example of such an arrangement is presented in Figure 11 which
shows a cross-sectional diagram of a portion of a vaporisation component 1100
for a vapour generation device viewed along a direction perpendicular to the
direction along the airflow channel 128 toward the mouthpiece 120. The first
surface 1104 of the evaporator 1102 is similar to that of Figure 2 in that the
first
surface 1104 is non-flat in having a region 1130 that is concavely shaped
relative
to the airflow channel 128 so as to provide a curved profile. The concave
region
1130 of the first surface 1104 further comprises a plurality of recessed
portions
1150 within the concave region 1130.
Whilst Figure 11 shows a first surface 1104 having a non-flat region 1130 that
substantially coincides with the arrangement of the recessed portions 1150
such
that recessed portions 1150 are within the non-flat region 1130, various other
arrangements of recesses in combination with non-flat surfaces can be
achieved.
In an example, at least one region of the first surface can be non-flat in one
or
more of the manners described with respect to Figures 2 to 9, with at least
another
region of the first surface comprising recessed portions as described with
reference to Figure 10. In another example, at least one region of the first
surface
can be non-flat in one or more of the manners described with respect to
Figures
2 to 9 and at least one sub-region within this region can comprise the
recessed
portions described with reference to Figure 10. In yet another example, at
least
one region of the first surface can comprise recessed portions as described
with
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reference to Figure 10, and at least one sub-region within this region can be
non-
flat in one or more of the manners described with reference to Figures 2 to 9.
The first surface of the evaporator described with reference to Figures 1 to
11 can
be further modified to comprise hydrophobic properties. Droplets from the
generated vapour flow may condense on the surface of the evaporator; the
hydrophobic properties are configured to repel droplets on the first surface
by the
Lotus effect. Advantageously, the hydrophobic properties help to inhibit the
build-
up of droplets on the evaporator surface. The repulsion of the droplets aids
in
removing the droplets from the first surface when combined with the airflow in
the
airflow channel. The build-up of droplets on the evaporator surface can
negatively
impact the operation of the evaporator; the removal of the droplets, aided by
the
hydrophobic properties, helps to negate this issue.
In an example, the
hydrophobic properties can provide superhydrophobicity with a contact angle
for
liquid droplets in excess of 150 .
In examples, the hydrophobic properties can be provided by a hydrophobic
layer,
a structured surface, or a combination thereof.
In some examples, the
hydrophobic properties can be provided by adding a chemical coating to the
first
surface of the evaporator. In other examples, the hydrophobic properties can
be
provided by applying a physical treatment to the first surface of the
evaporator. In
further examples, the hydrophobic properties can be provided by a combination
of adding a chemical coating and applying a physical treatment to the first
surface
of the evaporator.
At least a portion of the first surface of the evaporator can be a hydrophobic
structured surface; this hydrophobic structured surface can comprise micro-
structuring and/or nano-structuring by patterning the first surface of the
evaporator
such that the structuring is integrated into the evaporator itself. That is to
say, the
first surface of the evaporator is modified to comprise a plurality of micro-
scale
and/or nano-scale features that provide hydrophobic properties; this can be
achieved by the features providing a microscale and/or nanoscale roughness on
the surface.
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Alternatively or additionally to the structured surface being integrated into
the
evaporator itself, at least a portion of the first surface of the evaporator
can have
a hydrophobic layer arranged thereon to provide or further contribute to the
hydrophobic properties. This hydrophobic layer can be considered as a separate
material, with a hydrophobic properties, that at least partially coats the
first surface
of the evaporator. In this way, the hydrophobic layer at least partially forms
the
first surface. In examples, the hydrophobic layer can comprise at least one of
a
high temperature polymer, a rare earth oxide or ceramic, grafted organic
molecules such as those comprising a fluoro-alkyl or alkyl chain (self-
assembled
monolayer) or polymers such as Teflon-like polymers; such layers can be
deposited onto a silicon evaporator for example. The hydrophobic layer can be
micro-patterned or nano-patterned when formed on the first surface of the
evaporator, thereby forming a micro-structured or nano-structured surface in
the
hydrophobic layer itself. In an example, this patterning of the hydrophobic
layer
can be achieved with photoresist processes such photolithographic patterning.
The dimensions of the aforementioned structures of the surface (achieved
either
by the structuring being integrated into the evaporator itself, or the
structuring
being in the hydrophobic layer) may range from the order of hundreds of
nanometres to hundreds of micrometres. The requisite dimensions can be
determined based upon the desired contact angle of the liquid. In some
examples
the structured surface can comprise a hierarchical structure. Such a
hierarchical
structured surface is defined by a micro-scale roughness, wherein the features
providing the micro-scale roughness are themselves covered by a nano-scale
roughness. The structured surfaces can allow a liquid droplet on the surface
to
be in the Cassie-Baxter state, thereby exhibiting superhydrophobicity.
As described above, the hydrophobic properties of the surface can be provided
by the hydrophobic layer arranged on the first surface of the evaporator (i.e.
in the
absence of surface structuring integrated into the evaporator itself). Figure
12A
presents a cross-sectional diagram of an evaporator 1202A with a hydrophobic
layer 1250. The evaporator of Figure 12A comprises the features described with
reference to the vaporisation component 100 of Figures 1A and 1B (as in some
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cases denoted by the common reference numerals), but with the addition of the
hydrophobic layer 1250, and is integratable into a vaporisation component and
vapour generation device in accordance with that described with reference to
Figures 1A and 1B. In the example of Figure 12A, the hydrophobic layer 1250 is
5 itself patterned to form a plurality of micro/nanostructures. As is
depicted, the
hydrophobic layer 1250 repels the liquid droplet 1260 on the first surface
1204
such that contact angle is created. The airflow in the airflow channel 128 can
then
move the liquid droplet 1260 along the airflow channel 128. Figure 12C
presents
a three-dimensional perspective diagram of a region of the evaporator 1202A
10 showing the hydrophobic layer 1250 in combination with the evaporator
channels
108 and first openings 110 in the evaporator 1202A.
In other examples as described above, the hydrophobic properties of the
surface
can be provided by the structured surface integrated into the evaporator (i.e.
in
the absence of the hydrophobic coating). In further examples the hydrophobic
15 properties can be provided by a combination of both a hydrophobic layer
and a
structured surface integrated into the evaporator, for example by at least
partially
coating the structured surface with the hydrophobic layer as is depicted in
Figure
12R Figure 12B presents a variation of Figure 12A and shows a cross sectional
diagram of an evaporator 1202B having a first surface 1204B that has a
plurality
20 of micro/nano-structures 1252 integrated into it that are coated with a
hydrophobic
layer 1250. The evaporator of Figure 12B comprises the features described with
reference to the vaporisation component 100 of Figures 1A and 1B (as in some
cases denoted by the common reference numerals), but with the addition of the
plurality of micro/nano-structures 1252 and the hydrophobic layer 1250, and is
25 integratable into a vaporisation component and vapour generation device
in
accordance with that described with reference to Figures 1A and 1B. The
micro/nano-structures 1252 combine with the hydrophobic layer 1250 to provide
the hydrophobic properties that repel the liquid droplet 1260.
An exemplary method for fabricating a vaporisation component with an
evaporator
30 having a first surface with hydrophobic properties can comprise
modifying the first
surface of the evaporator to provide hydrophobic properties configured to
repel
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droplets from the vapour flow. In a specific example, modifying the first
surface
can comprise patterning the first surface of the evaporator such that the
first
surface comprises a structured surface configured to provide the hydrophobic
properties. Alternatively or additionally, modifying the first surface can
comprise
applying a hydrophobic layer to the first surface of the evaporator, for
example by
a deposition technique. In another example, modifying the first surface can
comprise patterning the hydrophobic layer such that the structured surface is
in
the hydrophobic layer.
The hydrophobic properties described can be incorporated into the evaporators
described with reference to each of Figures 1 to 11. When liquid is drawn
through
the evaporator channels 108 it may pool on the evaporator surface, either by
condensation from the vapour flow, or through not having been sufficiently
heated
in the evaporator channels 108. This pooling can then block the evaporator
channels 108 and prevent the evaporator channels 108 drawing more liquid
through by capillary force. The hydrophobic properties are particularly
beneficial
when incorporated into the first surface of the evaporators described with
reference to Figures 1 to 11 as the hydrophobic properties provide a repulsion
of
any liquid on the first surface of the evaporator, thereby inhibiting the
pooling of
any liquid on the first surface and reducing or preventing such blockages of
the
evaporator channels 108.
When incorporated into the evaporators described with reference to Figures 2
to
11, the first surface of the evaporator can provide an interference with the
airflow
in the airflow channel so as to affect the distribution of droplets in the
vapour flow
by way of the non-flat surface and/or the recessed portions. This can combine
with the repulsion of liquid droplets on the first surface provided by the
hydrophobic properties. For example, the perturbed airflow can project the
repelled liquid droplets into the vapour flow.
An advantage that can be realised through this combination of features is that
the
non-flat first surface and/or the recessed portions in the first surface
improve the
mixing and distribution of droplets in the vapour flow, and the hydrophobic
properties contribute to aiding the droplets to be carried away from the first
surface
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for incorporation into the vapour flow, and inhibiting the loss of vapour or
droplets
from the vapour flow due to condensation on the first surface, by way of the
hydrophobicity providing for the repulsion of such droplets. This combination
of
effects is particularly beneficial in enhancing the experience of the consumer
by
providing a desirable distribution of droplets in the vapour inhaled by the
consumer.
Another advantage that can be realised through this combination of features is
that the hydrophobic first surface can contribute to inhibiting the blockage
of the
evaporator channels 108 by repelling condensed liquid droplets from the
surface
of the evaporator. The perturbed airflow, provided by the non-flat first
surface
and/or the recessed portions in the first surface can then carry these
repelled liquid
droplets away from the first surface of the evaporator. This also decreases
the
chance of coalescence of these repelled droplets on the first surface forming
larger droplets that could negatively impact the efficiency of the evaporator
operation, for example through blocking evaporator channels and/or affecting
the
heating profile of the evaporator.
Whilst the description relating to Figures 2 to 12 has been described with
reference to an evaporator having evaporator channels passing therethrough,
the
shapes, structures and modifications of the first surfaces described with
reference
to Figures 2 to 12 can be readily applied to any other type of evaporator or
heater
in a vapour generation device, aerosol generation device, or electronic
cigarette
as appropriate.
It will be readily understood that the features of any of the embodiments
described
herein can be readily combined with the features of any of the other
embodiments
described herein without falling outside of the scope of the present
disclosure. In
particular, any features described with reference to any one of the examples
of
evaporators and vaporisation components of Figures 1 to 12 can be readily
combined with the other examples of evaporators and vaporisation components
of Figures Ito 12.
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