Aerosol Delivery Carrier Substrate for Uniform Heating
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Solution Overview
Problem
Aerosol delivery devices that heat tobacco can face challenges in achieving uniform heating across the cartridge, leading to potential pyrolysis and health risks due to non-uniform temperature distribution.
Innovation Solution
The aerosol delivery system employs a carrier cartridge with a heat-resistant carrier substrate that can be heated uniformly, preventing pyrolysis and ensuring consistent aerosol release. The substrate is configured to hold an aerosol-forming precursor and is designed to be penetrable by a heater element, promoting efficient heat transfer and aerosol generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heater element directly contacts tobacco in the cartridge, then heating efficiency is improved, but uniform temperature distribution deteriorates leading to pyrolysis
Solution Approach 1:
The patent introduces a heat-resistant carrier substrate as an intermediary between the heater element and the aerosol-forming precursor. The heater element contacts the carrier substrate rather than directly heating the precursor, which acts as a heat transfer medium. This mediator distributes thermal energy uniformly across the precursor while preventing direct contact that would cause localized overheating and pyrolysis.
Solution Approach 2:
The carrier substrate is designed with specific thermal properties that enable it to conduct heat uniformly across its surface area. The substrate's material composition and structural characteristics are optimized to provide consistent heat distribution to different regions of the precursor, ensuring uniform heating without creating hot spots that would lead to pyrolysis.
2Productivity
If heating temperature is increased to improve aerosol generation, then aerosol release efficiency is improved, but pyrolysis risk increases
Solution Approach 1:
The patent utilizes the carrier substrate's thermal properties as a controlling parameter to manage the heating process. The substrate's thermal conductivity, heat capacity, and thermal stability are selected to maintain optimal heating parameters that efficiently generate aerosol while preventing temperature excursions that would cause pyrolysis. The substrate acts as a thermal buffer that stabilizes the heating parameters.
Solution Approach 2:
The carrier substrate is designed as a heat-resistant material or composite material with specific thermal characteristics. These materials are engineered to provide both efficient heat transfer for aerosol generation and thermal protection against pyrolysis. The composite structure may include materials with complementary thermal properties that balance heating efficiency and pyrolysis prevention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures uniform heating of the aerosol-forming precursor, reducing the risk of pyrolysis and enhancing the consistency and safety of aerosol delivery, while maintaining a user experience similar to traditional smoking products.
Implementation Method 1
heating of the carrier substrate to cause release of an aerosol-forming precursor therefrom
Implementation Method 2
a heating element operable to heat a carrier substrate
Implementation Method 3
heating, as opposed to burning, the tobacco may reduce the odour and health risks that can arise through combustion and pyrolytic degradation of tobacco
Data Source
AI summary
There is disclosed an aerosol delivery system comprising: an aerosol-generating device comprising: a device housing having an open-ended heating chamber configured to receive a carrier cartridge; a heater element disposed within the heating chamber and configured to receive at least a first end of a carrier cartridge, said heating element operable to heat a carrier substrate of a carrier unit of said carrier cartridge to cause release of an aerosol-forming precursor therefrom to generate an aerosol when gas is passed through the carrier cartridge; and a carrier cartridge comprising a carrier unit, said carrier unit comprising a carrier substrate configured to hold an aerosol-forming precursor comprising a nicotine-containing and/or flavoured fluid, gel, wax, or powder. Also disclosed are a carrier cartridge, carrier unit, methods of manufacturing one or more components of said system, and a kit-of-parts for assembling the system.