Aerosol Cartridge Wick Layout for Angle-Independent Puff Delivery
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Solution Overview
Problem
Handheld aerosol-generating systems, such as electrically operated smoking devices, face issues with aerosol production cessation when the liquid substrate is not in contact with the capillary system due to device angle and are prone to leakage, leading to waste and inconsistent puff delivery due to capillary saturation changes.
Innovation Solution
A cartridge design with a liquid storage portion comprising two parts in fluid communication, where the first part contains a heater assembly and capillary material in contact with it, and the second part has a capillary material spaced apart from the heater, allowing for efficient liquid supply and reducing residual liquid, featuring a planar heater assembly with conductive filaments and a capillary material with a gradient of porosity to enhance capillary action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the liquid storage portion is filled with capillary material to deliver liquid to the wick, then the risk of leakage and holding angle dependency is reduced, but residual liquid remains in the capillary material after usage leading to wastage
Solution Approach 1:
The liquid storage portion is divided into two distinct parts: a first part filled with capillary material in contact with the heater assembly, and a second part that is substantially empty and arranged for supplying liquid to the first part. This segmentation allows the capillary material to be limited to only the amount needed for immediate vaporization, preventing residual liquid waste while maintaining reliable liquid delivery and leakage prevention.
2Reliability
If the liquid storage portion is filled with capillary material to ensure consistent liquid supply, then aerosol-generating performance is maintained, but inconsistency in puff deliveries occurs due to decreasing saturation of the capillary medium during usage
Solution Approach 1:
The second part of the liquid storage portion is pre-filled with liquid aerosol-forming substrate and arranged to supply liquid to the first part containing the capillary material. This preliminary arrangement ensures that the capillary material remains continuously saturated with liquid throughout usage, maintaining consistent puff deliveries and aerosol-generating performance without the inconsistency that occurs when capillary material becomes progressively depleted.
3Quantity of substance
If the tank is designed to hold liquid substrate, then liquid supply is ensured, but the system stops generating aerosol when held at angles where liquid is not in contact with the capillary system
Solution Approach 1:
The capillary material in the first part automatically draws liquid from the second part through capillary action, enabling the system to self-regulate liquid supply regardless of device orientation. This eliminates the need for gravity-dependent liquid flow, allowing the device to function consistently at any holding angle without requiring the liquid to be in direct contact with the capillary system through gravity alone.
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 cartridge design ensures consistent aerosol production independent of device angle, reduces leakage, and minimizes residual liquid, maintaining high-quality performance comparable to current cartridges while allowing for multiple puffs without flooding, thus addressing the issues of waste and inconsistency.
Implementation Method 1
a first capillary material, provided in contact with the heater assembly, and a second capillary material in contact with the first capillary material and spaced apart from the heater assembly by the first capillary material
Implementation Method 2
The vapouriser typically comprises a coil of heater wire wound around an elongate wick soaked in liquid aerosol-forming substrate
Data Source
AI summary
A heater assembly for an aerosol-generating system is provided, including: an electrically insulating support having an aperture; an electrical heating element disposed across the aperture in the electrically insulating support, being configured to heat a liquid aerosol-forming substrate to form an aerosol, and being substantially flat; capillary material, wherein a portion of the capillary material is in contact with the electrical heating element, and the capillary material is configured to convey the liquid aerosol-forming substrate to the electrical heating element; and two electrical contacts respectively connected to ends of the electrical heating element, the two electrical contacts supported by the electrically insulating support. An aerosol-generating system including an aerosol-generating device and a cartridge is also provided.