Aerosol Consumable with Sorbent-Adsorbed Active Substance
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Solution Overview
Problem
Existing consumables for non-combustible aerosol provision devices face challenges in achieving consistent and efficient aerosol generation, as the evaporation rates of solvents and active substances during manufacturing can lead to inconsistent product quality and significant substance loss.
Innovation Solution
A consumable design featuring a support with separate aerosol generating material and a substance to be delivered, where the substance is absorbed or adsorbed onto a sorbent material, allowing for controlled aerosolization at lower temperatures and improved consistency, and a method of manufacturing that applies these components separately to optimize their distribution and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvents and active substances are applied together during manufacturing, then manufacturing process is simpler, but evaporation rates cause inconsistent product quality and significant substance loss
Solution Approach 1:
The patent divides the manufacturing process into separate stages: first applying the solvent-containing slurry and drying it to form a dried layer, then separately applying the active substance to the dried layer. This segmentation prevents simultaneous evaporation issues and ensures consistent product quality while maintaining manufacturing simplicity.
2Productivity
If heating temperature is increased to improve aerosol generation efficiency, then aerosol volume increases, but substance loss during manufacturing increases
Solution Approach 1:
The patent performs preliminary drying of the solvent-containing layer before applying the active substance. This preliminary action removes the solvent in advance, preventing substance loss during subsequent heating stages while still enabling efficient aerosol generation when the device is used.
3Loss of time
If solvent evaporation is accelerated during manufacturing, then drying time is reduced, but active substance loss increases
Solution Approach 1:
The patent segments the evaporation process into two distinct phases: first, the solvent in the slurry is evaporated during the drying step to form a dried layer; second, the active substance is applied to this dried layer where no further evaporation occurs. This segmentation reduces drying time while preventing active substance loss.
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 solution enables faster aerosol formation, consistent flavor profile, and increased aerosol volume per unit of heat energy, with improved storage characteristics and reduced substance loss during manufacturing.
Implementation Method 1
the substance to be delivered is absorbed or adsorbed onto a sorbent material
Implementation Method 2
the substance to be delivered is absorbed or adsorbed onto a sorbent material
Implementation Method 3
the substance to be delivered volatilizes on heating of one or both of the support or the aerosol generating material
Data Source
AI summary
A consumable for use with an aerosol provision device including a support, an aerosol generating material, and a substance to be delivered that may be caused to volatilize, in which the support supports the aerosol generating material, and the substance to be delivered volatilizes on heating of one or both of the support or the aerosol generating material.