Aerosol-Forming Sheet With Angled Heating Section
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Solution Overview
Problem
Existing aerosol delivery devices face challenges in efficiently evaporating solutions within the device while minimizing condensation on internal components, leading to a less compact design and increased manufacturing costs.
Innovation Solution
An aerosol-forming member comprising a sheet of material with a capillary structure that can wick and heat a solution, where the first section is heated relative to the second and third sections, forming a channel that directs airflow and reduces condensation on internal components, and is integrated with a liquid reservoir matrix for continuous solution replenishment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heating element is used to evaporate the solution, then aerosol generation efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the wicking function and heating function into a single integrated sheet structure. The sheet comprises a wicking portion that draws solution via capillary action and a heating portion that evaporates the solution, both functions merged in one component rather than separate elements. This integration reduces device complexity while maintaining aerosol generation efficiency.
Solution Approach 2:
The sheet structure serves multiple functions simultaneously: it acts as a solution reservoir (through the liquid reservoir matrix), a wick (via capillary structure), and a heater (through the heating portion). This multi-functionality eliminates the need for separate components, reducing manufacturing cost and device complexity while preserving effective aerosol generation.
2Object-affected harmful factors
If the heating portion is isolated from the liquid reservoir matrix, then condensation on internal components is reduced, but solution replenishment efficiency decreases
Solution Approach 1:
The sheet structure implements local quality differentiation: the heating portion is thermally isolated from the liquid reservoir matrix to prevent condensation, while the wicking portion maintains direct capillary connection for efficient solution replenishment. This localized functional differentiation allows the heating area to remain separate thermally while the solution supply path remains connected through the capillary structure.
Solution Approach 2:
The wicking portion acts as an intermediary between the liquid reservoir matrix and the heating portion. It transfers solution via capillary action from the reservoir to the heating area, enabling thermal isolation between the heating portion and liquid reservoir matrix while maintaining efficient solution replenishment through the mediating wick structure.
3Adaptability or versatility
If multiple separate components are used for wicking and heating, then functional control is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the wicking function and heating function into a single sheet component with distinct functional zones. The sheet integrates the wicking portion and heating portion in one manufacturable unit, reducing the number of separate components and assembly steps while maintaining independent functional control through the differentiated structure.
Solution Approach 2:
The sheet comprises composite structures including a liquid reservoir matrix and a capillary structure with different functional zones. This composite design allows different regions of the same component to perform different functions (wicking vs. heating) while being manufactured as a single integrated piece, reducing manufacturing cost while preserving functional control.
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
This configuration allows for efficient evaporation of solutions into inhalable aerosols, reduces condensation on internal components, and results in a more compact and cost-effective aerosol delivery device with improved user comfort.
Implementation Method 1
The sheet of material comprises a capillary structure configured to wick a solution
Implementation Method 2
the first section is configured to be heated relative to the second section
Implementation Method 3
This vapor condenses within the aerosol delivery device as it mixes with air so as to form droplets or aerosol which is suitable for inhalation
Data Source
AI summary
An aerosol-forming member comprising a sheet of material configured to wick and to heat a solution. The sheet of material has a first section and a second section. The first section extends at an angle relative to the second section, wherein the first section is configured to be heated relative to the second section.