Aerosol Formulation Sealing via Phase Transition
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Solution Overview
Problem
Aerosol-generating systems face issues with leakage of formulations due to inadequate sealing, particularly when the material fails to retain the formulation as designed, leading to unwanted leakage during use or due to changes in pressure or temperature.
Innovation Solution
A formulation comprising one or more aerosol formers and polymeric thickening agents with a content of greater than or equal to 0.5% by weight, which forms a solid layer upon cooling after heating, creating a barrier to seal the reservoir and prevent leakage, and can be re-melted for repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical liquid nicotine formulation is used in an aerosol-generating system, then the system can generate aerosol effectively, but the formulation may leak from the reservoir due to inadequate sealing
Solution Approach 1:
The patent changes the physical-chemical parameters of the formulation by adding polymeric thickening agents (increasing viscosity) and utilizing phase transition materials that solidify at lower temperatures. This transforms the formulation from a purely liquid state to a material that can transition between liquid and solid states, enabling it to form sealing barriers that prevent leakage while maintaining aerosol-generating capability.
Solution Approach 2:
The patent exploits phase transitions of the formulation material. The formulation contains materials that transition from liquid to solid phase at specific temperature thresholds (below body temperature). During aerosol generation, the material is heated and vaporized; after use, it cools and solidifies to form a sealing barrier, preventing leakage. This cyclic phase transition enables both functional performance and sealing reliability.
2Productivity
If the formulation is heated to generate aerosol, then vaporization efficiency is maintained, but the material may fail to seal properly due to temperature-induced changes
Solution Approach 1:
The formulation is designed to undergo reversible phase transitions based on temperature. During aerosol generation, heating causes the material to transition to liquid/vapor phases for efficient vaporization. After use, cooling causes it to transition to solid phase, forming a sealing barrier. This temperature-dependent phase transition resolves the contradiction between maintaining vaporization efficiency during operation and achieving sealing capability during storage.
Solution Approach 2:
The formulation exhibits periodic behavior through cyclic heating and cooling. During the heating phase (aerosol generation), the material is in a liquid/vapor state for efficient vaporization. During the cooling phase (between uses), it transitions to solid state for sealing. This periodic transformation between functional states allows the system to alternate between aerosol generation and leakage prevention modes.
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 formulation effectively reduces the risk of leakage by forming a solid barrier that seals the reservoir, preventing flooding and allowing for repeated use without compromising the efficiency of nicotine vaporization.
Implementation Method 1
When the formulation cools after being heated, at least a portion of the formulation in the region of the heater may solidify to form a solid layer
Implementation Method 2
The formulation may comprise one or more polymeric thickening agents. The formulation may have a polymeric thickening agent content of greater than or equal to about 0.5 percent by weight
Implementation Method 3
Some known aerosol-generating systems comprise a thermal atomiser such as an electric heater that is configured to heat and vaporise the formulation to generate an aerosol
Data Source
AI summary
A formulation for an aerosol-generating system is provided, the formulation including: one or more aerosol formers; one or more metal salts; and one or more polymeric thickening agents, in which the formulation has a polymeric thickening agent content of greater than or equal to about 0.5 percent by weight, and in which the one or more metal salts include one or more metal stearates. An aerosol-generating article for the aerosol-generating system, and an aerosol-generating system, are also provided.