Aerosol-Generating Material Thickness and Density Optimization
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Solution Overview
Problem
Existing aerosol-generating materials for non-combustible aerosol provision systems face challenges in achieving optimal thickness, area density, and tensile strength, which affect heating efficiency, handling, and aerosol formation, with materials being either too thick for efficient heating or too thin for structural integrity.
Innovation Solution
Aerosol-generating material comprising a sheet or shredded sheet of tobacco material, aerosol-former material, and binder, with a thickness of at least 100 μm and area density of 100 g/m² to 250 g/m², processed to have a tensile strength of at least 4 N/15 mm, and incorporating a filler like fibrous material to enhance structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of aerosol-generating material is increased to improve structural integrity, then tensile strength is improved, but heating efficiency deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness parameter within 100-300 μm and area density within 100-250 g/m² ranges. This optimization resolves the contradiction by finding the optimal parameter values that provide sufficient structural integrity while maintaining heating efficiency, avoiding both excessive thickness and insufficient strength.
Solution Approach 2:
The patent uses composite materials by combining tobacco material with binder and aerosol-former material in specific ratios (tobacco material 70-90 wt%, binder 5-20 wt%, aerosol-former material 10-25 wt%). This composite approach allows the material to achieve both mechanical strength and heating efficiency through the synergistic properties of different components.
2Ease of operation
If the area density of aerosol-generating material is increased to improve handling and structural integrity, then ease of operation is improved, but heating efficiency deteriorates
Solution Approach 1:
The patent optimizes the area density parameter within the 100-250 g/m² range to resolve the contradiction between handling ease and heating efficiency. This parameter optimization ensures the material is sufficiently dense for easy handling while remaining thin enough for efficient heating in the vaporization device.
3Use of energy by moving object
If the thickness of aerosol-generating material is decreased to improve heating efficiency, then heating efficiency is improved, but structural integrity deteriorates
Solution Approach 1:
The patent applies parameter changes by setting the thickness parameter within the optimal 100-300 μm range. This prevents the material from being too thin and fragile while maintaining sufficient heating efficiency, resolving the contradiction between structural integrity and heating performance.
Solution Approach 2:
The patent uses composite materials with specific composition ratios to achieve both thinness for heating efficiency and strength for structural integrity. The binder and aerosol-former material components provide mechanical reinforcement that allows the use of thinner material without sacrificing strength.
4Use of energy by moving object
If the area density of aerosol-generating material is decreased to improve heating efficiency, then heating efficiency is improved, but handling and structural integrity deteriorate
Solution Approach 1:
The patent optimizes the area density parameter within the 100-250 g/m² range to resolve the contradiction between heating efficiency and handling ease. This ensures the material is sufficiently dense for easy handling and structural stability while remaining thin enough for efficient heating.
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 provides a material that balances heating efficiency, handling ease, and aerosol formation, ensuring consistent aerosol generation with improved structural integrity and reduced power consumption.
Implementation Method 1
tobacco heating devices heat an aerosol-generating material such as tobacco to form an aerosol by heating, but not burning, the substrate
Data Source
AI summary
An aerosol-generating material having a sheet or shredded sheet of aerosolizable material including tobacco material, an aerosol-former material and a binder, wherein the sheet or shredded sheet has a thickness of at least about 100 μm and an area density of from about 100 g/m2 to about 250 g/m2. A process of manufacturing the aerosol-generating material and an article including comprising the aerosol-generating material are also disclosed.