Aerosol Generating Material Composition and Processing
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Solution Overview
Problem
Current methods for producing aerosol-generating materials for non-combustible aerosol provision systems face challenges in achieving optimal area density, tensile strength, and volatile content retention, leading to issues with processing efficiency and sensory properties.
Innovation Solution
A process involving the formation of a first composition with a binder and aerosol former, and a second composition with tobacco material and filler, combined in a specific ratio to create an aerosol-generating material with controlled particle size distribution and reduced volatile content, enhancing burst strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce aerosol-generating material, then the material can be manufactured, but the area density, tensile strength, and volatile content retention are suboptimal
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of the aerosol-generating material. Specifically, it defines a mixture comprising tobacco material, filler, binder, and aerosol former in specific proportions (tobacco material 40-80 wt%, filler 10-40 wt%, binder 1-10 wt%, aerosol former 1-10 wt%). This parameter optimization achieves optimal area density while maintaining adequate tensile strength and volatile content retention.
Solution Approach 2:
The patent employs composite materials by combining multiple components (tobacco material, filler, binder, and aerosol former) in a specific composite structure. The filler material (such as cellulose, wood fiber, or plant fiber) is integrated with tobacco material and binder to create a composite aerosol-generating material that achieves both optimal area density and sufficient tensile strength, resolving the contradiction between these two properties.
2Productivity
If conventional manufacturing methods are used, then production can proceed, but processing efficiency is reduced and sensory properties are compromised
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition parameters of the aerosol-generating material. The specific ratio ranges (binder 1-10 wt%, aerosol former 1-10 wt%) are designed to achieve the right balance between processing efficiency and sensory properties. This parameter optimization allows for easier manufacturing while maintaining desirable sensory characteristics.
Solution Approach 2:
The patent applies local quality by ensuring uniform distribution of specific components throughout the aerosol-generating material. The binder and aerosol former are distributed locally and uniformly within the tobacco material matrix, creating regions with optimized properties that enhance both processing efficiency and sensory characteristics.
Data Source
AI summary
A process for preparing an aerosol generating material including forming a first composition having a first binder and an aerosol former, forming a second composition having a tobacco material, a filler and optionally a second binder, combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture including the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture and processing the mixture of the first composition and the second composition to form the aerosol generating material.