Aerosol Matrix Extrusion and Vacuum Drying for Uniform Pore Structure
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Solution Overview
Problem
Existing methods for manufacturing aerosol generating substrates are complicated, costly, and inefficient, with high environmental pollution and low production efficiency.
Innovation Solution
A manufacturing method involving extrusion molding at normal temperatures (10 °C to 90 °C) followed by drying under negative pressure in a vacuum environment, combined with optional cooling and slitting processes, to produce a stable and uniform aerosol generating substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for aerosol generating substrates, then manufacturing precision and product stability can be maintained, but device complexity, production cost, and environmental pollution increase significantly while production efficiency remains low
Solution Approach 1:
The manufacturing process is divided into distinct operational stages: material preparation, extrusion molding, drying, and optional cooling. Each stage is independently optimized, allowing for simplified equipment design at each step while maintaining overall process efficiency and product quality
Solution Approach 2:
The patent employs specific parameter ranges (extrusion temperature: 10-90°C, drying temperature: 20-100°C, vacuum pressure: 0-101.325 kPa) to optimize the manufacturing process. These controlled parameter changes enable efficient production while simplifying equipment requirements compared to traditional methods that demand complex high-precision systems
2Manufacturing precision
If traditional manufacturing methods are used for aerosol generating substrates, then product quality can be maintained, but manufacturing cost and environmental pollution increase
Solution Approach 1:
The patent specifies optimized parameter ranges including extrusion temperature (10-90°C), drying temperature (20-100°C), and vacuum pressure (0-101.325 kPa) that achieve uniform substrate quality while minimizing equipment complexity and manufacturing cost
Solution Approach 2:
The extrusion mold and drying apparatus are designed as simple, cost-effective components that can be easily replaced or adjusted, reducing initial investment and maintenance costs while maintaining consistent product quality through parameter control rather than complex machinery
3Productivity
If extrusion temperature is increased to improve material flow, then production efficiency increases, but energy consumption and risk of burning increase
Solution Approach 1:
The patent identifies an optimal extrusion temperature range of 10-90°C that balances material flow characteristics with energy efficiency. This parameter optimization enables adequate extrusion speed while minimizing energy consumption and preventing material degradation or burning
Solution Approach 2:
The patent replaces thermal energy-intensive processes with mechanical extrusion systems that operate at lower temperatures. The extrusion device uses mechanical force to propel material through the mold, substituting for high-temperature thermal processing and thereby reducing energy consumption while maintaining productivity
4Loss of time
If drying temperature is increased to reduce drying time, then production efficiency increases, but product stability and pore structure uniformity deteriorate
Solution Approach 1:
The patent specifies an optimized drying temperature range of 20-100°C under vacuum conditions (0-101.325 kPa) that achieves efficient moisture removal while preserving uniform pore structure and product stability. The vacuum environment enhances drying efficiency within this moderate temperature range, eliminating the need for high-temperature rapid drying
Solution Approach 2:
The patent employs a vacuum environment (inert atmosphere with reduced oxygen and pressure) during drying, which prevents oxidation and degradation of the substrate materials. This inert environment enables controlled moisture removal at moderate temperatures, maintaining pore structure uniformity and product stability while achieving acceptable drying times
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 method ensures high production efficiency, low manufacturing costs, and achieves uniform internal pore distribution, enhancing the release efficiency of aerosol and aroma while maintaining product stability and reducing environmental impact.
Implementation Method 1
The extrusion substrate is dried under negative pressure in a vacuum environment
Implementation Method 2
The extrusion substrate is dried under negative pressure in a vacuum environment
Implementation Method 3
The extrusion substrate is dried under the negative pressure by at least one of microwave heating, resistance heating, or infrared heating
Implementation Method 4
The extrusion substrate is dried under the negative pressure by at least one of microwave heating, resistance heating, or infrared heating
Data Source
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AI summary
An aerosol generating matrix manufacturing method, comprising: performing room temperature extrusion molding on a mixed material, to cause the mixed material to form an extruded matrix; performing negative pressure drying on the extruded matrix in a vacuum environment. The manufacturing method combines room temperature extrusion molding with negative pressure drying, which can not only achieve a uniform and stable aerosol generating matrix having uniform internal pore distribution and high processability, but also achieve continuous production of the aerosol generating matrix with high production efficiency and low manufacturing costs. In addition, an aerosol generating matrix manufacturing device is provided.