Aerosol Delivery Device Mouthpiece Micro-Patterned Surface
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Solution Overview
Problem
Aerosol delivery devices, such as e-cigarettes, face the issue of liquid aerosol precursor droplets condensing and exiting the mouthpiece, leading to inefficiency and an unsatisfactory user experience due to wasted aerosol and potential liquid contact with surrounding surfaces.
Innovation Solution
The implementation of a micro-patterned surface with capillary channels or an absorptive component, such as cellulose acetate combined with wood pulp and PVA, within the mouthpiece to inhibit liquid droplets from exiting, either by directing them away or entrapping them, thereby minimizing waste and enhancing aerosol delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If aerosol precursor is heated and vaporized to form inhalable aerosol, then aerosol delivery is achieved, but liquid droplets may condense and exit the outlet causing waste and user experience issues
Solution Approach 1:
The patent employs a porous wicking material positioned at the outlet to capture liquid droplets through capillary action. The porous structure allows vapor to pass through while retaining liquid, preventing liquid carryover and improving aerosol delivery efficiency without sacrificing precursor material.
Solution Approach 2:
The patent introduces a condensation chamber as an intermediary component between the heating element and the outlet. This chamber provides a controlled environment where condensed liquid can be collected and redirected, acting as a mediator that separates vapor flow from liquid droplets to prevent waste.
2Temperature
If aerosol precursor is heated to high temperature to vaporize effectively, then aerosol formation is improved, but liquid droplets may form due to condensation and exit the device
Solution Approach 1:
The patent divides the aerosol delivery path into distinct functional zones: a heating zone for vaporization, a condensation chamber for liquid separation, and a delivery zone for aerosol output. This segmentation allows each zone to optimize its function while preventing composition instability caused by liquid contamination.
Solution Approach 2:
The patent implements preliminary condensation and liquid removal actions before the aerosol reaches the outlet. By providing a condensation chamber with wicking material upstream of the outlet, liquid droplets are removed in advance, ensuring stable aerosol composition at the point of delivery.
3Productivity
If the outlet is designed for easy aerosol flow, then aerosol delivery is efficient, but liquid droplets can easily exit the outlet
Solution Approach 1:
The patent applies local quality changes by positioning a porous wicking material specifically at the outlet region where liquid droplet capture is most critical. This localized treatment maintains efficient aerosol flow through the main channel while creating a selective barrier at the outlet that captures liquid without significantly impeding vapor flow.
Solution Approach 2:
The patent extracts the liquid droplet removal function from the main aerosol flow path by implementing a separate condensation chamber and wicking system. This extraction allows the main outlet to remain optimized for aerosol flow while the extracted liquid removal mechanism handles droplet capture independently.
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 solution effectively reduces the exit of liquid droplets, improving aerosol delivery efficiency and user experience by preventing condensation from being pulled out during inhalation and ensuring a more consistent aerosol delivery.
Implementation Method 1
the micro-pattern comprising a plurality of capillary channels sized and arranged to direct liquid away from the outlet
Implementation Method 2
an absorptive component formed from cellulose acetate combined with wood pulp and a polyvinyl alcohol (PVA) binder disposed within a mouthpiece
Data Source
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AI summary
An aerosol delivery device is disclosed. The aerosol delivery device includes an atomizer (310) and a body (314). The body has an outlet (328) and houses the atomizer. The aerosol delivery device also includes a structure configured to inhibit liquid droplets of an aerosol precursor from exiting the outlet. Embodiments of the structure include micro-patterned surfaces, absorbers, and macro structures to create droplet capturing chambers.