Aerosol Substrate Channel Structure for Low-Resistance Puffing
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Solution Overview
Problem
Existing vapor generating products experience high inhalation resistance and significant variability in aerosol volume between puffs.
Innovation Solution
The aerosol generating substrate features channels and micropores that facilitate airflow, with airway holes and grooves designed to enhance heat transfer and reduce inhalation resistance, while the functional section includes a filtering component to improve inhalation uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional aerosol generating substrate structure is used, then manufacturing is simple, but inhalation resistance is high and aerosol delivery uniformity is poor
Solution Approach 1:
The substrate structure is segmented into multiple functional regions: heating region with heating elements, aerosol generation region with micropores, and airway region with channels. This segmentation allows each region to be optimized for its specific function, reducing overall inhalation resistance while maintaining manufacturing feasibility through modular construction
Solution Approach 2:
The invention introduces a three-dimensional network of channels and micropores within the substrate, transitioning from a two-dimensional surface structure to a volumetric flow path system. This dimensional enhancement creates multiple airflow pathways that reduce resistance while the structured arrangement maintains manufacturability
2Reliability
If traditional aerosol generating substrate structure is used, then structure is simple, but aerosol volume consistency between puffs is poor
Solution Approach 1:
Different regions of the substrate are assigned different local qualities: the heating region has high thermal conductivity for efficient heating, the micropore region has controlled porosity for consistent aerosol generation, and the channel region has optimized geometry for uniform flow distribution. This local differentiation ensures reliable aerosol delivery while the systematic design keeps manufacturing manageable
Solution Approach 2:
The invention optimizes critical parameters including micropore size distribution (0.1-10 μm), channel dimensions (length 1-5mm, diameter 10-100 μm), and porosity (30-70%) to achieve consistent aerosol generation. These parameter specifications provide reliable performance while being achievable through standard manufacturing processes
3Ease of operation
If larger channel cross-sectional area is used, then inhalation resistance decreases, but substrate surface area for aerosol generation decreases
Solution Approach 1:
The invention resolves this contradiction by developing channels in the third dimension (through the substrate thickness) rather than expanding them on the two-dimensional surface. This allows the substrate to maintain its external surface area for aerosol generation while internal channels provide low-resistance airflow pathways through the volumetric structure
Solution Approach 2:
The channel structure is nested within the substrate matrix, with channels positioned internally rather than occupying external surface area. This nesting arrangement allows the substrate to maximize its external surface area for heating and aerosol generation while containing efficient airflow channels within its volume
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 design reduces inhalation resistance and enhances the uniformity of aerosol delivery, providing a better user experience by ensuring consistent aerosol release and smoother airflow.
Implementation Method 1
a heating element configured to heat the aerosol generating substrate
Implementation Method 2
an aerosol generating substrate... When heated, a substrate of the aerosol generating substrate releases aerosols
Implementation Method 3
the aerosols converge into the channel through the micropores and are delivered to an inhalation end under the action of a negative inhalation pressure
Data Source
Figure 1~2
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Figure 5~6
AI summary
An aerosol generating substrate (10) and an aerosol generating product. The aerosol generating substrate (10) is provided with channels (10a); the channels (10a) pass through at least one end of the aerosol generating substrate (10) in the length direction; micropores (10d) are formed in the aerosol generating substrate (10); the micropores (10d) are communicated with the channels (10a). The channels (10a) of the aerosol generating substrate (10) can increase the surface area of the aerosol generating substrate (10), thereby facilitating heat transfer and improving heating efficiency. The aerosol generating substrate (10) releases an aerosol when heated, the aerosol is collected into the channels (10a) by means of the micropores (10d) and is conveyed to a vaping end under the action of vaping negative pressure, and the channels (10a) can reduce the vaping resistance of users during vaping, thereby improving user experience.