Inductively Heated Aerosol Substrate with Airflow Channels
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Solution Overview
Problem
Current aerosol generating devices face challenges in optimizing the characteristics of the aerosol generated, particularly in terms of efficiency and ease of use, when combined with aerosol generating articles.
Innovation Solution
The aerosol generating article comprises a substantially planar substrate with an inductively heatable susceptor and airflow channels, designed for use with a portable aerosol generating device, ensuring efficient heating and directed airflow to maximize vapour and aerosol generation without burning the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an induction heating system with susceptor is used to heat the aerosol generating substrate, then heating efficiency and temperature control are improved, but device complexity increases due to the additional induction coil and susceptor components
Solution Approach 1:
The susceptor is integrated directly into the aerosol generating substrate, merging the heating function with the substrate itself. This combination eliminates the need for separate heating elements while maintaining efficient induction heating, thereby improving heating efficiency without proportionally increasing device complexity
Solution Approach 2:
The susceptor acts as an intermediary component that converts electromagnetic energy from the induction coil into thermal energy directly at the substrate location. This mediator enables precise local heating with high efficiency while keeping the induction coil external and separate, managing device complexity through functional separation
2Productivity
If airflow channels are formed in the aerosol generating substrate, then aerosol delivery and vapour generation are improved, but manufacturing complexity increases due to additional forming steps
Solution Approach 1:
The substrate is segmented into functional regions including airflow channels, susceptor zones, and aerosol generation areas. This segmentation allows optimized aerosol delivery through dedicated flow paths while enabling modular manufacturing processes that can create complex structures through standardized forming steps
Solution Approach 2:
The manufacturing process utilizes parameter changes in the substrate material during forming to create airflow channels. By adjusting material properties or processing parameters during manufacturing, complex channel structures are created without adding significant manufacturing complexity, enabling efficient aerosol delivery
3Quantity of substance
If the aerosol generating substrate is heated to high temperature to generate sufficient vapour, then aerosol quantity is improved, but risk of burning or combusting the substrate increases
Solution Approach 1:
The susceptor is positioned in specific locations within the substrate to create localized heating zones. This local quality approach generates sufficient vapour quantity at targeted areas without uniformly heating the entire substrate to combustion temperatures, thereby maintaining aerosol quantity while reducing combustion risk through spatially selective heating
Solution Approach 2:
The patent replaces conventional direct contact heating mechanisms with induction heating technology. This substitution uses electromagnetic fields to generate heat within the susceptor material itself, providing precise temperature control that achieves sufficient vapour generation while preventing substrate combustion through non-contact and controllable 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
This configuration enables rapid, efficient, and reliable vapour generation, optimizing the quantity and delivery of aerosol to the user, while minimizing residue build-up and maintenance requirements.
Implementation Method 1
an inductively heatable susceptor positioned in the aerosol generating substrate
Implementation Method 2
heating the aerosol generating substrate to generate an aerosol or vapour by heating an aerosol generating substrate to a temperature typically in the range 150° C. to 300° C.
Implementation Method 3
Heating the aerosol generating substrate to a temperature within this range, without burning or combusting the aerosol generating substrate, generates a vapour which typically cools and condenses to form an aerosol for inhalation by a user of the device
Data Source
AI summary
An aerosol generating article for use with an aerosol generating device includes a substantially planar aerosol generating substrate, at least one airflow channel extending along the substantially planar aerosol generating substrate, and an inductively heatable susceptor positioned in the aerosol generating substrate. The aerosol generating article can optionally include a wrapping member surrounding the substantially planar aerosol generating substrate and the at least one airflow channel. Methods of manufacturing the aerosol generating article are also described.