Aerosol Composition with Embedded Susceptor for Heat Transfer
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Solution Overview
Problem
Current aerosol-generating systems for non-combustible aerosol provision, such as tobacco heating devices, face challenges in efficiently generating aerosols without combustion, requiring innovative compositions and manufacturing processes to enhance aerosol production and user experience.
Innovation Solution
An aerosol-generating composition comprising a binder, an aerosol former, and a susceptor partially embedded in the aerosol-generating material, which can be in the form of a slurry, sheet, or fibrous sheet, heated by a varying magnetic field to produce aerosols, with the susceptor being in the form of particles, loops, or fibrous materials for effective heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a susceptor is embedded in aerosol-generating material to enable non-combustible aerosol production, then aerosol generation efficiency is improved, but manufacturing complexity increases due to the embedding process
Solution Approach 1:
The patent combines the susceptor and aerosol-generating material into a single integrated composition during the slurry formation stage. The susceptor particles are mixed with the slurry containing binder and aerosol former, allowing simultaneous processing rather than separate embedding steps. This merging approach maintains aerosol generation efficiency while reducing manufacturing complexity by consolidating multiple operations into one cohesive process.
Solution Approach 2:
The slurry formulation serves multiple functions simultaneously: it acts as the binder matrix, provides the aerosol former, and serves as the medium for susceptor distribution. This multi-functional approach eliminates the need for separate embedding processes, reducing manufacturing steps while maintaining the heat transfer efficiency required for effective aerosol generation.
2Temperature
If the susceptor is partially embedded in the aerosol-generating material, then heat transfer efficiency is improved, but the structural stability of the material may be compromised
Solution Approach 1:
The patent employs partial embedding of the susceptor in the aerosol-generating material, creating local variations in susceptor concentration and depth. This local quality approach allows regions with higher susceptor content for efficient heat transfer while maintaining other regions with sufficient material integrity for structural stability. The binder composition is specifically formulated to accommodate this heterogeneous distribution.
Solution Approach 2:
The patent creates a composite material system combining the susceptor particles, binder matrix, and aerosol former in specific proportions. This composite structure leverages the thermal properties of the susceptor while the binder provides structural cohesion. The composite formulation ensures that even with partial susceptor embedding, the overall material maintains adequate structural stability for handling and device integration.
3Reliability
If aerosol-generating material is formed as a slurry with embedded susceptor, then aerosol quality is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary mixing of the susceptor with the slurry components before final material formation. This preliminary action ensures uniform susceptor distribution and proper embedding during the slurry-to-material transition. By preparing the susceptor-slurry mixture in advance with controlled parameters, the process achieves consistent aerosol quality while managing manufacturing complexity through pre-planned, standardized procedures.
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 composition enables efficient aerosol generation with improved heat transfer and stability, enhancing the manufacturing process and user experience by providing a consistent and high-quality aerosol without combustion, thus addressing the limitations of existing systems.
Implementation Method 1
a susceptor at least partially embedded in the aerosol-generating material... the susceptor comprises a plurality of susceptor elements heatable by penetration with a varying magnetic field
Data Source
AI summary
An aerosol-generating composition having aerosol-generating material including a binder and an aerosol former and at least one susceptor at least partially embedded in the aerosol-generating material.