Alginate Aerosol Element for Stable High-Payload Encapsulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aerosol-generating substrates face challenges in encapsulation, particularly with hydrophilic aerosol formers like glycerin and propylene glycol, leading to instability, leakage, and adverse sensory effects due to high temperatures, and existing gel compositions struggle with geometric stability and efficient aerosol delivery.
Innovation Solution
An aerosol-generating element with a solid continuous alginate matrix structure encapsulating an aerosol-generating formulation, comprising at least 80% by weight of alkaloids or cannabinoids and polyhydric alcohols, which is stable and minimizes encapsulation material, allowing efficient aerosol release at temperatures between 150°C to 350°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrophilic aerosol formers like glycerin and propylene glycol are used in encapsulated nicotine formulations, then aerosol generation is facilitated, but instability and leakage occur due to incompatibility with hydrophilic encapsulation materials
Solution Approach 1:
The patent uses a hydrophobic encapsulation material as an intermediary barrier between the hydrophilic aerosol former (glycerin/propylene glycol) and the external environment. This hydrophobic material prevents direct interaction between water and the encapsulation layer, eliminating the incompatibility issue that causes leakage and instability.
Solution Approach 2:
The patent changes the key parameter of the encapsulation material from hydrophilic to hydrophobic. This parameter change fundamentally alters the interaction between the encapsulation layer and the aerosol former, preventing water from penetrating the encapsulation and causing instability or leakage.
2Reliability
If hydrophobic encapsulation materials are used to prevent leakage, then encapsulation stability improves, but high processing temperatures are required which risk degradation of the nicotine formulation
Solution Approach 1:
The patent selects a hydrophobic encapsulation material with a specific processing temperature range (below 150°C) that is lower than conventional hydrophobic materials. This parameter change allows adequate encapsulation stability while avoiding thermal degradation of the nicotine formulation during manufacturing.
3Reliability
If high levels of hydrophilic encapsulation material are used to produce stable encapsulated products, then product stability improves, but insufficient payload of nicotine formulation is provided
Solution Approach 1:
The hydrophobic encapsulation material acts as an intermediary that prevents water from interacting with the encapsulation layer. This eliminates the need for high levels of hydrophilic encapsulation material, allowing maximum nicotine payload while maintaining stability through the hydrophobic barrier.
4Ease of manufacture
If conventional encapsulation techniques are used with hydrophilic materials, then ease of manufacture is maintained, but geometric stability and efficient aerosol delivery are compromised
Solution Approach 1:
The patent changes the hydrophilic nature of conventional encapsulation materials to hydrophobic, maintaining the simplicity of the encapsulation process while dramatically improving geometric stability and aerosol delivery efficiency through the hydrophobic barrier mechanism.
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 solution provides a stable, efficient, and robust aerosol delivery with minimal volume loss, maintaining sensory quality and enabling easy handling and manufacturing, while maximizing the aerosol-generating formulation content.
Implementation Method 1
The aerosol-generating formulation is trapped within the solid continuous matrix structure and releasable from the solid continuous matrix structure upon heating of the aerosol-generating element
Implementation Method 2
releasable from the solid continuous matrix structure upon heating of the aerosol-generating element
Implementation Method 3
During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.
Data Source
AI summary
There is provided an aerosol-generating element for use in an aerosol-generating article or system. The aerosol-generating element comprises a solid continuous matrix structure and an aerosol-generating formulation dispersed within the solid continuous matrix structure. The aerosol-generating formulation is trapped within the solid continuous matrix structure and releasable from the solid continuous matrix structure upon heating of the aerosol-generating element. The solid continuous matrix structure is an alginate matrix. The aerosol-generating formulation dispersed within the solid continuous matrix structure comprises at least one alkaloid or cannabinoid compound, a polyhydric alcohol, and about 2 percent by weight to about 8 percent by weight of a carboxylic acid. Further, the aerosol-generating formulation dispersed within the solid continuous matrix structure accounts for at least about 80 percent by weight of a total weight of the aerosol-generating element. The aerosol-generating element comprises less than about 15 percent by weight of water.