Amorphous Aerosol Material Gelation for Easier Heat-Not-Burn Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aerosol generating technologies face challenges in efficiently producing inhalable aerosols from solid aerosolizable materials while minimizing manufacturing costs and processing issues, particularly in the production of amorphous solids used in heat-not-burn devices and e-cigarette/tobacco hybrid devices.
Innovation Solution
A method involving the use of a setting agent comprising Ca2+ and counterions with a molar mass less than 400 gmol−1 to create an amorphous solid aerosol generating material, which includes shaping a slurry with gelling and aerosol generating agents, optionally with active substances and flavorants, and drying to form a stable amorphous solid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a setting agent with higher Ca2+ concentration is used, then the amorphous solid stability and aerosol generation efficiency are improved, but the processing difficulty and manufacturing complexity increase
Solution Approach 1:
The patent changes the chemical parameters of the setting agent by selecting counterions with specific molar masses (less than 400 g/mol) and optimizing the Ca2+ concentration (at least 15% of the molar mass of Ca2+ ions and counterions). This parameter optimization allows achieving high amorphous solid stability with improved processability, resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent creates a composite setting agent system combining Ca2+ ions with specific counterions (acetate, formate, carbonate, hydrogencarbonate, lactate, or chloride) in optimized ratios. This composite approach enables the setting agent to provide both the necessary stability for amorphous solid formation and the appropriate handling properties during manufacturing, simultaneously addressing both reliability and ease of manufacture.
2Quantity of substance
If the molar mass of counterions in the setting agent is reduced, then the Ca2+ concentration can be increased with smaller mass, but the selection range of suitable counterions is limited
Solution Approach 1:
The patent identifies six suitable counterions (acetate, formate, carbonate, hydrogencarbonate, lactate, and chloride) that all satisfy the molar mass requirement (less than 400 g/mol). These counterions provide universal applicability across different formulation needs, allowing the setting agent to achieve high Ca2+ concentration efficiency while maintaining versatility in selection. Each counterion offers different advantages for various application scenarios.
3Productivity
If a slurry is shaped and dried to form an amorphous solid, then the aerosol generation capability is improved, but the manufacturing time and energy consumption increase
Solution Approach 1:
The patent incorporates the setting agent into the slurry before shaping, allowing the amorphous solid structure to begin forming during the shaping process itself. This preliminary action reduces the subsequent drying time and energy requirements, as the material is already partially set. The setting agent facilitates rapid gelation and amorphous solid formation, accelerating the overall manufacturing process while maintaining high aerosol generation capability.
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 method reduces manufacturing costs and processing issues by allowing a higher Ca2+ concentration with a smaller mass of setting agent, resulting in a stable amorphous solid that efficiently produces inhalable aerosols with controlled water content and improved handling properties.
Implementation Method 1
a setting agent comprising Ca2+ and one or more counterions is added to the slurry before and/or during (b) and/or (c), the setting agent having an average molar mass of less than about 400 gmol−1
Implementation Method 2
drying the gel to form an amorphous solid
Data Source
AI summary
A method of making an aerosol generating material comprising an amorphous solid comprises (a) providing a slurry comprising: 1-60 wt % of a gelling agent; and 5-80 wt % of an aerosol generating agent; and optionally, 0.1-60 wt % of at least one active substance and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid. The setting agent comprises Ca2+ and one or more counterions is added to the slurry before and/or during shaping the slurry and/or setting the slurry to form the gel, the setting agent having an average molar mass of less than about 400 gmol−1.