Amorphous Aerosol Substrate Gelation for Stable Heat Delivery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aerosol generation technologies face challenges in efficiently producing inhalable aerosols from solid aerosolizable materials, particularly in maintaining stability and consistency of the aerosol-forming substrates during manufacturing and ensuring effective heat transfer and aerosol delivery.
Innovation Solution
The method involves forming an aerosol-forming substrate by creating a slurry with amorphous solid components, applying it to a carrier with a setting agent, and drying it to form a gel, which is then attached to a carrier layer, allowing for improved bonding and controlled aerosol flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a slurry is applied to a carrier with a setting agent to form a gel and dry it to create an amorphous solid layer, then the bonding strength and stability of the aerosol-forming substrate are improved, but the manufacturing complexity and process time increase
Solution Approach 1:
The invention changes the physical-chemical parameters of the carrier by incorporating a setting agent that undergoes phase transition from liquid slurry to solid gel upon drying. This parameter change enables the carrier to bond strongly with the amorphous solid layer while maintaining manufacturing feasibility through a simple drying process rather than complex bonding mechanisms
Solution Approach 2:
The setting agent acts as an intermediary substance between the carrier and the amorphous solid layer. It forms a gel structure during the drying process that facilitates strong bonding between the carrier and the deposited layer, eliminating the need for complex adhesive systems or multiple processing steps
2Ease of manufacture
If the slurry is applied directly to form a gel layer, then the manufacturing process is simplified, but the heat transfer efficiency and aerosol delivery consistency may be compromised
Solution Approach 1:
The invention applies local quality by creating an amorphous solid layer with specific physical properties (porosity, surface area, thermal conductivity) that are optimized for heat transfer and aerosol generation. This localized structural modification ensures consistent aerosol delivery while maintaining the simplicity of the gel-forming manufacturing process
Solution Approach 2:
The amorphous solid layer formed through gel drying inherently develops a porous structure that facilitates heat transfer and controlled aerosol release. This porous morphology ensures reliable aerosol delivery consistency without requiring complex manufacturing interventions
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 method simplifies manufacturing, enhances the stability of the aerosol-forming substrate, improves heat transfer efficiency, and ensures consistent aerosol delivery, thereby improving the overall performance of aerosol generation devices.
Implementation Method 1
applying the slurry to a carrier, wherein the carrier comprises a setting agent, such that the slurry gels on contact with the carrier
Implementation Method 2
drying the gel to form an amorphous solid
Implementation Method 3
The heating volatilises at least one component of the material, typically forming an inhalable aerosol
Data Source
AI summary
Disclosed herein is a method of making an aerosol-forming substrate (103), the aerosol-forming substrate comprising an aerosol-forming layer attached to a carrier layer, wherein the aerosol-forming layer comprises an amorphous solid, the method comprising: (a) forming a slurry comprising components of the amorphous solid or precursors thereof, (b) applying the slurry to a carrier, wherein the carrier comprises a setting agent, such that the slurry gels on contact with the carrier, and (c) drying the gel to form an amorphous solid.