Amorphous Solid Aerosol Generation via Slurry Deposition
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Solution Overview
Problem
Existing non-combustible aerosol generation systems face challenges in producing a consistent and efficient aerosol release profile due to variations in the composition and handling of aerosol-generating materials, leading to unpredictable performance and user experience.
Innovation Solution
A method is developed to create an amorphous solid through a slurry comprising a gelling agent, aerosol-forming material, and active constituents, using a positive displacement pump for precise deposition and drying to form a stable, predictable aerosol-generating material with controlled water content and thickness, optimized for efficient aerosol production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to handle aerosol-generating materials, then material composition can be varied, but aerosol release profile becomes inconsistent and unpredictable
Solution Approach 1:
The invention uses a composite slurry material comprising aerosol-generating material, gelling agent, and optional additives that when deposited and dried forms a gel structure. This composite approach maintains material composition flexibility while the gel matrix provides structural consistency that ensures predictable aerosol release profiles upon heating.
Solution Approach 2:
The invention controls the physical state and moisture content parameters of the aerosol-generating material by transforming it into a gel form through controlled drying. This parameter change from liquid/slurry to dried gel state provides consistent structural properties that ensure reliable aerosol release while allowing flexibility in the chemical composition of the original slurry.
2Productivity
If material composition is varied to optimize performance, then aerosol generation efficiency can be improved, but manufacturing precision decreases
Solution Approach 1:
The gelling agent acts as an intermediary that binds the aerosol-generating material and optional additives into a unified gel structure. This intermediary component allows varied compositions to be incorporated while maintaining consistent physical properties during manufacturing, thereby preserving both compositional flexibility and manufacturing precision.
Solution Approach 2:
By controlling the drying process to achieve consistent moisture content reduction across different slurry compositions, the invention maintains manufacturing precision. The standardized transformation from wet slurry to dried gel state ensures that variations in chemical composition do not compromise the structural consistency or dimensional control of the final product.
3Reliability
If slurry is deposited without precise control, then manufacturing process is simpler, but aerosol release profile becomes unpredictable
Solution Approach 1:
The invention replaces manual or gravity-based deposition methods with a positively controlled deposition system that uses controlled application and drying processes. This substitution of deposition mechanics ensures precise control over material placement and thickness, achieving predictable aerosol release profiles while maintaining relatively simple overall process equipment requirements.
4Reliability
If material is dried to controlled moisture content, then aerosol generation consistency is improved, but processing time increases
Solution Approach 1:
The invention optimizes the drying parameters including temperature, humidity, and airflow to achieve the target moisture content reduction (e.g., from ~80% to ~20% water content) in minimal time. By carefully controlling these drying parameters, the process achieves consistent aerosol generation reliability while minimizing the time penalty associated with moisture removal.
Solution Approach 2:
The drying process is designed to remove sufficient moisture to achieve the desired gel consistency and aerosol generation reliability, but not necessarily to complete dryness. This partial drying approach achieves the functional requirement for consistent aerosol release while avoiding the excessive time consumption that would result from removing all moisture.
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 ensures a consistent and desirable aerosol release profile upon heating, enhancing user experience by providing a stable and efficient aerosol generation with optimized material properties, including tensile strength and resistance to elongation.
Implementation Method 1
depositing one or more predetermined quantities of the slurry onto a carrier using a positive displacement pump
Implementation Method 2
setting the predetermined quantities of slurry to form a gel
Implementation Method 3
drying the gel to form an amorphous solid
Implementation Method 4
drying the gel to form an amorphous solid
Data Source
AI summary
A method of making an amorphous solid is provided. The method comprises: (a) forming a slurry comprising: 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) depositing one or more predetermined quantities of the slurry onto a carrier using a positive displacement pump; (c) setting the predetermined quantities of slurry to form a gel; and (d) drying the gel to form an amorphous solid. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.