Amorphous Solid Drying for Non-Combustible Aerosol Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing amorphous solids for non-combustible aerosol provision systems face challenges in achieving the right water content and minimizing cracking, which affects aerosol generation efficiency and user satisfaction.
Innovation Solution
A method involving forming a slurry with a gelling agent, aerosol forming material, and active constituent or flavorant, shaping it, setting it to form a gel, and drying at controlled temperatures (80° C to 140° C) for less than 60 minutes to create an amorphous solid with optimal water content and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the gel is dried at high temperature for extended periods to achieve low water content, then water content is reduced, but cracking occurs in the amorphous solid
Solution Approach 1:
The drying process uses periodic temperature variation with multiple stages: initial drying at 80-100°C, then elevated temperature at 100-140°C for 30-60 minutes, followed by cooling. This periodic thermal treatment achieves thorough drying while preventing crack formation through controlled temperature transitions.
Solution Approach 2:
The invention changes the temperature parameter dynamically during drying - starting at moderate temperature (80-100°C), then elevating to higher temperature (100-140°C) for a controlled period, and finally cooling. This parameter variation optimizes both water removal and structural integrity.
2Productivity
If the gel is dried quickly to reduce processing time, then productivity increases, but water content control and crack prevention become difficult
Solution Approach 1:
The drying process is divided into periodic stages with specific time durations: initial drying phase, elevated temperature phase for 30-60 minutes, and cooling phase. This structured periodic approach achieves rapid yet controlled drying, balancing productivity with precision.
Solution Approach 2:
Before the main elevated temperature drying, an initial drying phase at 80-100°C is performed to prepare the gel structure. This preliminary action prevents sudden thermal shock and enables faster subsequent drying while maintaining control over water content and preventing cracks.
3Quantity of substance
If conventional drying methods are used to achieve low water content, then water removal is effective, but crack formation occurs reducing aerosol generation efficiency
Solution Approach 1:
The periodic drying protocol with controlled temperature stages and cooling ensures thorough water removal without causing cracks that would compromise aerosol generation efficiency. The method achieves both low water content and structural integrity.
Solution Approach 2:
By dynamically changing temperature parameters during drying - moderate initial temperature, elevated intermediate temperature, and controlled cooling - the method achieves effective water removal while preventing crack formation, thereby maintaining aerosol generation efficiency.
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 effectively controls water content and prevents cracking, enhancing aerosol generation efficiency and user satisfaction by producing an amorphous solid with desired properties.
Implementation Method 1
drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes
Implementation Method 2
setting the slurry to form a gel
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) shaping the slurry; (c) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid; wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.