Amorphous Aerosol Solid Drying to Prevent Cracking and Delamination
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Solution Overview
Problem
Existing methods for producing amorphous solids in non-combustible aerosol provision systems face challenges in achieving the right water content, minimizing cracking, and preventing delamination during drying, which affects aerosol generation and user satisfaction.
Innovation Solution
A method involving the formation of a slurry with specific weight percentages of gelling agent, aerosol forming material, and active constituent, followed by drying from both sides or using a thermally-conductive support material to control water content and minimize cracking and delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gel is dried using conventional single-side heating, then the drying process is simple, but the amorphous solid develops cracks and delaminates from the support material
Solution Approach 1:
The drying process is segmented into two distinct phases: first drying the bottom surface of the gel, then drying the top surface. This segmentation allows controlled moisture removal from each surface independently, preventing the formation of cracks and delamination that occur with conventional single-side continuous drying.
Solution Approach 2:
The drying process employs periodic action by alternating between drying the bottom surface and the top surface of the gel. This periodic switching of heating sides enables balanced moisture evaporation, maintaining structural integrity and preventing defects in the final amorphous solid.
2Productivity
If the water content in the amorphous solid is not properly controlled, then the manufacturing process is simple, but aerosol generation efficiency deteriorates
Solution Approach 1:
The invention controls water content by changing the drying parameters - specifically the duration and temperature of heating applied to each surface. By adjusting these parameters, the final water content in the amorphous solid is optimized for efficient aerosol generation without requiring complex additional control systems.
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 produces an amorphous solid with optimal water content, reducing cracking and delamination, thereby improving aerosol generation efficiency and user satisfaction.
Implementation Method 1
setting the slurry to form a gel
Implementation Method 2
drying the gel to form an amorphous solid; wherein the drying comprises a first period of supplying heat to the bottom surface of the gel and a second period of supplying heat to the top surface of the gel
Implementation Method 3
shaping the slurry on a thermally-conductive support material; wherein the drying comprises heating the thermally-conductive support material
Data Source
AI summary
An amorphous solid and related method of making including (a) forming a slurry having 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 on a support material, wherein the slurry has a bottom surface proximal to the support material, and a top surface opposite the bottom surface; (c) setting the slurry to form a gel with bottom and top surfaces corresponding to the bottom and top surfaces of the slurry; and (d) drying the gel to form an amorphous solid; wherein the drying includes a first period of supplying heat to the bottom surface of the gel and a second period of supplying heat to the top surface of the gel.