Amorphous Solid Aerosol Generation with Uniform Setting Agent
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Solution Overview
Problem
Existing non-combustible aerosol generation systems face challenges in producing a consistent and homogeneous aerosol release profile due to uneven distribution of setting agents in amorphous solids, leading to inconsistent performance and user experience.
Innovation Solution
A method of forming an amorphous solid by creating a slurry with a gelling agent, aerosol forming material, and active constituents, applying a setting agent to achieve even distribution, and drying to form a solid with a substantially constant setting agent concentration, ensuring consistent release profiles upon heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a setting agent is applied to form an amorphous solid for aerosol generation, then the solid structure is established and aerosol generation is enabled, but the setting agent distribution becomes uneven leading to inconsistent release profiles
Solution Approach 1:
The setting agent is applied to the slurry surface before drying occurs, allowing the setting agent to be incorporated into the matrix during the drying process rather than being applied afterward. This preliminary application ensures uniform distribution throughout the amorphous solid, resolving the inconsistency in release profiles while maintaining reliable aerosol generation.
Solution Approach 2:
The patent applies the setting agent to the slurry surface in a controlled manner, changing the physical state and distribution parameters of the setting agent from a concentrated surface application to a uniformly distributed component throughout the dried amorphous solid. This parameter change ensures consistent release profiles while maintaining the structural integrity needed for reliable aerosol generation.
2Ease of manufacture
If the setting agent is applied to the slurry surface to enable setting, then the gel formation is achieved, but the setting agent concentration becomes non-uniform throughout the solid
Solution Approach 1:
The setting agent is applied to the slurry surface during the manufacturing process, allowing it to be incorporated uniformly as the gel sets and dries. This preliminary application during manufacturing, rather than post-processing, ensures both ease of manufacture and uniform concentration distribution, resolving the contradiction between manufacturing simplicity and precision.
Solution Approach 2:
The drying process itself serves to distribute the setting agent uniformly throughout the gel matrix. As the slurry dries to form the amorphous solid, the setting agent that was applied to the surface becomes uniformly distributed throughout the resulting solid, eliminating the need for additional mixing or distribution steps while achieving manufacturing precision.
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 results in a homogenous amorphous solid with a consistent release profile, enhancing user experience and aerosol generation efficiency by ensuring even distribution of the setting agent throughout the solid.
Implementation Method 1
applying a setting agent to a surface of the slurry so that the slurry sets to form a gel
Implementation Method 2
drying the gel to form an amorphous solid
Data Source
AI summary
An amorphous solid and related methods of making an amorphous solid 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; (c) applying a setting agent to a surface of the slurry so that the slurry sets to form a gel; and (d) drying the gel to form an amorphous solid; wherein the amorphous solid has a substantially constant concentration of setting agent throughout.