Amorphous Solid Shaping via Stencil for Aerosol Systems
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Solution Overview
Problem
Existing non-combustible aerosol generation systems face challenges in producing a consistent and predictable aerosol release profile due to the lack of control over the shape and composition of amorphous solids used in these systems, which affects heating efficiency and consumer experience.
Innovation Solution
A method is developed to create an amorphous solid by forming a slurry with a gelling agent, aerosol-forming material, and active constituents, shaping it using a stencil, setting it to form a gel, and drying it to achieve a controlled shape and composition, ensuring reliable aerosol release. This method includes using a carrier for support and optimizing the slurry composition to balance water content and thickness for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a slurry is shaped without using a stencil, then the manufacturing process is simpler, but the shape control and manufacturing precision of the amorphous solid deteriorate
Solution Approach 1:
A stencil is introduced as an intermediary tool during the shaping process. The stencil acts as a template that defines the desired shape of the amorphous solid, allowing precise shape control without requiring complex direct shaping equipment. The slurry is applied to the stencil, which mediates the transfer of the desired shape to the final product.
Solution Approach 2:
The stencil is prepared in advance with the desired shape pattern before the slurry application. This preliminary preparation of the shaping template allows for consistent and repeatable shape control across multiple production cycles, improving manufacturing precision without adding complexity to the actual shaping operation.
2Ease of manufacture
If the slurry contains high water content, then the slurry is easier to shape and manipulate, but the drying time and energy consumption increase
Solution Approach 1:
The water content of the slurry is optimized to a specific range (sufficiently low to minimize drying time, but high enough to maintain shapeability). This parameter optimization allows the slurry to be shaped effectively while reducing the subsequent drying time and energy requirements. The exact water content is tuned based on the specific application requirements.
3Reliability
If the amorphous solid has inconsistent shape and composition, then manufacturing is simpler, but the aerosol release predictability and reliability deteriorate
Solution Approach 1:
The stencil serves as a consistent intermediary that ensures uniform shape and composition across all amorphous solids produced. By using the same stencil template for each production cycle, the process achieves high repeatability and consistency in the final product dimensions and shape, which directly translates to predictable aerosol release characteristics.
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 enables the production of amorphous solids with controlled shape and composition, enhancing the predictability and efficiency of aerosol release, improving heating efficiency, and user experience by optimizing the balance of water content and thickness, thus addressing the challenges faced by existing systems.
Implementation Method 1
setting the slurry to form a gel
Implementation Method 2
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; and 5-80 wt % of an aerosol forming material; 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry using a stencil; (c) setting the 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.