Carbon Aerosol-Forming Substrate for Uniform Heating
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Solution Overview
Problem
Existing aerosol-forming substrates have low thermal conductivity, leading to uneven temperature distribution and reduced efficiency in releasing volatile compounds, and often require separate susceptor elements for induction heating, increasing costs.
Innovation Solution
Incorporating thermally conductive particles such as graphite, expanded graphite, graphene, carbon nanotubes, charcoal, or diamond into the aerosol-forming substrate, along with fibers and a binder, to enhance thermal conductivity and tensile strength, allowing for more uniform heating and potentially eliminating the need for a susceptor element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermally conductive particles are incorporated into the aerosol-forming substrate, then thermal conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by incorporating thermally conductive particles (such as graphite, expanded graphite, graphene, carbon nanotubes, charcoal, or diamond) into the aerosol-forming substrate matrix. This creates a composite structure that combines the base substrate material with high thermal conductivity particles, achieving enhanced thermal conductivity (k ≥ 0.1 W/mK) while maintaining the substrate's functional properties for aerosol generation.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the substrate by controlling the type, amount, and distribution of thermally conductive particles. By adjusting particle concentration and selecting different particle types with varying thermal conductivities, the substrate's overall thermal conductivity can be tuned to meet specific performance requirements while balancing manufacturing considerations.
2Temperature
If thermally conductive particles are incorporated into the aerosol-forming substrate, then temperature distribution uniformity is improved, but production cost increases
Solution Approach 1:
The patent applies local quality by strategically distributing thermally conductive particles throughout the substrate to create regions of enhanced thermal conductivity where needed. This ensures uniform temperature distribution across the substrate during heating, particularly near the heating element, while allowing other regions to maintain their base material properties, optimizing both performance and cost-effectiveness.
3Productivity
If the substrate has higher thermal conductivity, then usage efficiency is improved, but material cost increases
Solution Approach 1:
The patent optimizes the concentration and type of thermally conductive particles to achieve the minimum required thermal conductivity (k ≥ 0.1 W/mK) necessary for adequate usage efficiency. By carefully controlling particle content and selecting cost-effective particle types (such as graphite or charcoal versus more expensive graphene or diamond), the patent balances usage efficiency improvements with material cost considerations.
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 improved thermal conductivity results in a more even temperature distribution, higher efficiency in releasing volatile compounds, and reduces the power requirements and time needed for aerosol formation, while also enhancing the substrate's tensile strength and production feasibility.
Implementation Method 1
The improved substrate has an increased thermal conductivity... the thermally conductive particles may increase the thermal conductivity of the aerosol-forming substrate... provide a more even temperature distribution throughout the substrate during use
Implementation Method 2
a blade is inserted into the aerosol-forming substrate and heated in order to heat the aerosol-forming substrate
Implementation Method 3
heat the aerosol-forming substrate and cause the aerosol-forming substrate to release volatile compounds. These compounds then cool to form an aerosol
Data Source
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AI summary
There is provided an aerosol-forming substrate comprising, on a dry weight basis: between 10 and 90 wt % carbon particles; between 7 and 60 wt % of an aerosol former; between 2 and 20 wt % of fibres; and between 2 and 10 wt % of a binder. Each of the carbon particles consists of one or more of graphite, expanded graphite, graphene, carbon nanotubes, charcoal, and diamond. There is also provided an aerosol-generating article comprising the aerosol-forming substrate and a method of forming the aerosol-forming substrate.