Regenerated Cellulose Substrate for Aerosol Storage
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Solution Overview
Problem
Existing aerosol delivery devices face challenges in efficiently storing and transporting aerosol precursor compositions, which affects the formation and release of aerosols, particularly in devices that aim to provide improved moisture control and increased storage capacity.
Innovation Solution
The use of a substrate formed from regenerated cellulose fibers with a multi-lobal cross-section and hydrophobic additives, configured in multiple layers for enhanced storage and release of aerosol precursor compositions, in conjunction with a heater for vaporization, to improve the aerosol delivery device's performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a substrate is formed from regenerated cellulose fibers with multi-lobal cross-section and hollow structure, then the storage capacity for aerosol precursor composition is significantly increased, but the device complexity increases due to multi-layer configuration
Solution Approach 1:
The substrate utilizes regenerated cellulose fibers with hollow, substantially cylindrical cross-sections and multi-lobal structures that create extensive porous networks. These porous fibers provide increased internal volume for aerosol precursor composition storage while maintaining a compact external form factor, resolving the contradiction between storage capacity and device complexity.
Solution Approach 2:
The substrate combines multiple layers of regenerated cellulose fibers with different properties: hydrophilic layers for aerosol precursor absorption and storage, and hydrophobic layers for moisture control and selective permeability. This composite structure achieves enhanced storage capacity while using natural cellulose-based materials that simplify manufacturing compared to synthetic alternatives.
2Reliability
If hydrophobic additives are incorporated into regenerated cellulose fibers, then moisture control is improved, but the manufacturing complexity increases
Solution Approach 1:
The substrate incorporates hydrophobic additives into regenerated cellulose fibers to modify the hydrophilicity parameter of specific layers. This creates a gradient structure where hydrophilic layers maximize aerosol precursor absorption while hydrophobic layers provide moisture control and prevent unwanted liquid migration, achieving reliable moisture control through parameter optimization rather than complex manufacturing processes.
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 substrate exhibits a significantly increased storage capacity for aerosol precursor compositions, allowing for efficient aerosol formation and release, with a loading capacity of at least 2000% relative to its initial dry weight, and a basis weight of about 100 gsm to 250 gsm, enhancing the overall performance of the aerosol delivery device.
Implementation Method 1
The substrate comprises a second layer comprising the regenerated cellulose fibers that include a hydrophobic additive
Implementation Method 2
a heater operatively arranged for vaporization of the aerosol forming liquid
Implementation Method 3
a substrate at least partially formed from regenerated cellulose fibers; an aerosol forming liquid retained by the substrate
Data Source
Figure 1
Figure 2~3
Figure 4~5D
AI summary
The present disclosure relates to aerosol delivery devices (100), methods of forming such devices, and elements of such devices. In some embodiments, the present disclosure provides substrates for use in storing an aerosol precursor liquid and/or transporting the liquid to a heater (134,230,330,430,830) for vaporization. The substrates can be formed form fibers (500) that can provide improved absorbency and/or transport qualities. Multi-layer substrates (700) are also disclosed and can include a high absorbency layer (760) and a hydrophobic layer (770).