Convergent Aerosol Generator for Surface Acoustic Wave Atomization

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Solution Overview

Problem

Existing aerosol-generating devices using surface acoustic waves for atomizing liquid aerosol-forming substrates face inefficiencies due to non-uniformity in piezoelectric materials, leading to suboptimal energy transfer.

Innovation Solution

The aerosol-generator employs a surface acoustic wave atomiser with a substrate and transducers configured to generate acoustic wavefronts matching the interface shape, utilizing interdigital transducers with varying electrode spacings and directions, and optionally incorporating reflectors and absorbers to enhance energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If surface acoustic waves are used to atomize liquid aerosol-forming substrate, then aerosol generation is achieved without combustion, but non-uniformity in piezoelectric materials reduces energy transfer efficiency

Engineering Contradiction:

Improveenergy transfer efficiencyVSAvoidatomization efficiency

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent applies local quality by varying the spacing between interleaved electrodes of the transducer across different regions. The spacing is adjusted to compensate for non-uniform piezoelectric properties in different areas of the substrate, ensuring uniform surface acoustic wave generation and improved energy transfer efficiency throughout the atomization region.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the geometric parameters of the transducer, specifically the spacing between interleaved electrodes, to optimize surface acoustic wave generation. By adjusting this parameter across the substrate, the system compensates for material non-uniformity and maximizes energy transfer efficiency for atomization.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If standard transducer configuration is used, then device simplicity is maintained, but acoustic wavefront shape does not match interface shape reducing atomization efficiency

Engineering Contradiction:

Improveatomization efficiencyVSAvoidtransducer configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements local quality by creating regions with different electrode spacings tailored to generate specific wavefront shapes. The transducer is designed with varying local characteristics to produce acoustic wavefronts that match the liquid-substrate-atmosphere interface geometry, thereby maximizing atomization efficiency without requiring complex external shaping components.

Inventive Principle:

Principle #3Local quality

3Shape

If uniform electrode spacing is used in transducer, then manufacturing is simplified, but anisotropy in surface acoustic wave velocity results in distorted acoustic wavefront

Engineering Contradiction:

Improveacoustic wavefront shapeVSAvoidtransducer fabrication

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies local quality by varying the electrode spacing in different directions across the transducer to compensate for anisotropy in surface acoustic wave velocity. This directional adjustment of local geometry corrects wavefront distortion caused by material anisotropy while maintaining a systematic fabrication approach.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces asymmetry in the transducer electrode spacing to counterbalance the inherent anisotropy in the piezoelectric substrate. By deliberately creating an asymmetric electrode pattern, the system achieves symmetric or desired wavefront shapes despite the anisotropic nature of the underlying material.

Inventive Principle:

Principle #4Asymmetry

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

This configuration improves the efficiency of energy transfer to the liquid aerosol-forming substrate, optimizing atomization and aerosol production.

Implementation Method 1

at least one transducer positioned on the active surface of the substrate for generating surface acoustic waves for defining an acoustic wavefront on the active surface of the substrate

Methodology Applied

Scientific EffectSurface acoustic wave: Surface Acoustic Wave

Implementation Method 2

non-uniformity in piezoelectric materials used to generate surface acoustic waves

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS12582158B2Convergent aerosol-generator

Publication Date: 2026.03.24 PHILIP MORRIS PRODUCTS SA

AI summary

An aerosol-generator for an aerosol-generating device is provided, including: a surface acoustic wave atomiser including: a substrate including an active surface defining an atomisation region, and at least one transducer positioned on the active surface to generate surface acoustic waves for defining an acoustic wavefront on the active surface; and a supply element arranged to supply a liquid aerosol-forming substrate to the atomisation region so that liquid aerosol-forming substrate in the atomisation region defines an interface between the active surface, the liquid aerosol-forming substrate, and the atmosphere, in which the at least one transducer and the supply element are configured so that a shape of the acoustic wavefront at the interface corresponds to a shape of at least part of the interface. An aerosol-generating device including the aerosol-generator is also provided.