Dried Plant-Extract Substrates for Stable Aerosol Generation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional aerosol-generating materials, particularly those containing tobacco extracts, suffer from volatility issues leading to decreased flavor and nicotine content over time, requiring high energy input and short shelf life, and are susceptible to moisture absorption affecting quality.

Innovation Solution

A substrate comprising a support coated with a dried aerosol-generating material formed from a plant extract, which includes a high concentration of flavor and active components, applied without a binder, and optionally protected by a moisture-impermeable coating, allowing for low water content and enhanced stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If conventional aerosol-generating materials are used, then they can generate aerosol, but they suffer from volatility issues leading to decreased flavor and nicotine content over time

Engineering Contradiction:

Improveflavor and nicotine content stabilityVSAvoidflavor and nicotine loss

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The plant material is extracted and the extract is dried before being applied to the support, creating a stable, low-moisture aerosol-generating material that prevents volatility issues during storage and use

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The moisture content of the aerosol-generating material is reduced from high (conventional) to low (dried extract, ≤5% water content), which stabilizes the flavor and nicotine content by preventing degradation and volatility

Inventive Principle:

Principle #35Parameter changes

2Power

If conventional aerosol-generating materials are used, then they can generate aerosol, but they require high energy input

Engineering Contradiction:

Improveenergy inputVSAvoidhigh energy consumption

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The material is dried to low moisture content (≤5% water), which reduces the energy required for heating during aerosol generation while maintaining effective aerosol formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The dried extract is combined with a carrier material (such as glycerol or propylene glycol) to create a composite aerosol-generating material that requires lower energy input for effective aerosol generation

Inventive Principle:

Principle #40Composite materials

3Duration of action of stationary object

If conventional aerosol-generating materials are used, then they can generate aerosol, but they have short shelf life

Engineering Contradiction:

Improveshelf lifeVSAvoidmaterial degradation

Core Design Contradiction:

Duration of action of stationary objectVSLoss of substance

Solution Approach 1:

The extract is dried and applied to the support before use, creating a stable, long-lasting aerosol-generating material that maintains its properties over extended periods

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The moisture content is reduced to ≤5% through drying, which prevents microbial growth and material degradation, thereby extending shelf life

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If conventional aerosol-generating materials are used, then they can generate aerosol, but they are susceptible to moisture absorption affecting quality

Engineering Contradiction:

Improvemoisture absorptionVSAvoidquality stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The aerosol-generating material is dried to low moisture content (≤5% water), which reduces its hygroscopicity and susceptibility to moisture absorption from the environment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A moisture-impermeable coating is applied over the dried extract to create a protective barrier that prevents moisture absorption while allowing controlled aerosol generation during use

Inventive Principle:

Principle #30Flexible shells and thin films

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 solution provides a substrate with increased shelf life, reduced energy requirements, and improved aerosol quality by maintaining flavor and nicotine content, while minimizing moisture absorption.

Implementation Method 1

drying a precursor material whilst in contact with the support

Methodology Applied

Scientific EffectDrying: Evaporation

Implementation Method 2

the substrate comprises a moisture impermeable coating surrounding the aerosol-generating material

Methodology Applied

Scientific EffectMoisture impermeability: Physical Containment

Data Source

PatentUS20250221445A1A substrate comprising an aerosol-generating material on a support and uses thereof

Publication Date: 2025.07.10 NICOVENTURES TRADING LTD

AI summary

The invention relates to substrates comprising a support at least partially coated with an aerosol-generating material formed by drying a precursor material whilst in contact with the support, the precursor material comprising an extract from a flavour- and/or active-containing plant material and optionally an aerosol-former material. The substrates may be used to generate an aerosol. For example, the substrates may be used in combustible or non-combustible aerosol-provision systems. The invention also relates to aerosol-provision systems comprising the substrates, and methods of providing a substrate.