Electrosprayed Aerosol-Forming Substrates Without Thermal Drying
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Solution Overview
Problem
Existing methods for producing aerosol-forming substrates in smoking alternatives, such as heat-not-burn devices and e-cigarette/tobacco hybrid devices, face inefficiencies in manufacturing due to the need for solvent removal steps and potential chemical alteration of tobacco/nicotine materials during heating, which affect the composition and organoleptic properties of the aerosol.
Innovation Solution
The use of electrospraying to create aerosol-forming substrates, which allows for even dispersal and adherence of charged particles onto a surface without the need for subsequent solvent removal, enabling homogeneous material thickness and selective application of flavors or components, thereby optimizing manufacturing efficiency and maintaining chemical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to produce aerosol-forming substrates, then manufacturing can proceed with existing processes, but solvent removal steps are required and chemical alteration of tobacco/nicotine materials occurs during heating
Solution Approach 1:
The patent replaces thermal processing (heating/drying methods) with electrospraying technology to deposit aerosol-forming material onto substrates. This substitution eliminates the need for high-temperature heating steps that cause chemical alteration of tobacco and nicotine compounds, while still achieving effective material deposition and solvent evaporation through the electrospraying process itself
Solution Approach 2:
The patent changes the processing parameters from high-temperature thermal treatment to controlled electrospraying conditions. By using electrospraying, the process operates at lower temperatures during material deposition, preventing thermal degradation of sensitive compounds while maintaining manufacturing efficiency through rapid solvent evaporation inherent to the electrospraying mechanism
2Manufacturing precision
If conventional coating methods are used, then material can be applied to substrate, but solvent removal steps are required adding to process complexity
Solution Approach 1:
The patent replaces multi-step conventional coating and drying processes with a single electrospraying operation. The electrospraying system inherently provides uniform material distribution through charged particle dynamics while the rapid solvent evaporation occurs during or immediately after deposition, eliminating the need for separate drying ovens or solvent removal equipment
Solution Approach 2:
The patent combines multiple functions into the single electrospraying process: material deposition, uniform distribution, and solvent evaporation all occur in one integrated step. This merging of functions reduces the overall number of manufacturing steps and equipment required while maintaining or improving material homogeneity on the substrate
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
Electrospraying results in a homogeneous, efficient manufacturing process that minimizes heating requirements, preserves the chemical composition of tobacco/nicotine materials, and allows for customizable aerosol generation by varying flavors and thicknesses, enhancing the quality and consistency of the aerosol produced.
Implementation Method 1
the method comprising electrospraying the aerosol-forming material or component or precursor thereof
Implementation Method 2
The particles from a single plume all have the same charge and consequently disperse evenly (due to the consequent electrostatic forces)
Data Source
AI summary
Described herein is a method of making an aerosol-forming substrate. The aerosol-forming substrate comprises an aerosol-forming material which comprises nicotine and/or a tobacco material. The method comprises electrospraying the aerosol-forming material or component or precursor thereof.