Heat Diffuser and Retention Medium for Convective Aerosol Heating

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Solution Overview

Problem

Existing aerosol-generating systems face challenges in evenly heating aerosol-forming substrates, leading to inconsistent aerosol characteristics due to over-heating or under-heating, particularly with liquid aerosol-forming substrates that can cause overheating upon depletion.

Innovation Solution

A heat diffuser comprising a thermally conductive, non-combustible porous body that absorbs heat from an electric heating element, transferring it to air drawn through the body for even heating of the aerosol-forming substrate, with features like high surface area-to-volume ratio and thermal conductivity to enhance heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If direct contact heating with electric heater is used, then heating efficiency is improved, but heating uniformity deteriorates leading to over-heating or under-heating of aerosol-forming substrate

Engineering Contradiction:

Improveheating efficiencyVSAvoidheating uniformity

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The patent introduces air as an intermediary medium between the electric heater and aerosol-forming substrate. The heater heats the air, which then flows through porous channels to heat the substrate uniformly via convection, eliminating direct contact heating issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs forced convection of air through the porous body to achieve uniform heating. The heated air flow through the porous structure provides consistent thermal distribution to the aerosol-forming substrate, resolving the heating uniformity problem.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If heating is applied to liquid aerosol-forming substrate, then aerosol generation is improved, but overheating occurs when substrate is depleted

Engineering Contradiction:

Improveaerosol generationVSAvoidoverheating risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Air serves as a thermal buffer and intermediary, allowing heat transfer to the liquid substrate without direct heater-substrate contact. When substrate is depleted, the air flow continues to carry heat away, preventing dangerous overheating of the device components.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the heating mechanism from direct conductive heating to convective heating through air flow. This parameter change allows continuous aerosol generation while maintaining temperature control, as the moving air prevents heat accumulation even when liquid substrate is depleted.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If porous body with high surface area-to-volume ratio is used, then heat transfer efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidporous body structure

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent utilizes a porous body with high surface area-to-volume ratio to maximize heat transfer between the heated air and the aerosol-forming substrate. The porous structure provides extensive surface area for efficient thermal exchange while maintaining a compact form factor.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The porous body is constructed from thermally conductive materials that combine structural integrity with high thermal conductivity. This composite approach achieves both the required heat transfer efficiency and mechanical strength without excessive complexity.

Inventive Principle:

Principle #40Composite materials

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 heat diffuser provides more uniform heating of the aerosol-forming substrate, reducing the risk of overheating and maintaining consistent aerosol characteristics, especially with liquid substrates, by using convection rather than conductive heating.

Implementation Method 1

the porous body being thermally conductive such that, in use, air drawn through the porous body is heated by the heat absorbed by the porous body

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

air drawn through the porous body is heated by the heat absorbed by the porous body

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250295172A1Method of aerosol-generating article including heat diffuser and retention medium

Publication Date: 2025.09.25 ALTRIA CLIENT SERVICES LLC

AI summary

The method includes forming a heat diffuser that defines a cavity for receiving at least a portion of a heater, establishing a retention medium with a channel, and connecting a heat diffuser to the retention medium to form an aerosol-generating article, the heat diffuser including a non-combustible porous body configured to absorb heat from the heater and heat the retention medium.