Integrated Aerosol Cartridge Merging Solid and Liquid Substrates

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Solution Overview

Problem

Existing aerosol-generating systems, such as electronic vaping devices, often require separate replacement of tobacco-based substrates and nicotine solutions, leading to impractical size and maintenance challenges.

Innovation Solution

A cartridge design that integrates both solid and liquid aerosol-forming substrates with a separate heater section, utilizing a porous carrier material and a liquid transfer element to facilitate simultaneous replacement and efficient aerosol formation, while allowing for a compact and cost-effective device structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate tobacco-based substrate and nicotine solution are used, then aerosol generation function is achieved, but device size becomes impractically large and maintenance complexity increases

Engineering Contradiction:

Improveaerosol generation functionVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines the tobacco-based substrate and nicotine solution into a single integrated cartridge assembly. The cartridge housing contains both the solid tobacco substrate and the liquid nicotine solution reservoir, with airflow channels connecting them. This merging eliminates the need for separate components, reducing overall device size while maintaining the dual-function aerosol generation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cartridge is designed as a universal component that performs multiple functions: it serves as both the tobacco substrate holder and the nicotine solution reservoir, while also incorporating airflow management features. This multi-functional design allows a single component to replace what would traditionally require multiple separate parts, addressing both size reduction and functional integration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate tobacco-based substrate and nicotine solution are used, then aerosol generation function is achieved, but replacement and maintenance complexity increases

Engineering Contradiction:

Improveaerosol generation functionVSAvoidmaintenance complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By merging the tobacco substrate and nicotine solution into a single cartridge unit, the patent simplifies maintenance operations. Users replace one integrated cartridge rather than managing separate components, reducing the complexity of replacement procedures while ensuring both tobacco and nicotine components are simultaneously replaced to maintain proper functioning.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The device is segmented into a reusable main body and a replaceable cartridge. This segmentation allows the complex aerosol-generation components (tobacco substrate, nicotine solution, airflow channels) to be packaged in a pre-assembled cartridge unit that can be easily replaced as a single module, simplifying user maintenance while maintaining functional complexity where needed.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If integrated cartridge design is used, then device size is reduced and replenishment is simplified, but manufacturing precision requirements increase

Engineering Contradiction:

Improvedevice sizeVSAvoidcartridge assembly precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The cartridge is pre-assembled with all components (tobacco substrate, nicotine solution reservoir, airflow channels) configured and positioned correctly during manufacturing. This preliminary assembly ensures precise alignment and spacing of internal components before the cartridge is installed in the device, allowing for reduced overall device size while maintaining the necessary manufacturing precision within the controlled manufacturing environment.

Inventive Principle:

Principle #10Preliminary action

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 design simplifies the replenishment process, reduces the size of the aerosol-generating system, and enables easier cleaning and reuse of the heater section, enhancing user convenience and reducing manufacturing costs.

Implementation Method 1

a porous carrier material within the cartridge housing and holding a liquid aerosol-forming substrate

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

The heater section may comprise an electric heater

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Data Source

PatentUS20230140060A1Aerosol-generating system including solid and liquid aerosol-forming substrates

Publication Date: 2023.05.04 ALTRIA CLIENT SERVICES LLC

AI summary

An aerosol-generating system may include a cartridge, a heater section, and an aerosol-generating device. The cartridge may include a cartridge housing, a solid aerosol-forming substrate positioned within the cartridge housing, and a liquid aerosol-forming substrate positioned within the cartridge housing. The heater section is separate from the cartridge and includes an electric heater. The aerosol-generating device may include a device housing configured to receive the cartridge and a power supply for supplying electrical power to the electric heater. The power supply may be positioned within the device housing.