Laminate Aerosol Material Structure to Prevent Charring
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Solution Overview
Problem
Existing aerosol generating devices face challenges in efficiently heating aerosol-forming materials without burning, leading to compromised heating efficiency, power consumption, and hygiene issues due to residue formation and charring.
Innovation Solution
A laminate aerosol generating material comprising an amorphous solid aerosol-forming layer attached to a carrier layer, with specific thicknesses and materials to optimize heating efficiency and handleability, and positioning the aerosol-forming layer within a defined distance from the heater to prevent charring and residue formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the aerosol-forming layer is positioned closer to the heater to improve heating efficiency, then power consumption is reduced, but charring and residue formation increase
Solution Approach 1:
The patent introduces a carrier layer as an intermediary between the heater and the aerosol-forming layer. This carrier layer acts as a protective mediator that prevents direct contact between the heater and the aerosol-forming material, thereby eliminating charring and residue formation while maintaining efficient heating through thermal conduction from the heater to the aerosol-forming layer.
2Ease of manufacture
If a thicker carrier layer is used to improve handleability and prevent charring, then manufacturing ease is improved, but heating efficiency decreases
Solution Approach 1:
The patent optimizes the thickness parameter of the carrier layer to a specific range (10 μm to 2.5 mm) that balances mechanical handleability with thermal efficiency. This parameter optimization ensures the carrier layer is thick enough to provide structural support and prevent charring, yet thin enough to allow efficient heat transfer from the heater to the aerosol-forming layer.
3Use of energy by moving object
If the aerosol-forming layer is made thinner to improve heating efficiency, then power consumption is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent divides the aerosol generating material into two distinct functional layers: a carrier layer that provides structural support and handleability, and a thinner aerosol-forming layer that optimizes heating efficiency. This segmentation allows each layer to be optimized independently - the carrier layer for mechanical properties and the aerosol-forming layer for thermal efficiency - while maintaining precise positioning through the laminate structure.
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 ensures rapid and efficient heating of the aerosol-forming material, improves power consumption, and enhances hygiene by minimizing residue formation and maintaining flavor delivery.
Implementation Method 1
a heater configured to heat but not burn the aerosol generating material
Implementation Method 2
The heating volatilizes at least one component of the material, typically forming an inhalable aerosol
Implementation Method 3
The heating volatilizes at least one component of the material, typically forming an inhalable aerosol
Data Source
AI summary
Described herein is a laminate aerosol generating material, wherein the material comprises an aerosol-forming layer attached to a carrier layer, wherein the aerosol-forming layer comprises an amorphous solid, and wherein the carrier layer has a thickness from about 10 μm to about 2.5 mm.