Mechanical Aerosol Converter Mouthpiece for E-Cigarette

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Solution Overview

Problem

Electronic smoking articles often fail to provide optimal organoleptic characteristics due to issues with aerosol particle size and temperature, leading to an inconsistent sensory experience for users.

Innovation Solution

Incorporating a mechanical aerosol converter (MAC) within the mouth end insert of the electronic smoking article, which reduces aerosol particle size and cools the aerosol through thermal energy transfer, enhancing the mixing and swirling of the aerosol before delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the heater temperature is increased to improve aerosol generation, then the aerosolization efficiency is improved, but the aerosol temperature increases causing harshness and reduced organoleptic characteristics

Engineering Contradiction:

Improveaerosol generation efficiencyVSAvoidaerosol temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The mouth end insert is divided into multiple functional zones: a cooling zone with cooling channels, a mixing zone with turbulence promoters, and a delivery zone with selective outlets. This segmentation allows independent optimization of temperature control, mixing efficiency, and aerosol delivery characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mouth end insert acts as an intermediary component between the heater and the user's mouth. It includes cooling channels that introduce cooler air, turbulence promoters that enhance mixing, and selective outlets that direct aerosol flow, thereby mediating the temperature and composition of the final aerosol delivered to the user.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the aerosol particle size is reduced to improve sensory experience, then the smoothness and pleasantness are improved, but the device complexity increases due to additional cooling and mixing components

Engineering Contradiction:

Improvesensory experience qualityVSAvoidmouth end insert structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Multiple functions are merged into a single integrated mouth end insert component. The cooling channels, turbulence promoters, mixing zones, and selective outlets are combined in one piece that fits into the device, reducing overall system complexity while achieving the desired aerosol modification.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mouth end insert serves multiple functions simultaneously: cooling the aerosol, enhancing mixing, reducing particle size through turbulence promoters, and controlling delivery to selective outlets. This multi-functionality in a single component reduces the need for separate devices for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If the aerosol is cooled to improve organoleptic characteristics, then the harshness is reduced, but the aerosol condensation may increase affecting delivery consistency

Engineering Contradiction:

Improveaerosol temperatureVSAvoidaerosol delivery consistency

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

Different regions of the mouth end insert have different thermal and flow characteristics. The cooling channels are positioned to cool the aerosol in specific zones, while turbulence promoters and selective outlets are strategically placed to ensure consistent delivery. This local optimization ensures cooling occurs without compromising delivery reliability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system dynamically balances cooling and delivery through controlled airflow patterns. The cooling channels are designed to cool the aerosol as it passes through, while the turbulence promoters ensure continuous mixing and prevent condensation. The selective outlets provide controlled delivery paths that maintain consistency despite temperature variations.

Inventive Principle:

Principle #15Dynamics

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 results in a more consistent and improved sensory experience by reducing aerosol temperature and particle size, providing a smoother and more pleasant vapor for the user.

Implementation Method 1

a heater operable to heat the liquid aerosol formulation to a temperature sufficient to volatilize the liquid aerosol formulation and form an aerosol

Methodology Applied

Scientific EffectVolatilization: Evaporation

Implementation Method 2

The MAC portion is operable to reduce the size of particles in the aerosol and cool the aerosol produced by the electronic smoking article

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS20240335623A1Electronic smoking article

Publication Date: 2024.10.10 ALTRIA CLIENT SERVICES LLC

AI summary

An electronic smoking article includes an aerosol generator and a mouth end insert. The mouth end insert includes a mechanical aerosol converter surface having the capacity to improve characteristics of aerosol produced by the aerosol generator, including sensory attributes.