Aerosol Generating Matrix Extrusion with Hot Air Drying
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Solution Overview
Problem
The manufacturing method of aerosol generating substrates is complex, leading to low production efficiency and a propensity for disintegration and falling during use.
Innovation Solution
A method involving room temperature extrusion and hot air drying is employed, with specific temperature and pressure conditions, to form an extrusion substrate with airways, followed by hardening and slitting, using a system comprising an extrusion device, hot air drying device, and optional microwave or ultrasonic assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for aerosol generating substrates, then the production process can be completed, but the production efficiency is low and the substrate is prone to disintegration and falling during use
Solution Approach 1:
The patent combines multiple manufacturing steps (extrusion, drying, hardening) into an integrated continuous process. The extrusion device directly forms the substrate structure, which then undergoes in-line drying and hardening, eliminating separate handling steps that cause disintegration. This merging of operations improves both productivity and structural integrity.
Solution Approach 2:
The patent applies preliminary hardening treatment during the manufacturing process itself, forming a robust structure before the substrate is subjected to use conditions. The hardening step creates cross-linked bonds in the polymer matrix that prevent disintegration during subsequent handling and use, addressing the reliability issue proactively.
2Manufacturing precision
If complex manufacturing processes are used, then the substrate can be formed with required properties, but the production efficiency decreases
Solution Approach 1:
The patent implements a continuous manufacturing process where the substrate moves continuously through extrusion, drying, and hardening zones without interruption. The extrusion device forms the substrate, which then travels through the drying chamber and into the hardening zone in a seamless flow, maintaining production speed while ensuring quality formation of the substrate structure.
Solution Approach 2:
The manufacturing system performs multiple functions (forming, drying, hardening) within an integrated apparatus. The extrusion device not only forms the substrate geometry but also initiates the structural development that continues through drying and hardening, reducing the need for separate specialized equipment and simplifying the overall process.
3Reliability
If the substrate structure is made robust to prevent disintegration, then reliability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent achieves improved substrate robustness by changing physical parameters during processing - specifically temperature and time parameters in the drying and hardening zones. The gradual temperature increase and extended dwell time create cross-linked polymer structures that enhance structural integrity without requiring additional mechanical reinforcement or complex multi-step processes.
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 approach enhances production efficiency, ensures a one-piece structure with improved yield and reduced disintegration, facilitating storage and use by maintaining structural integrity during heating and sucking.
Implementation Method 1
The extrusion substrate is subjected to hot air drying... a temperature for the hot air drying is comprised between 50 °C and 200 °C... a moisture content of the extrusion substrate after drying is comprised between 3% and 20%
Implementation Method 2
A material mixture is subjected to room temperature extrusion to form an extrusion substrate... an extrusion pressure for the room temperature extrusion is comprised between 0.5 bar and 300 bar
Data Source
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AI summary
A manufacturing method for an aerosol generating matrix, which method comprises: extruding a mixed material at room temperature to form an extruded matrix, wherein the mixed material is a component of an aerosol generating matrix; and subjecting the extruded matrix to hot air drying. The mixed material is extruded at room temperature and has good fluidity, the surface smoothness of the extruded matrix is good, and the extrusion forming effect is good, thereby ensuring good extrusion efficiency and a relatively fast production speed, improving the yield. Hot air drying enables the extruded matrix to be dried in batches, and the drying speed is fast; and the water content of the extruded matrix is reduced by means of hot air drying, facilitating storage and use of the aerosol generating matrix. In addition, further provided is a manufacturing system for an aerosol generating matrix.