Mesh Vaporizer Structure to Prevent Aerosol Liquid Dripping

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Solution Overview

Problem

Existing aerosol-generating systems face issues with liquid aerosol-forming substrate dripping from the heater due to localized cooling, leading to inconvenience and inefficiency.

Innovation Solution

A vaporizer design incorporating a thermally conductive tube element with a mesh inside and a heater outside, where the mesh is heated indirectly via the tube element, ensuring uniform heating and vaporization of the liquid substrate without direct contact, and using a micropump for on-demand liquid delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If liquid aerosol-forming substrate is dispensed directly onto the heater, then vaporization can occur, but liquid drips from low temperature areas of the heater without being vaporized

Engineering Contradiction:

Improvevaporization efficiencyVSAvoidliquid leakage

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

A mesh is introduced as an intermediary component between the liquid substrate and the heater. The mesh receives liquid from the dispenser, distributes it uniformly across its surface, and allows heated air to pass through for vaporization. This intermediary structure prevents liquid from pooling in low-temperature areas while ensuring adequate contact with heated regions, thereby eliminating liquid leakage without compromising vaporization efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mesh structure creates local variations in liquid distribution and heat transfer. By having the mesh extend beyond the heater boundaries, liquid is distributed to areas that would otherwise be cold spots, ensuring uniform vaporization across the entire liquid surface while preventing dripping from unheated peripheral areas

Inventive Principle:

Principle #3Local quality

2Object-generated harmful factors

If a wick is used to deliver liquid to the vaporizer, then liquid dripping is avoided, but leakage of liquid from the enclosed heated wick occurs

Engineering Contradiction:

Improveliquid dripping preventionVSAvoidliquid leakage

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The harmful function of the wick (enclosing and heating liquid) is extracted and replaced by a mesh structure that distributes liquid openly. The mesh allows liquid to be held and distributed without enclosure, preventing the pressure buildup and leakage issues associated with enclosed heated wicks while maintaining the benefit of controlled liquid delivery

Inventive Principle:

Principle #2Taking out (Extraction)

3Loss of energy

If the heater is enclosed by a thermal insulation element, then heat loss is reduced, but the structure becomes more complex and larger

Engineering Contradiction:

Improveheat lossVSAvoidstructure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

A thin thermal insulation element is applied as a coating or wrap around the heater and mesh assembly. This thin film provides adequate thermal insulation to reduce heat loss while adding minimal structural complexity and maintaining a compact device form factor. The insulation layer acts as a simple protective shell rather than a complex insulating structure

Inventive Principle:

Principle #30Flexible shells and thin films

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 design prevents liquid leakage and ensures efficient vaporization of the liquid aerosol-forming substrate, improving vaporization efficiency and reducing the need for frequent replacements.

Implementation Method 1

the heater including an electrical resistive heater

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the heater is configured to indirectly heat the mesh and the received amount of liquid aerosol-forming substrate by heat conduction via the tube element

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

The tube element is thermally conductive. The heater is configured for heating the mesh and the received amount of liquid aerosol-forming substrate to a temperature sufficient to volatilize at least a part of the received amount of liquid aerosol-forming substrate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

The wick may be made of a porous wicking material. Such a porous wicking material is capable of retaining the liquid and spreading the liquid on the surface of the heater

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 5

The heater vaporizes the liquid retained in the wick

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 6

heating the mesh and the received amount of liquid aerosol-forming substrate to a temperature sufficient to volatilize at least a part of the received amount of liquid aerosol-forming substrate

Methodology Applied

Scientific EffectVolatilization: Evaporation

Data Source

PatentUS20260033545A1Vaporizer for an aerosol-generating system and vaporizing method

Publication Date: 2026.02.05 ALTRIA CLIENT SERVICES LLC

AI summary

The vaporizer includes a tube element defining an inner volume for receiving an amount of liquid aerosol-forming substrate, a mesh in the inner volume of the tube element, and a heater outside, the heater including an electrical resistive heater, and the heater is configured to heat the mesh and the received amount of liquid aerosol-forming substrate to a temperature sufficient to volatilize at least a part of the received amount of liquid aerosol-forming substrate.