Microporous Aerosol Substrate Channels for Lower Inhalation Resistance

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Solution Overview

Problem

Aerosol generating products experience high inhalation resistance and significant variation in aerosol volume between puffs.

Innovation Solution

The aerosol generating substrate features a channel extending through its length with micropores in communication, enhancing heat transfer and reducing inhalation resistance by facilitating smoother airflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a conventional aerosol generating substrate is used, then the structure is simple, but the inhalation resistance is high and aerosol volume variation is significant

Engineering Contradiction:

Improveinhalation resistanceVSAvoidsubstrate structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The substrate is divided into multiple functional layers: a heating-resistant base layer, an atomizing agent layer, and a microporous coating layer. This segmentation allows each layer to perform its specific function optimally while collectively reducing inhalation resistance and improving aerosol delivery consistency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A microporous coating layer is applied to the substrate surface, creating numerous small pores that facilitate smooth airflow and reduce inhalation resistance. The porous structure allows aerosols to be delivered more consistently while maintaining a relatively simple overall device structure.

Inventive Principle:

Principle #31Porous materials

2Quantity of substance

If heating temperature is increased to improve aerosol generation, then aerosol volume increases, but the substrate may burn instead of vaporizing

Engineering Contradiction:

Improveaerosol volumeVSAvoidburning of substrate

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The optimal heating temperature range is identified and controlled (40-80°C for heat-not-burn types, 150-300°C for ignition types). By precisely controlling this parameter, sufficient aerosol volume is generated without causing substrate burning, achieving the desired balance between aerosol quantity and preventing harmful combustion effects.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

An atomizing agent is introduced as an intermediary substance that facilitates vaporization at lower temperatures. This agent mediates between the heating source and the substrate, enabling effective aerosol generation without requiring excessive heat that would cause burning.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Use of energy by moving object

If the substrate material is changed to improve heat transfer, then heating efficiency increases, but material selection becomes more restricted

Engineering Contradiction:

Improveheating efficiencyVSAvoidmaterial selection flexibility

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The substrate is constructed as a composite structure combining a heat-resistant base material with an atomizing agent coating. This composite approach maintains heating efficiency by using thermally stable materials while the coating layer provides the necessary vaporization properties, allowing for versatile material selection.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different parts of the substrate have different material properties: the base layer uses heat-resistant materials for structural integrity and heat transfer, while the coating layer uses atomizing agents for vaporization. This local differentiation allows optimal performance without restricting overall material selection flexibility.

Inventive Principle:

Principle #3Local quality

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 substrate design improves inhalation uniformity and reduces resistance, ensuring consistent aerosol delivery and enhanced user experience.

Implementation Method 1

a channel that extends through at least one end of the aerosol generating substrate along a length direction; and a plurality of micropores, the plurality of micropores being in communication with the channel

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

enhancing heat transfer and reducing inhalation resistance by facilitating smoother airflow

Methodology Applied

Scientific EffectAirflow: Convection

Implementation Method 3

an aerosol generating substrate such as a tobacco raw material, a fragrant raw material, and/or an atomizing agent which can volatilize upon heating to generate aerosols

Methodology Applied

Scientific EffectVolatilization: Evaporation

Data Source

PatentUS20250344753A1Aerosol generating substrate and aerosol generating product

Publication Date: 2025.11.13 SMOORE INTERNATIONAL HOLDINGS LIMITED

AI summary

An aerosol generating substrate includes: a channel that extends through at least one end of the aerosol generating substrate along a length direction; and a plurality of micropores, the plurality of micropores being in communication with the channel. In an embodiment, the channel includes at least one airway hole. The at least one airway hole is disposed inside the aerosol generating substrate and extends through two opposite ends of the aerosol generating substrate along the length direction.