Microtextured Liquid Transport Element for Uniform Aerosol Wicking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aerosol delivery devices, such as electronic cigarettes, face issues with heating inefficiency, non-homogeneous wicking of liquid components, non-uniform heating or vaporization, presence of heat sinks, and pyrolysis/deposition of char at the wick and coil interface, leading to a negative sensory impact and reduced device lifespan.
Innovation Solution
The use of a nonfibrous liquid transport element with a microtextured surface for surface wicking, combined with a patterned electrical resistance heating element, enhances uniform heating and vaporization efficiency while minimizing charring and pyrolysis, and includes a secondary liquid transport element for improved flow path management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a wick/coil design is used in the atomizer, then the device can deliver aerosol, but heating efficiency is poor and non-uniform heating occurs
Solution Approach 1:
The patent removes the fibrous wick material from the atomizer design, extracting the problematic component that caused non-uniform wicking and heating. Instead, a wickless atomizer structure is employed where liquid is delivered directly to the heating element through capillary channels formed in the atomizer body itself, eliminating the source of non-homogeneous liquid distribution and improving both heating efficiency and uniformity
Solution Approach 2:
The atomizer incorporates porous material directly into the heating element structure, creating integrated capillary channels that provide uniform liquid distribution across the heating surface. This porous structure replaces the separate wick component and ensures homogeneous liquid supply to the heating element, resolving the heating uniformity issue while maintaining efficient vaporization
2Quantity of substance
If a wick/coil design is used, then liquid transport is achieved, but pyrolysis and char deposition occur at the wick and coil interface
Solution Approach 1:
The patent eliminates the wick material entirely from the atomizer design, removing the interface between wick and coil where pyrolysis and charring occur. The wickless design with integrated capillary channels prevents organic material from decomposing at high temperatures, thereby eliminating the harmful pyrolysis products and char deposition that limit device lifespan
Solution Approach 2:
The patent introduces an intermediary porous structure within the atomizer body that serves as the liquid transport medium instead of using a separate wick. This intermediary porous material is positioned to deliver liquid directly to the heating element without contact between organic wick material and the high-temperature coil, preventing pyrolysis while maintaining effective liquid supply
3Quantity of substance
If fibrous wicking material is used, then liquid can be transported, but non-homogeneous wicking of liquid components occurs
Solution Approach 1:
The patent removes the fibrous wicking material that causes non-homogeneous liquid distribution. Instead, liquid transport is achieved through precisely engineered capillary channels formed directly in the atomizer body, providing uniform and controlled liquid delivery to the heating element without the irregularities inherent in fibrous materials
Solution Approach 2:
The atomizer employs porous material with controlled pore structure and distribution to achieve homogeneous liquid wicking. The porous structure is engineered to provide uniform capillary action across the entire liquid delivery surface, ensuring consistent liquid distribution to the heating element and eliminating the non-homogeneous wicking problems associated with traditional fibrous materials
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 microtextured surface wicking and patterned heating element configuration improves heating uniformity and efficiency, reduces charring/pyrolysis, and extends the device's operational life by providing a steady supply of aerosol precursor composition to the heating zone.
Implementation Method 1
a nonfibrous liquid transport element having a microtextured surface adapted for surface wicking of the liquid aerosol precursor composition across the microtextured surface
Implementation Method 2
an atomizer comprising an electrical resistance heater wire wrapped around a fibrous wicking material
Data Source
AI summary
The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a reservoir containing a liquid aerosol precursor composition and an atomizer including an electrical resistance heating element and a nonfibrous liquid transport element having a microtextured surface adapted for surface wicking of the liquid aerosol precursor composition across the microtextured surface, the microtextured surface of the liquid transport element being in fluid communication with the reservoir and in fluid communication with the electric resistance heating element.