Non-Linear Aerosol Strands for Lower-Temperature Aerosol Generation
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Solution Overview
Problem
Existing aerosol-generating materials, such as those used in heat-not-burn devices and hybrid devices, face challenges in efficiently forming aerosols and may require high temperatures, leading to potential inefficiencies and material wastage.
Innovation Solution
The development of aerosol-generating materials in the form of non-linear strands, comprising an aerosol-generating agent, crosslinked binder, and optionally fillers, flavorants, and acids, which are formed through a process involving solvent mixing, ejection, and cross-linking, allowing for efficient aerosol generation at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional aerosol-generating materials are used, then aerosol generation is achieved, but material weight and transportation costs increase due to lower fill values
Solution Approach 1:
The patent applies curvature by forming the aerosol-generating material into non-linear strands with curved configurations rather than straight forms. This curvature increases the fill value by allowing more material to be packed into the same volume space, thereby reducing overall material weight while maintaining aerosol generation capability
Solution Approach 2:
The patent changes the physical parameters of the material by introducing a crosslinked binder system that modifies the strand structure. This crosslinking creates a three-dimensional network that enhances material density and fill value, allowing more material to be contained within the same volume, thus reducing transportation weight
2Temperature
If high temperatures are used for aerosol generation, then volatilisation occurs, but energy consumption increases and material wastage occurs
Solution Approach 1:
The patent changes the chemical parameters of the binder system to enable effective aerosol generation at lower temperatures. The crosslinked binder composition is specifically designed to facilitate volatilisation at reduced thermal input, thereby decreasing energy consumption and preventing material wastage that would occur at higher temperatures
Solution Approach 2:
The patent employs a composite material system combining aerosol-generating agent with a crosslinked binder. This composite structure optimizes the thermal properties of the material, allowing it to achieve effective aerosol generation at lower temperatures compared to conventional materials, thus reducing energy consumption and material degradation
3Device complexity
If linear strand form is used, then material structure is simple, but fill value and space utilization are reduced
Solution Approach 1:
The patent introduces curvature into the strand structure, transforming linear forms into non-linear configurations. This curvature increases space utilization and fill value without significantly complicating the manufacturing process, as the curved strands can still be produced through conventional extrusion or formation methods
Solution Approach 2:
The patent adds dimensional complexity by creating non-linear three-dimensional strand structures rather than simple one-dimensional linear forms. This dimensional change allows the material to occupy space more efficiently, increasing fill value while maintaining a relatively simple production approach
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 non-linear strands provide higher fill values, reducing material weight and transportation costs, while maintaining efficient aerosol production, and can be used in non-combustible aerosol provision systems.
Implementation Method 1
contacting the ejected mixture with a solution comprising a cross-linking agent
Implementation Method 2
The heating volatilises at least one component of the material, typically forming an inhalable aerosol
Implementation Method 3
ejecting the mixture through a nozzle such that the mixture moves with a velocity; and contacting the ejected mixture with a solution comprising a cross-linking agent, where the velocity of the mixture is reduced on contact with the solution
Data Source
AI summary
The invention provides an aerosol-generating material in the form of one or more non-linear strands, wherein the aerosol-generating material comprises: an aerosol-generating agent; a crosslinked binder; optionally one or more fillers; and optionally an active and/or a flavourant and/or an acid. The invention also provides aerosol-generating compositions comprising the aerosol-generating material, consumables for use within a non-combustible aerosol provision system, and non-combustible aerosol provision systems. The invention also provides methods for producing the aerosol-generating material.