Non-Linear Aerosol Strands for Low-Tangle Mixing and Packing
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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 handling and processing due to high tangling of strands, which complicates the formation of homogeneous mixtures with other materials like tobacco, and they often have lower packing efficiency leading to increased weight and transportation costs.
Innovation Solution
The development of aerosol-generating materials in the form of non-linear strands with an average of less than 5 contact points per strand, aligned in parallel, which are produced through a method involving solvent mixing, ejection, cross-linking, and drying to create untangled, high-fill-value strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aerosol-generating material is used in the form of tangled strands, then the material can be easily produced, but the handling and processing becomes difficult and homogeneous mixing with other materials is complicated
Solution Approach 1:
The patent applies curvature by transforming linear strands into non-linear curved strands. The strands are formed with controlled curvature characteristics where the ratio of curved length to straight-line distance is within specific ranges (0.5-2.0). This curvature prevents tangling while maintaining ease of production through extrusion processes, resolving the contradiction between easy manufacture and ease of handling.
2Ease of manufacture
If aerosol-generating material uses traditional strand configuration, then production is simple, but packing efficiency is reduced leading to increased weight and transportation costs
Solution Approach 1:
The curved strand configuration with controlled curvature ratios enables superior packing efficiency compared to linear strands. The non-linear geometry allows strands to nest and arrange more effectively in storage and transportation, increasing density without complicating the extrusion production process, thus reducing transportation weight while maintaining production simplicity.
Solution Approach 2:
The patent changes the geometric parameters of the strands by introducing controlled curvature within specific ratio ranges. This parameter modification optimizes both packing efficiency for reduced transportation weight and maintains compatibility with standard extrusion manufacturing processes.
3Ease of manufacture
If strands are highly tangled, then material formation is straightforward, but formation of homogeneous mixtures with tobacco and other materials is complicated
Solution Approach 1:
The controlled curvature of strands prevents entanglement and creates a more open, accessible structure that facilitates uniform distribution and mixing with tobacco and other materials. The non-linear geometry allows better interpenetration and contact between different components, ensuring homogeneous mixtures while maintaining straightforward extrusion formation.
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 facilitate easier handling and formation of homogeneous mixtures, reduce overall weight, and increase packing efficiency, leading to lower material and transportation costs while maintaining chemical composition consistency.
Implementation Method 1
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
Implementation Method 2
a crosslinked binder; optionally one or more fillers; and optionally an active and/or flavourant and/or an acid
Data Source
AI summary
The invention provides an aerosol-generating material in the form of one or more non-linear strands, wherein each non-linear strand has a number of contact points with other non-linear strands, the average number of contact points per non-linear strand being less than about 5. 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.