Polymer Matrix Aerosol Element for Nicotine Encapsulation
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Solution Overview
Problem
Existing aerosol-generating substrates face challenges in encapsulating nicotine formulations due to hydrophilic aerosol formers like glycerin and propylene glycol, leading to instability, leakage, and degradation issues, especially when heated, which affects the sensory profile and efficiency of aerosol delivery.
Innovation Solution
A solid continuous matrix structure comprising a polymer matrix with a high content of polyhydric alcohol, such as glycerin, traps the nicotine formulation, allowing for controlled release upon heating, minimizing encapsulation material and maintaining stability and geometric integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrophilic encapsulation materials are used to encapsulate nicotine formulation, then stability and containment are improved, but aerosol former payload is insufficient due to high material requirements
Solution Approach 1:
The invention uses a composite encapsulation system combining a hydrophilic polymer matrix (such as gelatin or alginate) with a hydrophobic coating layer (such as shellac or ethyl cellulose). This composite structure allows the hydrophilic material to provide stability and containment while the hydrophobic layer prevents excessive material consumption, thereby maintaining high nicotine formulation payload.
Solution Approach 2:
The invention changes the physical and chemical parameters of the encapsulation system by controlling the molecular weight, concentration, and cross-linking degree of the hydrophilic polymer. These parameter adjustments optimize the balance between encapsulation stability and payload capacity, reducing the amount of material needed while maintaining effectiveness.
2Quantity of substance
If hydrophobic encapsulation materials are used to encapsulate nicotine formulation, then material efficiency is improved, but thermal degradation occurs at processing and operating temperatures
Solution Approach 1:
The invention combines hydrophobic coating materials with low thermal stability requirements with hydrophilic polymer matrices that can withstand processing temperatures. The hydrophobic layer provides material efficiency while the hydrophilic matrix maintains structural integrity at elevated temperatures, preventing degradation.
Solution Approach 2:
The invention applies different material properties to different regions of the encapsulation structure. The inner hydrophilic matrix provides thermal stability during processing, while the outer hydrophobic coating provides material efficiency and controlled release properties, with each layer optimized for its specific function.
3Productivity
If high polyhydric alcohol content is used in aerosol-generating formulation, then aerosol generation efficiency is improved, but leakage and instability increase
Solution Approach 1:
The invention uses a composite formulation system where polyhydric alcohols (such as glycerin and propylene glycol) are combined with nicotine salts and flavoring agents in specific ratios. This composite formulation maintains high aerosol generation efficiency while the balanced composition prevents leakage and instability issues.
Solution Approach 2:
The invention optimizes the concentration parameters of polyhydric alcohols within specific ranges (e.g., glycerin at 20-40% and propylene glycol at 10-30%) to achieve the optimal balance between aerosol generation efficiency and formulation stability, preventing both leakage and insufficient performance.
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 solution provides a stable and efficient aerosol delivery with minimal leakage and adverse effects on the sensory profile, allowing for higher nicotine content and improved handling and manufacturing of aerosol-generating articles, with efficient heat utilization and controlled aerosol generation between 150°C to 350°C.
Implementation Method 1
an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material
Implementation Method 2
During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.
Implementation Method 3
volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source
Implementation Method 4
volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article
Implementation Method 5
As the released compounds cool, they condense to form an aerosol
Data Source
AI summary
An aerosol-generating element for an aerosol-generating article or system is provided, the aerosol-generating element including: a solid continuous matrix structure; and an aerosol-generating formulation dispersed within the structure, in which the formulation is trapped within the structure and releasable from the structure upon heating of the aerosol-generating element, in which the structure is a polymer matrix including one or more matrix-forming polymers, in which the formulation dispersed within the structure includes at least one alkaloid or cannabinoid compound and a polyhydric alcohol, in which a polyhydric alcohol content in the formulation dispersed within the structure accounts for at least 30 percent by weight based on a total weight of the aerosol-generating element, and in which the aerosol-generating element has an equivalent diameter of at least about 0.5 millimetres and an ovality from about 2 percent to about 30 percent.