Rigid Monolith Atomizer with Planar Heater for Uniform Vaporization
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Solution Overview
Problem
Existing aerosol delivery devices face challenges in achieving efficient vapor formation and uniform heating, often resulting in incomplete vaporization and potential charring of fluid transport elements, particularly when using porous monoliths as fluid transport elements.
Innovation Solution
The integration of a rigid, porous monolith fluid transport element with a planar heating surface and strategically designed apertures, combined with a heater and thermal insulator, enhances vapor formation by optimizing heat flux density and reducing energy requirements for vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a porous monolith is used as a fluid transport element, then vapor formation is improved, but charring occurs due to uneven heating
Solution Approach 1:
The patent introduces apertures at specific locations on the porous monolith to create localized regions of improved heat distribution. The apertures are strategically positioned to receive additional thermal energy, creating local quality variations that prevent charring in high-heat zones while maintaining efficient vapor formation where needed.
Solution Approach 2:
The apertures act as intermediary structures that facilitate heat transfer from the heating element to the porous monolith. By providing direct thermal pathways through the apertures, the patent mediates the heat distribution to eliminate uneven heating and prevent charring while maintaining vapor formation efficiency.
2Productivity
If heating power is increased to improve vapor production, then vaporization efficiency increases, but energy consumption increases
Solution Approach 1:
The patent modifies the thermal parameters of the system by introducing apertures that change the heat distribution pattern. This allows the system to achieve the same vapor production at lower temperatures or with less total energy input, as the heat is more efficiently directed to where it is needed for vaporization.
Solution Approach 2:
The porous monolith structure provides a large surface area for vaporization, allowing efficient heat transfer from the heating element. The porous structure enables the material to absorb and distribute heat throughout its volume, improving vapor production efficiency while reducing the total energy required compared to non-porous alternatives.
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
This configuration improves vapor production efficiency, reduces energy demands, and minimizes charring, providing a more uniform heating experience and increased aerosol precursor vaporization.
Implementation Method 1
the rigid monolith is formed from a porous material capable of wicking an aerosol precursor composition into proximity of the heating surface through capillary action
Implementation Method 2
the heater is positioned exterior to the reservoir so as to vaporize at least a portion of the aerosol precursor composition that is transported from the reservoir via the fluid transport element
Implementation Method 3
The atomizer particularly can include at least a fluid transport element and a heater... combined with a heater and thermal insulator
Data Source
AI summary
An atomizer and an aerosol delivery device are described, where the atomizer has a fluid transport element formed from a rigid monolith having a first side and a second side opposite to the first side. The atomizer also has a heater. The heater provides a substantially planar heating surface. The heating surface is positioned to face the first side of the rigid monolith.