Shape-Transformable Aerosol Substrate for Compact Storage
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Solution Overview
Problem
Existing aerosol-generating devices using aerosol-forming substrates are not optimized for storage, as they require a large surface area for vaporization but are not space-efficient, leading to challenges in packaging and transportation.
Innovation Solution
A method and device that utilize a shape-transformable flat aerosol-forming substrate, which can be molded into a non-flat shape within a device housing, allowing for a larger surface area to be used in a compact form, facilitating efficient storage and transportation while maintaining effective aerosol formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a large surface area substrate is used for aerosol formation, then aerosol formation effectiveness is improved, but storage space efficiency deteriorates
Solution Approach 1:
The flat aerosol-forming substrate is nested within the device housing in a compressed state, similar to how a smaller object fits inside a larger one. The substrate is stored in a flat configuration that occupies minimal space within the housing cavity, and only expands to its full surface area when deployed for aerosol formation.
Solution Approach 2:
The substrate transitions from a static flat state during storage to a dynamic expanded state during use. This dynamic transformation allows the same substrate to occupy different volumes depending on whether it is being stored or used for aerosol generation, resolving the contradiction between storage efficiency and surface area requirements.
2Volume of moving object
If a flat substrate is used, then storage efficiency is improved, but aerosol formation surface area is reduced
Solution Approach 1:
The substrate utilizes the third dimension (depth/height) within the device housing by being positioned at an angle or in a layered configuration. This allows the flat substrate to occupy horizontal space efficiently while still providing sufficient vertical surface area for aerosol formation when heated.
Solution Approach 2:
The substrate dynamically transforms from a compact flat state during storage to an expanded three-dimensional configuration during use, maximizing surface area only when needed for aerosol generation while minimizing volume during storage and transport.
3Volume of moving object
If the device housing is made compact, then portability is improved, but substrate transformation space is reduced
Solution Approach 1:
The device housing is segmented into distinct functional zones: a compression zone with the moulding cavity for substrate transformation, and a storage zone for the flat substrate. This segmentation allows the compact housing to accommodate both the transformation process and the stored substrate without requiring excessive overall volume.
Solution Approach 2:
The substrate is pre-compressed into a flat state before insertion into the device, and the moulding cavity is pre-configured with the exact geometry needed for transformation. This preliminary preparation eliminates the need for complex real-time transformation mechanisms, reducing device complexity while maintaining compact dimensions.
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 enables the use of larger aerosol-forming substrates in smaller devices, ensuring efficient heating and aerosol formation, while simplifying storage and reducing damage during transport by transforming flat substrates into three-dimensional shapes within the device.
Implementation Method 1
aerosol-forming substrate adapted to change shape when pressed into the moulding cavity and being transformed into a non-flat aerosol-forming substrate
Implementation Method 2
heating element arranged on a first internal surface having a shape comprising a frustum
Data Source
AI summary
The method for providing an aerosol-generating device for use with a shape-transformable aerosol-forming substrate comprises providing an aerosol-generating device comprising a device housing comprising a moulding cavity. The moulding cavity at least partially corresponds to a moulding space between a first mould half and a second mould half of a mould, the first mould half and the second mould half being internal surfaces of the device housing. The method further comprises the step of providing a flat aerosol-forming substrate adapted to change shape when pressed into the moulding cavity and being transformed into a non-flat aerosol-forming substrate. The invention also refers to a flat aerosol-generating article and a kit comprising a flat aerosol-generating article and an aerosol-generating device.