Solid Aerosol Consumable with Integrated Heater
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Solution Overview
Problem
Existing aerosol provision systems, such as e-cigarettes, face challenges in efficiently generating vapor using solid aerosol forming materials, which can be prone to leakage and require complex manufacturing processes, while liquid-based systems are more prone to leakage and less efficient in vapor generation.
Innovation Solution
A consumable component with a solid aerosol forming material housed in an outer chamber, where a heater is used to vaporize the material, allowing air to flow through openings in the end walls, enabling efficient vapor generation and rapid inhalation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid-based aerosol precursor material is used, then the system can generate vapor, but the system is prone to leakage and less efficient in vapor generation
Solution Approach 1:
The patent changes the physical state of the aerosol precursor material from liquid to solid form. This parameter change eliminates leakage issues inherent in liquid systems while enabling efficient vapor generation through direct heating of solid elements, resolving both reliability and productivity concerns
2Productivity
If solid aerosol forming material is used, then vapor generation efficiency is improved, but the manufacturing process becomes complex
Solution Approach 1:
The solid aerosol forming material is divided into multiple discrete elements that can be individually manufactured and then assembled into the consumable component. This segmentation simplifies the manufacturing process by allowing each element to be produced using standard techniques and facilitates quality control
Solution Approach 2:
The patent employs a disposable consumable component containing solid aerosol forming elements. This approach simplifies manufacturing by eliminating the need for complex cleaning, maintenance, or sterilization processes, while allowing the use of cost-effective materials and production methods for single-use components
3Reliability
If solid aerosol forming material in separate compartment is used (WO 2019/073237), then leakage is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the solid aerosol forming elements, heater, and housing into a single integrated consumable component. This consolidation eliminates the need for separate compartments and complex interconnections, reducing structural complexity while maintaining leak resistance through the inherent stability of solid materials and simple sealed construction
4Productivity
If air flow through end walls is enabled, then vapor generation efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The end walls are designed with porous structures or arrays of small openings that allow air flow while being tolerant of manufacturing variations. This approach enables efficient vapor generation through controlled air passage without requiring high-precision manufacturing, as the porous structure naturally accommodates typical manufacturing tolerances
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 system provides a simpler, leak-resistant, and efficient method for vapor generation using solid aerosol forming materials, improving user experience and reducing manufacturing complexity compared to liquid-based systems.
Implementation Method 1
a heater arranged to vaporise a portion of aerosol precursor material to generate a vapour
Implementation Method 2
air is drawn in through the air inlet, along the flow path where the air mixes with vaporised precursor material and forms a condensation aerosol
Implementation Method 3
a heater located within the interior chamber and configured to heat the elements of solid aerosol forming material during use to generate a vapour
Data Source
Figure 1
Figure 2
Figure 3~4G
AI summary
A consumable component for an aerosol provision system comprising: an outer housing comprising an outer wall extending between first and second end walls to define an interior chamber; a plurality of elements of solid aerosol forming material for generating an aerosol for user inhalation, wherein the plurality of elements of solid aerosol forming material are retained within the interior chamber by the housing and wherein the first and second end walls comprise openings to allow air to flow into the interior chamber through the first end wall and out of the interior chamber through the second end wall during use, and a heater located within the interior chamber and configured to heat the elements of solid aerosol forming material during use to generate a vapour for user inhalation.