Spherical Substrates for Aerosol Delivery Devices

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Solution Overview

Problem

Current aerosol delivery devices for nicotine and therapeutic drugs face issues such as the presence of cancer-causing agents, device fragility leading to leakage and fire risks, and the need for additional equipment and time for preparation and cleaning, which hinder a consistent and safe vaping experience.

Innovation Solution

Development of substrates formed from a base material and an aerosol former, designed to be easily loaded and unloaded, with a spherical or rod-like shape for optimal heat transfer, which can be extruded or spheronized to create pellet substrates that eliminate the need for additional equipment and reduce the risk of device damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional e-cigarettes use liquid nicotine cartridges, then nicotine delivery is achieved, but device fragility and leakage risk increase

Engineering Contradiction:

Improvedevice reliabilityVSAvoidleakage and fire risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state of nicotine from liquid to solid form by incorporating it into a substrate matrix. This parameter change eliminates leakage risks associated with liquid cartridges while maintaining controlled vaporization through thermal energy input during inhalation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite substrate comprising a matrix material (such as polyethylene glycol, gelatin, or starch) combined with solid nicotine or nicotine salts. This composite structure provides both mechanical stability for reliable device operation and controlled release properties for consistent nicotine delivery.

Inventive Principle:

Principle #40Composite materials

2Productivity

If vaporizers use dry herb material as substrate, then aerosol vaporization is achieved, but additional equipment and preparation time are required

Engineering Contradiction:

Improvevaporization efficiencyVSAvoidpreparation and cleaning equipment

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The nicotine is pre-incorporated into the substrate material during manufacturing, eliminating the need for users to separately prepare or load nicotine. The substrate is ready for direct use, requiring only insertion into the vaporizer device and immediate vaporization upon heating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The substrate can be designed as a disposable component that is pre-filled with nicotine in controlled doses. After use, the entire substrate is discarded, eliminating cleaning requirements and reducing device complexity while maintaining efficient vaporization performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Use of energy by moving object

If spherical or rod-like substrates are used, then heat transfer is optimized, but manufacturing precision requirements increase

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidsubstrate shape consistency

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent specifies spherical, rod-like, or capsule-shaped substrates as these geometries provide optimal heat distribution during vaporization. The curved surfaces ensure uniform thermal contact with the heating element, improving energy efficiency and consistent vaporization across the entire substrate.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 substrates provide a safe, reliable, and convenient method for vaporizing and delivering aerosols, reducing the risk of device damage and fire, while ensuring consistent and enjoyable inhalation experiences without the need for extra preparation or cleaning.

Implementation Method 1

heat a liquid, referred to as 'e-liquid' or 'liquid nicotine,' containing nicotine and in some instances flavoring, to convert the liquid into an aerosol

Methodology Applied

Scientific EffectVaporization: Evaporation

Implementation Method 2

a heat conductor in thermal and heat conducting relation to the heat generator and in vaporizing relation to the substrate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11510870B1Substrates for vaporizing and delivering an aerosol

Publication Date: 2022.11.29 PHILIP MORRIS PRODUCTS SA

AI summary

Substrates for use with an aerosol delivery device to vaporize and deliver an aerosol to a user include a base material, an aerosol former and an aerosol agent. In a method for forming the substrates, a mixture of substrate materials is extruded and then spheronized to produce pellet substrates that are generally spherical, substantially spherical or rounded, or in the form of relatively short rods having rounded ends. In another method for forming the substrates, a base material is coated with a first coating and optionally the base material having the first coating thereon is subsequently coated with a second coating so as to produce pellet substrates having a relatively smooth, dry exterior surface. In this manner, the substrates are formable relative to one another and can be easily and readily loaded into and removed from the aerosol delivery device.