Tubular Filter Segment for Selective Aerosol Particle Filtration

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Solution Overview

Problem

Existing electronic smoking articles lack an effective mechanism to selectively filter aerosol particles and vapors, which affects the particle size distribution and sensory experience of the aerosol produced.

Innovation Solution

Incorporating a tubular filter segment downstream of the heater, which selectively filters aerosol particles and vapors by modifying the particle size distribution, while maintaining larger particles centrally within the aerosol flow, and optionally using additives impregnated or coated on the filter to enhance the sensory attributes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a tubular filter segment is added to selectively filter aerosol particles and vapors, then the particle size distribution and aerosol composition are improved, but the device complexity increases

Engineering Contradiction:

Improveparticle size distributionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The filter is segmented into multiple zones with different pore sizes (first zone with larger pores, second zone with smaller pores) to selectively filter different particle sizes. This segmentation allows precise control over particle size distribution while maintaining a manageable device structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tubular filter segment utilizes porous materials with controlled pore sizes to achieve selective filtration. The porous structure enables the filter to capture specific particle sizes while allowing others to pass through, improving aerosol composition without requiring complex mechanical filtering mechanisms.

Inventive Principle:

Principle #31Porous materials

2Manufacturing precision

If the tubular filter segment filters smaller particles and vapor phase components, then the aerosol composition is improved, but the quantity of substance delivered to the user is reduced

Engineering Contradiction:

Improveaerosol compositionVSAvoidquantity of substance

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The porous filter material is designed with specific pore size distributions that allow larger aerosol particles to pass through while trapping smaller particles and vapor phase components. This selective permeability improves aerosol composition by removing unwanted fractions while preserving the majority of the aerosol substance.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The filter's pore size parameters are carefully selected and adjusted to optimize the balance between filtration effectiveness and substance delivery. By controlling the pore size distribution, the system achieves improved aerosol composition while minimizing loss of total substance quantity.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If additives are impregnated or coated on the filter to enhance sensory attributes, then the sensory experience is improved, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvesensory experienceVSAvoidease of manufacture

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Additives are applied locally to specific regions or zones of the tubular filter segment rather than uniformly throughout the entire device. This localized application enhances sensory attributes at the point of contact with the aerosol while simplifying the manufacturing process compared to system-wide modifications.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The additive application process utilizes controlled parameters such as concentration, temperature, and deposition methods to achieve consistent sensory enhancement. By standardizing these parameters, the manufacturing complexity is reduced despite the additional functional layer.

Inventive Principle:

Principle #35Parameter changes

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 tubular filter segment effectively filters smaller particles and vapor phase components, improving the aerosol composition and sensory experience by adjusting the particle size distribution and delivering additives, thereby enhancing the overall vaping experience.

Implementation Method 1

a heater operable to at least partially volatilize the liquid aerosol formulation and form an aerosol

Methodology Applied

Scientific EffectVolatilization: Evaporation

Implementation Method 2

a tubular filter segment downstream of the heater, the tubular filter segment operable to selectively filter aerosol particles and vapors from the aerosol, whereby a particle size distribution of the aerosol is modified

Methodology Applied

Scientific EffectAerosol filtration: Filter (physical)

Data Source

PatentUS20240245118A1Electronic smoking article

Publication Date: 2024.07.25 ALTRIA CLIENT SERVICES LLC

AI summary

An electronic smoking article includes a liquid aerosol formulation, a heater operable to at least partially volatilize the liquid aerosol formulation and form an aerosol and a tubular filter segment downstream of the heater. The tubular filter segment is operable to selectively filter aerosol particles and vapors from the aerosol.