Aerosol-generating system having a heater assembly and a cartridge for an aerosol-generating system having a fluid permeable heater assembly
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Solution Overview
Problem
Handheld aerosol-generating systems, such as electrically operated smoking systems, face challenges in producing cartridges that are both inexpensive and robust due to the complexity and cost of manufacturing the wick and coil assembly, as well as the need for a robust mouthpiece to protect these components during transport.
Innovation Solution
A fluid permeable heater assembly comprising a plurality of electrically conductive filaments fixed across the opening of a liquid storage portion, which is robust, easy to manufacture, and allows for increased contact area with the aerosol-forming substrate, utilizing a substantially flat and planar design with capillary action to enhance vaporization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a wick and coil assembly is used in the cartridge, then the heater can effectively vaporize the liquid substrate, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The system is divided into two separate parts: a disposable cartridge containing only the liquid substrate and a reusable device portion containing the heater assembly. This segmentation allows the complex heater to be manufactured once and reused, while the simple cartridge can be easily and cheaply manufactured and disposed of after use.
Solution Approach 2:
The cartridge is designed as a disposable, low-cost component that contains only the liquid substrate without the expensive wick and coil assembly. After the liquid is consumed, the entire cartridge is discarded and replaced, eliminating the need for complex manufacturing in each disposable unit.
2Reliability
If a robust mouthpiece is included in each cartridge to protect the delicate wick and coil assembly, then the heater assembly is protected during transport, but the material cost of each cartridge increases
Solution Approach 1:
The delicate heater assembly (wick and coil) is extracted from the disposable cartridge and placed in the reusable device portion. This extraction eliminates the need for protective structures in each cartridge, as the delicate components remain permanently housed in the durable device portion where they can be adequately protected.
3Reliability
If electrical contacts between the heater wire and device portion are delicately handled during manufacture, then reliable electrical connection is achieved, but the manufacturing process becomes more difficult and time-consuming
Solution Approach 1:
The system separates the electrical connection requirements from the disposable cartridge. Electrical contacts are only present in the reusable device portion, which is manufactured once with careful attention to connection reliability. The disposable cartridge requires no electrical connections, allowing for rapid, simple manufacturing without compromising electrical reliability.
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 solution reduces production costs and enhances the efficiency of aerosol generation by providing a robust and cost-effective heater assembly that can be easily handled during manufacturing, while ensuring efficient vaporization through increased contact area and capillary action.
Implementation Method 1
fluid permeable heater assembly comprising a plurality of electrically conductive filaments
Implementation Method 2
electrically conductive filaments, wherein the fluid permeable heater assembly is fixed to the housing and extends across the opening of the housing
Implementation Method 3
suitable for vapourising a liquid
Data Source
AI summary
An aerosol-generating system including a liquid storage portion is provided, the portion including a rigid housing holding a liquid aerosol-forming substrate, the housing having an opening and a fluid permeable heater assembly including a plurality of electrically conductive filaments, wherein the fluid permeable heater assembly is fixed to the housing and extends across the opening of the housing. The provided heater assembly that extends across an opening of a liquid storage portion allows for a robust construction that is relatively simple to manufacture and allows for a large contact area between the heater assembly and liquid aerosol-forming substrate. The heater assembly may be substantially flat, allowing for simple manufacture.