Aerosol Heater Arrays with Non-Adjacent Sequential Activation
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Solution Overview
Problem
Existing aerosol-generating systems face an increased likelihood of thermal decomposition of the aerosol-forming substrate due to preheating by spatially proximal heating elements, which can lead to inefficient nicotine delivery and substrate degradation.
Innovation Solution
An aerosol-generating system with individually activatable heating elements arranged in an array, controlled by a circuitry that activates them sequentially to avoid consecutive activation of spatially adjacent elements, allowing each element to cool before reactivation and minimizing preheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple heating elements are used to generate aerosol, then aerosol generation capacity is improved, but thermal decomposition of substrate increases due to preheating by adjacent elements
Solution Approach 1:
The heating system is divided into multiple spatially separated heating elements arranged in an array pattern, where each element operates independently. This segmentation allows the system to maintain high aerosol generation capacity while reducing thermal interference between elements, as the spatial separation prevents preheating of adjacent elements' substrate.
Solution Approach 2:
The control circuitry activates heating elements in a sequential, periodic manner rather than simultaneously. By cycling through the array and activating elements one at a time or in non-adjacent sequences, the system maintains high overall productivity while ensuring each element completes its heating cycle before adjacent elements are activated, preventing thermal decomposition.
2Productivity
If heating elements are activated consecutively for efficient aerosol production, then aerosol output is improved, but substrate stability deteriorates due to extended heating time
Solution Approach 1:
The system implements periodic activation sequences where heating elements are cycled through in a controlled pattern. Each element is activated for a specific duration then deactivated before adjacent elements are activated, maintaining high aerosol output through continuous cycling while limiting the cumulative heating time on any single substrate portion, thereby preserving substrate stability.
Solution Approach 2:
The control circuitry is pre-programmed with optimal activation sequences that anticipate thermal effects. By carefully planning the activation order and timing of each element in the array, the system maximizes aerosol production while preemptively avoiding conditions that would cause substrate decomposition, such as consecutive activation of adjacent elements.
3Ease of operation
If spatially adjacent heating elements are activated consecutively, then device operation is simplified, but thermal decomposition risk increases
Solution Approach 1:
The control circuitry automatically manages the complex activation sequencing without requiring user intervention. The system self-regulates the activation patterns of multiple heating elements, implementing non-adjacent sequential activation algorithms that prevent thermal decomposition while maintaining simplified operation for the user. The intelligent control system handles the complexity internally, keeping the user interface simple.
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 approach reduces the likelihood of thermal decomposition, enhances nicotine delivery efficiency, and maintains substrate stability by ensuring each heating element is activated at optimal times and distances, thereby improving aerosol quality and extending cartridge life.
Implementation Method 1
Heat produced by a heating element thermally vaporises the substance disposed on the heating element
Implementation Method 2
Heat produced by a heating element thermally vaporises the substance disposed on the heating element
Implementation Method 3
The vaporised substance condenses in the air flow of air to form a condensation aerosol
Data Source
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AI summary
There is provided aerosol-generating system (200) comprising a cartridge (100). The cartridge comprises a heater assembly comprising at least four individually activatable heating elements (116, 118... 140) arranged in an array. There is an aerosol-forming substrate on each of the heating elements. The system also comprises an aerosol-generating device (201) configured to engage the cartridge. The aerosol-generating device comprises a power supply (206) and control circuitry (212). The control circuitry is configured to control a supply of power from the power supply to each of the heating elements to generate an aerosol. The control circuitry is configured to activate the heating elements sequentially such that no two spatially adjacent heating elements are activated consecutively.