Aerosol Heater Assembly Rolling for Firm Layer Bonding
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Solution Overview
Problem
Aerosol-generating devices face issues with film insulators swelling or delaminating in high-temperature and high-humidity environments, and layers of the heater assembly may not be firmly pressed during manufacturing, leading to lifting and defects.
Innovation Solution
A method of manufacturing a heater assembly where a sheet is rolled around a main roller with a susceptor and electrically conductive track, passing through spaces between sub-rollers, and heated and pressed to form multiple layers, with specific temperature and pressure settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a film insulator is used for the heater assembly, then the heater can be manufactured with simple structure, but the film insulator swells or delaminates in high-temperature and high-humidity environments
Solution Approach 1:
The patent divides the insulator into multiple layers (first insulating layer and second insulating layer) with different material compositions. The first layer uses polyimide for basic insulation, while the second layer uses a swelling-resistant material to prevent delamination in high-humidity environments. This segmentation allows each layer to perform its specific function, resolving the contradiction between simple structure and reliability.
Solution Approach 2:
The patent employs composite material construction by combining polyimide with swelling-resistant materials in a multi-layer insulator structure. This composite approach maintains the electrical insulation properties of polyimide while adding the dimensional stability of swelling-resistant materials, thereby preventing delamination in high-temperature and high-humidity conditions without significantly increasing structural complexity.
2Productivity
If layers are rolled during manufacturing, then the heater assembly can be formed efficiently, but layers may not be firmly pressed and lifting occurs
Solution Approach 1:
The patent applies a coating layer to the surface of the insulator before the rolling process. This preliminary action enhances the surface properties of the insulator, improving adhesion between layers during subsequent rolling and pressing operations. The pre-applied coating ensures that layers bond firmly during manufacturing, preventing lifting defects while maintaining manufacturing efficiency.
Solution Approach 2:
The patent controls pressing parameters (pressure, temperature, and time) during the rolling process to optimize layer bonding. By adjusting these parameters within specific ranges, the process ensures firm pressing of layers without causing delamination or lifting, thereby maintaining both manufacturing efficiency and bonding quality.
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
Prevents layer lifting and ensures even heating, enhancing the stability and performance of the heater assembly in various environments.
Implementation Method 1
the sheet is heated by the main roller and is heated and pressed by the sub-rollers
Implementation Method 2
the sheet is heated by the main roller and is heated and pressed by the sub-rollers
Implementation Method 3
a susceptor and an electrically conductive track disposed on the sheet are rolled around the main roller together with the sheet and then are thermally fused to the sheet
Data Source
AI summary
A method of manufacturing a heater assembly for aerosol-generating devices is disclosed. The method includes preparing a sheet formed to be elongated, placing a susceptor and an electrically conductive track on the sheet, and rolling the sheet around a main roller, with the susceptor and the electrically conductive track placed on the sheet. The rolling includes rolling the sheet around the outer circumferential surface of the main roller while allowing the sheet to sequentially pass through spaces defined between the main roller and each of a plurality of sub-rollers adjacent to the main roller.