Aerosol Heating Assembly Sintered Electrode Leads
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Solution Overview
Problem
Existing aerosol-forming apparatus heating bodies face issues with cracking and oxidation due to poor conduction holes and complex brazing processes, and high costs associated with precious metal brazing materials.
Innovation Solution
A heating assembly is designed with a heating rod wrapped by a base film, a heating film, and electrode leads, where the base film, heating film, and electrode leads are sintered together, eliminating the need for brazing and reducing exposure to oxidation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conduction holes are opened on the film tape to connect conductive films, then electrical connection is achieved, but the film tape has risks of cracking and breaking
Solution Approach 1:
The invention extracts the harmful conduction holes from the film tape structure and replaces them with electrode leads that pass through the heating rod. This eliminates the stress concentration points that cause cracking while maintaining electrical connectivity through the sintering process.
Solution Approach 2:
The invention introduces electrode leads as an intermediary element that connects the conductive films without requiring holes in the film tape. The leads are sintered to the heating rod and conductive films, providing a reliable electrical connection path that avoids compromising the film tape integrity.
2Reliability
If brazing process is used to connect outer conductive film to electrode lead, then electrical connection is achieved, but the process is complicated and components are exposed to oxidation and corrosion
Solution Approach 1:
The invention replaces the mechanical brazing process with a sintering process. Instead of using brazing materials and complex joining techniques, the electrode leads and conductive films are directly sintered to the heating rod, creating a robust electrical connection without exposure to oxidation and corrosion risks associated with brazing.
3Reliability
If brazing material such as silver paste is used to connect conductive films, then good conductivity is achieved, but large amount is required and costs are high
Solution Approach 1:
The invention eliminates the need for expensive brazing materials like silver paste by using a sintering process that creates direct metallic bonds between the electrode leads and conductive films. This approach uses minimal material and significantly reduces costs while maintaining good electrical conductivity.
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 solution prevents oxidation and corrosion of the heating components, reduces the risk of cracking, and lowers costs by eliminating the need for complex brazing processes, enhancing the reliability and longevity of the heating assembly.
Implementation Method 1
the base film, the heating film, and the two electrode leads are sintered together by co-firing
Data Source
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AI summary
The present invention relates to an aerosol-forming apparatus and a heating assembly thereof. The heating assembly includes: a heating rod; a base film wrapping at least part of the heating rod; a heating film arranged between the base film and the heating rod; and two electrode leads. Each electrode lead includes a conduction portion, and the conduction portion is arranged between the base film and the heating rod and connected to the heating film. The heating film and the conduction portions of the electrode leads are all located inside the base film, and are not exposed with no risk of oxidation and corrosion, and the electrode leads do not need to be connected in a welding process. In addition, there is no need to open a hole on the base film, thereby reducing risks of cracking.