Aerosol Heater Assembly with Bonded Induction Coil for Efficient Manufacturing
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Solution Overview
Problem
There is a need for a heater assembly in aerosol generating devices that is excellent in electrical efficiency, manufacturability, and productivity, particularly for induction heating-type systems.
Innovation Solution
The heater assembly includes an accommodation portion, an induction coil, a susceptor, and a support element, with the induction coil having a conductor, insulator, and bonding member, and is manufactured by forming the susceptor assembly, locating it in the accommodation portion, winding the induction coil to fit the shape, and fixing it with a bonding element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the induction coil is wrapped with a bonding element to fix its shape, then the structural stability is improved, but the device complexity increases
Solution Approach 1:
The bonding element is integrated into the induction coil assembly during the winding process, merging the shaping and fixing functions into a single integrated structure rather than adding a separate complex fixing mechanism
Solution Approach 2:
The bonding element acts as an intermediary material that simplifies the fixing process by providing a self-adhering layer that automatically bonds the induction coil to the accommodation portion when heated, eliminating the need for complex mechanical fastening systems
2Ease of manufacture
If the heater assembly configuration is simplified to reduce manufacturing costs, then the ease of manufacture is improved, but the electrical efficiency may deteriorate
Solution Approach 1:
The invention changes the physical state of the bonding member from solid to molten and back to solid through temperature control, enabling simple assembly processes while maintaining the precise geometric parameters of the induction coil that ensure electrical efficiency
Solution Approach 2:
The bonding member performs self-service by automatically bonding the induction coil to the accommodation portion through its own melting and solidifying process, eliminating the need for complex external fixing mechanisms that would increase device complexity
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 configuration improves electrical efficiency, enhances assembly properties, and reduces manufacturing costs by simplifying the heater assembly's configuration.
Implementation Method 1
a susceptor located in the accommodation portion and configured to generate heat by an alternating magnetic field generated by a current flowing through the induction coil
Implementation Method 2
a susceptor located in the accommodation portion and configured to generate heat by an alternating magnetic field generated by a current flowing through the induction coil
Data Source
AI summary
A heater assembly for heating an aerosol generating material includes an accommodation portion configured to accommodate the aerosol generating material; an induction coil coupled to an outer surface of the accommodation portion; a susceptor located in the accommodation portion and configured to generate heat by an alternating magnetic field generated by a current flowing through the induction coil; and a support element coupled to the susceptor such that the susceptor is spaced apart from an inner surface of the accommodation portion by the support element, wherein the induction coil includes a wire including a conductor, an insulator surrounding the conductor, and a bonding member surrounding the insulator.