Atomizer Coil Spacing for Combustion-Free Aerosol Generation
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Solution Overview
Problem
Existing aerosol delivery devices, such as electronic cigarettes, face challenges in producing aerosol without combusting tobacco, while avoiding incomplete combustion and pyrolysis products, and improving manufacturing efficiency.
Innovation Solution
The design incorporates a liquid transport element with a wire continuously wound to form heating elements, featuring varying pitches, which are connected to heater terminals to efficiently heat aerosol precursors, allowing for the production of aerosol without combustion and enabling cost-effective and efficient manufacturing of atomizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional combustion methods are used to produce aerosol, then aerosol generation is achieved, but incomplete combustion and pyrolysis products are generated
Solution Approach 1:
The patent replaces the mechanical/chemical combustion system with an electrical heating system. A wire heating element wrapped around a liquid transport element heats the liquid aerosol precursor to a temperature sufficient for vaporization without combustion, thereby eliminating incomplete combustion and pyrolysis products while maintaining reliable aerosol generation.
2Ease of manufacture
If discrete heating elements are used in atomizers, then heating function is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the heating element and liquid transport element into a single integrated structure. The wire heating element is wrapped around the liquid transport element, creating a unified component that performs both heating and liquid transport functions, thereby simplifying manufacturing and reducing device complexity.
Solution Approach 2:
The integrated heating element structure serves multiple functions simultaneously: the wire provides heating, the wrapping structure provides thermal contact, and the overall assembly facilitates liquid transport. This multi-functionality reduces the number of separate components needed and simplifies the atomizer manufacturing process.
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 effectively produces aerosol without combustion products, enhancing the manufacturing efficiency of atomizers by using a continuous wire winding process, resulting in improved performance and reduced production costs.
Implementation Method 1
a wire and a liquid transport element... configured to heat a material... to form an inhalable substance
Data Source
AI summary
The present disclosure relates to atomizers for an aerosol delivery device such as a smoking article. The atomizer may include a liquid transport element and a wire extending along at least a portion of a longitudinal length thereof. The wire may define contact portions configured to engage heater terminals and a heating portion configured to produce heat. The heating portion may include a variable coil spacing. In other atomizers, the wire may extend at least partially through the liquid transport element proximate the contact portions. Related inputs, cartridges, aerosol production assemblies, and methods of forming atomizers are also provided.