Bondable Litz Inductor Coil Shaping for Stable Aerosol Heating
Solution Overview
Problem
Aerosol provision devices face challenges in maintaining the shape and efficiency of inductor coils over time, leading to deformation and reduced heating performance.
Innovation Solution
A method of forming inductor coils using litz wire with a bondable coating, where the coils are shaped on a support member and the coating is activated to retain the shape, allowing the coils to be removed and connected to a power source without losing their structure, ensuring consistent heating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If inductor coils are formed without a bondable coating, then the manufacturing process is simpler, but the coils deform and lose their shape over time
Solution Approach 1:
The bondable coating is applied to the wire strands before forming the inductor coil, allowing the coating to set and stabilize the coil shape after formation. This preliminary preparation enables shape retention without requiring complex post-processing steps.
Solution Approach 2:
The bondable coating undergoes a parameter change through activation (heating or chemical treatment) that transforms it from a flexible state to a rigid, shape-retaining state. This parameter change allows the coil to maintain its predetermined shape without continuous external support.
2Reliability
If inductor coils are formed on a support member without bondable coating, then the initial shaping is easier, but the coils cannot be removed without losing their structure
Solution Approach 1:
The bondable coating is prepared in advance on the wire strands, enabling the coil to be formed on a support member and then removed while maintaining its shape. The coating acts as a preliminary structural reinforcement that allows easy removal from the support member without deformation.
3Manufacturing precision
If traditional wire is used without bondable coating, then the material cost is lower, but the heating performance degrades over time due to deformation
Solution Approach 1:
The wire strands are composite structures combining a conductive core material with a bondable coating layer. This composite structure provides both the electrical conductivity needed for heating and the structural stability required to maintain precise geometric shape over time, ensuring consistent heating performance.
4Duration of action of stationary object
If the inductor coil shape is not stabilized, then manufacturing is more flexible, but the device lifetime is reduced due to deformation
Solution Approach 1:
The bondable coating undergoes a parameter change through activation that permanently sets the coil's geometric parameters. This parameter change locks the coil in its predetermined shape, preventing deformation over time and extending device lifetime, while the activation process remains a relatively simple step in the manufacturing sequence.
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 method ensures that the inductor coils retain their shape and maintain efficient heating performance, increasing the device's lifetime and flexibility during manufacturing, while also allowing for pre-assembly of coils, which enhances the overall performance of aerosol provision devices.
Implementation Method 1
activating the bondable coating such that the inductor coil substantially retains the predetermined shape
Implementation Method 2
an aerosol provision device inductor coil formed from a litz wire
Data Source
AI summary
A method of forming an aerosol provision device inductor coil comprises providing a litz wire comprising a plurality of wire strands, wherein each of the plurality of wire strands comprise a bondable coating. The method further comprises forming an inductor coil from the litz wire on a support member, wherein the inductor coil has a predetermined shape. The method further comprises activating the bondable coating such that the inductor coil substantially retains the predetermined shape, and removing the inductor coil from the support member.