Capillary Tube Heater Assembly for Consistent Aerosol Liquid Feed
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Solution Overview
Problem
Conventional heater assemblies in electronic aerosol provision systems, such as electronic cigarettes, do not efficiently supply liquid to the heater element and vary in the amount of energy required for vaporization based on the properties of the aerosol-generating material.
Innovation Solution
A heater assembly with a substrate and capillary tubes having flared ends that extend through a heater layer, providing a more efficient liquid supply and facilitating aerosol generation by optimizing the flow of liquid to the heater element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heater assemblies are used, then the structure is simple, but the liquid supply to the heater element is inefficient
Solution Approach 1:
The substrate is configured with a porous structure that enables capillary action to draw liquid from the reservoir to the heater element. The porosity allows liquid to move through the substrate without requiring additional pumping mechanisms, thus improving liquid supply efficiency while maintaining structural simplicity.
Solution Approach 2:
The invention introduces a vertical dimension to liquid supply by extending capillary tubes through the heater layer from the reservoir side to the heater element side. This three-dimensional arrangement ensures consistent liquid delivery to the heating zone, improving supply efficiency compared to conventional two-dimensional wick-based systems.
2Productivity
If the heater assembly is designed for efficient liquid supply, then aerosol generation is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The substrate and heater layer are combined into an integrated structure where the porous substrate serves both as a structural support and as the liquid transport medium. The capillary tubes are formed directly within the substrate during manufacturing, merging multiple functions into a single component that enhances aerosol generation while simplifying the overall manufacturing process.
Solution Approach 2:
The substrate performs multiple functions simultaneously: it provides structural support, enables liquid transport through capillary action, and serves as a mounting platform for the heater layer. This multi-functionality improves aerosol generation efficiency without requiring separate components for each function, thereby maintaining ease of manufacture.
3Productivity
If capillary tubes with flared ends are used, then liquid flow to the heater element is optimized, but the manufacturing precision requirements increase
Solution Approach 1:
The capillary tubes are designed with a flared end geometry that changes the internal diameter parameter along the tube length. The flare angle and dimensions are optimized to enhance liquid flow to the heater element while remaining compatible with standard manufacturing tolerances. This parameter optimization improves liquid flow efficiency without excessively increasing manufacturing precision requirements.
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
Enhances the efficiency of liquid supply to the heater element, ensuring consistent and effective aerosol generation by adapting to the properties of the aerosol-generating material.
Implementation Method 1
one or more capillary tubes extending from another surface of the substrate through the heater layer
Implementation Method 2
a heater layer configured to generate heat when supplied with energy
Implementation Method 3
electrical power is supplied to the heating element to vaporize source liquid in the vicinity of the heating element to generate an aerosol
Data Source
AI summary
A heater assembly for an aerosol provision system, the heater assembly including: a substrate; a heater layer configured to generate heat when supplied with energy, the heater layer provided on a first surface of the substrate; and one or more capillary tubes extending from another surface of the substrate through the heater layer provided on the first surface of the substrate. The ends of the one or more capillary tubes at the heater layer are configured to provide a flared end having an opening at the surface of the heater layer opposite the first surface of the substrate, wherein the flared end has an increasing characteristic dimension of extent along the direction from the another surface of the substrate to the opening in the heater layer. Also described is a cartomoizer including the heater assembly, an aerosol provision system including the heater assembly, and a method for manufacturing the heater assembly