Capillary Sheet Heater for Aerosol Devices
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Solution Overview
Problem
Existing aerosol generation devices, such as electronic cigarettes, face issues with ineffective liquid transport and vaporization due to the combined heating and wicking functions in mesh heaters, which restrict heating parameters and lead to vaporization outside intended areas.
Innovation Solution
A dedicated heating element is used in conjunction with a capillary sheet of heat conductive fibre mesh to optimize wicking and heating functions, allowing for improved liquid transport and vaporization by creating temperature gradients across the mesh.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a mesh heater combines both heating and wicking functions, then the device structure is simplified, but the heating parameters are restricted and liquid transport efficiency deteriorates
Solution Approach 1:
The heater is divided into two separate components: a dedicated heating element (such as a coil or heating wire) and a separate wicking element (capillary sheet). The heating element generates heat through resistive heating, while the wicking element transports liquid via capillary action. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between structural simplicity and functional effectiveness.
Solution Approach 2:
The heating function is extracted from the mesh structure and placed into a separate heating element. The mesh is retained solely for its wicking function, where its porous structure facilitates liquid transport through capillary forces. This extraction eliminates the compromise that existed when the mesh had to simultaneously perform both heating and wicking functions.
2Volume of moving object
If a mesh heater combines heating and wicking functions, then the device is more compact, but vaporization occurs outside the intended area
Solution Approach 1:
The heating element is positioned to contact only a specific region of the wicking element, creating a localized heating zone. This ensures that vaporization occurs only in the intended area where the heating element contacts the mesh, preventing unintended vaporization in other regions. The local quality of heating is maintained while keeping the overall device compact.
3Productivity
If the mesh structure is optimized for capillary action, then liquid transport improves, but heating efficiency deteriorates
Solution Approach 1:
By separating the heating and wicking functions into different components, the mesh can be optimized exclusively for capillary liquid transport without compromise on heating efficiency. The porosity, fiber diameter, and mesh density can be tuned to maximize liquid uptake and transport, while the heating element independently provides the necessary thermal energy.
Solution Approach 2:
The wicking element acts as an intermediary between the liquid reservoir and the heating element. It efficiently transports liquid to the heating zone through capillary action, ensuring that the heating element receives adequate liquid supply without requiring the mesh itself to generate heat. This intermediary role allows optimal design for liquid transport.
4Reliability
If a dedicated heating element is used with a separate capillary sheet, then heating and wicking functions are optimized, but device complexity increases
Solution Approach 1:
The heating element and wicking element are combined into a single integrated heater assembly where the heating element contacts the wicking element in a fixed arrangement. This merging maintains the functional benefits of separate components while presenting them as a unified device, minimizing the perceived complexity increase.
Solution Approach 2:
The wicking element serves multiple functions: it transports liquid from the reservoir, provides a surface for the heating element to contact, and acts as a support structure. This multi-functionality reduces the need for additional components, offsetting the complexity increase from having separate heating and wicking elements.
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 enhances the efficiency of liquid transport and vaporization, enabling a greater volume of vapor to be generated while extending the heater's lifespan by providing structural support and optimizing both wicking and heating functions.
Implementation Method 1
a capillary sheet comprising a sheet of heat conductive fibre mesh configured to provide capillary action in use
Implementation Method 2
The electrical resistance of the conductive material causes heat to be generated as the electric current passes through the material, a process commonly known as resistive heating
Implementation Method 3
a heating element in contact with the sheet of conductive fibre mesh and arranged to heat the sheet of conductive fibre mesh
Implementation Method 4
heat an aerosol generating liquid in order to generate an aerosol, or vapour, for inhalation by a user
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
The present invention relates to a heater (1) for an aerosol generating device (100). The heater includes a capillary sheet (10) comprising a sheet of heat conductive fibre mesh configured to provide capillary action in use and a heating element (20) in contact with the sheet of conductive fibre mesh and arranged to heat the sheet of conductive fibre mesh. By using a dedicated heating component, in particular a heating element in contact with the mesh in order to transfer heat to the mesh, the mesh heater material and structure can be configured to optimise the wicking properties and the heating element can be optimised to provide the required heating function.