Capillary Wick Membrane Heater for Aerosol Generation
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Solution Overview
Problem
Handheld electrically operated smoking systems face challenges in manufacturing costs and optimal operation due to the complexity of the wick and coil assembly, which can lead to non-homogeneous liquid distribution and inefficiencies in aerosol generation.
Innovation Solution
A container design featuring a tubular liquid retention element with an air-permeable capillary wick membrane and a substantially flat electrical heater, providing a large contact area for efficient vaporization and robust construction, along with a tubular element to prevent leakage and additional retention elements for improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wick and coil assembly is used for vaporization, then aerosol generation is enabled, but manufacturing complexity increases and liquid distribution becomes non-homogeneous
Solution Approach 1:
The vaporization system is divided into separate functional components: a capillary wick membrane for liquid transport and a flat heater element for heating. This segmentation allows each component to be optimized independently, simplifying manufacturing while ensuring homogeneous liquid distribution through the capillary structure of the membrane.
Solution Approach 2:
The traditional mechanical wick and coil assembly is replaced with a capillary wick membrane that uses capillary action (a physical phenomenon) to transport liquid. This substitution eliminates the complexity of assembling and positioning coil wires within the wick structure, greatly simplifying manufacturing while maintaining reliable liquid supply to the heater.
2Ease of manufacture
If a complex wick and coil assembly is used, then aerosol generation is achieved, but manufacturing costs increase
Solution Approach 1:
By separating the liquid transport function (capillary membrane) from the heating function (flat heater), the system achieves simpler manufacturing with lower costs. The segmented design allows for more efficient aerosol generation as each component can be optimized for its specific function without the compromises required by an integrated complex assembly.
Solution Approach 2:
Replacing the complex mechanical wick-coil assembly with a capillary membrane system reduces manufacturing steps and material requirements, lowering production costs. The capillary membrane provides reliable liquid delivery that maintains or improves aerosol generation efficiency compared to traditional assemblies.
3Stability of the object's composition
If liquid retention material is used in the cartridge, then liquid supply is maintained, but gravitational effects cause non-homogeneous liquid distribution in certain orientations
Solution Approach 1:
The capillary wick membrane is a porous material that uses capillary action to transport liquid from the retention element to the heater. This mechanism is orientation-independent, allowing the device to function reliably in any orientation without liquid distribution problems caused by gravity. The porous structure maintains stable liquid supply while providing adaptability to different orientations.
4Use of energy by moving object
If a traditional coil heater is used, then vaporization is achieved, but contact area with liquid is limited reducing efficiency
Solution Approach 1:
The heater is designed as a flat planar element rather than a three-dimensional coil structure. This dimensional change from a volumetric coil to a surface-based heater increases the contact area with the liquid supplied by the capillary membrane, improving vaporization efficiency. The flat heater provides a larger surface area for heat transfer while maintaining a simple structure.
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 solution enhances aerosol generation efficiency, reduces manufacturing costs, and mitigates orientation-related issues, resulting in a more reliable and efficient aerosol-generating device.
Implementation Method 1
an air permeable capillary wick membrane comprising at least one electrical heater
Implementation Method 2
an air permeable capillary wick membrane comprising at least one electrical heater
Implementation Method 3
enables the aerosol-generating substrate to be vapourised more efficiently
Data Source
AI summary
There is provided a container for an aerosol-generating substrate for use in an electrically heated aerosol-generating device, including a casing having at least one air inlet and at least one air outlet; a tubular liquid retention element containing the aerosol-generating substrate; an air permeable capillary wick membrane including at least one electrical heater, the air permeable capillary wick membrane being disposed on an end face of the tubular liquid retention element, such that an airflow pathway is provided from the at least one air inlet through a portion of the air permeable capillary wick membrane to the at least one air outlet; and a tubular element disposed within the tubular liquid retention element, and extending from the at least one air inlet towards the air permeable capillary wick membrane, where a longitudinal length of the tubular element is equal to a longitudinal length of the tubular liquid retention element.