Coated Susceptor for Rapid Aerosol Generation
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Solution Overview
Problem
Current aerosol-generating systems for non-combustible aerosol provision, such as tobacco heating devices, face challenges in achieving rapid aerosol generation and user satisfaction due to limitations in heating efficiency and aerosol delivery time.
Innovation Solution
A susceptor with a coating covering at least 20% of its outer surface, composed of aerosol-generating and/or aerosol-modifying materials, is inserted into the aerosol generating material portion, allowing for induction heating and rapid aerosol production, with the coating thickness being 300 microns or less to enhance heating efficiency and prevent degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a susceptor without coating is used, then heating efficiency is maintained, but aerosol generation capability and user satisfaction are insufficient
Solution Approach 1:
The susceptor is designed as a composite structure with a metal core (for efficient induction heating) and an outer coating layer (for aerosol generation). This combines the advantages of both materials: the metal provides rapid heating through induction, while the coating material (containing aerosol-generating compounds) enables effective aerosol formation and delivery to the user.
2Productivity
If coating thickness is increased to improve aerosol generation, then aerosol delivery is enhanced, but heating efficiency decreases and degradation increases
Solution Approach 1:
The coating thickness is precisely controlled within the range of 1-300 micrometers, with optimal values identified in the 10-50 micrometer range. This parameter optimization ensures sufficient aerosol-generating material is present while maintaining adequate heat transfer efficiency and preventing excessive energy loss.
Solution Approach 2:
The coating is applied to cover at least 20% of the susceptor's outer surface area, with embodiments showing complete or substantial coverage. This localized application ensures aerosol generation occurs at the heat transfer interface while maintaining overall system efficiency.
3Reliability
If coating thickness is increased to prevent degradation, then protection is improved, but heating efficiency and aerosol generation are reduced
Solution Approach 1:
The coating thickness is optimized to 1-300 micrometers, providing sufficient barrier protection against moisture and oxygen ingress that would cause susceptor degradation, while remaining thin enough to allow efficient heat conduction and maintain high aerosol generation rates.
4Productivity
If coating covers entire surface to maximize aerosol generation, then aerosol delivery is improved, but manufacturing complexity and material cost increase
Solution Approach 1:
The coating is applied to cover at least 20% of the susceptor's outer surface area, with embodiments showing complete or substantial coverage. This partial-to-full coverage approach provides sufficient aerosol generation capability while allowing flexibility in manufacturing processes and material usage.
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 coated susceptor enables faster aerosol delivery, improved user satisfaction, and reduced degradation by preventing moisture and oxygen ingress, while maintaining efficient heating and aerosol generation.
Implementation Method 1
an aerosol generating device comprising an induction transmitter for inductively heating the susceptor
Implementation Method 2
reduced degradation by preventing moisture and oxygen ingress
Data Source
AI summary
A susceptor (14) for insertion into an aerosol generating material portion (13) of an article (1) is described, the susceptor (14) comprising a coating on at least 20% of the outer surface of the susceptor, wherein the coating comprises an aerosol generating and/or aerosol modifying material and which has a thickness of 300 microns or less. A method of forming the susceptor (14), an article (1) comprising the susceptor (14), a method of manufacturing the article (1), and an aerosol generating system comprising the article are also described.