Induction Coil Support Geometry for Faster Aerosol Susceptor Heating
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Solution Overview
Problem
Existing induction heating systems for aerosol-generating devices face challenges in achieving a sufficient temperature level within a short period, particularly when operating intermittently, such as on a user's demand, due to inefficiencies in heating a susceptor within the induction coil.
Innovation Solution
The use of a cylindrical-helical induction coil with a wire recess pattern and a coil support tube allows for a reduced radial distance between the coil and the susceptor, enhancing magnetic field strength and heating efficiency by using a coil wire with a circular cross-section and a flux concentrator to focus the magnetic field, thereby increasing heating speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the radial distance between the induction coil and the susceptor is reduced to increase magnetic field strength and heating efficiency, then the heating speed improves, but the device structure becomes more complex and manufacturing difficulty increases
Solution Approach 1:
The wire recess pattern is pre-formed in the coil support tube, allowing the induction coil to be positioned at an optimal radial distance from the susceptor before operation. This preliminary structural arrangement ensures maximum magnetic field strength without requiring complex adjustable mechanisms during use.
Solution Approach 2:
The coil support tube acts as an intermediary component between the induction coil and the susceptor. By incorporating wire recesses in its outer circumference, it mediates the spatial relationship, maintaining a reduced radial distance that enhances heating efficiency while preserving structural integrity and simplifying assembly.
2Productivity
If a flat susceptor with large surface area is used to enhance heat transfer to the aerosol-forming substrate, then heating efficiency improves, but the time to reach sufficient temperature level increases when operating intermittently
Solution Approach 1:
The induction coil is configured with non-uniform winding density or variable turn spacing along its length, creating zones of different magnetic field strength. The region corresponding to the susceptor's center (where heat transfer to substrate is most critical) receives enhanced magnetic field intensity, enabling faster local heating without requiring the entire large-surface susceptor to reach maximum temperature.
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 results in faster attainment of desired temperature levels in the susceptor, improving heating efficiency and reducing power losses, while maintaining a compact design and compliance with regulatory standards.
Implementation Method 1
at least one cylindrical-helical induction coil for generating an alternating magnetic field allowing to inductively heat a susceptor within an interior space of the induction coil
Implementation Method 2
The field is used to induce at least one of heat generating eddy currents or hysteresis losses in a susceptor
Implementation Method 3
The field is used to induce at least one of heat generating eddy currents or hysteresis losses in a susceptor
Implementation Method 4
The wire recess pattern allows to place the induction coil closer to the location of the susceptor. The reduced radial distance leads to an increase of the magnetic field strength at the location of the susceptor
Data Source
AI summary
An induction heating module for an aerosol-generating device, including: a cylindrical-helical induction coil to generate an alternating magnetic field to inductively heat a susceptor within the coil to heat an aerosol-forming substrate in thermal contact or thermal proximity with the susceptor, the coil formed by turns of a coil wire having circular cross-section; and a coil support including a support tube, the coil being wound around a circumference of the tube including a wire recess pattern and two flux concentration recesses for receiving a respective annular protrusion portion of a flux concentrator, the pattern being axially arranged between two flux concentration recesses, the circumference having a non-circular flattened transverse cross-sectional shape including two opposing flat sections connected by two opposing partially curved sections, the coil wound around the circumference such that a transverse cross-sectional shape of the coil follows the non-circular flattened transverse cross-sectional shape of the circumference.