Composite Susceptor Induction Heating for Thin Aerosol Generators
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Solution Overview
Problem
Existing smoking alternatives, such as heat-not-burn tobacco products, face challenges in efficiently generating aerosols without combustion, particularly in terms of energy transfer efficiency and susceptor material cost and durability.
Innovation Solution
An aerosol generating apparatus using a composite susceptor with a support portion and susceptor portion, driven by an induction element with a waveform comprising a fundamental frequency and higher frequency components, allowing for efficient inductive heating and reduced susceptor thickness, optionally coated with ferromagnetic materials like nickel or cobalt, and protected by a heat-resistant layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional susceptor material is used for inductive heating, then the heating function is achieved, but the susceptor material cost increases and durability decreases due to thin susceptor requirements
Solution Approach 1:
The patent applies composite materials by combining a support portion (made from durable materials like metal or ceramic) with a susceptor portion (made from ferromagnetic materials like nickel or cobalt). This composite structure allows the susceptor to be thinner while maintaining both durability and heating efficiency, as the support portion provides mechanical strength and the susceptor portion provides the necessary inductive heating properties.
2Ease of manufacture
If the susceptor thickness is reduced to lower material cost, then manufacturing cost decreases, but energy transfer efficiency deteriorates
Solution Approach 1:
The composite susceptor structure allows reduced susceptor thickness while maintaining energy transfer efficiency. The support portion compensates for the reduced thickness by providing structural integrity and thermal mass, while the susceptor portion maintains sufficient ferromagnetic properties for efficient inductive heating when combined with the support structure.
Solution Approach 2:
The patent changes the physical and chemical parameters of the susceptor by using ferromagnetic materials with specific properties (nickel or cobalt) and controlling the thickness within specific ranges (5-50 microns). By optimizing these parameters and combining them with the support portion, the system achieves efficient energy transfer despite the reduced thickness.
3Ease of manufacture
If a thin susceptor portion is used, then manufacturing cost decreases, but the susceptor becomes more fragile and less durable
Solution Approach 1:
The composite susceptor combines a thin susceptor portion (5-50 microns) with a support portion made from stronger materials. The support portion provides the necessary mechanical strength and structural stability, while the thin susceptor portion maintains the required ferromagnetic properties for inductive heating. This division of functions allows cost reduction through thinner material usage while maintaining durability through the support 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 apparatus achieves efficient aerosol generation with improved energy transfer efficiency and reduced susceptor material costs, while maintaining durability and efficiency in heating aerosol generating materials without combustion.
Implementation Method 1
an induction element arranged for inductive energy transfer to the susceptor portion in use; and a driving arrangement arranged to drive the induction element with an alternating current in use thereby to cause the inductive energy transfer to the susceptor portion in use, thereby to cause the heating of the aerosol generating material by the composite susceptor
Data Source
AI summary
An aerosol generating apparatus has a composite susceptor for heating an aerosol generating material in use thereby to generate an aerosol. The composite susceptor comprises a support portion and a susceptor portion supported by the support portion. The apparatus comprises an induction element arranged for inductive energy transfer to the susceptor portion in use; and a driving arrangement arranged to drive the induction element with an alternating current in use thereby to cause the inductive energy transfer to the susceptor portion, thereby to cause the heating of the aerosol generating material by the composite susceptor, thereby to generate the aerosol. The alternating current has a waveform comprising a fundamental frequency component having a first frequency and one or more further frequency components each having a frequency higher than the first frequency. A method of operating the aerosol generating apparatus is also disclosed.