Corrugated Susceptor Forming for Thin-Foil Heating Reliability
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Solution Overview
Problem
Existing methods for manufacturing inductively heatable aerosol-generating article susceptors face challenges in achieving high reliability and reproducibility, particularly with very thin susceptor materials, and offer limited flexibility in heating profiles and sensorial medium deposition.
Innovation Solution
A method involving a compression stage with progressively narrowing and constant compression gaps, using toothed or screw-shaped belts to deep draw and shape susceptor material into corrugated forms, allowing for precise surface modifications and sensorial medium injection, and an alternative method using a cutting stage to create bands with alternating plain and expanded portions for enhanced heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the sheet material is reduced to decrease susceptor mass, then material mass is reduced, but manufacturing reliability and reproducibility deteriorate
Solution Approach 1:
The patent employs very thin susceptor sheet material (0.03-0.5mm) that is formed into a corrugated structure. The thin film approach reduces mass while the corrugation provides structural integrity, resolving the contradiction between using thin material for weight reduction and maintaining manufacturing reliability.
Solution Approach 2:
The susceptor is formed with corrugated surfaces featuring crests and troughs, creating curved geometries that enhance inductive heating efficiency. This curvature also provides structural strength to the thin material, enabling reliable manufacturing despite reduced thickness.
2Weight of moving object
If the thickness of the sheet material is reduced to decrease susceptor mass, then material mass is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The susceptor material undergoes preliminary corrugation formation before final assembly. The compression stage pre-forms the corrugated structure with precise geometry, ensuring manufacturing precision is maintained even with very thin material that would be difficult to handle in later stages.
Solution Approach 2:
The patent specifies precise parameter ranges for susceptor thickness (0.03-0.5mm) and corrugation geometry (crest-to-trough distances of 0.5-5mm). By controlling these parameters through the compression forming process, high manufacturing precision is achieved despite using extremely thin materials.
3Area of stationary object
If a sheet-like susceptor is used to provide extensive heat emission surface, then heat emission surface area is increased, but susceptor mass increases disproportionally
Solution Approach 1:
The corrugated structure with crests and troughs creates a three-dimensional surface that provides extensive heat emission area while maintaining low mass. The curved surfaces of the corrugations enhance inductive heating efficiency and provide structural strength, allowing thin material to achieve high surface area without proportional mass increase.
Solution Approach 2:
The patent uses thin susceptor material (0.03-0.5mm) formed into a corrugated configuration. This thin-film approach with three-dimensional structuring provides extensive heat emission surface area while keeping the mass low, as the surface area increase comes from geometric configuration rather than material quantity.
4Device complexity
If conventional compression methods are used for thin susceptor material, then manufacturing process is simple, but manufacturing reliability deteriorates
Solution Approach 1:
The compression process is divided into distinct stages: a first portion with progressively narrowing compression gap for initial forming, and a second portion with constant compression gap for final shaping. This segmentation of the compression process improves reliability by controlling the deformation of thin material in controlled steps, while adding only moderate complexity to the manufacturing process.
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 method enables the production of reliable, reproducible, and flexible susceptors with reduced material mass, improved heat emission efficiency, and precise sensorial medium deposition, enhancing aerosol formation and user experience.
Implementation Method 1
the oppositely arranged compression elements are configured to have matching surface structures and to define a progressively narrowing compression gap in a processing direction, and guiding the band of susceptor material through the narrowing compression gap of the compression stage, such that the matching surface structures of the compression elements deep draw the band of susceptor material
Implementation Method 2
The induction source is configured for generating an alternating electromagnetic field to inductively heat a susceptor by at least one of eddy currents and hysteresis losses
Implementation Method 3
The induction source is configured for generating an alternating electromagnetic field to inductively heat a susceptor by at least one of eddy currents and hysteresis losses
Implementation Method 4
The induction source is configured for generating an alternating electromagnetic field to inductively heat a susceptor by at least one of eddy currents and hysteresis losses
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method for manufacturing a susceptor for an inductively heatable aerosol-generating article, wherein the method comprises the steps of providing a band of susceptor material and providing a compression stage. The compression stage comprises oppositely arranged compression elements, wherein in a first portion of the compression stage, the compression elements are arranged to define a progressively narrowing compression gap and wherein in a second portion of the compression stage the compression elements are arranged to define a constant compression gap there between and wherein the oppositely arranged compression elements are configured to have matching surface structures. The band of susceptor material is guided through the narrowing compression gap of the compression stage, such that the matching surface structures of the compression elements deep draw the band of susceptor material. The invention also relates to a susceptor element having successively arranged plain and expanded portions and to a method of manufacturing thereof.