Corrugated Susceptor Forming for Thin Induction-Heated Aerosol Articles
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Solution Overview
Problem
Existing susceptors for inductively heatable aerosol-generating articles are inefficient in terms of mass usage, as they often have a disproportionate mass to heat emission surface, and there is a need for methods that allow for high reliability, reproducibility, and flexibility in manufacturing, especially for very thin materials and the deposition of sensorial medium during the shaping process.
Innovation Solution
A method involving a compression stage with progressively narrowing and constant compression gaps, using toothed or screw-shaped elements to deep draw susceptor material into a corrugated shape, and a sensorial medium injection process to deposit the medium onto the susceptor, allowing for precise control over the heating profile and material thickness.
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 mass efficiency improves, but manufacturing reliability deteriorates
Solution Approach 1:
The compression stage is segmented into two distinct portions: a first portion with progressively narrowing compression gap and a second portion with constant compression gap. This segmentation allows the thin susceptor material to be gradually formed without sudden stress concentration, maintaining manufacturing reliability while enabling reduced material thickness.
Solution Approach 2:
The compression gap is made dynamic in the first portion, progressively narrowing along the processing direction to gradually deform the thin material. This dynamic approach contrasts with the static constant gap in the second portion, allowing controlled formation of very thin susceptor material that would otherwise be difficult to manufacture reliably.
2Weight of moving object
If the sheet material is made thinner to reduce mass, then mass efficiency improves, but manufacturing precision deteriorates
Solution Approach 1:
The compression stage is divided into two portions with different gap configurations. The first portion's progressively narrowing gap enables gradual material deformation with high precision control, while the second portion's constant gap ensures consistent final shaping. This segmentation maintains manufacturing precision even for very thin materials.
Solution Approach 2:
The compression gap parameter is changed along the processing direction in the first portion, transitioning from a larger initial gap to a smaller final gap. This parameter change enables progressive deformation of thin material with controlled precision, avoiding sudden stress that would compromise formation accuracy.
3Device complexity
If a constant compression gap is used throughout the compression stage, then device complexity is reduced, but the ability to process very thin materials deteriorates
Solution Approach 1:
The compression stage is segmented into two portions with different gap characteristics. This segmentation adds some complexity but enables the processing of very thin materials that would be impossible with a simple constant gap design. The added complexity is justified by the significant improvement in processing capability.
Solution Approach 2:
The compression gap is made dynamic in the first portion rather than constant throughout. This dynamic configuration, while slightly more complex, provides the necessary control to progressively form very thin susceptor material without damage, enhancing the overall processing capability.
4Adaptability or versatility
If sensorial medium is deposited after the shaping process, then manufacturing flexibility is reduced, but process simplicity is improved
Solution Approach 1:
The sensorial medium deposition process is merged with the shaping process by integrating the deposition device with the compression stage. This allows simultaneous shaping and deposition in one integrated operation, increasing manufacturing flexibility without proportionally increasing overall process complexity.
Solution Approach 2:
The sensorial medium is deposited during the shaping process rather than afterward. This preliminary action allows the medium to be placed while the material is being formed, enabling better integration and control before final assembly, thereby enhancing manufacturing flexibility.
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 method enables the production of thin, reliable, and reproducible susceptors with enhanced heat emission efficiency and flexibility, reducing material waste and improving aerosol formation by optimizing the susceptor's structure and sensorial medium distribution.
Implementation Method 1
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
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.