Curved Heating Element Structure for Longer-Lasting Atomizers
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Solution Overview
Problem
Existing aerosol generating devices suffer from localized breakage of the heating element due to high temperatures, reducing the service life of the heating assembly and atomizer.
Innovation Solution
A heating assembly with a heating element having arc-shaped structures of variable curvature and electrode connection portions positioned close to the center, reducing thermal stress and improving heat concentration, thereby preventing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If resistance heating is used to heat the aerosol-forming matrix, then the atomization effect is improved, but the heating element is prone to localized breakage at high temperatures
Solution Approach 1:
The heating element employs different structural characteristics at different locations: the central portion has a larger cross-sectional area for heat generation, while the end portions have smaller cross-sectional areas and arc-shaped structures for stress reduction. This local differentiation allows the heating element to maintain high temperature for effective atomization while reducing thermal stress concentration at critical locations.
Solution Approach 2:
The end portions of the heating element are designed with arc-shaped structures having variable radius of curvature. This curved geometry eliminates sharp corners and abrupt transitions, distributing thermal stress more uniformly and preventing stress concentration that would lead to localized breakage during repeated heating and cooling cycles.
2Duration of action of moving object
If the heating element operates at high temperature for extended periods, then the atomization effect is maintained, but localized breakage occurs reducing service life
Solution Approach 1:
The heating element's cross-sectional area varies along its length, with the central portion having a larger area for sustained heat generation and the end portions having smaller areas. This parameter variation allows the element to maintain effective operating temperature for extended durations while the reduced cross-section at the ends minimizes thermal mass and stress accumulation, preventing breakage during prolonged operation.
3Ease of manufacture
If the heating element has uniform structure, then manufacturing is simplified, but thermal stress concentration occurs at junctions
Solution Approach 1:
The heating element features localized arc-shaped structures at the end portions with variable radius of curvature, while the central portion maintains a more uniform structure for efficient heat generation. This local structural differentiation strengthens the stress-prone junction areas without significantly complicating the overall manufacturing process, as the arc-shaped ends can be integrated into the forming 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 design reduces thermal stress and extends the service life of the heating element by ensuring uniform heating and minimizing localized breakage, enhancing the atomization effect.
Implementation Method 1
the heating element generates heat through its internal resistance
Implementation Method 2
another portion of the heat from the heating element is transferred to the porous substrate to heat another part of the aerosol-forming matrix within the pores
Data Source
Figure 1~2
AI summary
Disclosed are a heating assembly, an atomizer, and an aerosol generating device. The heating assembly is disposed on at least one surface of a porous substrate. The porous substrate is configured to guide an aerosol-forming matrix. The heating assembly comprises two electrode connection portions configured to be connected to electrodes and a heating element connected between the two electrode connection portions. Both ends of the heating element each have a same arc-shaped structure with a variable radius of curvature, and a connection point between the arc-shaped structure and each of the electrode connection portions is disposed close to a center of the heating element.