Dual-Zone Heater Assembly for Localized Aerosol Substrate Heating
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Solution Overview
Problem
Existing aerosol-generating devices face challenges in providing a robust, inexpensive heating assembly that efficiently heats aerosol-forming substrates while ensuring localized heat generation and preventing flame ignition, particularly when used with non-consumable elements like tubes at the distal end.
Innovation Solution
A heating assembly with a dual-portion electrically resistive heating element, where the first portion has a higher temperature and resistance, and a heater mount made from a mouldable polymer like PEEK, providing structural support and engagement with non-consumable elements, while maintaining controlled temperature gradients and material compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heater is inserted into a solid aerosol-forming substrate for direct heating, then heating efficiency is improved, but the device becomes more complex and less robust
Solution Approach 1:
The heating element is divided into two distinct portions: a first portion for direct insertion into the aerosol-forming substrate to provide efficient heating, and a second portion longer than the first that extends beyond the substrate. This segmentation allows the heater to perform its heating function effectively while the extended second portion provides structural stability and ease of handling, thus resolving the contradiction between heating efficiency and device complexity.
Solution Approach 2:
The heater substrate acts as an intermediary component that supports the heating element. It provides a stable base for the heating element while allowing the first portion to contact the aerosol-forming substrate for efficient heating. The heater substrate simplifies the overall device structure by consolidating the support function, thereby improving heating efficiency without proportionally increasing device complexity.
2Ease of manufacture
If the heating element is made robust and simple to manufacture, then manufacturing cost is reduced, but temperature control and localized heat generation become more difficult
Solution Approach 1:
The heating element has different portions with different lengths and presumably different thermal characteristics. The first portion is shorter and designed for direct contact with the aerosol-forming substrate to provide localized heat generation. The second portion is longer and extends beyond the substrate, likely serving as a handle or structural element. This local differentiation allows simple manufacturing of each portion while achieving precise temperature control at the heating zone.
Solution Approach 2:
By segmenting the heating element into distinct portions with different functions (heating vs. structural/handling), the design allows each segment to be optimized independently. The first portion can be designed for efficient heat transfer to the substrate, while the second portion provides structural integrity. This segmentation enables simpler manufacturing of individual components while maintaining overall temperature control precision through the functional differentiation.
3Temperature
If the heating assembly is designed for high operating temperatures, then heating effectiveness is improved, but the risk of flame ignition increases
Solution Approach 1:
The harmful function (combustion/ignition) is extracted or prevented by designing a heating system that operates below the ignition temperature of the aerosol-forming substrate. The heating element is configured to provide sufficient heat for vaporization and aerosol formation without reaching temperatures that would cause flame ignition. This extraction of the harmful combustion function allows high operating temperatures for effective heating while eliminating the ignition risk.
Solution Approach 2:
The design incorporates preliminary protective measures by controlling the maximum operating temperature to remain below the ignition point of the substrate materials. The heating element is engineered with specific thermal properties and power limitations that prevent temperature excursions into the combustion range. This preliminary anti-action against potential ignition ensures high heating effectiveness is achieved safely without creating flame hazards.
4Reliability
If a tube is added at the distal end to protect from flame ignition, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The second portion of the heating element serves multiple functions: it extends beyond the aerosol-forming substrate to provide structural support and stability, acts as a handle for insertion and removal, and potentially serves as a protective barrier. By making this portion multi-functional, the design achieves safety and structural benefits without adding separate components, thus improving reliability while minimizing increases in device complexity.
Solution Approach 2:
The protective function against flame ignition is merged with the structural support function of the heating element itself. The second portion of the heating element, which extends beyond the substrate, serves both as a structural component for handling and insertion, and as a protective element that prevents direct flame contact with the substrate. This merging eliminates the need for a separate protective tube, improving safety without significantly increasing device complexity or manufacturing cost.
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 solution ensures efficient heating of aerosol-forming substrates, reduces the risk of ignition, and maintains device robustness, while being cost-effective and suitable for use with aerosol-generating articles having non-consumable elements.
Implementation Method 1
a heater comprising a heating element and a heater substrate. The heating element comprises an electrically resistive heating element
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A heating assembly for heating an aerosol-forming substrate, comprises a heater (14) comprising an electrically resistive heating element (82) and a heater substrate (81); and a heater mount (26) coupled to the heater (14). The electrically resistive heating element (82) comprises a first portion (84) and a second portion (86) configured such that, when an electrical current is passed through the heating element (82) the first portion (84) is heated to a higher temperature than the second portion (86). The first portion (84) of the heating element (82) is positioned on a heating area (91) of the heater substrate (81) and the second portion (86) of the heating element (82) is positioned on a holding area (93) of the heater substrate (81), the heater mount (26) being fixed to the holding area (93) of the heater substrate (81). The second portion (86) of the electrically resistive heating element (82) is longer than the first portion (84) of the heating element (82), which allows the heating element (82) to penetrate an aerosol-forming substrate located within an aerosol-forming article.