Electroless Plated Heater Element for Aerosol Devices
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Solution Overview
Problem
Existing heating devices for aerosol generation in smoking alternatives face inefficiencies in heat distribution and maintenance due to the use of conductive materials and adhesives, which can impact the heating process and device longevity.
Innovation Solution
A heater element with a non-electrically conductive support coated with electroless plating of nickel or cobalt, capable of being heated by a varying magnetic field, is designed to be resiliently deformable and expandable, allowing for even heat distribution and easy insertion into a chamber, with optional additional heating materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conductive materials and adhesives are used in heating devices for aerosol generation, then structural integrity and material attachment are improved, but heat distribution efficiency and device longevity deteriorate
Solution Approach 1:
The patent removes conductive materials and adhesives from the heating element structure, replacing them with a non-conductive support structure that directly holds the heating coil. This extraction eliminates the thermal barriers and adhesive layers that impeded heat distribution, while maintaining structural integrity through the mechanical framework of the support structure.
Solution Approach 2:
The patent applies different material properties to different parts of the heating element: the support structure uses non-conductive materials with high thermal resistance to concentrate heat, while the heating coil uses high-resistivity wire for efficient heat generation. This local differentiation of material properties optimizes both structural integrity and heat distribution efficiency in their respective zones.
2Stability of the object's composition
If conductive materials and adhesives are used in heating devices, then assembly and structural stability are improved, but maintenance requirements and device longevity worsen
Solution Approach 1:
The patent eliminates adhesives from the assembly process, using a mechanical support structure that holds the heating coil through physical attachment points. This removal of adhesive materials eliminates the degradation and failure modes associated with adhesive breakdown over time, thereby extending device longevity while maintaining structural stability through the rigid support framework.
3Manufacturing precision
If electroless plating is applied to non-electrically conductive support, then even heat distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces mechanical or manual methods of achieving uniform heat distribution with electroless plating, a chemical process that automatically deposits conductive material evenly across the non-conductive support surface. This substitution of chemical processes for mechanical ones achieves superior manufacturing precision in heat distribution uniformity while the automated nature of electroless plating actually reduces overall manufacturing complexity compared to manual assembly methods.
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 provides consistent and efficient aerosol generation with improved heat distribution and reduced maintenance, as the electroless plating ensures even heating and the deformable design accommodates various configurations for optimal performance and user convenience.
Implementation Method 1
heating material that is heatable by penetration with a varying magnetic field
Implementation Method 2
the heating material comprises an electroless plating on the support
Data Source
AI summary
A heater element for an aerosol provision device is disclosed. The heater element includes a support and heating material that is heatable by penetration with a varying magnetic field, wherein the heating material includes an electroless plating on the support.