Electrophoretic Deposition for Aerosol-Generating Heating Element
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Solution Overview
Problem
Current aerosol-generating systems are costly and wasteful due to disposable heating elements, and lack precise control over the volume and characteristics of the aerosol generated, as the aerosol-forming substrate is not easily reusable or positioned close to the heating element.
Innovation Solution
The method involves depositing an aerosol-forming substrate onto a heating element using electrophoretic deposition, where a voltage is applied between the heating element and an auxiliary electrode submerged in a deposition liquid, allowing for the aerosol-forming substrate to be reused and precisely controlled in proximity to the heating element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disposable heating elements are used in aerosol-generating systems, then the system is easier to manufacture and operate, but the operating cost increases and waste is generated
Solution Approach 1:
The patent enables recovery and reuse of the heating element by depositing fresh aerosol-forming substrate material onto it after the original substrate is depleted. This allows the heating element to be regenerated and reused multiple times, eliminating the need for disposable heating elements and reducing waste while maintaining ease of operation through a simple regeneration process
2Manufacturing precision
If the aerosol-forming substrate is positioned close to the heating element, then the control over aerosol generation is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the aerosol-forming substrate directly onto the heating element surface through electrophoretic deposition, creating an integrated structure where the substrate is positioned in close proximity to the heating element. This merging approach achieves precise control over aerosol generation while avoiding the need for separate, complex positioning mechanisms, thereby reducing overall device complexity
Solution Approach 2:
The patent replaces complex mechanical positioning systems with electrophoretic deposition, an electrochemical process that precisely positions the aerosol-forming substrate onto the heating element surface. This substitution of mechanical systems with electrochemical processes achieves precise positioning while simplifying the overall device structure
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 approach enables the reuse of the heating element, reduces waste, and provides precise control over the aerosol generation, ensuring consistent and efficient aerosol production by maintaining the aerosol-forming substrate close to the heating element.
Implementation Method 1
supplying a voltage between the heating element and the auxiliary electrode to deposit an aerosol-forming substrate on the heating element by electrophoretic deposition
Implementation Method 2
passing an electrical current through an electrically resistive heating element, giving rise to Joule heating of the heating element
Implementation Method 3
Inductive heating systems have also been proposed, in which Joule heating occurs as a result of eddy currents induced in a susceptor heating element
Data Source
AI summary
A method of forming an aerosol-generating component of an aerosol-generating system, and a system for forming an aerosol-generating component of an aerosol-generating system, the method comprising: submerging at least a portion of a heating element (1) in a deposition liquid (6): submerging at least a portion of an auxiliary electrode (4) in the deposition liquid (6): and supplying a voltage between the heating element (1) and the auxiliary electrode (4) to deposit an aerosol-forming substrate on the heating element (1) by electrophoretic deposition.