External Heater Temperature Profiling for Consistent Aerosol Output
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Solution Overview
Problem
Aerosol-generating devices with portable power supplies face inconsistencies in user experience due to varying battery charge states, leading to inconsistent heating times and aerosol production, especially with external heaters that lack direct contact with the substrate, resulting in longer pre-heating phases and potential overheating issues.
Innovation Solution
A method controlling the power to the heating element in aerosol-generating devices to maintain consistent aerosol production by adjusting temperature through multiple phases, using an external heater assembly with a flexible substrate and a power management system that limits energy supply to maintain a threshold average power, ensuring consistent aerosol delivery and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an external heater assembly is used to simplify device structure and improve robustness, then device complexity is reduced and robustness is improved, but the heater lacks direct contact with the substrate resulting in longer pre-heating phases and inconsistent heating performance
Solution Approach 1:
The patent implements dynamic power adjustment during the pre-heating phase, transitioning from high power to reduced power based on temperature feedback. The controller monitors heater temperature and adjusts power delivery accordingly, enabling the external heater to reach operational temperature faster while preventing overheating, thus resolving the contradiction between simplified structure and effective heating performance
Solution Approach 2:
The system incorporates temperature sensing and feedback control mechanisms that continuously monitor the heater and substrate temperatures. This feedback enables real-time power adjustment, allowing the external heater assembly to compensate for the lack of direct contact with the substrate, thereby reducing pre-heating time while maintaining structural simplicity and robustness
2Loss of time
If high power is supplied to the heater assembly during pre-heating to reduce heating time, then pre-heating duration is reduced, but the power supply voltage variability causes inconsistent heating performance and aerosol generation
Solution Approach 1:
The system dynamically adjusts power delivery based on real-time temperature feedback and power supply voltage monitoring. During pre-heating, the controller modulates power levels to maintain consistent heating performance despite voltage variability, ensuring reliable and consistent aerosol generation while minimizing pre-heating time
Solution Approach 2:
The patent employs parameter changes in the power delivery profile, transitioning from high power initial heating to reduced power maintenance heating. The controller adjusts power parameters based on temperature thresholds and voltage conditions, ensuring consistent heating performance and aerosol generation across varying battery charge states while optimizing pre-heating duration
3Weight of moving object
If the power supply is depleted, then portability is maintained, but the maximum voltage decreases resulting in longer heating times and lower aerosol generation
Solution Approach 1:
The system dynamically adapts power delivery based on the power supply's charge state. The controller monitors voltage levels and adjusts heating power accordingly, maintaining consistent aerosol generation performance across the full range of battery charge states. This dynamic adaptation ensures that productivity remains stable even as the portable power supply is depleted
Solution Approach 2:
The patent implements parameter changes in the heating profile based on power supply voltage levels. The controller adjusts power delivery parameters to compensate for voltage decline as the battery depletes, ensuring consistent aerosol generation quantity and quality throughout the power supply's operational life, thereby maintaining productivity while preserving portability
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 minimizes pre-heating time, maintains consistent aerosol production across varying battery charge states, and prevents overheating, enhancing user experience and device efficiency by optimizing energy use and substrate heating.
Implementation Method 1
a heater comprising at least one heating element configured to externally heat the aerosol-forming substrate... The heater assembly is heated when it is supplied with power from a power supply
Data Source
AI summary
A method of controlling aerosol production in an aerosol-generating device is provided, the device including a heating chamber to receive an aerosol-generating article including an aerosol-forming substrate, a heater including a heating element to externally heat the substrate, and a power source to provide power to the heating element; and the method including: controlling the power provided such that in an initial period a temperature of the heating element increases from an initial to a first temperature between 230° C.-270° C., drops in a second period to a second temperature below the first, and increases in a third period to a third temperature higher than the second, and the device generating the aerosol during a usage session, dividing the session into n sequential time intervals, and limiting the power during any or each of intervals such that a threshold energy for that interval is not exceeded.