Flat Connector Frame Eliminates Soldering in Aerosol Heater
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Solution Overview
Problem
Existing heating assemblies for aerosol-generating devices face challenges in reliability, manufacturing quality, robustness, and ease of manufacturing.
Innovation Solution
A heating assembly comprising a heater casing, a heating element with at least two heater contacts, a connector frame with at least two connector contacts, and electric circuitry, where the connector frame is used to electrically connect the heating element and the electric circuitry, eliminating the need for electrical wiring and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical wiring and soldering methods are used to connect the heating element with the electric circuitry, then reliable electrical connection can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the traditional mechanical electrical connection system (wiring and soldering) with a direct mechanical contact system. The connector frame provides rigid structural support that inherently maintains electrical contact between the heating element and circuit board through mechanical pressure, eliminating the need for separate electrical wiring and soldering operations.
Solution Approach 2:
The patent merges the structural support function and electrical connection function into a single integrated connector frame. This unified component simultaneously provides mechanical support for the heating element and establishes electrical contact with the circuit board, reducing the number of separate components and assembly steps.
2Reliability
If traditional electrical wiring and soldering methods are used, then reliable electrical connection can be achieved, but manufacturing time and productivity are reduced
Solution Approach 1:
The connector frame is pre-designed and pre-positioned within the housing to establish electrical contact pathways before the heating element is installed. The circuit board is also pre-positioned with contact points, so that when the heating element is inserted, electrical connection is automatically established without requiring separate wiring or soldering steps during final assembly.
Solution Approach 2:
The patent replaces time-consuming electrical wiring and soldering operations with a rapid mechanical contact system. The rigid connector frame and circuit board contact points provide immediate electrical connection through simple mechanical insertion, dramatically reducing assembly time while maintaining connection reliability.
3Reliability
If complex electrical wiring and soldering processes are used, then reliable electrical connection can be achieved, but manufacturing quality and robustness are compromised
Solution Approach 1:
The patent segments the electrical connection function into distinct, pre-positioned contact points on the circuit board and corresponding contact surfaces on the connector frame. This segmentation allows each contact interface to be independently optimized and positioned with high precision during manufacturing, improving overall assembly quality and reducing variability.
Solution Approach 2:
The patent replaces precision-critical soldering operations with a more robust mechanical contact system. The rigid connector frame and circuit board contact points provide tolerant, alignment-friendly electrical connections that are less sensitive to manufacturing variations, improving manufacturing precision and quality consistency.
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 proposed heating assembly enhances reliability, manufacturing quality, and robustness, while simplifying the manufacturing process by eliminating the need for complex electrical connections, resulting in a more efficient and reliable heating solution for aerosol-generating devices.
Implementation Method 1
The heating element may comprise at least two heater contacts... heat aerosol-forming substrate to a temperature at which one or more components of the aerosol-forming substrate are volatilised
Data Source
AI summary
A heating assembly for an aerosol-generating device is provided, the heating assembly including: a heater casing; a heating element including at least two heater contacts; a connector frame; and electric circuitry, the connector frame including at least two connector contacts and being arranged on the heater casing, the at least two connector contacts being electrically connected with the at least two heater contacts and with the electric circuitry, the at least two connector contacts being arranged to directly contact the electric circuitry, and the at least two connector contacts being flat. An aerosol-generating device including the heating assembly is also provided. A method for manufacturing the heating assembly for an aerosol-generating device is also provided.