Heater assembly
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Solution Overview
Problem
Conventional thin film heaters for aerosol generating devices lack accurate and reliable temperature monitoring, with existing methods for detecting heating temperature being imprecise and requiring complex assembly procedures.
Innovation Solution
A heater assembly is designed with a flexible heating element and integrated temperature sensor on a flexible dielectric backing film, secured by an adhesive, allowing for precise temperature measurement and simplified assembly by using a heat shrink film for attachment to a heating chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is mounted in proximity to the sealed dielectric envelope of the thin film heater, then temperature monitoring is enabled, but the measurement precision and reliability are insufficient
Solution Approach 1:
The temperature sensor is integrated directly into the thin film heater assembly by mounting it on the same flexible dielectric backing film as the heating element. This merging of components allows the sensor to be positioned in direct thermal contact with the heating element, enabling accurate temperature measurement without the measurement errors that occur when the sensor is mounted separately in proximity to the sealed envelope.
2Reliability
If additional pieces of thin film are used to wrap around the heater assembly to hold the thin film heater against the heating chamber, then the thin film heater can be secured, but the assembly procedure becomes more complex
Solution Approach 1:
The adhesive layer is integrated into the flexible dielectric backing film itself, eliminating the need for separate adhesive components. The backing film serves dual functions: providing mechanical support for the heating element and providing adhesive surfaces to secure both the temperature sensor and the heater assembly to the heating chamber, thereby simplifying the overall assembly procedure.
Solution Approach 2:
The flexible dielectric backing film performs multiple functions simultaneously: it acts as the structural support for the heating element, provides adhesive surfaces for attaching the temperature sensor, and serves as the interface for securing the entire heater assembly to the heating chamber. This multi-functionality reduces the number of separate components needed and simplifies assembly.
3Measurement precision
If the temperature sensor is positioned close to the heating element on the adhesive surface, then accurate temperature readings are obtained, but the assembly requires precise positioning
Solution Approach 1:
The adhesive layer on the flexible dielectric backing film provides self-alignment and self-positioning for the temperature sensor and heating element. The adhesive surfaces allow the components to be naturally positioned and secured in the correct relative locations during assembly, eliminating the need for complex positioning mechanisms or precision alignment procedures while ensuring accurate temperature measurement.
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 integrated temperature sensor provides accurate temperature readings, simplifies assembly, and enhances heat transfer efficiency while reducing thermal mass and assembly complexity.
Implementation Method 1
a flexible dielectric backing film with an adhesive on a surface of the flexible dielectric backing film, wherein the temperature sensor and the flexible heating element are supported adjacent to each other on the adhesive on the surface of the flexible backing film
Implementation Method 2
This is generally achieved by attaching the thin film heater with an adhesive or other fastening means to hold the thin film heater against the heating chamber during use
Implementation Method 3
One such application is within the field of aerosol generating devices such as reduced risk nicotine delivery products, including e-cigarettes and tobacco vapour products. Such devices heat an aerosol generating substance within a heating chamber to produce a vapour.
Data Source
AI summary
A heater assembly for an aerosol generating device includes a flexible heating element; a temperature sensor; and a flexible dielectric backing film with an adhesive on a surface of the flexible dielectric backing film, wherein the temperature sensor and the flexible heating element are supported adjacent to each other on the adhesive on the surface of the flexible backing film. The heater assembly allows for a more precise measurement of the heater temperature to be obtained while simplifying the assembly process.