Flexible heater and electronics

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Solution Overview

Problem

Existing aerosol-generating devices face challenges in manufacturing heaters that are easy to produce, cost-effective, compact, robust, reliable, and capable of homogeneous heating of aerosol-forming substrates.

Innovation Solution

A flexible electrically insulating substrate with integrated heating elements and control electronics, rolled into a tubular shape, allowing for easier and cheaper manufacturing, and featuring resistive or induction heating with temperature control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the heating element and control electronics are provided separately, then the heater structure is simple, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvemanufacturing easeVSAvoidheater structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the heating element and control electronics onto a single flexible electrically insulating substrate. This integration reduces the number of separate components, simplifies assembly procedures, and lowers manufacturing complexity while maintaining functional performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible electrically insulating substrate serves multiple functions simultaneously: it provides electrical insulation, supports the heating element, and carries the control electronics. This multi-functionality reduces the overall component count and simplifies the heater structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If traditional rigid substrates are used, then structural stability is good, but the heater size and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidheater weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent employs a flexible electrically insulating substrate instead of traditional rigid substrates. This flexible substrate maintains sufficient structural stability for the heater application while being significantly lighter and more compact, enabling a more portable and compact heater design.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If the heating element is integrated on the substrate, then manufacturing cost decreases, but the heating homogeneity may be affected

Engineering Contradiction:

Improvemanufacturing costVSAvoidheating homogeneity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent designs the heating element with spatially varying characteristics on the flexible substrate, allowing different regions to provide appropriate heating intensity. This enables homogeneous overall heating while accommodating the integrated manufacturing approach on the substrate.

Inventive Principle:

Principle #3Local quality

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 results in a compact, reliable heater that facilitates homogeneous heating of aerosol-forming substrates, enhancing the smoking experience with customizable heating options and efficient energy use.

Implementation Method 1

The heating element may be provided on the second portion of the flexible electrically insulating substrate

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The flexible electrically insulating substrate may be rolled into a tube. By rolling the flexible electrically insulating substrate into a tube, the flexible electrically insulating substrate assumes a tubular shape

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12582167B2Flexible heater and electronics

Publication Date: 2026.03.24 PHILIP MORRIS PRODUCTS SA

AI summary

A heater for an aerosol-generating device is provided, the heater including: a flexible electrically insulating substrate including a first portion, a second portion, and a fourth portion, in which the flexible electrically insulating substrate is rolled into a tube; control electronics disposed on the first portion of the flexible electrically insulating substrate; a heating element including an induction coil and being disposed on the second portion of the flexible electrically insulating substrate; and a susceptor element arranged on the fourth portion of the flexible electrically insulating substrate. An aerosol-generating device is also provided, including a cavity to receive an aerosol-generating article including an aerosol-forming substrate, and the heater. A system is also provided, including the aerosol-generating device and the aerosol-generating article including the aerosol-forming substrate.