Fluid-Permeable Heater Assembly With Over-Molded Cap Rigidity
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Solution Overview
Problem
Existing aerosol-generating systems face challenges in manufacturing efficient and stable heater assemblies that effectively vaporize liquid aerosol-forming substrates, particularly in ensuring proper mesh integrity and electrical conductivity while maintaining structural rigidity.
Innovation Solution
A method involving the use of a mesh strip with alternating mesh densities, over-molding a cap onto the heating element, and integrating electrically conductive contact areas to enhance stability and conductivity, with a capillary medium for improved vaporization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mesh strip with alternating mesh densities is used, then vaporization efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The mesh strip is divided into multiple sections with different mesh densities (first mesh density in vaporization zones, second mesh density in non-vaporization zones). This segmentation allows optimized vaporization efficiency in critical areas while maintaining structural integrity in other areas, resolving the contradiction between productivity and device complexity.
Solution Approach 2:
Different regions of the mesh strip are assigned different mesh densities according to their functional requirements. The vaporization zones require higher mesh density for efficient liquid distribution, while non-vaporization zones can use lower density. This local quality differentiation improves overall vaporization efficiency without uniformly increasing manufacturing complexity across the entire mesh.
2Strength
If a cap is over-molded onto the heating element, then structural rigidity is improved, but manufacturing time increases
Solution Approach 1:
The cap and heating element are combined into a single integrated component through over-molding, where the cap is molded directly onto the heating element in one continuous process. This merging eliminates separate assembly steps, reduces manufacturing time, and simultaneously improves structural rigidity by creating a unified structure.
Solution Approach 2:
The heating element is prepared with specific edge areas and surface characteristics before the cap over-molding process. This preliminary preparation ensures proper adhesion and alignment during over-molding, enabling the process to be completed efficiently in a single step while achieving the desired structural rigidity.
3Reliability
If electrically conductive contact areas are integrated onto the mesh, then electrical conductivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The electrically conductive contact areas are integrated directly into the mesh structure during the same manufacturing process, rather than being added as separate components. This merging ensures precise electrical connection while eliminating the need for separate alignment and attachment steps, thereby reducing overall manufacturing precision requirements.
Solution Approach 2:
The mesh is constructed as a composite structure combining conductive materials (for electrical contact areas) with the mesh substrate. This composite approach ensures reliable electrical conductivity while the integrated manufacturing process maintains appropriate precision levels without requiring extreme tolerances.
4Ease of manufacture
If the mesh is cut within a portion having the second mesh density, then ease of manufacture is improved, but mesh integrity may be compromised
Solution Approach 1:
The mesh strip is designed with alternating sections of different mesh densities, where the second mesh density section is specifically positioned to accommodate cutting operations. This local differentiation allows easier cutting in designated areas while preserving the integrity and functionality of the first mesh density sections that require higher structural stability.
Solution Approach 2:
The mesh strip is segmented into functional zones with different mesh densities. The cutting is performed within the second mesh density section, which is structurally designed to accommodate cutting without compromising the overall mesh integrity. This segmentation strategy balances ease of manufacture with structural stability.
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 robust, fluid-permeable heater assembly that ensures efficient vaporization of aerosol-forming substrates, improving the rigidity and manufacturing simplicity of the heater assembly while maintaining high thermal performance.
Implementation Method 1
an electrically operated heater assembly acting as a vaporiser
Implementation Method 2
a capillary medium like an elongated wick soaked in the liquid aerosol-forming substrate
Data Source
AI summary
A method for manufacturing a fluid permeable heater assembly includes providing a heating element, and over-molding a cap on edge areas of one side of the heating element. The cap includes a hollow body having a first cap opening and a second cap opening. The first cap opening is opposite to the second cap opening, and the heating element is mounted on the cap such that the heating element extends across the first cap opening.