Over-Molded Heater Assembly Cap for Mesh Stability and Conductivity
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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 provision of a heating element with alternating mesh densities, over-molding a cap onto edge areas, and integrating electrically conductive contact areas to enhance stability and conductivity, with a capillary medium guidance for improved vaporization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform mesh structure is used for the heating element, then the manufacturing process is simple, but the vaporization efficiency and liquid distribution are insufficient
Solution Approach 1:
The heating element employs a non-uniform mesh structure with varying mesh densities in different regions. The first mesh section has a first mesh density while the second mesh section has a second mesh density, allowing optimized liquid distribution and vaporization efficiency in different areas of the heating element without complicating the overall manufacturing process
2Manufacturing precision
If the cap is molded separately and then assembled, then the manufacturing precision is easier to control, but the structural rigidity and assembly complexity increase
Solution Approach 1:
The cap is integrated directly onto the heating element through over-molding, combining two previously separate components into a single integrated assembly. This reduces the number of assembly steps, improves structural rigidity, and maintains manufacturing precision while reducing overall device complexity
3Reliability
If the mesh density is increased throughout the heating element, then the liquid retention is improved, but the electrical conductivity and heat distribution are reduced
Solution Approach 1:
Different regions of the heating element have different mesh densities optimized for their specific functions. The first mesh section with first mesh density optimizes for liquid retention while the second mesh section with second mesh density maintains electrical conductivity and heat distribution, allowing each region to perform its intended function effectively
4Volume of moving object
If the heating element is made thinner to reduce device size, then the device compactness is improved, but the structural stability and mesh integrity are compromised
Solution Approach 1:
The heating element integrates the mesh structure with the cap material through over-molding, creating a composite structure that enhances mechanical strength and mesh integrity while maintaining a thin profile. The integrated design provides structural support without significantly increasing the overall device size
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 more stable and efficient heater assembly that effectively vaporizes aerosol-forming substrates, improving the rigidity and manufacturing simplicity of the device while ensuring precise mesh integrity and electrical conductivity.
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.