Aerosol Heater Circuit Layout With Heat Spreader Sensor Isolation

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Solution Overview

Problem

Conventional aerosol-generating devices experience sensor malfunctions due to heat transfer from heaters, leading to device failures.

Innovation Solution

Incorporation of a heat spreader that contacts the circuit board and extends away from the heater, with a thermal interface material between the heat spreader and the device casing, to manage heat distribution and protect sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a heater is used to heat the aerosol-generating substance, then the aerosol generation function is improved, but the sensor temperature increases causing malfunction

Engineering Contradiction:

Improveheating functionVSAvoidsensor operation

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The device is divided into distinct functional zones: a heating zone with the heater for aerosol generation and a separate sensor zone for detection. The heat spreader extends away from the heater to create thermal isolation between these zones, allowing the heater to operate at full power while the sensors remain in a cooler, reliable operating environment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A heat spreader is introduced as an intermediary component between the heater and the sensors. This heat spreader extends in a direction away from the heater and contacts the circuit board at a position remote from the heater, acting as a thermal mediator that distributes heat away from sensitive components while maintaining the heating function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If heat is transferred to the outside of the heater, then the heating efficiency is improved, but the sensor temperature increases causing malfunction

Engineering Contradiction:

Improveheating efficiencyVSAvoidheat transfer to sensors

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The heat spreader is designed with spatially varying thermal properties: it has high thermal conductivity in regions away from the heater to efficiently distribute heat, while the sensor mounting area remains relatively cool. This local quality differentiation allows efficient heat transfer from the heater while protecting sensors from excessive heat.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heat spreader extends in a direction away from the heater, utilizing the longitudinal dimension of the device to redirect heat flow. Instead of heat transferring directly to sensors in the horizontal plane, the heat spreader channels thermal energy along its extended structure, effectively using spatial dimensionality to separate heat generation from heat-sensitive components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Effectively reduces heat transfer to sensors, preventing malfunctions and ensuring reliable device operation.

Implementation Method 1

a heat spreader in contact with the circuit board, wherein at least a portion of the heat spreader extends in a direction away from the heater

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a thermal interface material (TIM) that is disposed between the heat spreader and a body casing and is in contact with the heat spreader and the body casing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20260020614A1Aerosol-generating device

Publication Date: 2026.01.22 KT&G CO LTD

AI summary

An aerosol-generating device is disclosed. The aerosol-generating device includes a body including an insertion space with one side open, a heater configured to heat the insertion space, at least one sensor disposed adjacent to the insertion space, a circuit board on which the at least one sensor is disposed, and a heat spreader in contact with the circuit board. At least a portion of the heat spreader extends in a direction away from the heater.