Heater Module Holder Assembly for Tolerance-Tolerant Aerosol Devices
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Solution Overview
Problem
Existing aerosol-generating devices face challenges in easy assembly, compact design, and maintaining a reliable connection between the heater module and the heater casing, particularly due to manufacturing tolerances.
Innovation Solution
The device incorporates a heater module holder with a protruding upstream connection section that fits into a mounting recess of the heater casing upstream part, allowing a mounting gap and flexible sealing element for relative movement, enabling easy alignment and secure positioning despite manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the heater module is directly connected to the heater casing without a holder, then the device structure is simpler, but the assembly is more difficult and the connection is less reliable
Solution Approach 1:
A heater module holder is introduced as an intermediary component between the heater module and the heater casing. The holder includes a connection section that fits into a mounting recess in the heater casing, providing a reliable mechanical connection and simplifying the assembly process while maintaining structural integrity.
2Volume of moving object
If the heater module is directly connected to the heater casing without a holder, then the device is more compact, but the connection reliability is reduced
Solution Approach 1:
The heater module holder acts as a mediator that ensures reliable connection between the heater module and heater casing. The connection section with mounting recess provides secure mechanical engagement, while the flexible sealing element ensures airtight sealing, maintaining compactness without sacrificing reliability.
Solution Approach 2:
A flexible sealing element is incorporated between the heater module holder and the heater casing to ensure airtight sealing. The flexible element compensates for manufacturing tolerances and maintains reliable connections while preserving the compact device structure.
3Manufacturing precision
If tight tolerances are used for connecting the heater module to the heater casing, then the connection is more precise, but the manufacturing cost increases
Solution Approach 1:
The connection design incorporates flexibility to accommodate manufacturing tolerances. The flexible sealing element and the clearance between the connection section and mounting recess allow for dynamic adjustment during assembly, enabling precise connections without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The flexible sealing element compensates for variations in manufacturing tolerances by deforming to create an airtight seal. This allows the connection to maintain precision and reliability while being easier and less expensive to manufacture.
4Stability of the object's composition
If the heater module holder is rigidly fixed to the heater casing, then the positioning is more stable, but the assembly is more difficult
Solution Approach 1:
The connection between the heater module holder and heater casing is designed to be dynamically adjustable. The flexible sealing element and clearance in the mounting recess allow for easy positioning and assembly, while still providing stable positioning once assembled through the mechanical engagement of the connection section.
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
This design facilitates easy assembly, ensures a reliable connection, and maintains a continuous airflow path while accommodating manufacturing variations, resulting in a compact and functional aerosol-generating device.
Implementation Method 1
The heating module may comprise a heating element and including a heating chamber for receiving the aerosol-generating article. Upon heating to a target temperature, the aerosol-forming substrate vaporises to form an aerosol.
Implementation Method 2
Upon heating to a target temperature, the aerosol-forming substrate vaporises to form an aerosol.
Data Source
AI summary
An aerosol-generating device is provided, including: a heater casing having a heater casing downstream part and a heater casing upstream part, the heater casing housing a heater module, the heater module being mounted in the heater casing on a heater module holder, the heater module holder being connected to the heater casing upstream part, the heater module holder including a protruding upstream connection section configured to connect to the heater casing upstream part, the heater casing upstream part including a mounting recess configured to receive the protruding upstream connection section, and an inner surface of the mounting recess being spaced apart from an opposing outer surface of the protruding upstream connection section for creating a mounting gap. A method for assembling an aerosol-generating device is also provided.