Heater Moulding Surface Deforms Solid Aerosol Substrate
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Solution Overview
Problem
Existing heaters for aerosol generating devices face challenges in improving heating speed and efficiency, which are essential for effective aerosol generation without combustion or burning.
Innovation Solution
The proposed heater configuration includes a heating element with a moulding surface that deforms and heats the aerosol generating substrate, with a thick conductive track and a serpentine configuration to enhance heat delivery and efficiency. Additionally, the heater is designed to protrude from the base by a significant distance to reach closer to the substrate's center, improving heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional heater configuration is used, then the structure is simple and easy to manufacture, but the heating speed and efficiency are insufficient
Solution Approach 1:
The heating element is extended in the vertical dimension by protruding from the base surface. This dimensional change allows the heating element to reach closer to the center of the substrate, creating a three-dimensional heating configuration that improves heat delivery efficiency and speed compared to conventional planar heaters.
Solution Approach 2:
The heating element is positioned to concentrate thermal energy delivery at specific locations where it is most needed - closer to the center of the substrate. This local quality approach ensures that heat is delivered more efficiently to the critical heating zones, improving overall heating speed without requiring a complete redesign of the entire heater structure.
2Productivity
If a conventional heater configuration is used, then the manufacturing process is simple, but the heating efficiency is insufficient
Solution Approach 1:
The heating element protrudes vertically from the base, creating a three-dimensional structure that improves heat delivery efficiency by reaching closer to the substrate center. This dimensional modification can be integrated into existing manufacturing processes while significantly enhancing heating performance.
Solution Approach 2:
The protrusion distance of the heating element is optimized to be at least 0.5mm, a specific parameter change that maximizes heating efficiency by positioning the heat source closer to the substrate center. This parameter optimization improves heating efficiency without requiring fundamentally new manufacturing capabilities.
3Loss of energy
If the heating element protrudes closer to the substrate center, then heat delivery efficiency improves, but the heater structure becomes more complex
Solution Approach 1:
The heating element extends in the vertical dimension by protruding from the base surface, allowing heat to be delivered more directly to the substrate center. This vertical extension reduces thermal energy loss by shortening the heat transfer path while adding only moderate structural complexity compared to redesigning the entire heating system.
Solution Approach 2:
The heating element is positioned to concentrate thermal energy delivery at the substrate center where it is most needed. This localized approach improves heat delivery efficiency by reducing energy loss in critical zones without requiring complex modifications to the entire heater structure.
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 configuration significantly enhances heating speed and efficiency, allowing for more uniform heat delivery to the aerosol generating substrate, which leads to improved aerosol generation and user experience.
Implementation Method 1
a heating element attached to a support surface of the base, wherein the heating element comprises a moulding surface configured to deform and heat the aerosol generating substrate
Implementation Method 2
the conductive track has a serpentine configuration. This configuration increases the resistance of the conductive track in a given area of the support surface
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A heater for heating a consumable comprising a solid aerosol generating substrate, the heater comprising: a base; and a heating element attached to a support surface of the base, wherein the heating element comprises a moulding surface configured to deform and heat the aerosol generating substrate.