Heater Pin Bonding Structure for Moisture-Resistant Aerosol Heating
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Solution Overview
Problem
The existing aerosol generating devices face issues such as water or moisture ingress, heater malfunction, overheating, reduced durability, and manufacturing inefficiencies, along with potential rotation or separation of the heater in the circumferential direction.
Innovation Solution
The device incorporates a heater pin with a ceramic material, a resistive heater fixed using ceramic bonding agents, and a moisture-resistant second bonding material to prevent water ingress and enhance durability, while a support bar and bonding materials improve manufacturing efficiency and heater stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a heater is disposed in a heater pin without proper sealing, then the heater can be easily installed, but water or moisture can enter the inside of the heater pin causing malfunction
Solution Approach 1:
A moisture-proof film is disposed at the bottom of the cavity in the heater pin to prevent water or moisture from entering the heater assembly. The film acts as a flexible barrier that seals the cavity while allowing for thermal expansion and contraction during operation.
Solution Approach 2:
The bonding assembly comprises a first bonding material and a second bonding material with different properties. The first bonding material provides adhesive bonding between the heater and heater pin, while the second bonding material provides moisture resistance and fills the opening. This composite approach combines the advantages of both materials to achieve both easy installation and reliable protection.
2Device complexity
If the heater is fixed with bonding material only, then the manufacturing process is simple, but the heater may rotate or separate in the circumferential direction
Solution Approach 1:
The bonding assembly uses a composite structure with a first bonding material for adhesive bonding and a second bonding material for structural support and moisture resistance. This composite approach provides both circumferential stability and axial positioning without overly complicating the manufacturing process.
Solution Approach 2:
Different regions of the bonding assembly have different properties: the first bonding material provides localized adhesive bonding at the heater interface, while the second bonding material provides structural support and moisture resistance in the opening region. This localized differentiation optimizes both stability and manufacturing simplicity.
3Ease of manufacture
If the opening of the cavity is left open for heater installation, then the manufacturing process is simple, but water or moisture can enter the inside of the heater pin
Solution Approach 1:
A moisture-proof film is disposed at the bottom of the cavity to prevent water or moisture from entering through the opening. The film maintains the opening accessible for heater installation while providing a barrier against moisture ingress during operation.
Solution Approach 2:
The moisture-proof film and second bonding material are prepared in advance to seal the opening after heater installation. This preliminary preparation allows the opening to remain accessible during assembly while ensuring protection against moisture is established before the device is put into service.
4Device complexity
If a single bonding material is used to fix the heater, then the manufacturing process is simple, but the heater durability and resistance to overheating are reduced
Solution Approach 1:
The bonding assembly comprises a first bonding material and a second bonding material with different properties. The first bonding material provides adhesive bonding between the heater and heater pin, while the second bonding material provides moisture resistance and thermal stability. This composite structure enhances heater durability and overheating resistance without significantly complicating the manufacturing process.
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 effectively prevents moisture ingress, reduces overheating, enhances heater durability, and improves manufacturing efficiency, ensuring stable heater operation and extended replacement periods.
Implementation Method 1
a first bonding material injected into the cavity to fix the heater
Implementation Method 2
a second bonding material injected into the cavity to cover the first bonding material so as to fill an opening of the cavity
Implementation Method 3
a resistive heater fixed using ceramic bonding agents
Data Source
AI summary
An aerosol generating device and a method of manufacturing the aerosol generating are provided. The aerosol generating device includes: a body comprising an insertion space; a heater pin protruding upward from a lower end of the insertion space; a heater disposed in a cavity of the heater pin; a first bonding material injected into the cavity to fix the heater; and a second bonding material injected into the cavity to cover the first bonding material so as to fill an opening of the cavity.