Hybrid Filament Heating Mesh for Consistent Aerosol Wetting

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Solution Overview

Problem

Aerosol-generating systems face challenges in achieving consistent aerosol production due to variations in wetting of the heating element with liquid aerosol-forming substrate, leading to issues like 'dry puff' and thermal decomposition, and manufacturing inconsistencies result in product-to-product variability.

Innovation Solution

A hybrid heating element comprising a plurality of first filaments for heating and second filaments for conveying liquid aerosol-forming substrate, ensuring consistent wetting and improved vaporization by increasing the contact area with the substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional wick and coil heater assemblies are used, then the heating element can be heated to generate aerosol, but consistent wetting of the heating element is difficult to achieve due to variations between different wicks

Engineering Contradiction:

Improveconsistent wettingVSAvoidvariation between wicks

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent combines the heating function (first filament) and wicking function (second filament) into a single integrated heating element structure. The first and second filaments are positioned adjacent to each other and extend in the same direction, creating a unified component that ensures consistent liquid substrate delivery and heating, eliminating the variability associated with separate wick and coil assemblies.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If manual assembly processes are used for heater assemblies, then manufacturing flexibility is maintained, but the likelihood of variation between different heater assemblies increases and cost and complexity increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidvariation between assemblies

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The heating element integrates multiple functions (heating and wicking) into a single component with filaments positioned adjacent to each other, simplifying the assembly structure and reducing the number of parts that require manual assembly. This integration maintains manufacturing flexibility while reducing variation between assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating element serves multiple functions simultaneously: the first filament provides heating while the second filament provides liquid substrate conveyance. This multi-functionality in a single component reduces assembly complexity and improves consistency across different heater assemblies.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If a single filament structure is used, then the device complexity is reduced, but the ability to consistently wet the heating element and produce consistent aerosol is compromised

Engineering Contradiction:

Improvestructure simplicityVSAvoidaerosol consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent merges heating and wicking functions into a single integrated element with filaments positioned adjacent to each other, maintaining structural simplicity while improving aerosol consistency through the coordinated action of both filament types.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating element uses composite filament structures where the first filament (for heating) and second filament (for wicking) work together as an integrated system. This composite approach enables both structural simplicity and functional reliability for consistent aerosol generation.

Inventive Principle:

Principle #40Composite materials

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 hybrid heating element ensures consistent aerosol production over successive uses and between different systems, reducing manufacturing variability and enhancing manufacturing efficiency.

Implementation Method 1

The heating element may comprise a first filament. The first filament may be configured to heat a liquid aerosol-forming substrate

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

The heating element may comprise a second filament. The second filament may be configured to convey a liquid aerosol-forming substrate to wet at least a portion of the heating element with liquid aerosol-forming substrate

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 3

configured to heat a liquid aerosol-forming substrate to generate an aerosol

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentUS12616245B2Heating element having heat conductive and wicking filaments

Publication Date: 2026.05.05 PHILIP MORRIS PRODUCTS SA

AI summary

A heating element for an aerosol-generating system is provided, the heating element including: a plurality of first filaments; and a plurality of second filaments, in which the plurality of first filaments are configured to heat a liquid aerosol-forming substrate, the plurality of second filaments are configured to convey the liquid aerosol-forming substrate to wet at least a portion of the heating element with the liquid aerosol-forming substrate, and the heating element is arranged to form a mesh, the plurality of first filaments being arranged in a first direction and the plurality of second filaments being arranged in a second direction, and the second direction being transverse to the first direction. A heater assembly, a cartridge, and a method of manufacturing a heating element, are also provided.