Induction Heated Susceptor for Aerosol Delivery
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Solution Overview
Problem
Traditional aerosol delivery devices using direct resistive heating elements suffer from significant heat loss, high power consumption, complex manufacturing processes, and non-uniform heating, leading to reduced aerosol production rates and potential charring of aerosol precursors.
Innovation Solution
The implementation of an induction-based heating system, where an induction transmitter generates an oscillating magnetic field to heat an induction receiver via eddy currents, eliminating the need for direct electrical connections and allowing for wireless heating of aerosol precursors, thereby reducing heat loss and improving uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If direct resistive heating elements are used, then heating function is achieved, but heat loss increases and power consumption increases
Solution Approach 1:
The patent replaces direct resistive heating (mechanical/electrical contact system) with induction heating (electromagnetic field system). The induction transmitter generates an oscillating magnetic field that induces eddy currents in the susceptor, which then generates heat internally without direct electrical contact. This substitution eliminates heat loss through conduction and convection pathways present in direct heating elements, thereby reducing overall energy loss while maintaining effective heating power consumption.
Solution Approach 2:
The susceptor acts as an intermediary between the induction transmitter and the aerosol precursor. The oscillating magnetic field from the transmitter induces eddy currents in the susceptor, which then converts electromagnetic energy to thermal energy internally. This intermediary mechanism allows efficient energy transfer with minimal heat loss to the surrounding environment, as the heat is generated within the susceptor itself rather than being conducted from an external heating element.
2Ease of manufacture
If direct electrical connections are used for heating elements, then heating function is achieved, but device complexity increases due to manufacturing requirements
Solution Approach 1:
The patent extracts and eliminates the direct electrical connection components (wires, connectors, contacts) from the heating system. By using induction heating, the system no longer requires physical electrical pathways between the power source and the heating element. This removal of complex connection requirements simplifies the manufacturing process, reduces assembly steps, and eliminates tolerance issues associated with ensuring good electrical contact between multiple components.
Solution Approach 2:
The patent replaces the mechanical/electrical connection system with an electromagnetic field-based system. The induction transmitter wirelessly transmits energy through electromagnetic induction to the susceptor, eliminating the need for direct electrical connections. This substitution dramatically simplifies the device structure and manufacturing process, as there are no wires to route, connectors to assemble, or contact points to maintain within tight tolerances.
3Object-affected harmful factors
If conventional heating elements are used, then heating is achieved, but heating uniformity decreases leading to precursor charring
Solution Approach 1:
The patent applies local quality by enabling the susceptor to generate heat uniformly throughout its structure through induced eddy currents. The oscillating magnetic field penetrates the susceptor and induces currents that generate heat locally within the material itself, rather than heat being conducted from an external source. This results in more uniform temperature distribution across the heating surface, preventing localized overheating and precursor charring while maintaining effective heating temperature.
Solution Approach 2:
The susceptor serves as an intermediary that converts electromagnetic energy to thermal energy uniformly across its structure. The oscillating magnetic field induces eddy currents throughout the susceptor material, which then generates heat internally and uniformly. This intermediary mechanism ensures even heat distribution to the aerosol precursor, preventing the localized hot spots that cause charring in direct heating systems while maintaining the necessary heating temperature for vaporization.
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 solution enhances aerosol production efficiency, reduces power consumption, simplifies manufacturing, and minimizes precursor charring, resulting in a more effective and user-friendly aerosol delivery device.
Implementation Method 1
The induction receiver may also be configured to absorb aerosol precursor through capillary action or other means to convey aerosol precursor from a source to a heated portion of the induction receiver. Thereby, by directing alternating current through the induction transmitter, eddy currents may be generated in the induction receiver via induction.
Implementation Method 2
The eddy currents flowing through the resistance of the material defining the induction receiver may heat it by Joule heating.
Implementation Method 3
The induction transmitter may include a coil configured to create an oscillating magnetic field (e.g., a magnetic field that varies periodically with time) when alternating current is directed therethrough. The induction receiver may be positioned at least partially within or adjacent to the induction transmitter
Implementation Method 4
The induction receiver may also be configured to absorb aerosol precursor through capillary action or other means to convey aerosol precursor from a source to a heated portion of the induction receiver
Implementation Method 5
The eddy currents flowing through the resistance of the material defining the induction receiver may heat it by Joule heating. Thereby, the induction receiver, which may function as an atomizer, may be wirelessly heated to form an aerosol from an aerosol precursor composition absorbed by the induction receiver.
Data Source
AI summary
An aerosol delivery device is described that includes an aerosol precursor staged within a reservoir and an atomizer configured to generate heat through induction. The atomizer has an induction transmitter and an induction receiver. The induction receiver is in operational contact with the aerosol precursor within the reservoir and is configured to wick the aerosol precursor into range of the induction transmitter to be heated and vaporized.