Induction Heater Coil Assembly for Stable Shape and Efficient Heating
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Solution Overview
Problem
There is a need for a heater assembly that is excellent in electrical efficiency, manufacturability, and/or productivity, particularly for induction heating-type aerosol generating devices.
Innovation Solution
The heater assembly includes an induction coil with a conductor, insulator, and bonding member, configured to maintain a specific shape and separated from the accommodation portion by a support element, along with a susceptor to generate heat from an alternating magnetic field, and a method of manufacturing involving winding and fixing the coil at a predetermined temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the induction coil is wound around the accommodation portion to generate an alternating magnetic field for heating the susceptor, then heating efficiency is improved, but the coil may deform or change shape during the heating process, affecting manufacturing precision and assembly quality
Solution Approach 1:
A shape fixing member is introduced as an intermediary component between the induction coil and the accommodation portion. This member maintains the coil's wound shape during the heating process, preventing deformation while allowing the coil to function effectively. The shape fixing member acts as a mediator that preserves geometric integrity without interfering with the electromagnetic heating function.
Solution Approach 2:
The induction coil is pre-shaped and fixed in its desired configuration before being installed in the heating device. The shape fixing member is positioned in advance to maintain the coil's geometry during subsequent heating operations, ensuring that the coil retains its optimal shape for both manufacturing and assembly purposes.
2Reliability
If multiple components (induction coil, susceptor, accommodation portion) are assembled together, then the heater assembly achieves functional completeness, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
The induction coil and the shape fixing member are combined into a single integrated component. The shape fixing member is embedded within or attached to the coil structure, eliminating the need for separate installation steps. This merging reduces the number of assembly operations while ensuring that both the heating function and shape stability are achieved simultaneously.
3Use of energy by moving object
If the induction coil is designed with high inductance to improve electrical efficiency, then energy loss is reduced, but the coil structure becomes more complex and manufacturing cost increases
Solution Approach 1:
The shape fixing member is strategically positioned at specific locations along the induction coil where shape maintenance is most critical. Rather than uniformly complicating the entire coil structure, the fixing members are placed locally at key points to provide sufficient shape stability while minimizing overall structural complexity and manufacturing cost.
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 improves electrical efficiency, assembly properties, and reduces manufacturing costs while maintaining high productivity.
Implementation Method 1
an induction coil (340) wound around an outer surface of the accommodation portion (310), and a susceptor (320) located in the accommodation portion (310) and heated by an alternating magnetic field, which is induced by a current flowing through the induction coil (340)
Implementation Method 2
a susceptor (320) located in the accommodation portion (310) and heated by an alternating magnetic field, which is induced by a current flowing through the induction coil (340)
Data Source
Figure 1~3A
Figure 3B~4A
Figure 4B
AI summary
A heater assembly for heating an aerosol generating material includes an accommodation portion configured to accommodate the aerosol generating material; an induction coil coupled to an outer surface of the accommodation portion; a susceptor located in the accommodation portion and configured to generate heat by an alternating magnetic field generated by a current flowing through the induction coil; and a support element coupled to the susceptor such that the suspector is spaced apart from an inner surface of the accommodation portion by the support element, wherein the induction coil includes a wire including a conductor, an insulator surrounding the conductor, and a bonding member surrounding the insulator.