Induction Heating Module with Wire Recess and Flux Concentrator
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Solution Overview
Problem
Existing induction heating systems for aerosol-generating devices face challenges in achieving a sufficient temperature level within a short period of time, particularly when operating intermittently, such as on a puff by puff basis, especially when using a flat susceptor, such as a sheet-like susceptor, which is a susceptor.
Innovation Solution
The induction heating module incorporates a cylindrical-helical coil with a wire recess pattern and a flux concentrator to reduce the radial distance between the induction coil and the susceptor, using a cylindrical-helical induction coil with a circular cross-section and a flux concentrator to enhance magnetic field strength and heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heating element is integrated into the atomizer assembly, then heating efficiency and vaporization performance are improved, but contamination of the heating element and degradation of taste quality occur due to accumulation of viscous oils and resinous by-products
Solution Approach 1:
The device is divided into two separate assemblies: an atomizer assembly containing the heating element, and a vaporization chamber containing the wick and reservoir. The wick acts as an intermediary that transfers heated vapor from the atomizer to the user, preventing direct contact between the heating element and the consumable liquid, thus avoiding contamination while maintaining heating efficiency.
Solution Approach 2:
The wick serves as an intermediary component between the heating element and the consumable liquid. It absorbs the liquid and transports it to the heating element for vaporization, then delivers the heated vapor to the user. This intermediary role prevents the heating element from directly contacting and becoming contaminated by the liquid, thereby maintaining both heating efficiency and taste quality.
2Ease of manufacture
If the heating element is exposed to direct contact with consumable liquid, then ease of manufacture is improved, but the heating element becomes contaminated and requires frequent cleaning or replacement
Solution Approach 1:
The device is segmented into a reusable atomizer assembly and a replaceable vaporization chamber. The vaporization chamber containing the wick can be easily replaced when depleted, while the atomizer assembly with the heating element remains clean and functional. This segmentation simplifies manufacturing and reduces maintenance requirements.
Solution Approach 2:
The vaporization chamber containing the wick is designed as a disposable component that is replaced rather than cleaned. This eliminates the need for frequent cleaning or replacement of the expensive heating element, reducing maintenance frequency and costs while keeping the overall device simple to manufacture.
3Power
If the wick is positioned too close to the heating element, then heat transfer efficiency is improved, but resinous by-products accumulate on the wick and alter flavor profile
Solution Approach 1:
The wick is positioned in close proximity to the heating element to maximize heat transfer efficiency, but the design accepts that some by-product accumulation will occur on the wick. Since the wick is disposable and replaceable, this localized contamination does not affect overall flavor consistency, allowing optimal heat transfer while maintaining reliable performance.
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 allows for efficient heating of the susceptor, achieving a desired temperature level within a shorter period of time, while maintaining a compact design and reducing resistive power losses.
Implementation Method 1
an induction heating module (1520) configured to inductively heat the atomizing element (1522)
Implementation Method 2
Induction heating module for use in an inductively heating aerosol-generating device
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
An induction heating module (30) for use in an inductively heating aerosol-generating device (1) comprises an induction coil (13) for inductively heating a susceptor (22) within an interior space of the induction coil in order to heat an aerosol-forming substrate in thermal contact or thermal proximity with the susceptor, wherein the induction coil is formed by a coil wire. The induction heating module further comprises a coil support (17) for supporting the induction coil, which comprises a support tube (32), wherein the induction coil is wound around an outer circumference of the support tube. The outer circumference of the support tube comprises a wire recess pattern (39) in which the coil wire is received. A flux concentrator (50) is provided, and the support tube comprises two recesses (38) which receive at least a portion of the flux concentrator. An aersol-generating device and an aerosol-generating system comprising the induction heating module are also described.