Inductive Susceptor Cartridge for E-Cigarette Assembly

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Solution Overview

Problem

The complexity and cost of manufacturing and assembly of traditional e-cigarette cartridges are high due to their numerous components, which complicates the efficient heating of aerosol generating liquids.

Innovation Solution

A cartridge design featuring an inductively heatable susceptor and a liquid transfer element, with a recess for a coil support that allows for efficient electromagnetic coupling with an induction coil, reducing the number of components and simplifying the structure, using a susceptor ring and porous capillary material for effective heat transfer and vapor generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a traditional cartomizer design with integrated liquid store, wick, and heater is used, then the cartridge is self-contained and easy to use, but the number of components increases leading to complex and costly manufacturing and assembly

Engineering Contradiction:

Improveease of useVSAvoidnumber of components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The cartridge is divided into distinct functional modules: a reusable body housing the induction coil and control electronics, and a replaceable cartridge containing the reservoir and susceptor. This segmentation allows each module to be optimized independently and simplifies manufacturing and assembly of individual components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reusable body is designed to accommodate different cartridge types through a standardized interface, allowing one body unit to serve multiple functions with different flavor cartridges. The induction heating system provides universal compatibility with various susceptor materials.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If traditional heating elements and cotton wicks are used, then liquid transfer is simple, but heating efficiency and vapor generation are limited

Engineering Contradiction:

Improvesimplicity of constructionVSAvoidheating efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The traditional resistive heating element and cotton wick system is replaced with an inductive heating system using a susceptor. The induction coil generates an electromagnetic field that directly induces eddy currents in the susceptor, eliminating the need for thermal conduction through a wick and significantly improving heating efficiency and response time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The heating mechanism changes from low-frequency resistive heating to high-frequency electromagnetic induction, enabling much faster heating rates and more efficient energy transfer to the aerosol-generating liquid. The susceptor material properties are optimized to maximize electromagnetic coupling with the induction coil.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the induction coil is integrated into the cartridge, then electromagnetic coupling with the susceptor is maximized, but the cartridge structure becomes more complex

Engineering Contradiction:

Improveelectromagnetic coupling efficiencyVSAvoidcartridge structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The induction coil is extracted from the cartridge and relocated to the reusable body. Only the essential heating components (susceptor and reservoir) remain in the cartridge, which simplifies cartridge structure while maintaining efficient electromagnetic coupling through optimized positioning and shielding in the body housing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A magnetic shield or flux guide is introduced as an intermediary between the induction coil in the body and the susceptor in the cartridge. This intermediary component directs and concentrates the electromagnetic field, maximizing coupling efficiency without requiring the coil to be physically integrated into the cartridge structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If more components are added to improve heating efficiency, then vapor generation improves, but manufacturing and assembly costs increase

Engineering Contradiction:

Improvevapor generation efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The cartridge with reservoir and susceptor is designed as a disposable or replaceable component with a simplified structure that reduces manufacturing complexity. By concentrating the complex and expensive components (induction coil, electronics, battery) in the reusable body, the disposable cartridge can be manufactured more simply and cost-effectively.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

Multiple functions are merged into the reusable body: power management, temperature control, induction coil housing, and user interface. This consolidation eliminates the need for separate components and reduces overall assembly complexity, while the simple cartridge requires minimal assembly.

Inventive Principle:

Principle #5Merging (Combining)

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 design simplifies the cartridge structure, reduces costs, and enhances the efficiency of aerosol generation by achieving good electromagnetic coupling and uniform heating of the aerosol generating liquid, leading to improved vapor production and user experience.

Implementation Method 1

an inductively heatable susceptor for heating the aerosol generating liquid, and a liquid transfer element configured to convey aerosol generating liquid from the reservoir towards the inductively heatable susceptor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an induction coil; and a coil support projecting from the proximal end which supports the induction coil

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

heating the aerosol generating liquid to volatise at least one component of the aerosol generating liquid and thereby generate a vapour which cools and condenses to form an aerosol

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

generate a vapour which cools and condenses to form an aerosol

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 5

a liquid transfer element configured to convey aerosol generating liquid from the reservoir towards the inductively heatable susceptor

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20230389611A1A Cartridge for an Aerosol Generating Device, an Aerosol Generating Device and an Aerosol Generating System

Publication Date: 2023.12.07 JT INTERNATIONAL SA

AI summary

A cartridge for an aerosol generating device includes a reservoir for containing an aerosol generating liquid, an inductively heatable susceptor for heating the aerosol generating liquid, and a liquid transfer element configured to convey aerosol generating liquid from the reservoir towards the inductively heatable susceptor. The inductively heatable susceptor includes a susceptor ring extending around the liquid transfer element. The cartridge includes a recess configured for receiving, in a releasable connection a coil support having an induction coil of an aerosol generating device. An aerosol generating device, and an aerosol generating system including the aerosol generating device and a cartridge releasably connected to the aerosol generating device, are also described.