Inductor Coil Shape Control via Bondable Coating
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Solution Overview
Problem
Existing aerosol provision devices face challenges in efficiently forming inductor coils with controlled cross-sectional shapes for optimal heating effects, as existing methods struggle to accurately mold multi-strand wires into specific shapes without compromising the wire's integrity or requiring complex manufacturing processes.
Innovation Solution
A method involving a multi-strand wire with a bondable coating is wound around a support member featuring a channel that sets the wire's shape, with the bondable coating activated to retain the shape, allowing for the formation of inductor coils with tailored cross-sectional dimensions and shapes, such as greater longitudinal than lateral dimensions, to reduce energy losses and enhance heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multi-strand wire is wound around a support member to form an inductor coil, then the coil structure is formed, but the wire cannot retain its shaped configuration without additional mechanisms
Solution Approach 1:
The wire includes a temperature-sensitive shape memory component that changes its physical state based on temperature. When heated above a transition temperature, the wire transitions from a first configuration to a second configuration, allowing it to retain the desired cross-sectional shape formed during winding without additional mechanical constraints
Solution Approach 2:
The multi-strand wire is constructed with composite materials including shape memory alloy strands combined with other conductive materials. This composite structure provides both the electrical conductivity needed for inductor function and the shape memory properties needed to retain the cross-sectional configuration
2Manufacturing precision
If complex manufacturing processes are used to mold multi-strand wires into specific shapes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The desired cross-sectional shape is pre-formed in the wire during the winding process by manipulating the wire as it is being wound around the support member. The shape memory effect then locks in this pre-formed shape, eliminating the need for subsequent complex molding or shaping operations
Solution Approach 2:
The wire's shape memory properties enable it to self-retain its formed configuration without requiring external molds, fixtures, or complex manufacturing equipment. The material itself provides the mechanism for shape retention, simplifying the manufacturing process
3Loss of energy
If inductor coils with optimized cross-sectional shapes are produced, then heating efficiency is improved, but energy losses increase without proper shape control
Solution Approach 1:
By controlling the cross-sectional shape parameters of the wire through the shape memory effect, the inductor coil achieves optimal magnetic field distribution. This reduces eddy current losses and improves coupling efficiency with the heating element, thereby reducing energy losses while maintaining high heating efficiency
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 method enables the production of inductor coils with precise cross-sectional shapes, improving heating efficiency and reducing energy losses, while simplifying the manufacturing process by using a bondable coating and a channel-shaped support member to maintain the wire's shape and dimensions.
Implementation Method 1
activating the bondable coating such that the multi-strand wire substantially retains a shape determined by the channel
Implementation Method 2
at least one of the inductor coils of any of the fourth and fifth and tenth aspects for generating a varying magnetic field for penetrating a susceptor to thereby cause heating of the susceptor
Data Source
AI summary
In one aspect a support member is provided. The support member is for forming an inductor coil of an aerosol provision device, and defines an axis about which a multistrand wire of the inductor coil is windable. An outer surface of the support member comprises a channel to receive the wire. In another aspect there is provided a method of forming an inductor coil for an aerosol provision device. The method comprises providing a multi-strand wire comprising a plurality of wire strands, wherein at least one of the plurality of wire strands comprises a bondable coating; winding the multi-strand wire around a support member defining an axis; activating the bondable coating such that the multi-strand wire substantially retains a shape determined by the support member; reducing a cross-sectional width of the support member in a direction perpendicular to the axis; and removing the multistrand wire from the support member.