Modular Heating Assembly for Aerosol Devices

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Solution Overview

Problem

Consumable cartridges used in aerosol generating devices, such as electronic cigarettes, are complex, costly to manufacture, and difficult to recycle, impacting the sustainability of these devices.

Innovation Solution

A modular heating assembly for aerosol generating devices that is separate from the cartridge, allowing for easy replacement and reducing manufacturing costs, comprising a heater tray with a heating plate and electrical contacts for automatic connection, enabling multiple cartridge use before heating assembly replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the heating assembly is integrated into the cartridge, then the cartridge structure is simplified, but the manufacturing cost increases and recyclability decreases

Engineering Contradiction:

Improvecartridge structureVSAvoidmanufacturing cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The heating assembly is separated from the cartridge, creating two independent components. The cartridge contains only the liquid reservoir and cap, while the heating assembly includes the heating element, wick, and airflow channel. This segmentation simplifies cartridge manufacturing and enables separate recycling of each component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating assembly is extracted from the cartridge structure and positioned in the airflow channel of the device body. This extraction allows the cartridge to be a simple, low-cost container while the heating assembly serves as a reusable component that can be recycled.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If the heating assembly is integrated into the cartridge, then the cartridge functions are complete, but the recyclability and sustainability decrease

Engineering Contradiction:

Improvecartridge functionalityVSAvoidsustainability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By segmenting the system into reusable heating assembly and disposable cartridge, the heating components can be recycled and reused multiple times, improving sustainability while the cartridge maintains its complete liquid delivery function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The disposable cartridge is discarded after use while the heating assembly is recovered and reused. This allows the valuable heating components to be sustained across multiple cartridge cycles, improving overall system sustainability.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If the heating assembly is separate and replaceable, then the sustainability improves, but the risk of electrical connection errors increases

Engineering Contradiction:

ImprovesustainabilityVSAvoidelectrical connection reliability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The electrical contacts are designed to automatically connect when the heating assembly is inserted into the device. The spring-loaded contact ensures reliable electrical connection without requiring user intervention, eliminating the risk of connection errors while maintaining ease of replacement.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spring-loaded electrical contact acts as an intermediary that automatically establishes and maintains reliable electrical connection between the heating assembly and device, ensuring safe and error-free operation during replacement.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If the heating assembly allows easy replacement, then the user convenience improves, but the risk of damaging the heating plate increases

Engineering Contradiction:

Improvereplacement easeVSAvoidheating plate durability

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The heating plate is segmented as part of the removable heating assembly, protected by the heater tray structure during insertion and removal. This allows easy replacement of the entire assembly while protecting the heating plate from damage during handling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heater tray and housing structure provide protective cushioning around the heating plate during insertion and removal operations, preventing direct contact and potential damage to the fragile heating element while enabling easy replacement.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Enhances sustainability and user convenience by allowing multiple cartridge uses without frequent heating assembly replacement, simplifying the manufacturing process and reducing the risk of electrical damage during handling and operation.

Implementation Method 1

a heating plate (58) mounted on an upper face of the heater tray (56)... electrically connected to the heating plate

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP4449920A1A heating assembly for an aerosol generating device and a corresponding aerosol generating device

Publication Date: 2024.10.23 JT INTERNATIONAL SA

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AI summary

A heating assembly for an aerosol generating device (8), the heating assembly comprising a heater tray (56) and a heating plate (58) mounted on an upper face of the heater tray (56), the heating assembly forming a replaceable unit of the aerosol generating device (8) and being configured for sliding in and sliding out of a heater holder (54) of the aerosol generating device (58).