Multi-Layer Deposited Heater for Aerosol Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Handheld electrically operated aerosol-generating systems face challenges in manufacturing a robust and cost-effective heater assembly with improved aerosol characteristics, as existing wick and coil assemblies are fragile and difficult to produce in a repeatable and low-cost manner.
Innovation Solution
A multi-layer fluid permeable heater assembly is deposited onto a porous member, comprising a first layer of electrically conductive material and a second layer with higher conductivity to modify electrical resistance, improving contact and reducing 'hot spots, with a third layer for adhesion, allowing for efficient and robust aerosol generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wick and coil assembly is used for vaporisation, then aerosol can be produced effectively, but the assembly becomes fragile and difficult to manufacture in a repeatable and low-cost way
Solution Approach 1:
The patent replaces the mechanical wick and coil assembly with a deposited heater layer formed by depositing electrically conductive material onto a porous support. This eliminates the need for mechanical assembly of fragile coil and wick components, enabling robust, repeatable, and cost-effective manufacturing while maintaining aerosol generation effectiveness.
Solution Approach 2:
The patent uses a porous support structure with deposited heater material that allows liquid aerosol-forming substrate to permeate through while providing heating. This porous configuration maintains effective aerosol generation by allowing liquid contact with the heater while simplifying the overall structure for easier manufacturing.
2Ease of manufacture
If a single layer of electrically conductive material is used for the heater, then manufacturing is simpler, but finer adjustments to electrical resistance cannot be achieved
Solution Approach 1:
The patent divides the heater into multiple deposited layers of electrically conductive material. Each layer can be independently controlled during deposition, allowing finer adjustment of the overall electrical resistance by varying the number of layers, their thickness, or their material composition, while maintaining a deposited manufacturing process that remains relatively simple.
Solution Approach 2:
The patent adjusts electrical resistance by changing parameters of the deposited layers, such as the number of layers, thickness of each layer, or electrical conductivity of the material used in each layer. This provides precise control over resistance while keeping the manufacturing process straightforward through deposition techniques.
3Reliability
If the heater is deposited onto a porous member, then contact is improved and hot spots are reduced, but the structure becomes more complex
Solution Approach 1:
The patent merges the heater function with the porous support structure by depositing the electrically conductive heater material directly onto the porous member. This integration improves contact between the heater and the liquid substrate while eliminating the need for separate components, thereby reducing overall structural complexity despite the multi-layer heater design.
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 solution enhances aerosol characteristics, reduces mechanical and thermal stresses, and simplifies manufacturing by allowing finer adjustments to electrical resistance and improved adhesion, resulting in a more efficient and durable heater assembly.
Implementation Method 1
Electric current passing through the wire causes resistive heating of the wire which vaporises the liquid in the wick
Implementation Method 2
the vaporiser comprises a coil of heater wire wound around an elongate wick soaked in liquid aerosol-forming substrate. Electric current passing through the wire causes resistive heating of the wire which vaporises the liquid in the wick
Implementation Method 3
a porous member for conveying liquid aerosol-forming substrate to the fluid permeable heater
Data Source
AI summary
A heater assembly (300) for an aerosol-generating system, the heater assembly comprising: a fluid permeable heater (322) for heating a liquid aerosol-forming substrate to form an aerosol; a porous member (324) for conveying liquid aerosol-forming substrate to the fluid permeable heater, wherein the fluid permeable heater is deposited on to a porous outer surface (324a) of the porous member, the fluid permeable heater comprising: a first layer (326) of deposited electrically conductive material; a second layer (328) of deposited electrically conductive material, wherein the electrical conductivity of the second layer is greater than the electrical conductivity of the first layer such that the second layer modifies the electrical resistance of the fluid permeable heater to a required resistance.