Multi-part Heated Aerosol System Segmentation
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Solution Overview
Problem
Existing handheld electrically operated aerosol-generating systems are costly to produce due to the manufacturing expenses of the wick and coil assembly, as well as the mouthpiece portion, necessitating a more economical design.
Innovation Solution
A multi-part aerosol-generating system with a separate, one-time use aerosol substrate-containing part and a reusable heating element and transfer element, where the aerosol substrate reservoir is not refillable, allowing for simplified manufacturing and optional aesthetic customization through interchangeable covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional cartomizer design with integrated wick, coil, and mouthpiece is used, then the aerosol generation function is complete, but the manufacturing cost increases
Solution Approach 1:
The system is divided into three separate parts: a reusable body portion containing control electronics and power supply, a reusable cartridge portion containing the heating element and transfer element, and a disposable reservoir portion containing the aerosol-generating substrate. This segmentation allows the expensive heating components to be reused while only the consumable substrate is discarded, reducing overall manufacturing costs.
Solution Approach 2:
The heating element and transfer element are extracted from the disposable cartomizer and placed in a reusable cartridge portion. This extraction eliminates the need to manufacture expensive heating components with each disposable unit, significantly reducing per-unit manufacturing costs while maintaining full aerosol generation functionality.
2Duration of action of moving object
If the heating element and transfer element are integrated with the consumable substrate, then the aerosol generation is functional, but the frequency of replacing heating components increases
Solution Approach 1:
The heating element and transfer element are separated from the consumable substrate and placed in a reusable cartridge portion that can be used multiple times. Only the reservoir portion containing the aerosol-generating substrate is disposable, extending the lifecycle of the expensive heating components and reducing replacement frequency.
Solution Approach 2:
Only the reservoir portion containing the consumable substrate is designed as a disposable component, while the heating element and transfer element are preserved in a reusable cartridge. This selective disposability minimizes waste of expensive components while maintaining convenience for the user.
3Ease of manufacture
If the mouthpiece is integrated with the liquid reservoir, then the system is compact, but the manufacturing cost increases
Solution Approach 1:
The system separates the mouthpiece function into the reusable body portion from the disposable reservoir portion. This allows the reservoir to be manufactured as a simple, low-cost component without integrated mouthpiece features, reducing manufacturing complexity and cost while maintaining system functionality.
Solution Approach 2:
The reusable body portion serves multiple functions including housing the power supply, control electronics, and mouthpiece. This multi-functionality allows the disposable reservoir to be simplified to only contain the substrate storage function, reducing its manufacturing cost.
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 reduces production costs by eliminating the need to replace the heating element and transfer element with each aerosol substrate depletion and allows for standardized manufacturing with customizable aesthetics, while maintaining a compact, handheld form.
Implementation Method 1
electrically operated vaporizer
Implementation Method 2
heating element is operably coupled to the power supply when the second part is connected with the first part
Implementation Method 3
liquid transfer element
Data Source
Figure 1A
Figure 1B~1C
Figure 2A~2B
AI summary
A multi-part aerosol-generating assembly system (100) has a mouth end and a distal end, and includes a first part (10) having a housing (130) and a power supply (1 10) disposed in the housing (130). The system also includes a second part (20) releasably connectable with the first part (10). The second part (20) includes a heating element (220) and a liquid transfer element (210). The heating element (220) is operably coupled to the power supply (1 10) when the second part (20) is connected with the first part (10). The system further includes a third part (30) releasably connectable with the second part (20). The third part (30) includes a reservoir (200) containing a liquid aerosol generating substrate. The liquid aerosol generating substrate is in fluid communication with the liquid transfer element (210) when the third part (30) is connected with the second part (20). The system further includes a cover (40) disposable over the third part (30). The cover (40) is releasably securable in a position relative to the third part (30). The cover (40) defines the mouth end of the system.