Multi-Susceptor Induction Heating for Uniform Aerosol Generation

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing aerosol-generating devices with inductive heaters face challenges in achieving uniform heat distribution and efficient use of aerosol-forming substrates, leading to inconsistent aerosol production and potential substrate waste.

Innovation Solution

The device employs a system with multiple susceptors, each optimized for different alternating magnetic field frequencies, allowing sequential heating of aerosol-forming substrate portions through controlled frequency modulation, and uses inductive heating to minimize power consumption and substrate displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a single susceptor element is used in inductive heating, then the device structure is simple, but heat distribution is non-uniform and aerosol production is inconsistent

Engineering Contradiction:
Improveheat distribution uniformityVSAvoidsusceptor configuration
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The heating system is divided into multiple susceptor elements (first susceptor element and second susceptor element) that are spatially separated and independently controllable. Each susceptor element can be heated separately by the induction coil, allowing different regions of the aerosol-forming substrate to be heated to different temperatures or at different times, thereby achieving uniform heat distribution across the entire substrate.

Inventive Principle:
Principle #1Segmentation

2Reliability

If sequential heating with frequency modulation is implemented, then aerosol consistency is improved, but control system complexity increases

Engineering Contradiction:
Improveaerosol production consistencyVSAvoidcontrol system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The controller implements periodic heating cycles where the induction coil alternates between generating a first alternating magnetic field at a first frequency to heat the first susceptor element, and a second alternating magnetic field at a second frequency to heat the second susceptor element. This periodic action ensures that both susceptor elements receive adequate heating over time, maintaining consistent aerosol production from different regions of the substrate.

Inventive Principle:
Principle #19Periodic action

3Temperature

If multiple susceptor elements are used, then heat distribution and aerosol consistency are improved, but power consumption increases

Engineering Contradiction:
Improveheat distributionVSAvoidpower consumption
Core Design Contradiction:
TemperatureVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the heating process by sequentially activating different susceptor elements based on real-time requirements. The controller can modulate the duty cycle, frequency, and power level for each susceptor element independently, ensuring that energy is consumed efficiently by heating only the necessary regions at the necessary times, rather than continuously heating all elements at maximum power.

Inventive Principle:
Principle #15Dynamics

4Loss of substance

If inductive heating with multiple susceptors is used, then substrate displacement is minimized, but device manufacturing complexity increases

Engineering Contradiction:
Improvesubstrate displacementVSAvoiddevice assembly
Core Design Contradiction:
Loss of substanceVSEase of manufacture

Solution Approach 1:

The susceptor elements act as intermediary components that are inductively heated by the induction coil and then transfer thermal energy to the aerosol-forming substrate through thermal conduction. This indirect heating mechanism eliminates the need for direct contact between the induction coil and substrate, minimizing substrate displacement while still achieving effective heating. The susceptors serve as thermal mediators that decouple the electromagnetic field generation from the substrate heating process.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 approach ensures even heating, reduces power requirements, minimizes substrate waste, and enhances aerosol consistency, potentially reducing device size and cost while extending battery life.

Implementation Method 1

an induction element disposed around, or adjacent to, the heating zone... configured to provide an alternating electric current to the induction element to generate an alternating magnetic field within the heating zone

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The inductive heater typically comprises an inductor forming part of the aerosol-generating device and a conductive susceptor element arranged such that it is in thermal proximity to the aerosol-forming substrate. During use, the inductor generates an alternating magnetic field to generate eddy currents and hysteresis losses in the susceptor element, causing the susceptor element to heat up

Methodology Applied
Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

the inductor generates an alternating magnetic field to generate eddy currents and hysteresis losses in the susceptor element, causing the susceptor element to heat up

Methodology Applied
Scientific EffectHysteresis losses: Hysteresis

Implementation Method 4

a plurality of elongate susceptors arranged such that, during use, the plurality of elongate susceptors extend in a longitudinal direction of the chamber and are spaced apart from each other... the alternating magnetic field to heat the plurality of elongate susceptors and thereby heat at least a portion of an aerosol-generating article

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20260060312A1Aerosol generating system with multiple susceptors
Publication Date: 2026.03.05 PHILIP MORRIS PRODUCTS SA
  • US20260060312A1 patent drawing
  • US20260060312A1 patent drawing
  • US20260060312A1 patent drawing

AI summary

An aerosol-generating system is provided, including an aerosol-generating device having a housing, a heating chamber defining a heating zone, the heating chamber sized to receive an aerosol-forming substrate within the zone, an induction element around or adjacent the zone, first and second susceptors within the zone, a power supply, and a controller connected to the element to provide an alternating electric current to the element to generate an alternating magnetic field within the zone and sequentially provide a first alternating magnetic field having a first frequency for a first period of time followed by a second alternating magnetic field having a second frequency for a second period of time, the first and second susceptors respectively having a first/second shape, cross-section, length, width, and thickness, at least one of the first/second shapes, the first/second cross-sections, the first/second length dimensions, the first/second width dimensions, and the first/second thickness dimensions are different.