Non-Planar Heating Element for Aerosol Generation

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Solution Overview

Problem

Current non-combustible aerosol provision systems face challenges in achieving efficient aerosol generation and consistent delivery of aerosol-generating materials, particularly in maintaining thermal contact and structural integrity, which affects the quality and consistency of the aerosol produced.

Innovation Solution

The use of a non-planar susceptor element with elongate portions extending through or around the aerosol-generating material, providing enhanced thermal contact and structural support, combined with a moisture-impermeable wrapper and specific design features in the mouthpiece, such as a cooling section and tubular element, to optimize aerosol generation and delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a planar heating element is used, then the device structure is simple, but thermal contact with aerosol generating material is insufficient

Engineering Contradiction:

Improvethermal contact efficiencyVSAvoidheating element structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating element is designed with a non-planar, curved surface that conforms to the contours of the aerosol generating material. This curved geometry increases the surface area in contact with the material, improving thermal transfer efficiency without requiring a complex multi-component structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The heating element transitions from a two-dimensional planar structure to a three-dimensional non-planar structure by adding curvature and depth. This dimensional change allows the heating surface to wrap around or conform to the aerosol generating material, significantly enhancing thermal contact area and efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If aerosol generating material is loosely packed, then loading is easy, but structural integrity and material displacement control are poor

Engineering Contradiction:

Improvestructural integrityVSAvoidmaterial loading

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The aerosol generating material is divided into multiple discrete particles or segments that are individually positioned within the container. This segmentation allows each particle to be stabilized independently by the container walls and heating element, maintaining structural integrity while allowing easy loading of the segmented material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flexible retaining structure or thin film barrier is used to hold the aerosol generating material in place. This flexible element can adapt to the material volume and provide containment without requiring rigid, complex loading mechanisms, thus maintaining structural integrity while facilitating easy loading.

Inventive Principle:

Principle #30Flexible shells and thin films

3Temperature

If heating material has uniform height, then manufacturing is simple, but thermal distribution across material is inconsistent

Engineering Contradiction:

Improvethermal distribution uniformityVSAvoidheating material geometry

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The heating material is designed with varying height or thickness at different locations, creating local variations in thermal mass and heat distribution. Areas with greater material thickness receive proportionally more heat, compensating for thermal losses and achieving uniform temperature distribution across the entire aerosol generating material volume.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The geometric parameters of the heating material (height, thickness, or surface area) are varied across different zones to optimize thermal distribution. By changing these physical parameters locally, the system achieves uniform heating performance without requiring complex control systems or multi-component assemblies.

Inventive Principle:

Principle #35Parameter changes

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 configuration improves thermal contact and structural integrity, leading to more consistent and efficient aerosol generation, reducing material displacement and enhancing the quality of the aerosol produced, while maintaining the non-combustible nature of the system.

Implementation Method 1

a heating material in thermal contact with aerosol generating material

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240284961A1Component for use with a non-combustible aerosol provision device

Publication Date: 2024.08.29 NICOVENTURES TRADING LTD

AI summary

An aerosol-generating component for use with a non-combustible aerosol provision device includes a heating material in thermal contact with aerosol generating material, and the heating material includes a plurality of elongate portions or elements which extend through or around said aerosol generating material in a first direction. The elongate portions or elements of the heating material are substantially parallel. An article and a system are also described.