Opposed Planar Heater Cartridge for Condensation-Stable Aerosol Flow
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Solution Overview
Problem
Handheld aerosol-generating systems face issues with unwanted condensation and aerosol quality due to temperature differences between the heater assembly and the cartridge housing, leading to uneven heating and droplet formation.
Innovation Solution
The use of two substantially flat heater assemblies arranged opposite each other within the cartridge forms an airflow channel, ensuring uniform heating and reducing the impact of external temperature on aerosol formation, with optional electrical connection and placement strategies to enhance performance and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heater assembly is used in the cartridge, then the device complexity is reduced, but the temperature distribution becomes uneven causing unwanted condensation and poor aerosol quality
Solution Approach 1:
The heating function is segmented into two separate heater assemblies positioned opposite each other within the cartridge. Each heater assembly independently heats its respective side of the airflow channel, ensuring uniform temperature distribution across the entire channel without requiring a single complex heating system.
Solution Approach 2:
Each heater assembly is positioned to provide localized heating to specific regions of the airflow channel. The first heater assembly heats the air on one side while the second heater assembly heats the air on the opposite side, creating locally optimized temperature conditions that collectively achieve uniform overall heating.
2Use of energy by moving object
If the heater assembly is positioned close to the cartridge housing, then the heating efficiency is improved, but unwanted condensation occurs on the cartridge housing due to large temperature difference
Solution Approach 1:
The airflow channel acts as an intermediary space between the heater assemblies and the cartridge housing. By positioning the heater assemblies to face each other with the airflow channel in between, the design mediates the thermal interaction, allowing efficient heating of the air while preventing direct thermal coupling that would cause condensation on the housing.
Solution Approach 2:
The heating arrangement transitions from a single-sided configuration to a dual-sided facing configuration. The two heater assemblies are positioned in opposite dimensions, heating the airflow from both sides simultaneously. This dimensional change distributes the thermal load and prevents excessive temperature differences between the heater and housing surfaces.
3Ease of manufacture
If a single heater assembly is used, then the manufacturing cost is reduced, but the aerosol quality and droplet size control are compromised
Solution Approach 1:
The aerosol generation process is segmented into two independent heating zones created by the two heater assemblies. Each heater assembly can be independently optimized and manufactured using standard processes, and their combined effect produces superior aerosol quality with controlled droplet size that would be difficult to achieve with a single heater.
4Ease of manufacture
If the heater assembly is made substantially flat, then the ease of manufacture and robust construction are improved, but the heating surface area is limited
Solution Approach 1:
The heating solution transitions from a single large-area heater to two smaller flat heaters positioned in opposite dimensions. By utilizing the third dimension (depth of the cartridge) to position heaters on opposite sides, the design effectively doubles the heating surface area while maintaining the manufacturing simplicity and robustness of flat heater construction.
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 results in a more uniform aerosol with adjustable droplet size, independent of external conditions, and reduces the risk of leakage and overheating, while maintaining a robust and cost-effective design.
Implementation Method 1
a heater assembly is disclosed to vaporise the liquid aerosol-forming substrate
Implementation Method 2
an airflow channel is created adjacent to the liquid storage portion with the flat mesh on one side of the airflow channel and the housing of the cartridge on the other side of the airflow channel. The air flowing through this channel is exposed to a hot side
Data Source
AI summary
A cartridge for an aerosol-generating system may comprise a liquid storage portion, which includes a housing holding a liquid aerosol-forming substrate. The housing has a first and a second opening. The cartridge may further comprise a first and a second permeable planar heater assembly, wherein the first permeable planar heater assembly is fixed to the housing and extends across the first opening of the housing, and the second permeable planar heater assembly is fixed to the housing and extends across the second opening of the housing. The first and second permeable planar heater assemblies are arranged opposite each other such that they face each other and form an airflow channel in between.