Planar Heater Surface Structure for Uniform Aerosol Heating
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Solution Overview
Problem
Conventional aerosol-generating devices require higher temperatures to heat aerosol-generating substrates uniformly due to limited contact surface between the heating element and the substrate, leading to potential overheating and unwanted flavor release.
Innovation Solution
A planar aerosol-generating device with a heating element featuring a surface structure that enables lateral airflow between the heating element and the aerosol-generating article, allowing for uniform heating and optimized aerosol generation without the need for excessive temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a heating blade is used with limited contact surface, then the device structure is simple, but the heating element needs to be raised to higher temperatures to heat the substrate uniformly, leading to overheating and unwanted flavor release
Solution Approach 1:
The heating element transitions from a traditional blade configuration to a planar surface structure that extends laterally across the substrate. This dimensional change increases the contact area from a line contact (blade edge) to a surface contact (planar area), allowing uniform heating without requiring excessive temperature increases.
Solution Approach 2:
The planar heating surface provides uniform heat distribution across the entire substrate area. By distributing the heating function across multiple local points rather than concentrating it at a single blade contact point, the system achieves uniform temperature distribution without creating hot spots or overheating.
2Temperature
If the heating element temperature is increased to heat further substrate, then the substrate can be heated uniformly, but this results in overheating and release of unwanted flavors
Solution Approach 1:
By extending the heating element into a planar surface that contacts the substrate across its entire area, the system achieves uniform heat distribution without concentrating thermal energy. This dimensional expansion of the heating surface allows the substrate to be heated to the optimal temperature range for aerosol generation without exceeding it, thereby preventing unwanted flavor release.
3Temperature
If a planar heating surface with surface structure is used, then lateral airflow is enabled and uniform heating is achieved, but the device complexity increases
Solution Approach 1:
The heating surface is segmented into multiple functional zones with different surface structures. These segments work together to create lateral airflow patterns and distribute heat uniformly across the substrate. The segmentation allows complex airflow and heating functions to be achieved through modular surface features rather than complex three-dimensional components.
Solution Approach 2:
The traditional mechanical blade heating system is replaced with a planar surface structure that utilizes thermal radiation and convection principles. The surface structure creates lateral airflow through thermal effects rather than mechanical force, achieving uniform heating without the need for complex mechanical components.
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 achieves uniform aerosol generation with reduced power consumption, as the heating element can operate at lower temperatures, and the surface structure facilitates efficient airflow, enhancing the entrainment of volatile components and preventing overheating.
Implementation Method 1
a heating element having an essentially planar shape and configured for heating a planar aerosol-generating article
Implementation Method 2
at least a heating surface of the heating element comprises a surface structure which is configured for enabling lateral airflow between the heating surface and a planar aerosol-generating article
Implementation Method 3
heating the aerosol-generating substrate to a sufficiently high temperature for creating an aerosol for inhalation by the user
Data Source
AI summary
An aerosol-generating device for generating an inhalable aerosol is provided, the aerosol-generating device including: a heating chamber configured to receive a planar aerosol-generating article containing an aerosol-generating substrate; and a resistive heating element having an essentially planar shape and being configured to heat the planar aerosol-generating article, in which at least a heating surface of the resistive heating element includes a surface structure configured to enable lateral airflow between the heating surface and the planar aerosol-generating article after insertion of the planar aerosol-generating article into the heating chamber. A method for manufacturing an aerosol-generating device for generating an inhalable aerosol is also provided.