Planar Heating Element with Conductive Bead Layer for Uniform Aerosol Generation
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Solution Overview
Problem
Aerosol-generating devices face issues with local heating and random heating patterns, leading to incomplete vaporization and carbonization of the liquid aerosol-generating substrate, resulting in burnt taste and harmful substances due to the limitations of wick-heater structures in conventional designs.
Innovation Solution
A planar heating element comprising a porous wick with a conductive bead layer and terminal parts for uniform heat distribution, where conductive beads are stacked on the wick's surface to generate heat across a large area without local deviations, preventing liquid carbonization and enhancing atomization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a heater is located in a pattern form on the wick surface, then heating is concentrated in specific areas, but this causes local heating deviations, liquid carbonization, and non-uniform aerosol generation
Solution Approach 1:
The heater is divided into multiple independent heating units arranged in a grid pattern, where each unit can be independently controlled. This segmentation allows uniform heat distribution across the entire wick surface while preventing local overheating and carbonization issues associated with single-point heating.
Solution Approach 2:
Different regions of the wick are equipped with heating units having different heating capacities according to local requirements. The heating units are designed with varying power densities to compensate for heat loss patterns, ensuring uniform overall heating while allowing local adjustments to prevent carbonization.
2Area of stationary object
If a mesh network is used instead of pattern form heater, then heating area is increased, but instantaneous heating still occurs causing liquid carbonization and mesh structure deviations
Solution Approach 1:
The mesh network is further segmented into multiple independently controllable heating units. Each unit can be activated selectively to distribute heat uniformly across the expanded heating area, preventing instantaneous heating hotspots that cause liquid carbonization while maintaining the benefits of increased heating coverage.
Solution Approach 2:
The heating units operate in a sequential or periodic manner rather than simultaneously, distributing the heating process over time. This periodic activation pattern ensures uniform heat distribution across the large heating area while preventing instantaneous thermal shocks that cause carbonization.
3Adaptability or versatility
If the entire wick is replaced with a bead structure, then heating occurs randomly throughout the area, but this prevents prediction of aerosol-generating areas and creates local heating deviations
Solution Approach 1:
The bead structure is designed with varying properties in different regions - some beads are equipped with heating units while others serve as non-heating zones. This local differentiation allows precise control over heating locations, enabling prediction of aerosol-generating areas while maintaining comprehensive heating coverage through the distributed bead arrangement.
Solution Approach 2:
The bead structure serves as an intermediary between the power source and the liquid substrate. Each bead acts as an independent heating unit that can be selectively activated, providing controlled heat distribution throughout the wick area while maintaining predictability over where aerosol generation occurs.
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 ensures uniform heat distribution across the wick's surface, preventing liquid carbonization and enhancing atomization efficiency, resulting in a consistent aerosol generation with reduced burnt taste and harmful substances, even at low power density.
Implementation Method 1
a conductive bead layer (20) for heating the absorbed liquid aerosol-generating substrate
Implementation Method 2
a porous wick (10) for absorbing a liquid aerosol-generating substrate
Implementation Method 3
an aerosol-generating device using a method of heating a liquid aerosol-generating substrate to vaporize the liquid
Data Source
Figure 1(A)~2
Figure 3
AI summary
The present invention relates to a planar heating element for generating an aerosol comprising a porous wick for absorbing a liquid aerosol-generating substrate, a conductive bead layer for heating the absorbed liquid aerosol-generating substrate, and a terminal part for delivering an electricity for heating to the conductive bead layer, a method for manufacturing the same, and an aerosol-generating device comprising the same.