Plate-Shaped Heating Element With Variable Thickness For Aerosol Devices
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Solution Overview
Problem
Conventional aerosol generating devices face limitations such as a long form factor and difficulty in adjusting aerosol temperature, leading to suboptimal vapor quality and consumer satisfaction due to elongated heating elements and lack of temperature control.
Innovation Solution
A plate-shaped heating element with a mesh surface, arranged perpendicular to the airflow, providing a temperature gradient through a central opening, allowing for controlled evaporation of vaporizable materials and adjustable aerosol temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire coil heating elements are used, then the heating element is cheap and easy to implement, but proper control of the heating temperature is not achieved
Solution Approach 1:
The heating element comprises a plate-shaped body with variable thickness, where the thickness gradually diminishes from the outer periphery toward the opening. This creates different thermal zones: the thicker outer periphery provides stable heating, while the thinner central region allows higher temperature gradients. The mesh material coating further enhances local heat distribution control, enabling precise temperature management across different areas of the heating element.
2Productivity
If elongated heating elements are used, then sufficient vapor generation is achieved, but the device has a long form factor and condensation occurs along the air path
Solution Approach 1:
The invention transitions from traditional linear/elongated heating elements to a plate-shaped (two-dimensional) heating structure. The plate-shaped body with variable thickness provides a large heating surface area in a compact form factor, eliminating the need for long elongated elements. The central opening allows air to pass through the heating element directly, shortening the condensation-prone air path while maintaining sufficient vapor generation through the extended plate surface.
3Area of stationary object
If elongated heating elements are used, then heating surface area is increased, but it proves difficult to adjust the aerosol temperature along the air flow channel
Solution Approach 1:
The plate-shaped heating element features variable thickness with a gradual transition from the outer periphery to the opening, creating distinct thermal zones. The thicker outer regions provide stable baseline heating, while the thinner central regions enable higher temperature gradients and faster heating. This local variation in thickness, combined with the mesh material coating, allows precise control of temperature distribution across the heating surface, enabling adjustable aerosol temperature along the air flow channel.
4Productivity
If the heating surface is arranged perpendicular to airflow, then heating efficiency is improved, but the device complexity increases
Solution Approach 1:
The heating element integrates multiple functions into a single plate-shaped component: the plate-shaped body provides the heating surface, the variable thickness profile creates temperature gradients, the central opening serves as both a structural feature and an airflow passage, and the mesh material coating enhances heat distribution. This merged design achieves perpendicular airflow heating efficiency without requiring separate components for each function, thereby limiting the increase in device complexity.
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 enhances user experience by improving heating control and aerosol quality, reducing condensation and leakage, and allowing for selective evaporation of substances, resulting in a more efficient and satisfying vapor generation process.
Implementation Method 1
heating element comprising a heating body extending from a first end to a second end and provided with at least first and second electric contact parts
Implementation Method 2
configured to allow gradient heating of a vaporizable material delivered from a vaporizable material reservoir to a heating surface of the heating element
Implementation Method 3
allow gradient heating of a vaporizable material delivered from a vaporizable material reservoir to a heating surface of the heating element
Data Source
Figure 1
Figure 2A~2C
Figure 3~4A
AI summary
A heating element (1) for an aerosol generating device, the heating element comprising a heating body (10) extending from a first end (10a) to a second end (10b) and provided with at least first and second electric contact parts (12, 13) wherein the heating body (10) is plate-shaped and comprises an opening (11) forming a substantially central airflow passage in the plate-shaped body (10); wherein the heating element is configured to provide a heating gradient between an outer periphery of the plate-shaped body (10) and the opening (11) therein; wherein the heating element further comprises a mesh material (14) on at least one side of the plate-shaped body (10). A thickness of the plate-shaped body measured in a transversal cross-section thereof perpendicular to sides of the plate-shaped body is variable from the outer periphery of the plate to the opening, and gradually diminishes between the outer periphery and the opening.