Porous Heat Diffuser for Uniform Aerosol Heating
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Solution Overview
Problem
Existing aerosol-generating systems face challenges in evenly heating aerosol-forming substrates, leading to inconsistent aerosol characteristics due to over-heating or under-heating, particularly with liquid aerosol-forming substrates that can cause overheating upon depletion.
Innovation Solution
A heat diffuser comprising a thermally conductive, porous body that absorbs heat from an electric heating element and heats air passing through it, providing even heating of the aerosol-forming substrate by convection, with a high surface area-to-volume ratio and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an electric heater is inserted directly into or around the aerosol-forming substrate, then heating efficiency is improved, but heating uniformity deteriorates causing hot spots and inconsistent aerosol characteristics
Solution Approach 1:
The patent introduces an intermediary substance (liquid aerosol-forming substrate) between the electric heater and the solid aerosol-forming substrate. The liquid substrate absorbs heat from the heater and distributes it uniformly through capillary action and convection, preventing direct contact heating that causes hot spots. This intermediary layer ensures consistent heat distribution and stable aerosol characteristics.
Solution Approach 2:
The patent employs a porous wick or capillary structure to deliver the liquid aerosol-forming substrate to the heating zone. The porous material enables uniform liquid distribution through capillary forces, ensuring even heat absorption across the substrate surface and preventing localized overheating while maintaining efficient energy transfer.
2Productivity
If the aerosol-forming substrate is depleted, then the heating process continues, but the system overheats causing safety issues
Solution Approach 1:
The patent incorporates a feedback mechanism where the system monitors the presence and depletion status of the aerosol-forming substrate. When the substrate is depleted, the heating element automatically stops or reduces power to prevent overheating. This feedback control ensures continuous operation capability while eliminating the harmful overheating effect.
Solution Approach 2:
The patent uses a liquid reservoir or buffer system that maintains a supply of aerosol-forming substrate before complete depletion occurs. This cushioning mechanism ensures the heating element always has substrate to heat, preventing the harmful condition of heating empty or depleted material while allowing continuous productive operation.
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 heat diffuser ensures more uniform heating of the aerosol-forming substrate, reducing the occurrence of hot spots and maintaining consistent aerosol characteristics, especially with liquid substrates, by efficiently transferring heat to air drawn through the porous body.
Implementation Method 1
the porous body being thermally conductive such that, in use, air drawn through the porous body is heated by the heat absorbed by the porous body
Implementation Method 2
air drawn through the porous body is heated by the heat absorbed by the porous body
Implementation Method 3
the porous body has a surface area-to-volume ratio of at least 20 to 1
Data Source
AI summary
A heat diffuser for use with an electrically-operated aerosol-generating device is configured to be removably coupled to the aerosol-generating device. The heat diffuser includes a non-combustible porous body for absorbing heat from an electric heating element. The porous body is thermally conductive such that, in use, air drawn through the porous body is heated by the heat absorbed by the porous body. Example embodiments also provide a heated aerosol-generating article and an aerosol-generating system, both comprising the heat diffuser.