Resonant Induction Heating for Aerosol Delivery Without Charring
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Solution Overview
Problem
Aerosol delivery devices face complications due to direct resistive heating methods, which lead to inefficient energy use, charring of aerosol precursor compositions, and complex electrical connections, increasing costs and potential points of failure.
Innovation Solution
The implementation of a resonant transformer system with a transmitter coupling device and a resonant receiver coupling device, utilizing wireless induction heating to heat the aerosol precursor composition without direct electrical connections, powered by a rechargeable supercapacitor or lithium-ion battery, and controlled by a PWM inverter and microprocessor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If direct resistive heating is used to heat the aerosol precursor composition, then heating can be achieved, but energy efficiency is poor and charring occurs
Solution Approach 1:
The patent replaces direct resistive heating (mechanical/electrical system) with induction heating (electromagnetic field system). The induction heating system uses a magnetic field to induce eddy currents in the aerosol precursor composition, which generates heat more efficiently and uniformly, avoiding the energy waste and charring associated with direct resistive heating.
Solution Approach 2:
The patent changes the heating method from direct contact resistive heating to non-contact induction heating. This parameter change allows for more precise control of heating parameters (frequency, power level), enabling efficient heating without exceeding temperature thresholds that would cause charring.
2Power
If direct electrical connections are made to the heating element, then power can be delivered, but device complexity increases and points of failure increase
Solution Approach 1:
The patent replaces direct electrical connections (mechanical contact system) with wireless induction power transfer (electromagnetic field system). The power source generates a magnetic field that induces currents in the heating element without physical contact, eliminating connectors, wires, and associated failure points while maintaining effective power delivery.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the power source and the heating element. This intermediary allows power to be transmitted without direct electrical contact, simplifying the device structure by eliminating the need for complex electrical connections and improving reliability.
3Temperature
If direct resistive heating is used, then heating function is achieved, but reliability decreases due to more points of failure
Solution Approach 1:
The patent replaces the mechanical/electrical heating system with an induction heating system. This substitution eliminates moving parts, connectors, and contact points that could fail, while maintaining the heating function through electromagnetic induction. The contactless nature of induction heating significantly improves device reliability.
4Power
If complex electrical connections are implemented, then power delivery is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces complex electrical connection systems with a simpler induction heating system. By using electromagnetic fields for power transfer, the design eliminates the need for intricate wiring, connectors, and assembly procedures, thereby reducing manufacturing complexity and cost while maintaining effective power delivery.
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 solution enables efficient aerosol production with reduced energy waste, minimized charring, and simplified device assembly, enhancing the reliability and user experience of aerosol delivery devices.
Implementation Method 1
The transmitter coupling device may include a coil configured to create an oscillating magnetic field (a magnetic field that varies periodically with time) when alternating current is directed therethrough
Implementation Method 2
by directing alternating current through the transmitter coupling device, eddy currents may be generated in the resonant receiver coupling device via induction
Implementation Method 3
The eddy currents flowing through the resistance of the material defining the resonant receiver coupling device may heat it by Joule heating
Implementation Method 4
Wireless heating, as used herein, refers to heating that occurs via an atomizer that is not physically electrically connected to the (electrical) power source
Data Source
AI summary
An aerosol delivery device includes a receptacle configured to receive a substrate configured to carry an aerosol precursor composition, and a resonant transformer including a transmitter coupling device and a resonant receiver coupling device that is positioned in proximity to the substrate when received in the receptacle. The aerosol delivery device also includes a pulse width modulation (PWM) inverter configured to drive the resonant transformer. The PWM inverter includes a bridge circuit coupled to the transmitter coupling device, and a PWM controller embodied as an integrated circuit and configured to output a PWM signal to the bridge circuit configured to drive the transmitter coupling device to generate an oscillating magnetic field and induce an alternating voltage in the resonant receiver coupling device when exposed to the oscillating magnetic field. The alternating voltage causes the resonant receiver coupling device to generate heat and thereby vaporize components of the aerosol precursor composition.