Shape-Memory Susceptor Heating Element for Aerosol Devices
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Solution Overview
Problem
Existing susceptor heating elements in aerosol-generating devices may lose their shape integrity upon repeated use, affecting consistent heat generation and user experience.
Innovation Solution
A susceptor heating element formed from a shape-memory material that can be deformed at lower temperatures but returns to its original shape when heated to the operating temperature of the aerosol-generating device, ensuring consistent shape and heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional susceptor heating element is used, then the device can generate heat for aerosol formation, but the susceptor loses its shape integrity upon repeated use
Solution Approach 1:
The patent applies parameter changes by utilizing the temperature-dependent shape memory effect of the susceptor material. The susceptor is designed to exist in different shapes at different temperatures: a first shape at room temperature for easy insertion and handling, and a second (original) shape at operating temperature for optimal heat generation. This parameter change with temperature ensures the susceptor maintains shape integrity throughout its lifespan while enabling repeated use.
Solution Approach 2:
The patent employs composite materials by using a shape memory alloy or shape memory polymer as the susceptor material. These materials combine magnetic permeability (for inductive heating) with shape memory properties (for shape recovery). The composite nature of the material allows the susceptor to exhibit both the heating characteristics of magnetic materials and the shape-stabilizing properties of shape memory materials, thereby maintaining shape integrity over repeated use cycles.
2Ease of manufacture
If the susceptor shape changes during use, then manufacturing is simpler, but heat generation consistency is affected
Solution Approach 1:
The patent applies preliminary action by pre-setting the susceptor's original shape at the manufacturing stage. The susceptor is formed into its optimal heat-generating shape (second shape) before being used in the device. This preliminary shaping ensures that when the susceptor is heated to operating temperature, it automatically recovers to this pre-determined optimal shape, guaranteeing consistent heat generation across its lifespan without requiring complex real-time shape control mechanisms.
Solution Approach 2:
The patent utilizes parameter changes by designing the susceptor to undergo controlled shape transformation with temperature. The susceptor material's physical state changes from a deformable first shape at room temperature to a stable second shape at operating temperature. This parameter change enables simple manufacturing (forming at room temperature) while ensuring reliable heat generation (stable shape at operating temperature).
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 shape-memory susceptor heating element maintains its original shape and optimal performance throughout its lifespan, ensuring consistent heat generation and user experience in aerosol-generating devices.
Implementation Method 1
The susceptor heating element is exposed to an alternating magnetic field, heat is generated in the susceptor heating element. The heating mechanism is mainly based on the generation of eddy currents and hysteresis effects in the susceptor heating element.
Implementation Method 2
The heating mechanism is mainly based on the generation of eddy currents and hysteresis effects in the susceptor heating element.
Implementation Method 3
The heating mechanism is mainly based on the generation of eddy currents and hysteresis effects in the susceptor heating element.
Implementation Method 4
A shape-memory material is a material that can be deformed at lower temperatures, but which returns to its original shape when heated to elevated temperatures.
Data Source
AI summary
A susceptor heating element is provided for an aerosol-generating device, the susceptor heating element being configured to heat an aerosol-forming substrate when received in the aerosol-generating device, and the aerosol-forming device including an induction coil configured to generate an alternating magnetic field when an alternating current is provided to the induction coil, the susceptor heating element being formed from a shape-memory material. An aerosol-generating article is also provided.