Sheet-Formed Heating Elements With Interconnected Loops for Atomizers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing smoking devices that utilize electrical energy to simulate smoking sensations without combusting tobacco fail to adequately reduce incomplete combustion and pyrolysis products, necessitating a more efficient and effective aerosol delivery system.

Innovation Solution

Aerosol delivery devices featuring heating elements formed from a sheet of material, integrated into a carrier with interconnected loops, that heat aerosol precursors without significant combustion, using electrical energy to produce inhalable substances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If electrical energy is used to heat aerosol precursors without combustion, then harmful combustion by-products are reduced, but manufacturing complexity increases due to precise heating element fabrication requirements

Engineering Contradiction:

Improvecombustion by-productsVSAvoidheating element fabrication

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The heating element is divided into multiple separate loops that are formed individually and then assembled together. Each loop can be independently fabricated with precise dimensions and then connected through tabs to form the complete heating element structure, reducing the overall fabrication complexity compared to creating a single complex piece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating loops are nested within the carrier structure, with the loops being received in recesses or cavities of the carrier. This nesting arrangement simplifies assembly by pre-positioning components and reduces the overall device footprint while maintaining manufacturing precision

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If heating elements are formed from sheet material with interconnected loops, then manufacturing efficiency improves, but control over heat distribution becomes more difficult

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidheat distribution control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The heating element incorporates variable resistance characteristics at different locations through the sheet material construction. By adjusting the dimensions, thickness, or material properties of specific sections of the sheet material, localized heat generation can be controlled to achieve uniform heat distribution across the heating surface

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heating element transitions from a two-dimensional sheet layout to a three-dimensional configuration with loops and tabs. This dimensional transformation allows for optimized heat distribution patterns while maintaining manufacturing efficiency through sheet material formation processes

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Weight of moving object

If a compact handheld device design is implemented, then portability improves, but space for aerosol reservoir and heating elements is reduced

Engineering Contradiction:

Improvedevice portabilityVSAvoidaerosol reservoir capacity

Core Design Contradiction:

Weight of moving objectVSVolume of stationary object

Solution Approach 1:

The heating element loops are nested within recesses of the carrier, and the aerosol reservoir is integrated into the same carrier structure. This multi-component nesting arrangement maximizes space utilization within the compact device footprint while maintaining adequate capacity for both heating and aerosol storage functions

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The device utilizes three-dimensional space efficiently by forming the heating element from folded and looped sheet material rather than a flat configuration. This vertical and spatial arrangement allows compact packaging while maintaining functional volume for aerosol reservoir and heating elements

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 provides a compact, handheld device that mimics traditional smoking experiences by delivering vapors and aerosols without significant combustion by-products, offering a more efficient and satisfying alternative to traditional smoking articles.

Implementation Method 1

heating elements formed from a sheet of a material... heat aerosol precursor... to form an inhalable substance

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12426632B2Heating elements formed from a sheet of a material and inputs and methods for the production of atomizers

Publication Date: 2025.09.30 R J REYNOLDS TOBACCO COMPANY

AI summary

The present disclosure relates to an input for production of atomizers and atomizers formed from a sheet of a material, and which may be employed in an aerosol delivery device such as a smoking article. The input may include a carrier and heating elements coupled thereto. The heating elements may include first and second ends and interconnected alternating loops disposed therebetween. The heating elements may be oriented parallel to a longitudinal axis of the carrier, or perpendicular thereto. The heating elements may be coupled to a liquid transport element by bending the interconnected loops at least partially around the liquid transport element. The ends of the heating element may be coupled to heater terminals. A related method for forming atomizers is also provided.