Susceptor Holder Assembly for Faster Aerosol Consumable Manufacturing
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Solution Overview
Problem
The manufacturing process for aerosol-generating device cartridges with inductive heating systems is cumbersome and unsuitable for large-scale production due to the need for precise positioning of the susceptor assembly through a slot in the susceptor holder.
Innovation Solution
A consumable assembly is designed with a susceptor holder comprising a hollow elongate portion and opposing slots, allowing a susceptor assembly on a strip of wicking material to be easily inserted and retained by attaching two portions of the holder, eliminating the need for precise slot positioning and facilitating efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the susceptor assembly is inserted through a slot in the wall of the susceptor holder, then the susceptor assembly can be secured within the holder, but the manufacturing process becomes cumbersome and unsuitable for large-scale production
Solution Approach 1:
The susceptor holder is divided into two separate portions: a first portion with an opening and two opposing slots, and a second portion that attaches to secure the assembly. This segmentation allows the susceptor assembly to be easily inserted through the opening while the slots receive the wicking material, and the second portion provides secure retention without requiring precise positioning through a single slot in the wall.
2Manufacturing precision
If precise positioning of the susceptor assembly through a slot is required, then the susceptor assembly can be retained, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The first portion of the susceptor holder is pre-configured with an opening and two opposing slots before assembly. The wicking material is positioned to extend through these slots in advance, so that when the susceptor assembly is inserted through the opening, the wicking material is already aligned with the slots. This preliminary arrangement eliminates the need for precise positioning during the actual assembly process, allowing for rapid and efficient manufacturing.
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 design simplifies the manufacturing process, enhances assembly efficiency, and ensures secure retention of the susceptor assembly, making it easier to produce and maintain fluid communication with the aerosol-forming substrate.
Implementation Method 1
the susceptor assembly may further comprise a wicking material configured to draw liquid aerosol-forming substrate from a reservoir in a cartridge to the susceptor to be heated
Data Source
AI summary
A method for manufacturing one or more consumable assemblies for an aerosol-generating device, including: providing susceptors across a width of a strip of wicking material to form respective susceptor assemblies; folding the strip widthways such that the susceptors are provided on an outer surface of each side of the folded strip; sliding first susceptor holder portions onto the strip to engage the susceptor assemblies, the first portions each including a hollow elongate portion having an opening at a connection end and two opposing slots extending from the opening at the connection end, the slots being configured to receive and engage the strip on either side of the susceptor assembly as it is received within the hollow portion; and attaching a second susceptor holder portion to the connection end of each of the first portions to retain the strip including the susceptor assemblies within the first portions.