Susceptor Layer Design for Inductive Aerosol Heating
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Solution Overview
Problem
Existing aerosol-generating devices using inductive heaters face challenges in manufacturing susceptor elements with varied configurations and efficiency due to the use of single-piece susceptor materials, which limits flexibility and increases costs.
Innovation Solution
An aerosol-generating device with an elongate susceptor element featuring a thermally insulative support body and a susceptor layer on its outer surface, allowing for adjustable heating portions and reduced heat loss, along with a removable design for easy replacement and cleaning, utilizing inductive heating to efficiently heat aerosol-forming substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-piece susceptor element is used, then the device structure is simple, but the manufacturing flexibility and adaptability are limited
Solution Approach 1:
The susceptor element is divided into a support body and a separate susceptor layer, allowing independent manufacturing and configuration of each component. This segmentation enables flexible arrangement of heating portions while maintaining structural simplicity through modular assembly.
Solution Approach 2:
The susceptor element combines a thermally insulative support body material with a susceptor layer material, creating a composite structure that provides both structural integrity and selective heating capabilities. This composite approach enables customized heating profiles while maintaining manufacturing flexibility.
2Ease of manufacture
If a single-piece susceptor element is used, then the manufacturing process is straightforward, but the cost and manufacturing complexity increase for varied configurations
Solution Approach 1:
By separating the susceptor element into a reusable support body and configurable susceptor layers, the system enables varied heating configurations without requiring new support bodies for each configuration. This reduces manufacturing costs while increasing adaptability.
Solution Approach 2:
The universal support body design can accommodate different susceptor layer configurations, allowing a single support body type to serve multiple heating applications. This multi-functionality reduces the number of unique components needed across different device variants.
3Ease of repair
If the susceptor element is fixed, then the device structure is simple, but the maintenance and cleaning efficiency are reduced
Solution Approach 1:
The susceptor layer is designed as a separable component from the support body, allowing easy removal for cleaning or replacement while leaving the support body intact. This segmentation enables efficient maintenance without disassembling the entire heating element.
Solution Approach 2:
The susceptor layer can be discarded after use or degradation and replaced with a fresh layer, while the expensive support body is recovered and reused. This approach reduces maintenance costs and simplifies the cleaning process.
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 flexible and cost-effective aerosol-generating device with improved energy conversion and extended device lifetime, as well as reduced manufacturing complexity and heat loss, enabling efficient aerosol formation with customizable heating profiles.
Implementation Method 1
the inductor coil generates an alternating magnetic field to heat the elongate susceptor element
Implementation Method 2
the inductor coil generates an alternating magnetic field to generate eddy currents and hysteresis losses in the susceptor element
Implementation Method 3
the inductor coil generates an alternating magnetic field to generate eddy currents and hysteresis losses in the susceptor element
Implementation Method 4
The elongate support body is formed from a thermally insulative material
Data Source
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AI summary
There is provided an aerosol-generating device (100) comprising a housing (110) defining a chamber (120) for receiving at least a portion of an aerosol-generating article (10), an inductor coil (130) disposed around at least a portion of the chamber (120), and an elongate susceptor element (160) projecting into the chamber (120). The aerosol-generating device (100) also comprises a power supply (140) and a controller (150) connected to the inductor coil (130) and configured to provide an alternating electric current to the inductor coil (130) such that, in use, the inductor coil (130) generates an alternating magnetic field to heat the elongate susceptor element (160) and thereby heat at least a portion of an aerosol-generating article (10) received in the chamber (120). The elongate susceptor element (160) comprises an elongate support body (170) and at least one heating portion formed from a susceptor layer (180) on an outer surface of the elongate support body (170). The elongate support body (170) is formed from a thermally insulative material and the susceptor layer (180) comprises one or more susceptor materials.