Variable-Thickness Heater Assembly for Uniform Aerosol Heating
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Solution Overview
Problem
Existing heater assemblies in electronic aerosol provision systems, such as e-cigarettes, do not provide uniform heating characteristics and can lead to temperature variations, known as 'hot-spots, which affect the performance and efficiency of aerosol generation.
Innovation Solution
A heater assembly with a substrate and a heater layer configured to generate heat, featuring capillary tubes extending through the heater layer, where the thickness of the heater layer and substrate is varied across different portions to control heating characteristics and reduce temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform thickness heater layer is used, then the manufacturing process is simple, but temperature uniformity deteriorates due to hot-spots
Solution Approach 1:
The heater layer is designed with non-uniform thickness, where the thickness varies at different positions along the longitudinal axis. Specifically, the heater layer has a first thickness at a first position and a second thickness at a second position, with the thickness gradient designed to compensate for heat loss patterns and eliminate hot-spots, achieving uniform temperature distribution across the heating element.
Solution Approach 2:
The physical parameter of the heater layer being modified is its thickness. By controlling the thickness to vary along the longitudinal axis (creating a gradient from thicker to thinner regions), the electrical resistance and heat distribution are optimized to achieve uniform temperature across the heater assembly during operation.
2Reliability
If variable thickness heater layer is used, then temperature uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The heater layer is designed with non-uniform thickness, where the thickness varies at different positions along the longitudinal axis. Specifically, the heater layer has a first thickness at a first position and a second thickness at a second position, with the thickness gradient designed to compensate for heat loss patterns and eliminate hot-spots, achieving uniform temperature distribution across the heating element.
3Productivity
If capillary tubes are added to the heater assembly, then aerosol generation efficiency is improved, but device complexity increases
Solution Approach 1:
The capillary tubes are integrated directly into the heater assembly structure, merging the heating function and the liquid delivery function into a single integrated component. The capillary tubes extend through the heater layer from the liquid reservoir side to the heating element side, allowing liquid to be delivered directly to the heating zone without requiring separate delivery mechanisms.
Solution Approach 2:
The capillary tubes utilize capillary action (hydraulic principle) to deliver liquid from the reservoir to the heating element. The capillary tubes are positioned to receive liquid from the liquid reservoir and deliver it to the heating element, utilizing capillary forces to transport the liquid without requiring external pumping or complex delivery systems.
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 uniform heating across the heater assembly, enhancing the efficiency and performance of aerosol generation by minimizing hot-spots and improving the delivery of aerosol-generating materials.
Implementation Method 1
a heater layer configured to generate heat when supplied with energy
Implementation Method 2
one or more capillary tubes extending from another surface of the substrate through the heater layer
Implementation Method 3
electrical power is supplied to the heating element to vaporise source liquid in the vicinity of the heating element to generate an aerosol for inhalation by the user
Data Source
AI summary
Described is a heater assembly for an aerosol provision system, the heater assembly including: a substrate; a heater layer configured to generate heat when supplied with energy, the heater layer provided on a first surface of the substrate; and one or more capillary tubes extending from another surface of the substrate through the heater layer provided at the first surface of the substrate, wherein the thickness of at least one of the heater layer and substrate is set so as to be different at different portions of the heater assembly. Also described is an aerosol provision system comprising a heater assembly and a method for manufacturing a heater assembly.