Alloy ceramic electric heater type infrared heating atomizing device

Abstract

This invention discloses an infrared heating atomizing device with an alloy ceramic heating element, belonging to the field of non-combustion electric heating atomization technology. The device mainly includes electrode leads, an alloy ceramic heating element, a high emissivity mesh, an annular gasket, a high thermal conductivity sleeve, an aluminum alloy shell, and a vacuum insulation layer. The alloy ceramic heating element is formed by pressing and high-temperature sintering, achieving overall heating. The electrode leads are pre-embedded in the heating element; upon energization, heat is generated simultaneously within the volume and converted into infrared radiation through the high emissivity mesh, non-contactly heating the aerosol-generating matrix. The high thermal conductivity sleeve conducts heat to the matrix sidewalls, achieving synergistic heating through radiation and conduction. The aluminum alloy shell, combined with the vacuum insulation layer and an outer aerogel coating, provides efficient heat insulation. This invention features rapid heating, uniform thermal field, and high temperature control accuracy, solving problems such as low thermal efficiency, poor uniformity, and thermal stress cracking in existing technologies. It is suitable for electronic cigarettes and herbal atomization applications.

Description

Technical Field

[0001] This invention belongs to the field of non-combustible electric heating elements and their atomization technology. It relates to an integral heating infrared electric heating structure with an alloy ceramic electric heating element and its technical solution for aerosol generation. Specifically, it is an alloy ceramic electric heating infrared heating atomization device, which is suitable for low-temperature heating and atomization of aerosol generation substrates and can be used for electronic smoke generation and herbal atomization. Background Technology

[0002] As public awareness of the health hazards of smoking deepens and tobacco control regulations become increasingly stringent in various countries, the large amounts of tar, carbon monoxide, and various harmful substances produced during the combustion of traditional cigarettes have become a significant public health issue. This has prompted the tobacco industry, as well as technology and manufacturing companies, to seek new tobacco alternatives. Against this backdrop, heated non-combustible (HNB) technology has emerged and rapidly developed, becoming one of the mainstream technological approaches in the field of harm-reduction tobacco products. The core principle of HNB technology is to heat the aerosol-generating matrix (such as tobacco sheets, reconstituted tobacco, or herbal extracts) to a temperature range sufficient to release nicotine and flavor compounds but far below the combustion temperature, thereby significantly reducing the release of harmful pyrolysis products at the source.

[0003] In recent years, HNB products have experienced rapid growth in the global market, becoming a technological frontier that major tobacco companies and technology companies are vying to develop. Performance optimization of related heating components has also become a research hotspot in this field.

[0004] MCH (Metal Ceramics Heater) refers to a ceramic heating element made by printing tungsten-molybdenum or silver-palladium-ruthenium series pastes onto a ceramic cast body, hot-pressing and stacking them, and then sintering the ceramic and metal together at 1600℃ under a hydrogen atmosphere. It has advantages such as corrosion resistance, high temperature resistance, long lifespan, good thermal conductivity, and fast thermal compensation. MCH ceramic heating elements are a new type of high-efficiency, environmentally friendly, and energy-saving ceramic heating element, saving 20-30% of energy compared to PTC ceramic heating elements while achieving the same heating effect. In HNB devices, the heating element is the core component that determines product performance; its heating method directly determines the heat field distribution, energy consumption level, preheating speed, and the final smoking experience. Currently, mainstream heating technologies can be divided into several categories, including center heating, peripheral heating, induction heating, and hot air heating. Center heating, represented by IQOS, uses needle-shaped or sheet-shaped MCH heating elements inserted into the center of the cigarette for heating. MCH heating elements typically form a thick-film resistive layer by printing tungsten or molybdenum paste onto the surface of a ceramic substrate such as alumina, which is essentially a "surface heating, inward conduction" heat transfer mode. However, this structure has inherent defects: the thick-film resistor is located on the surface of the heating element, and heat must be conducted from the surface to the interior of the ceramic. This process is limited by the low thermal conductivity of the ceramic material itself, resulting in hysteresis in thermal response, significant temperature gradients along the axial and radial directions of the heating element, and thermal stress concentration. Under high and low temperature cycling, it is very easy for microcracks or even crazing to occur in the ceramic substrate. At the same time, the heating element is directly inserted into the tobacco matrix and in physical contact with it. Volatile organic compounds in the tobacco are prone to forming a carbon deposit layer on the surface of the heating element at high temperatures, which not only degrades the heat transfer efficiency and produces a burnt odor, but also further aggravates the problems of local overheating and temperature unevenness.

[0005] The induction heating bladeless technology used in the IQOS ILUMA series is an improved solution. It moves the heating element from the main body of the device to inside the cartridge, where the device generates an alternating magnetic field through a coil, causing the metal plate inside the cartridge to induce eddy currents and heat up. While this technology eliminates the need to directly insert the heating element into the cigarette and removes residue, it relies on a special metal target cartridge, resulting in extremely strong material binding and a significant increase in cigarette cost. Furthermore, the closed-loop temperature control system of the induction heating chamber is complex, and the heat field distribution still shows obvious central heating marks, with radial temperature uniformity not fundamentally improved.

[0006] BAT glo, which uses an external heating method, employs electromagnetic induction or a resistive film to heat the tobacco from the outside. Heat is conducted layer by layer from the outside in, causing the outer layer of the tobacco matrix to be exposed to high temperatures for extended periods, making it prone to overheating and scorching. The core, however, experiences a slower heating due to the longer heat conduction path. Especially in the later stages of smoking, as the airflow carries away a significant amount of heat, the temperature difference between the inside and outside further widens, resulting in a pronounced coexistence of undercooked and scorched tobacco. Furthermore, the overall thermal efficiency is low, the preheating time is long, and the user experience is poor.

[0007] In addition, hot air heating is another emerging technology in recent years. It uses a honeycomb MCH heating element, with a thick-film resistor installed on the side wall of the MCH tube as the heat source. The heat generated by the thick-film resistor is first conducted to the honeycomb ceramic tube wall, and then the tube wall exchanges heat with the air flowing through the honeycomb through-holes, thereby indirectly heating the inhaled airflow. The heated air then enters the cartridge to atomize the aerosol matrix. However, this technology has several shortcomings: First, it still relies on the surface heating of the thick-film resistor and the indirect conduction of the ceramic wall, resulting in a slow thermal response and high heat loss; second, in order to ensure sufficient heat exchange time between the airflow and the channel wall to raise the air temperature to the target temperature, the through-holes must have sufficient axial length, which not only increases airflow resistance and reduces suction smoothness, but also makes the heating element larger and more energy-intensive; third, the heating uniformity is limited by the flow velocity distribution of the airflow in the honeycomb channels, and it is difficult to guarantee the temperature consistency of the airflow between the channels.

[0008] Among the aforementioned existing technologies, MCH (metal-ceramic heating element) and its related co-fired ceramic systems, HTCC (high-temperature co-fired ceramic) and LTCC (low-temperature co-fired ceramic), are currently the most widely used substrate material systems for heating elements. The basic heating mechanism of these three technologies relies on printing thick-film resistive pastes of precious metals or refractory metals onto the surface of a ceramic substrate. After co-firing, a surface resistive layer is formed. When electricity is applied, Joule heating is generated only in the thin surface layer, and the heat is then transferred to the target area or medium through the thermal conduction of the ceramic substrate. This surface heating and indirect conduction mode is limited by the thermal conductivity and volumetric heat capacity of the ceramic material itself, inevitably leading to the following common defects: the heating rate is constrained by the conduction path, making it difficult to achieve second-level rapid preheating; the uniformity of the thermal field in both time and space is insufficient, affecting the consistency and stability of aerosol release; due to the difference in thermal expansion coefficients between the heating layer and the substrate material, as well as the uneven temperature distribution inside the ceramic substrate, the problem of thermal stress concentration is prominent under frequent high and low temperature alternation conditions, significantly shortening the working life of the heating element; and the heating structure also faces the problems of carbon buildup and flavor degradation. It is particularly noteworthy that in hot air heating solutions, in order to achieve heat exchange between the airflow and the heating element, the length of the through-hole must be extended. However, this design not only increases the airflow pressure drop and energy loss, but also makes it difficult to shorten the preheating time, significantly increasing power consumption and failing to meet users' demand for immediate, rapid response.

[0009] In the prior art, Chinese patent CN110022622A discloses an alumina honeycomb ceramic heating element and its preparation method, including alumina honeycomb ceramic, a heating printed circuit, and wires; the heating printed circuit is arranged around the outer surface of the alumina honeycomb ceramic; the first and last ends of the heating printed circuit are provided with wires, and its core structure is that the heating printed circuit is arranged around the outer surface of the alumina honeycomb ceramic body. The essence of this technical solution is "surface heating", that is, after the heat is generated by the heating circuit, it needs to be conducted to the air in the honeycomb channel through the ceramic tube wall, which is an indirect heating. Therefore, this prior art has problems such as the heating rate being limited by the thermal conductivity of the ceramic material, the need for secondary heat transfer leading to large power consumption, and thermal stress concentration caused by the difference in thermal expansion coefficient between the thick film resistor and the ceramic substrate and the uneven temperature inside the ceramic, which easily leads to thermal stress cracking under high and low temperature cycling.

[0010] Chinese patent CN208510068U discloses an air heating unit for low-temperature smoke and the low-temperature smoke itself. Its core feature is the inclusion of at least two parallel heating elements to maintain operation even if some heating elements are damaged. However, this patent does not substantially improve the structure or heating method of the heating elements themselves; the heating elements remain traditional heating wires or similar components. This design has inherent limitations in terms of heating uniformity, heating rate, and thermal efficiency.

[0011] Compared with the above technologies, it is necessary to invent an integral heating alloy ceramic electric heating element. Through the integrated structure of the material itself, a uniform heat field distribution and rapid heating response are achieved. It does not require redundant design with multiple parallel sections to deal with local failure problems, and can fundamentally improve the reliability and heating performance of the heating element.

[0012] Chinese patent CN218073524U discloses an aerosol generating device and a heater for the aerosol generating device, which is formed by winding or bending a resistive metal or alloy sheet. It includes at least two wound resistance heating layers, and air is heated when it passes through the layers. Although this structure increases the heat exchange area, it is still essentially a surface heating method, with heat generated on the surface of the metal sheet. Furthermore, the wound structure may pose a risk of interlayer short circuits, and the manufacturing process is relatively complex. In addition, the alloy or metal sheet may creep and deform at high temperatures, leading to structural and temperature instability.

[0013] Compared with the above technologies, it is necessary to invent an alloy ceramic heating element that is integrally formed by powder pressing and sintering. This allows the alloy phase to be evenly distributed in the ceramic matrix, enabling uniform heating of the whole, resulting in a more compact and stable structure, simplified manufacturing process, and fundamentally avoiding the problems of interlayer short circuits and local overheating.

[0014] Chinese patent CN218245642U discloses a heating component and a non-combustible heating device. The heating element includes an insulation layer and a heating element embedded within the insulation layer, the heating element being made of an electromagnetic induction material. Its heating method relies on an alternating magnetic field generated by an external coil to induce heating in the heating element, which is an indirect heating method. Furthermore, the heating element itself is not uniformly distributed throughout the entire volume of the heating component.

[0015] Compared with the above technologies, the invention creates an alloy ceramic heating element with a resistance heating structure that can generate Joule heat in the entire volume of the heating element when energized, achieving true volume heating without the need for an external induction coil. The structure is simpler, the heating is more direct and uniform, and the thermal efficiency is higher.

[0016] Chinese patent CN114246367A discloses an electromagnetic induction heating aerosol forming device and its application, wherein the heating element comprises a mixture of ceramic and soft magnetic materials. Although the heating element of this device is also a composite of ceramic and conductor in terms of material composition, its heating principle is still electromagnetic induction heating, that is, the heating element heats up due to the eddy current effect in an alternating magnetic field. This necessitates the use of an induction coil in the device, and the heating efficiency is affected by the skin effect.

[0017] Compared with the above technologies, it is necessary to invent a technical solution that uses resistance heating and supplies power directly to the heating element through electrode leads. This solution utilizes the conductivity of the alloy phase to achieve the overall Joule heating effect, eliminating the need for an external induction coil. This makes the system simpler, the energy conversion efficiency higher, and the temperature control more direct and precise.

[0018] Based on the applicant's research and analysis, existing technologies generally employ multilayer co-fired ceramics, which are based on surface thick-film resistive heating. Heat is conducted from the surface of the heating element to the interior, resulting in slow heating rates, low thermal efficiency, and poor uniformity. Furthermore, the thermal stress concentration defects caused by surface heating easily lead to cracking of the ceramic matrix under high and low temperature cycling conditions. No existing technology has been found that can simultaneously achieve rapid preheating, uniform heating, non-contact operation, low power consumption, and an alloy ceramic heating element that differs from the traditional ceramic matrix surface-printed thick-film resistive layer structure, as well as from existing technologies that differentiate themselves from contact heating between the aerosol matrix and the heating element and indirect heating using hot air flow. Therefore, this invention creates an infrared radiation heating structure and aerosol generation device based on bulk-heated alloy ceramics, which can overcome the shortcomings of existing technologies and achieve rapid heating, low power consumption, and uniform temperature for low-temperature heating of the aerosol generation matrix. Summary of the Invention

[0019] The purpose of this invention is to overcome the shortcomings of the prior art and to design an alloy ceramic electrothermal infrared heating atomizing device that is different from the traditional ceramic substrate surface printed thick film resistive layer structure and is not a multi-layer co-fired ceramic, high-temperature co-fired ceramic, or low-temperature co-fired ceramic. It is used in electronic smoke generation technology and solves the problems of slow heating rate, low thermal efficiency, poor uniformity, and easy cracking of ceramic substrate under high and low temperature cycling conditions caused by thermal stress concentration defects due to surface heating.

[0020] To achieve the above objectives, the present invention relates to an alloy ceramic heating element type infrared heating atomizing device. Its main structure includes, from bottom to top, electrode leads, an alloy ceramic heating element, a high emissivity mesh, an annular gasket, and, located outside the alloy ceramic heating element, a high thermal conductivity sleeve, an aluminum alloy shell, a vacuum insulation tube layer, a sealing plug, a smoke-generating substrate, and a vacuum seal. These components are assembled into a single unit and encapsulated within the aluminum alloy shell. The alloy ceramic heating element is formed by a rational alloy composition ratio and a scientific process, pressing it together with the electrode leads and vent holes into a single integrated structure. Circular vent holes are regularly and evenly distributed across the cross-section of the alloy ceramic heating element. Two high-emissivity nickel wires... The electrode leads of the conductivity structure are symmetrically fixed as an electrical lead structure. These leads are pre-embedded in the preform during powder molding and pressing, eliminating the need for welding. After sintering, the exposed portion is plated with copper or silver to increase conductivity, used to connect the alloy ceramic heating element for power supply, reducing power loss under high current conditions. The integrated alloy ceramic heating element has multiple through-thickness vents within its cross-section, serving as airflow channels. The heating element has a cylindrical honeycomb structure. A high-emissivity mesh is tightly attached to the upper surface of the alloy ceramic heating element to ensure rapid and lossless heat conduction, converting heat into infrared radiation to heat the aerosol generation matrix, smoke-generating substrate, or smoke stick. The high-emissivity mesh is made of foamed silicon carbide or oxidized silicon carbide. The process involves processing foamed copper or copper mesh; annular gaskets with a circular disc structure are placed between the high-emissivity mesh and the smoke-generating substrate, or a 0.1-0.3mm miniaturized version of the high-thermal-conductivity sleeve replaces the structure and function of the annular gasket; the annular gasket physically isolates the high-emissivity mesh and the smoke source, preventing direct contact, while allowing infrared radiation to penetrate and radiate heat to the aerosol-generating matrix, smoke-generating substrate, or bottom of the cigarette; a cylindrical high-thermal-conductivity sleeve is fitted around the alloy ceramic heating element. The high-thermal-conductivity sleeve is made of copper, silver, silicon carbide, or aluminum nitride. The alloy ceramic heating element and the high-thermal-conductivity sleeve are tightly bonded without gaps to reduce thermal resistance, and are used to conduct heat from the alloy ceramic heating element to the sidewalls of the smoke-generating substrate or aerosol-generating matrix. This design increases the utilization rate of thermal energy and achieves a synergistic effect of bottom radiant heating and sidewall conduction heating. The aluminum alloy shell is a tubular structure made of aluminum alloy material, fitted around the outer periphery of a high thermal conductivity sleeve. The inner wall of the aluminum alloy shell, which has a vacuum seal on one side, is mirror-polished to reduce emissivity and block heat radiation. The vacuum insulation tube layer is an interlayer between the tube wall of the aluminum alloy shell and the high thermal conductivity sleeve. The vacuum insulation tube layer is evacuated to reduce heat conduction and convection. The outer wall of the aluminum alloy shell is coated with an aerogel insulation coating to further reduce heat loss. The electrode leads of the alloy ceramic heating element are fitted with sealing plugs made of aluminum alloy or stainless steel to form a sealed power connection terminal.

[0021] The vacuum insulation tube layer involved in this invention may be a double-layer sealed tubular vacuum cavity that is tightly fitted between an aluminum alloy shell and a high thermal conductivity sleeve, with the outer side of the aluminum alloy shell being smooth and without a vacuum seal.

[0022] The alloy ceramic heating element infrared heating atomizing device of the present invention may include a temperature sensor, which is selected from thermocouples, platinum resistance thermometers or high-temperature NTCs, and is used for temperature measurement. The probe of the temperature sensor is tightly attached to any position in the small hole or on the periphery of the alloy ceramic heating element, or at the corresponding position on the high thermal conductivity sleeve; or the intrinsic temperature coefficient of resistance (TCR-800ppm / K) of the alloy ceramic heating element can be used as a temperature sensor, and the temperature can be measured by directly measuring the change in resistance between the two leads as a function of temperature, without the need to install a separate temperature sensor.

[0023] The alloy ceramic heating element of this invention is made by mixing alloy powder and ceramic powder, adding a small amount of binder and sintering aid, and then pressing and sintering at high temperature. The alloy powder is selected from one or more of nickel-chromium alloy, iron-chromium-aluminum alloy, stainless steel, tungsten, molybdenum, nickel, and iron; the ceramic powder is selected from one or more of silicon dioxide, alumina, silicon nitride, aluminum nitride, or silicon carbide. During preparation, the alloy powder and ceramic powder are mixed in a certain proportion, a binder and sintering aid are added, and the mixture is pressed to obtain a green body. Then, it is sintered at high temperature under a protective atmosphere to obtain an integrated alloy ceramic heating element. The pressing method used for the green body is any one of dry pressing, injection molding, or isostatic pressing, with the electrode leads directly embedded in the green body.

[0024] Compared with existing technologies, this invention has the following advantages: First, it uses powder pressing and high-temperature sintering processes to prepare the heating element, eliminating the need for expensive thick-film printing, simplifying the production process, increasing product yield, and reducing manufacturing costs. In terms of structural design, the power supply leads are directly embedded in the heating element, forming it in one piece and eliminating the need for lead welding, further reducing costs. Second, the overall heating mode ensures a uniform thermal field without localized hot spots. The alloy phase is uniformly distributed in the ceramic matrix, resulting in uniform heating, rapid temperature rise, significantly reduced power consumption, and minimal temperature fluctuations during suction, with the temperature controllable within ±1℃. Third, the through-holes are clearly defined as airflow channels only, not channels for heat exchange between the airflow and the heating element. Even if the heating element is very thin (with a short airflow heat exchange channel), it can still rapidly heat the aerogel matrix. Fourth, the aluminum alloy outer shell, combined with a mirrored inner wall and an aerogel coating on the outer wall, effectively insulates the internal high temperature of 200℃ to 450℃ to below 40℃ on the outer wall, preventing burns. The vacuum insulation tube layer effectively blocks heat conduction and convection from the air, and the mirror-polished inner wall reduces infrared emissivity, minimizing heat radiation transfer. Fifth, the non-contact infrared heating avoids the burnt smell caused by direct contact between the tobacco matrix and the heating element in traditional contact heating, effectively reducing the release of harmful substances such as formaldehyde, acetaldehyde, and acrolein, and precisely controlling the release curve of effective components in the aerosol generation matrix. Infrared thermal radiation heating is fast, reducing preheating time to second-level preheating and reducing temperature fluctuations caused by airflow during inhalation (rapid reheating). Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the cross-sectional structure of the alloy ceramic electrothermal infrared heating atomizing device involved in this invention.

[0026] Figure 2 This is a top view schematic diagram of the alloy ceramic heating element involved in this invention.

[0027] Figure 3 This is a schematic diagram illustrating the microstructure principle of the alloy ceramic heating element involved in this invention.

[0028] Figure 4 This is a schematic diagram of the temperature control curve of the alloy ceramic electrothermal infrared heating atomizing device used for aerogel generation, as per the present invention, wherein the temperature control accuracy is + / -1℃.

[0029] Figure 5 This is a schematic diagram of the temperature rise curves of alloy ceramic heating elements of different thicknesses with an input power of 13W, as per the present invention.

[0030] Figure 6 This is a three-dimensional schematic diagram of the structural principle of the alloy ceramic electrothermal infrared heating atomizing device involved in this invention.

[0031] Figure 7This is a schematic diagram illustrating the structural principle of the high thermal conductivity sleeve involved in this invention.

[0032] Figure 8 This is a schematic diagram illustrating the structural principle of the aluminum alloy shell involved in this invention.

[0033] Figure 9 This is a schematic diagram illustrating the principle of the high emissivity mesh structure involved in this invention.

[0034] Figure 10 This is a schematic diagram illustrating the structural principle of the sealing plug involved in this invention.

[0035] Figure 11 This is a schematic diagram illustrating the structural principle of the alloy ceramic heating element involved in this invention.

[0036] Figure 12 This is a schematic diagram illustrating the structural principle of the alloy ceramic electrothermal infrared heating atomizing device during assembly, as per the present invention.

[0037] The components and their corresponding labels in the above-mentioned figures include: electrode lead 1, alloy ceramic heating element 2, high emissivity mesh 3, annular gasket 4, high thermal conductivity sleeve 5, aluminum alloy shell 6, vent hole 7, vacuum insulation tube layer 8, sealing plug 9, smoke-generating matrix 10, and vacuum seal 11. Detailed Implementation

[0038] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0039] Example 1:

[0040] This embodiment relates to an infrared heating atomizing device with an alloy ceramic heating element. Its main structure includes, from bottom to top, an electrode lead 1, an alloy ceramic heating element 2, a high emissivity mesh 3, and an annular gasket 4. It also includes a high thermal conductivity sleeve 5, an aluminum alloy shell 6, a vacuum insulation tube layer 8, a sealing plug 9, a smoke-generating substrate 10, and a vacuum seal 11, all arranged on the outside of the alloy ceramic heating element 2. These components are assembled into a single device body and encapsulated within the aluminum alloy shell 8. The alloy ceramic heating element 2 is formed by pressing the electrode lead 1 and vent holes 7 together with a rationally proportioned alloy composition using a scientific process. The circular vent holes 7 are regularly and evenly distributed and cut into the cross-section of the alloy ceramic heating element 2. Two high-conductivity nickel electrode leads 1 are symmetrically fixed as an electrical lead structure. These leads are pre-embedded in the preform during powder molding and pressing, requiring no welding. After sintering, the exposed portion is plated with copper or silver to increase conductivity. These leads connect to the alloy ceramic heating element 2 to provide power, reducing power loss under high current conditions. The integrated alloy ceramic heating element 2 contains multiple through-holes 7 within its cross-section, serving as airflow channels. The alloy ceramic heating element 2 has a thickness of 0.2mm to 4mm and a cylindrical honeycomb structure. A high-emissivity mesh 3 is tightly attached to the upper surface of the alloy ceramic heating element 2 to ensure rapid, lossless heat conduction and convert the heat into infrared radiation to heat the generated aerosol. The high-emissivity mesh 3 is made of foamed silicon carbide or oxidized foamed copper or copper mesh, and its thickness is 0.1 mm to 3 mm. A ring-shaped gasket 4 is disposed between the high-emissivity mesh 3 and the smoke source 10, with a thickness of 0.1 mm to 3 mm, or may be miniaturized by 0.1-0.3 mm on a high-thermal-conductivity sleeve 5 to replace the structure and function of the ring gasket 4. The ring gasket 4 is used to physically isolate the high-emissivity mesh 3 and the smoke source, avoiding direct contact, while allowing infrared rays to penetrate and radiate heat to the aerosol-generating matrix or smoke source 10 or the bottom of the cigarette. A cylindrical high-thermal-conductivity sleeve 5 is fitted around the alloy ceramic heating element 2. The heat-conducting sleeve 5 is made of copper, silver, silicon carbide, or aluminum nitride. The alloy ceramic heating element 2 is tightly bonded to the high thermal conductivity sleeve 5 without gaps to reduce thermal resistance. It is used to conduct the heat of the alloy ceramic heating element 2 to the sidewall of the smoke-generating substrate 10 or the aerosol-generating matrix, increasing the utilization rate of thermal energy and realizing the synergistic effect of bottom radiation heating and sidewall conduction heating. The aluminum alloy shell 6, with a thermal resistance greater than 60000K / W, is a tubular structure made of aluminum alloy material and is sleeved on the outer periphery of the high thermal conductivity sleeve 5. The inner wall of the aluminum alloy shell 6, which has a vacuum seal 11 on one side, is mirror-polished to reduce emissivity and block heat radiation. The vacuum insulation tube layer 8 is an interlayer between the tube wall of the aluminum alloy shell 6 and the high thermal conductivity sleeve 5, with a thickness of 0.A 5-2mm thick vacuum insulation tube layer 8 is evacuated to a vacuum level of 10⁻²-10⁻³ Pa to reduce heat conduction and convection. The outer wall of the aluminum alloy shell 6 is coated with an aerogel insulation layer to further reduce heat loss. The electrode leads 1 of the alloy ceramic heating element 2 are fitted with sealing plugs 9 made of aluminum alloy or stainless steel, forming a sealed power connection terminal.

[0041] The vacuum insulation tube layer 8 involved in this embodiment may be a double-layer sealed tubular vacuum cavity that is tightly attached between the aluminum alloy shell 6 and the high thermal conductivity sleeve 5. The outer side of the aluminum alloy shell 6 is smooth and has no vacuum seal 11.

[0042] The alloy ceramic heating element infrared heating atomizing device involved in this embodiment may include a temperature sensor. The temperature sensor is selected from one of thermocouples, platinum resistance thermometers, or high-temperature NTC devices and is used for temperature measurement. The probe of the temperature sensor is tightly attached to any position in the small hole or on the periphery of the alloy ceramic heating element 2, or at the corresponding position on the high thermal conductivity sleeve 5; or the intrinsic temperature coefficient of resistance (TCR-800ppm / K) of the alloy ceramic heating element 2 can be used as a temperature sensor, and the temperature can be measured by directly measuring the change in resistance between the two leads as a function of temperature, without the need to install a separate temperature sensor.

[0043] The alloy ceramic heating element 2 involved in this embodiment is made by mixing alloy powder and ceramic powder, adding a small amount of binder and sintering aid, and then pressing and sintering at high temperature. The alloy powder is selected from one or more of nickel-chromium alloy, iron-chromium-aluminum alloy, stainless steel, tungsten, molybdenum, nickel, and iron. The ceramic powder is selected from one or more of silicon dioxide, alumina, silicon nitride, aluminum nitride, or silicon carbide. During preparation, the above alloy powder and ceramic powder are mixed in proportion, binder and sintering aid are added, and then pressed to obtain a green body. Then, high-temperature sintering is carried out under a protective atmosphere to obtain an integrated alloy ceramic heating element 2. The pressing method used for the green body is any one of dry pressing, injection molding, or isostatic pressing, and the electrode lead 1 is directly embedded in the green body.

[0044] The conductive alloy phase of the alloy ceramic heating element 2 involved in this invention is uniformly dispersed in the ceramic matrix to form a three-dimensional conductive network. When energized, the current flows through the entire volume of the heating element, and heat is generated simultaneously in the internal three-dimensional space, rather than only on the surface. Therefore, it does not contain any thick film resistive layer printed on the surface. The alloy ceramic heating element 2 has a thickness of 0.2-4 mm, and multiple vent holes 7 with a diameter of 0.2-1.6 mm are uniformly distributed along the axial direction inside. The vent holes 7 only serve as channels for drawing airflow and do not serve as channels for heat exchange between the airflow and the heating element to heat the airflow. At a typical airflow rate of 17.5 mL / s, the pressure drop is about 800 Pa. With a heating element thickness of 2 mm and an input power of 13 W, it takes only 6 seconds to reach 400 °C, and only 3 seconds for a 1 mm thickness. Since the vent holes 7 do not perform heat exchange functions, the thickness of the alloy ceramic heating element 2 is significantly reduced, the airflow path is very short, and the airflow pressure drop is small.

[0045] In this embodiment, the temperature of the alloy ceramic heating element 2 is controlled within the range of 200℃-450℃ through feedback signals from the external circuit and the TCR (resistance change with temperature) of the heating element. The temperature is adjusted according to the different smoke-generating substrates 10, aerosol matrices, or smoke generation sources. In the preheating stage, the temperature is set slightly higher than the atomization point of the smoke-generating substrate 10. Taking advantage of the rapid heating of the alloy ceramic heating element 2 and the rapid heat transfer through thermal radiation of the high-emissivity mesh 3, preheating is achieved in seconds, with a preheating time of 3 to 16 seconds. In the suction stage, the temperature is adjusted back to the steady-state atomization temperature. The stability of the heating of the alloy ceramic heating element 2 and the characteristic of rapid heat replenishment through infrared radiation are used to suppress temperature fluctuations.

[0046] Example 2:

[0047] This embodiment relates to the specific preparation method of the alloy ceramic heating element 2 described in Embodiment 1. The specific preparation process is as follows: First, tungsten powder (25-35wt%) with an average particle size of 15μm and alumina powder (60-70wt%) are taken, and polyvinyl alcohol binder (3-8wt%) is added. Under uniform temperature and constant speed conditions, the mixture is repeatedly stirred and mixed evenly. Then, conventional dry pressing is performed using a tungsten steel mold to produce a circular green blank with a diameter of 5-9mm and a thickness of 0.5-2.5mm. Then, the green blank is sintered at a high temperature of 1300-1600℃ for 3-5 hours under hydrogen atmosphere protection to obtain the integrated alloy ceramic heating element 2. After testing, the resistivity of the obtained alloy ceramic heating element 2 is about 0.1Ω·m, and the bending strength is greater than 300MPa.

[0048] Example 3:

[0049] This embodiment relates to the assembly and atomization process of the infrared heating atomizing device described in Embodiment 1. The alloy ceramic heating element 2 prepared in Embodiment 2 is tightly fitted into the bottom of a copper high-thermal-conductivity sleeve 5 with nickel-plated inner and outer surfaces. A 0.2mm thick, blackened foamed copper high-emissivity mesh 3 is then tightly attached to the upper surface of the alloy ceramic heating element 2. The high-emissivity mesh 3 is blackened by oxidation to improve infrared emissivity. An aluminum alloy shell 6 is fitted over the nickel-plated copper high-thermal-conductivity sleeve 5. The smoke-generating substrate 10, aerosol generating matrix, smoke generating raw material, or cigarette is inserted into the device, so that… A 0.3mm gap is maintained between the bottom of the smoke-generating substrate 10 and the high-emissivity mesh 3. In the atomization working state, the alloy ceramic heating element 2, after being energized through the electrode leads, rapidly heats up to 400℃. The heat is quickly conducted to the high-emissivity mesh 3, causing it to emit high-intensity infrared rays. The infrared rays penetrate the 0.3mm air gap and irradiate the bottom matrix of the smoke-generating substrate 10, achieving non-contact radiative heating. At the same time, the high thermal conductivity sleeve 5 conducts heat to the side wall of the smoke-generating substrate 10, achieving auxiliary conduction heating. According to the test, the bottom of the smoke-generating substrate 10 reaches the atomization temperature of 260℃ within 8 seconds, and normal inhalation can begin.

[0050] Example 4:

[0051] This embodiment relates to the preparation of alloy ceramic heating elements 2 with different material ratios as described in Example 1. Nickel-chromium alloy powder (25wt%) with an average particle size of 10μm and aluminum nitride powder (60wt%) are taken, and an appropriate amount of sintering aid and organic binder (15wt%) are added. After being mixed evenly, they are injection molded into green bodies of the required shape. Tungsten wire electrode leads 1 are pre-embedded and sintered at 1650℃ for 3 hours under nitrogen atmosphere protection to obtain alloy ceramic heating elements 2, which have higher thermal conductivity and are suitable for application scenarios with higher requirements for heating rate.

[0052] Example 5:

[0053] This embodiment involves the assembly of devices with different structural parameters as described in Embodiment 1. An alloy ceramic heating element 2 with a thickness of 2 mm and a through hole diameter of 0.8 mm is installed at the bottom of a silver high thermal conductivity sleeve 5. A foam silicon carbide high emissivity mesh 3 with a thickness of 0.5 mm is tightly attached to the upper surface of the alloy ceramic heating element 2. An aluminum alloy shell 6 with a thickness of 1.0 mm is fitted on the outside of the silver high thermal conductivity sleeve 5. The inner wall is mirror polished and the outer wall is coated with an aerogel coating. An annular gasket 4 with a thickness of 0.5 mm is set between the bottom of the smoke-generating substrate 10 and the high emissivity mesh 3. This structure of the device is suitable for working occasions that require higher infrared radiation intensity.

[0054] The core technical features involved in this embodiment include non-hot air heating, non-electromagnetic heating, non-thick film resistor (MCH, LTCC, HTCC) heating, and non-contact heating methods; the alloy ceramic heating element 2 is a self-developed new material technology and integrated structure and its preparation process, which is currently a leading heating element material technology in the industry. It generates heat as a whole, and its resistivity is adjustable from 10⁻¹ to 10⁻⁵ Ω·m, which is difficult to achieve with existing heating element material technologies. It has high electrothermal conversion efficiency, low cost (only one-fifth to one-third the cost of other heating elements), and long lifespan, especially in high and low temperature cycling. When applied to e-cigarettes, the preheating and inhalation temperatures require only 13-18 watts or less, achieving second-level preheating in just 8-16 seconds, while existing technologies require over 20 seconds, far exceeding the industry standard of within 20 seconds. The design incorporates a high-emissivity mesh 3, which efficiently converts the heat from the heating element into infrared thermal radiation, using this radiation to heat the cigarette, achieving second-level rapid preheating and reducing temperature fluctuations during inhalation. A vacuum structure insulation is used to isolate the heating element's 400°C high temperature, reducing the temperature outside the insulation zone to below 40°C, while existing HNB (High-End Battery) technology requires temperatures above 60°C.

Claims

1. An infrared heating atomizing device with an alloy ceramic electric heating element, characterized in that, The main structure includes, from bottom to top, electrode leads, an alloy ceramic heating element, a high emissivity mesh, and an annular gasket, as well as a high thermal conductivity sleeve, an aluminum alloy shell, a vacuum insulation tube layer, a sealing plug, and a smoke-generating substrate located outside the alloy ceramic heating element. These components are assembled into a single unit and encapsulated within the aluminum alloy shell. The alloy ceramic heating element, electrode leads, and vent holes are integrally pressed together. Circular vent holes are regularly and evenly distributed across the cross-section of the alloy ceramic heating element. Two high-conductivity electrode leads are symmetrically fixed to the alloy ceramic heating element as lead structures. The cylindrical honeycomb structure of the alloy ceramic heating element contains multiple through-thickness vent holes as airflow channels. The high emissivity mesh is tightly packed... The high-emissivity mesh, made of foamed silicon carbide or anodized foamed copper or copper mesh, is tightly fitted to the upper surface of the alloy ceramic heating element. A ring-shaped gasket with a circular structure is placed between the high-emissivity mesh and the smoke-generating substrate, or a 0.1-0.3mm miniaturized version of the high-thermal-conductivity sleeve replaces the structure and function of the ring gasket. A cylindrical high-thermal-conductivity sleeve is fitted around the alloy ceramic heating element, with the alloy ceramic heating element and the high-thermal-conductivity sleeve tightly bonded without gaps to reduce thermal resistance. The aluminum alloy shell is a tubular structure made of aluminum alloy material, fitted around the high-thermal-conductivity sleeve. A vacuum insulation tube layer is placed between the tube wall of the aluminum alloy shell and the high-thermal-conductivity sleeve. Sealing plugs are fitted on the sides of the electrode leads of the alloy ceramic heating element, forming a sealed power connection terminal.

2. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The vacuum insulation tube layer is an interlayer between the tube wall of the aluminum alloy shell and the high thermal conductivity sleeve.

3. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 2, characterized in that: The aluminum alloy shell has a vacuum seal on one side, and a vacuum space is created inside the vacuum insulation tube layer through the vacuum seal.

4. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The vacuum insulation tube layer is a double-layer sealed tubular vacuum cavity that is tightly fitted between the aluminum alloy shell and the high thermal conductivity sleeve.

5. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The aforementioned alloy ceramic electric heating element infrared heating atomizing device also includes a temperature sensor, which is selected from one of thermocouples, platinum resistance thermometers, or high-temperature NTC devices, and is used for temperature measurement. The probe of the temperature sensor is tightly attached to any position in the small hole or on the periphery of the alloy ceramic electric heating element, or at the corresponding position on the high thermal conductivity sleeve.

6. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The alloy ceramic heating element is made by mixing alloy powder and ceramic powder, adding a small amount of binder and sintering aid, and then pressing and sintering at high temperature. The alloy powder is selected from one or more of nickel-chromium alloy, iron-chromium-aluminum alloy, stainless steel, tungsten, molybdenum, nickel, and iron; the ceramic powder is selected from one or more of silicon dioxide, alumina, silicon nitride, aluminum nitride, or silicon carbide. During preparation, the alloy powder and ceramic powder are mixed in a certain proportion, a binder and sintering aid are added, and the mixture is pressed to obtain a green body. Then, it is sintered at high temperature under a protective atmosphere to obtain an integrated alloy ceramic heating element. The pressing method used for the green body is any one of dry pressing, injection molding, or isostatic pressing, with the electrode leads directly embedded in the green body.

7. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The electrode leads are made of nickel.

8. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The high thermal conductivity sleeve is made of one of copper, silver, silicon carbide, or aluminum nitride.

9. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The outer wall of the aluminum alloy shell is coated with an aerogel heat insulation coating.

10. The alloy ceramic electrothermal element type infrared heating atomizing device according to claim 1, characterized in that: The sealing plug is made of aluminum alloy or stainless steel.

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