Inhalable Aerosol Heating Element with Insulating Base
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Solution Overview
Problem
Existing heating elements for inhalable aerosol systems are costly and labor-intensive to produce, requiring expensive materials and complex manufacturing processes.
Innovation Solution
A heating element comprising a base body with high temperature stability and thermal conductivity, an electrically insulating material, a heating structure arranged on the base body, and a cover layer to fix the heating structure, which can be made from affordable materials like anodized aluminum or steel coated with glass slip, with the heating structure applied using methods like screen printing or tape casting, and a cover layer of baked glass or injection-molded plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heating elements are used (metal sleeve with insulation layer and resistance element), then reliable heating function is achieved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple functions into the base body: it serves as both the structural support and the thermal contact mediator, eliminating the need for separate metal sleeve and insulation layer components. The heating structure is directly applied to the base body surface, merging the resistance element application with the base body formation process.
Solution Approach 2:
The patent employs inexpensive materials for the base body (aluminum, steel, or glass ceramic) and the heating structure (conductive paste or printed circuit board trace), replacing expensive traditional materials like metal sleeves with insulation layers and complex resistance element windings.
2Temperature
If traditional heating elements with multiple layers are used, then adequate thermal performance is achieved, but device complexity and production effort increase
Solution Approach 1:
The patent segments the heating structure into discrete conductive patterns (traces or pastes) applied only where heating is needed, rather than using a continuous metal sleeve. This allows simplified construction while maintaining effective thermal contact at the substance interface.
Solution Approach 2:
The base body acts as an intermediary between the heating structure and the substance, providing thermal conduction without requiring complex multi-layer insulation structures. The base body material itself (aluminum, steel, or glass ceramic) provides the necessary thermal properties.
3Reliability
If expensive materials like metal sleeves with dielectric layers are used, then electrical insulation is ensured, but manufacturing cost increases
Solution Approach 1:
The base body materials (aluminum, steel, or glass ceramic) inherently provide both structural support and electrical insulation properties, eliminating the need for separate dielectric layers. The heating structure is electrically isolated from the base body through the insulating nature of these materials or through design configuration.
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 enables the production of a heating element that is both inexpensive and simple to manufacture, while maintaining effective thermal performance and electrical insulation, thus addressing the cost and complexity issues of prior art.
Implementation Method 1
a heating structure arranged on the base body
Implementation Method 2
a base body comprising an electrically insulating material... The base body ideally has a high temperature stability and a high thermal conductivity
Data Source
AI summary
One aspect is a heating element for a system for providing an inhalable aerosol, including a base body with an electrically insulating material, a heating structure arranged on the base body, and a cover layer adapted to fix the heating structure on the base body. One aspect further relates to a method for producing a heating element for a system for providing an inhalable aerosol, to a system for providing an inhalable aerosol, and to a vaporizer unit for such a system.