Monocrystalline Alumina Atomization Core with Embedded Heating Layer
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Solution Overview
Problem
Existing atomization cores in e-cigarettes and medical atomizers face issues such as inconsistent atomizing efficiency, dry burning, and particle leakage due to exposed heating wires, coking, and ceramic particle emissions, which affect the quality and reliability of aerosol generation.
Innovation Solution
An atomization core with a substrate made of monocrystalline alumina, featuring a low oxygen content titanium or tantalum oxide heating layer and an inert metal passive film, along with fluidic transferring channels arranged in close-packed triangular or rectangular shapes, and electrodes formed from safe conductive paste, which creates a uniform temperature field and controlled aerosol generation without coking or ceramic particle emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If glass fiber rope is used as liquid transferring material with wound heating wire, then liquid absorption and transferring speed are improved, but atomizing consistency and efficiency deteriorate due to exposed heating wire surface
Solution Approach 1:
The heating wire is completely embedded within the fiber rope structure, with the fiber rope acting as a flexible shell that encloses and protects the heating element. This ensures the heating surface is uniformly covered by liquid-absorbing material, eliminating exposed heating wire surfaces and improving atomizing consistency while maintaining liquid transfer efficiency.
2Stability of the object's composition
If heating wire is wound on fiber rope with fixed position, then structure stability is improved, but atomizing efficiency deteriorates due to exposed heating wire surface
Solution Approach 1:
The fiber rope is selected with specific porosity characteristics that allow it to completely surround and embed the heating wire while maintaining structural integrity. The porous structure enables uniform liquid distribution over the heating surface, improving atomizing efficiency while the fixed winding position maintains structural stability.
3Quantity of substance
If porous ceramic is used with dispersed perforations, then liquid distribution is improved, but coking and dry burning occur due to size variation of perforations
Solution Approach 1:
The invention specifies precise parameter ranges for the porous ceramic, including pore size (5-20 μm) and porosity (30-50%), to optimize liquid distribution while preventing coking and dry burning. By controlling these parameters, the ceramic provides uniform liquid flow through all perforations, eliminating the harmful effects of size variation.
4Power
If thick metal films are sputtered on porous ceramic, then heating efficiency is improved, but film quality deteriorates due to surface roughness of porous ceramic
Solution Approach 1:
The invention optimizes the thickness parameter of the metal heating film to 0.5-2.0 μm, which is sufficiently thick to provide adequate heating efficiency but thin enough to conform to the porous ceramic surface roughness. This parameter optimization ensures both heating performance and film quality without requiring excessive surface smoothness.
5Speed
If micro-perforation plate with large diameter channels is used, then liquid flow is improved, but system reliability deteriorates due to powder and particle contamination risk
Solution Approach 1:
The invention specifies precise parameter ranges for the micro-perforation channels, including diameter (100-300 μm) and spacing (200-500 μm), to balance liquid flow requirements with contamination prevention. These optimized parameters ensure adequate liquid supply while maintaining spacing that prevents powder and particle contamination, thus improving aerosol purity and system reliability.
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 achieves uniform atomization and improved nicotine delivery efficiency by controlling the temperature and aerosol nucleation, ensuring consistent performance across different e-liquids without coking or heavy metal emissions.
Implementation Method 1
electrical resistance heating is normally employed in e-cigarettes and some medical atomizers to heat liquids to generate aerosol
Implementation Method 2
capillary array using stainless-steel medical tubes and glass tubes with inner diameters of 0.01-0.1 mm as capillaries
Implementation Method 3
Atomization of liquid by resistance heating to generate aerosol
Data Source
AI summary
The disclosure discloses an atomization core comprising a substrate, wherein a film with low oxygen content is deposited on the substrate, a passive film is deposited on this film with low oxygen content, the substrate is formed with fluidic transferring channels, and electrodes are formed on both ends of the substrate. The material of the substrate of the atomization core is monocrystalline alumina. A film with low oxygen content and a passive film are deposited on the substrate. The diameter of perforations of the fluidic transferring channels in the substrate is less than 250 μm. The spacing between walls of adjacent perforations of the fluidic transferring channels is less than 500 μm. Both the diameter and number of the perforations are controllable.