Atomizer Core With Insulator And Microchannels
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Solution Overview
Problem
Aerosol generating devices face issues with producing harmful constituents and lack control over aerosol dosage, leading to suboptimal user experience and safety concerns.
Innovation Solution
The development of an atomizer core with a substrate having microchannels and an insulator to reduce heat loss, allowing for efficient heating of aerosol precursors, combined with methods like laser treatment and etching for substrate modification, to enhance aerosol generation and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heater is used to heat the aerosol precursor, then aerosol generation is improved, but heat loss increases and temperature control becomes difficult
Solution Approach 1:
The device divides the heating function into separate heating zones within the substrate, allowing independent temperature control in different regions to optimize aerosol generation while minimizing overall heat loss
Solution Approach 2:
The substrate acts as an intermediary between the heater and the aerosol precursor, facilitating efficient heat transfer to the precursor while the insulator layer prevents heat loss to the environment
2Use of energy by moving object
If the substrate is made from electrically conductive materials, then heating efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The substrate's electrical conductivity parameter is modified through ion implantation or diffusion processes, transforming a non-conductive glass substrate into a conductive heating element without changing the fundamental substrate material or structure
Solution Approach 2:
The patent replaces traditional separate heater components with a substrate that has been modified to possess heating capabilities through electrical conductivity treatment, simplifying the overall device structure
3Productivity
If microchannels are created in the substrate, then aerosol precursor transfer is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical drilling or machining methods with laser treatment followed by chemical etching, enabling precise microchannel formation with complex geometries that would be difficult to achieve with mechanical processes
Solution Approach 2:
The substrate is treated with laser at selected positions to create localized modifications that guide subsequent etching, ensuring microchannels are formed only where needed with precise control over location, depth, and geometry
4Temperature
If an insulator is added between substrate and heater, then temperature control is improved, but device complexity increases
Solution Approach 1:
The insulator layer is integrated directly into the substrate structure during manufacturing, combining the insulating function with the substrate itself rather than adding it as a separate component, thus minimizing device complexity
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
This solution improves aerosol volume, vaping performance, and user experience by reducing heat loss and enhancing mechanical and thermal performance, while minimizing the production of harmful constituents and improving dosage control.
Implementation Method 1
a heater and an insulator disposed between the first surface and the second surface, wherein the insulator is disposed between the substrate and the heater; and a plurality of channels extending between the first surface and the second surface for transferring an aerosol precursor from the first surface through the substrate, the insulator and the heater to the second surface, wherein the heater is adapted to heat the aerosol precursor to form an aerosol at the second surface
Implementation Method 2
an insulator disposed between the first surface and the second surface, wherein the insulator is disposed between the substrate and the heater; and the insulator being adapted to insulate the substrate at least partially from heat generated by the heater
Implementation Method 3
treating the glass substrate at selected positions with laser to modify the properties of the glass substrate at the selected positions
Implementation Method 4
providing a substrate on a negative electrode of the electrolytic cell in a chemical solution; providing an electrode pin array as an anode of the electrolytic cell; applying a voltage between the perforation probe array and the negative electrode to corrode the substrate in the chemical solution; and generating perforations at selected points of the substrate
Data Source
AI summary
Atomizer cores, atomizer core substrates and methods of manufacturing atomizer core substrates are provided as well as aerosol generating devices incorporating same. In one example, the atomizer core comprises a core body having a first surface and a second surface. The core body includes a substrate and a heater with a plurality of channels extending between the first surface and the second surface for transferring an aerosol precursor from the first surface through the substrate and the heater to the second surface, the heater being adapted to heat the aerosol precursor to form an aerosol at the second surface. In other embodiments an insulator is disposed between the substrate and heater and adapted to insulate the substrate at least partially from heat generated by the heater.