Carbon Foam Atomizer Heater for Metal-Free Vaporization
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Solution Overview
Problem
Existing atomising devices, such as vaping and heat-not-burn products, face issues with metallic heaters that release harmful metals into the inhaled vapour, and conventional graphene heaters are brittle and unsuitable for large-scale applications due to poor adhesion and thickness limitations.
Innovation Solution
The use of laser-induced carbon foam, manufactured through a Dual Laser process, as a heating element that is both electrically conductive and porous, eliminating the need for metallic components and providing a robust, hydrophilic surface for efficient liquid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If metallic wire or mesh heaters are used in atomising devices, then heating efficiency and electrical conductivity are improved, but metallic contamination of inhaled vapour occurs causing health risks
Solution Approach 1:
The patent changes the material parameter from metallic to carbon-based foam, maintaining electrical conductivity while eliminating metallic contamination. The carbon foam heater achieves this by using carbonized polymer materials that provide comparable heating efficiency without releasing harmful metal particles into the vapour.
Solution Approach 2:
The patent employs composite carbon foam structures combining conductive carbon materials with porous foam matrices. This composite approach maintains the electrical conductivity needed for efficient heating while the carbon-based composition prevents metallic contamination of the inhaled vapour.
2Use of energy by moving object
If conventional graphene is used as heating element, then electrical conductivity is improved, but brittleness and poor adhesion limit its applicability
Solution Approach 1:
The patent uses carbonized polymer foam structures that inherently provide flexibility and mechanical robustness. The foam matrix structure allows the heating element to be flexible and adherent while maintaining electrical conductivity, overcoming the brittleness issues of conventional graphene.
Solution Approach 2:
The patent transforms polymer materials through carbonization to create carbon foam with enhanced mechanical properties. This parameter change from polymer to carbonized structure provides both the electrical conductivity of graphene-like materials and the mechanical strength of foam structures, eliminating brittleness and adhesion problems.
3Object-affected harmful factors
If carbon foam heating element is used, then metallic contamination is eliminated and wettability is improved, but manufacturing complexity increases due to laser processing requirements
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods with laser-induced carbonization. The laser processing directly transforms polymer materials into carbon foam structures in situ, eliminating the need for complex assembly of multiple components and simplifying the manufacturing process despite the advanced processing technique used.
Solution Approach 2:
The patent uses laser-induced parameter changes to transform polymer materials directly into functional carbon foam heating elements. By controlling laser parameters (power, speed, focus), the process creates the desired carbonized foam structure with appropriate porosity and conductivity, simplifying manufacturing compared to traditional multi-step processes.
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 carbon foam heating element reduces the risk of metallic contamination and enhances the performance and safety of atomising devices by ensuring rapid vaporization without flaking, offering improved wettability and adhesion, thus providing a safer inhalable vapour.
Implementation Method 1
using a high temperature process generated by a laser beam directed at a polymer or polyimide sheet material to manufacture the carbon foam component
Implementation Method 2
the heater is typically a metallic wire or metallic mesh which is resistively heated using a power source delivering 4V to 5V
Implementation Method 3
a wicking structure feeds liquid from a small reservoir in the device to the heating element
Data Source
AI summary
A method of manufacturing a component for an atomising device is disclosed; the component is made substantially of carbon foam. The method includes the step of using a high temperature process generated by a laser beam directed at a carbon-based pre-cursor material, such as a polymer or polyimide sheet material, to manufacture the carbon foam component. The component is electrically conductive, non-metallic and porous to e-liquid. The component can be a carbon foam based component that functions as both a wicking element and also a heating element.