Ceramic Heater Surface Electrode for Stable TCR and Fast Heating
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Solution Overview
Problem
Existing ceramic heat generation bodies for low-temperature cigarettes suffer from high thermal resistance, inconsistent temperature coefficient of resistance (TCR), and difficulty in insertion and extraction, leading to high defective rates and inaccurate temperature control.
Innovation Solution
A ceramic heat generation body comprising a ceramic rod matrix with a resistance heat generation element made of an alloy containing tungsten, manganese, and additives like ruthenium, tellurium, germanium, or vanadium, printed using a decalcomania process, allowing for consistent low TCR and easy insertion/extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If alumina ceramic green body is used as insulating layer and matrix with inner electrode embedded, then insulation performance is improved, but heat generation efficiency deteriorates due to heat absorption by alumina ceramic
Solution Approach 1:
The patent extracts the inner electrode from the alumina ceramic matrix and relocates it to the surface of the ceramic rod. This eliminates the heat absorption problem caused by embedding the electrode within the alumina ceramic, while the alumina ceramic continues to provide insulation and structural support as the outer matrix.
Solution Approach 2:
The patent uses a composite structure combining ceramic rod matrix (providing thermal conductivity and structural support) with alumina ceramic coating (providing insulation), rather than relying solely on alumina ceramic for both functions. This composite approach optimizes both heat generation efficiency and insulation performance.
2Reliability
If alumina ceramic green body is added to the structure, then insulation performance is improved, but the ceramic heat generation body becomes thicker and harder to insert into low-temperature cigarettes
Solution Approach 1:
The patent extracts the insulating function from the bulk alumina ceramic green body structure and implements it as a thin alumina ceramic coating layer on the surface of a compact ceramic rod matrix. This maintains the necessary insulation performance while dramatically reducing the overall thickness to enable easy insertion into low-temperature cigarettes.
Solution Approach 2:
The patent uses a thin alumina ceramic coating film applied on the surface of the ceramic rod matrix to provide insulation. This thin-film approach provides the necessary electrical insulation while minimizing the increase in overall dimensions, allowing the heater to fit into compact low-temperature cigarette devices.
3Ease of manufacture
If electronic paste products from prior art are used to prepare heat generation element, then manufacturing process is simplified, but TCR consistency deteriorates with extremely large deviation across different batches
Solution Approach 1:
The patent modifies the composition parameters of the electronic paste by adding specific metal elements (such as nickel, copper, or manganese) to the traditional tungsten-manganese base paste. This compositional change stabilizes the TCR across different batches while maintaining the simplicity of the screen printing manufacturing process.
Solution Approach 2:
The patent uses a composite electronic paste formulation combining tungsten, manganese, and additional metal elements (nickel, copper, or manganese) with specific oxide components. This composite paste composition achieves consistent TCR performance across batches while remaining compatible with existing screen printing manufacturing 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 solution enables quick heat generation, easy insertion and extraction, and consistent TCR across batches, reducing defective rates and ensuring reliable resistance control.
Implementation Method 1
a resistance heat generation element, which is an alloy containing tungsten, manganese and at least one selected from ruthenium, tellurium, germanium, and vanadium
Implementation Method 2
The ceramic heating body is a kind of high-efficiency heater with uniform heat distribution and excellent thermal conductivity
Data Source
AI summary
The present disclosure provides a ceramic heat generation body and a preparation method thereof. The ceramic heat generation body includes a ceramic rod matrix, and electronic paste is printed on a surface of the ceramic rod matrix in a decalcomania manner. The preparation method includes printing the electronic paste on the ceramic rod matrix in the decalcomania manner. In addition, the present disclosure further provides a use of the ceramic heat generation body in a heater for novel tobacco products.