Ceramic Aerosol Heater With Embedded Thermocouple Sensing

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Solution Overview

Problem

Existing aerosol generators in electronic aerosol provision systems face challenges in accurately measuring heater temperature, which affects the efficient vaporization of aerosol-generating materials, often due to the limitations of separate temperature sensors and resistance-based measurements.

Innovation Solution

Incorporating a thermocouple embedded within a ceramic electrical heater, which provides a temperature-dependent voltage via the thermoelectric effect, allowing for accurate temperature determination of the heater.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a separate temperature sensor is used to measure heater temperature, then temperature measurement is possible, but the measurement accuracy deteriorates due to air flow cooling effects

Engineering Contradiction:

Improveheater temperature measurement accuracyVSAvoidair flow cooling effects on sensor

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The temperature sensing function is merged with the heater element itself by embedding a thermocouple within the ceramic heater structure. This integration ensures the sensor measures the actual heater temperature without being subjected to air flow cooling effects that plague separate temperature sensors positioned nearby.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ceramic material serves as an intermediary that embeds and protects the thermocouple while allowing it to accurately sense the heater temperature. The ceramic provides thermal coupling between the heating element and the thermocouple while shielding the sensor from direct air flow exposure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If resistance-based temperature measurement is used for the heater, then temperature determination is possible, but the measurement reliability deteriorates due to variations in electrical parameters

Engineering Contradiction:

Improveheater temperature determination accuracyVSAvoidtemperature measurement reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The electrical resistance-based temperature measurement method is replaced with a thermocouple-based measurement system. The thermocouple generates a temperature-dependent voltage through the Seebeck effect, providing a more reliable temperature indication that is not affected by variations in heater electrical resistance or power supply fluctuations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If temperature control is improved through accurate measurement, then aerosol generation efficiency is improved, but device complexity increases due to additional sensing and control mechanisms

Engineering Contradiction:

Improveaerosol generation efficiencyVSAvoidtemperature sensing and control system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The temperature sensing capability is combined with the heater structure by embedding the thermocouple within the ceramic heater, eliminating the need for separate temperature sensor assemblies and reducing overall system complexity while improving measurement accuracy for better aerosol generation efficiency.

Inventive Principle:

Principle #5Merging (Combining)

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 approach enables precise temperature control of the heater, improving aerosol generation efficiency by ensuring accurate temperature measurements that reflect the actual heater temperature, unimpeded by air flow and without cooling effects, thus enhancing the overall performance of the aerosol provision system.

Implementation Method 1

a thermocouple embedded in the ceramic material and operable to provide a temperature-dependent voltage via the thermoelectric effect from which a temperature of the electrical heater can be determined

Methodology Applied

Scientific EffectThermoelectric effect: Seebeck Effect

Implementation Method 2

an electrical heater to which aerosol-generating material is delivered from the storage area, for example by a capillary wick, the electrical heater being powered from the battery under the control of the controller in the device

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

heating to generate aerosol

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentUS20230346040A1Aerosol generator for an electronic aerosol provision system

Publication Date: 2023.11.02 NICOVENTURES TRADING LTD

AI summary

An aerosol generator for an electronic aerosol provision system includes an electrical heater formed from a ceramic body, an aerosol-generating material transfer component also known as a wick for delivering aerosol-generating material from a storage area to the electrical heater for heating to generate aerosol, and a thermocouple embedded in the ceramic material and operable to provide a temperature-dependent voltage via the thermoelectric effect from which a temperature of the electrical heater can be determined. The wick may be a bundle of fibers or wadding in contact with the ceramic body. Alternatively, the wick may be formed from a porous ceramic. The porous ceramic either is bonded to a non-porous ceramic configured as the heater body, or is used for both wicking and heating so that both wick and heater are formed from a single portion of ceramic material.