Composite Heating Film for Oxidation-Resistant Atomization
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Solution Overview
Problem
The stability and service life of electronic atomization devices are compromised due to oxidation failure and over-burning of metal films, particularly when oil supply is insufficient, leading to high costs and reduced performance.
Innovation Solution
An atomization component with a heating film comprising a metal heating layer and an inorganic protection layer, where the metal heating layer consists of multiple sub-layers with different components, and the inorganic protection layer is applied to the metal heating layer's surface, reducing internal stress and protecting it from corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a heating metal film with high proportion of precious metal is used, then the heating performance is improved, but the cost increases and the metal film is prone to over-burning and agglomeration when oil supply is insufficient
Solution Approach 1:
The patent uses a composite metal film structure consisting of a base metal layer (cost-effective material) and a precious metal coating layer (thin layer providing necessary heating properties). This composite structure achieves good heating performance while reducing the overall precious metal content, thereby lowering cost and improving stability by preventing over-burning and agglomeration.
Solution Approach 2:
The precious metal is applied only as a thin coating layer on the surface of the base metal layer, rather than using high proportion throughout the entire metal film. This local application maintains the necessary heating performance at the surface while reducing the total precious metal content, addressing both performance and stability requirements.
2Power
If a heating metal film with high proportion of precious metal is used, then the heating performance is improved, but the service life is reduced due to oxidation failure during sintering and atomization
Solution Approach 1:
The composite structure with base metal layer and thin precious metal coating provides both good heating performance and enhanced durability. The base metal layer offers structural stability and resistance to oxidation during sintering and atomization processes, while the thin precious metal coating maintains necessary heating properties, thereby extending service life.
Solution Approach 2:
The patent employs a cost-effective base metal layer as the primary structural component that provides long-term durability and resistance to oxidation. The precious metal coating serves its heating function but is minimized in quantity, allowing the cheaper base metal to carry the bulk of the structural and longevity requirements.
3Power
If precious metal material is used in the heating metal film, then the heating performance is improved, but the production cost increases
Solution Approach 1:
The patent combines a cost-effective base metal layer with a thin precious metal coating layer. This composite approach maintains the necessary heating performance provided by the precious metal while significantly reducing the total amount of precious metal required, thereby lowering production costs.
Solution Approach 2:
The precious metal is applied locally as a thin surface coating rather than throughout the entire metal film. This localized application maintains the heating performance where it is most needed (at the surface contacting the aerosol-generating substrate) while minimizing the overall cost by reducing precious metal consumption.
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 enhances the stability and extends the service life of the atomization component by preventing over-burning and agglomeration, while reducing production costs through the use of less expensive inorganic materials.
Implementation Method 1
the heating film is arranged on the atomization surface, and when energized, is configured to heat and atomize an aerosol-generating substrate on the atomization surface
Implementation Method 2
The metal film is prone to oxidation failure during the sintering and atomization, especially when oil supply is insufficient during the atomization
Data Source
AI summary
An atomization component includes: a matrix; and a heating film. The matrix includes an atomization surface. The heating film is arranged on the atomization surface, and when energized, heats and atomizes an aerosol-generating substrate on the atomization surface. The heating film includes a metal heating layer and an inorganic protection layer that are stacked, the inorganic protection layer being arranged on a surface of the metal heating layer that is away from the matrix. The metal heating layer includes at least two sub-metal layers that are sequentially stacked. Any two adjacent sub-metal layers have different components.