Composite Heating Film Structure for Oxidation-Resistant Atomizers
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Solution Overview
Problem
Existing electronic atomizing devices face issues with metal film oxidation and failure due to insufficient oil supply, leading to reduced stability and lifespan, especially when using precious metals, which also increase costs.
Innovation Solution
An atomizing element with a substrate and a heating film comprising a metal heating layer and an inorganic protection layer, where the metal heating layer has multiple stacked sub-layers with different compositions, and the inorganic protection layer is applied to the metal heating layer's surface, reducing corrosion and improving stability and lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a 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 (nickel or stainless steel) and a precious metal coating layer. This composite structure provides both the heating performance needed from the base metal and the corrosion resistance from the precious metal coating, while using significantly less precious metal than traditional single-layer films. The multi-layer composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent applies precious metal coating specifically on the surface of the base metal layer where it is most needed for corrosion protection, rather than using precious metal throughout the entire film. This localized application maintains the heating performance where required while reducing overall precious metal content and cost, addressing both performance and reliability concerns.
2Power
If a metal film with high proportion of precious metal is used, then the heating performance is improved, but the cost of the atomizing element increases
Solution Approach 1:
The composite metal film structure allows the use of abundant, low-cost base metals (nickel, stainless steel) for the bulk of the heating film, with only a thin coating of precious metal providing the necessary corrosion resistance. This dramatically reduces the overall precious metal content and cost compared to traditional single-layer precious metal films, while maintaining adequate heating performance.
Solution Approach 2:
The patent employs a cost-effective base metal layer that can be easily replaced if needed, with the precious metal serving as a protective coating. This approach prioritizes cost reduction by using inexpensive materials for the bulk structure, accepting that the base metal layer may need replacement while the precious metal coating preserves the functional integrity during service.
3Reliability
If insufficient oil supply occurs during atomizing process, then the metal film is prone to oxidation failure and over-burning, but using precious metal reduces this risk
Solution Approach 1:
The composite structure provides oxidation resistance through the precious metal coating layer protecting the base metal from direct exposure to oxygen and combustion byproducts. This layered approach delivers the necessary protection against oxidation failure while minimizing precious metal consumption compared to using precious metal as the entire film structure.
Solution Approach 2:
The precious metal coating is applied locally on the surface of the base metal layer where oxidation resistance is most critical, rather than throughout the entire film thickness. This localized protection provides sufficient oxidation resistance to prevent failure during insufficient oil supply conditions while reducing overall 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 lifespan of the atomizing element by minimizing corrosion and failure, while reducing the need for precious metals, thus lowering costs and maintaining efficient atomization.
Implementation Method 1
The heating film is arranged on the atomizing surface and is capable of heating and atomizing an aerosol-generating substance on the atomizing surface in response to being energized
Implementation Method 2
The inorganic protection layer is arranged on a surface of the metal heating layer away from the substrate
Data Source
Figure 1~2
Figure 3~4
Figure 5~7b
AI summary
An atomizing element (11), an atomizer (10), and an electronic atomizing device. The atomizing element (11) includes a substrate (111) and a heating film (112). The substrate (111) includes an atomizing surface (1111), the heating film (112) is arranged on the atomizing surface (1111) and is capable of heating and atomizing an aerosol-generating substance on the atomizing surface (1111) in response to being energized. The heating film (112) includes an inorganic protection layer (1122) and a metal heating layer (1121) stacked with the inorganic protection layer (1122). The inorganic protection layer (1122) is located on a surface of the metal heating layer (1121) away from the substrate (111); and the metal heating layer (1121) includes at least two sequentially stacked sub-metal layers (1121a), and any adjacent two metal layers have different compositions.