Dense Ceramic Substrate Heating Element for Electronic Atomizers
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Solution Overview
Problem
Current porous ceramic heating elements are prone to oxidation, fragility, and reduced liquid absorption during sintering, limiting their application in electronic atomizers and humidifiers.
Innovation Solution
A heating element comprising a dense ceramic substrate with a resistive film formed by resistive slurry and a microporous liquid guiding member, where the resistive slurry is printed on the dense ceramic substrate instead of porous ceramic, and a second dense ceramic substrate is cladded around the first to prevent oxidation and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If resistive slurry is printed on porous ceramic surface, then liquid absorption amount is increased, but the metal film is easily oxidized and carburized during high temperature sintering
Solution Approach 1:
The patent applies inert atmosphere protection by using a porous ceramic substrate that creates a protective environment during sintering. The porous ceramic structure prevents direct contact between oxygen and the metal resistive slurry film during high-temperature processing, thereby preventing oxidation and carburization while maintaining liquid absorption capabilities.
Solution Approach 2:
The patent uses a composite structure combining porous ceramic substrate with metal resistive slurry film. This composite material approach allows the porous ceramic to provide both mechanical support and oxidation protection, while the metal slurry provides the necessary electrical resistance for heating functionality.
2Power
If resistance wire is wound around glass fiber or oil-absorbing cotton, then heating function is achieved, but glass fiber produces debris and oil-absorbing cotton is easy to burn
Solution Approach 1:
The patent employs porous ceramic material as the substrate, which provides a stable, non-combustible structure with controlled porosity for liquid absorption. The porous ceramic does not produce debris like glass fiber and does not burn easily like oil-absorbing cotton, while still maintaining the ability to absorb and guide liquid to the heating element.
Solution Approach 2:
The patent changes the material parameters by transitioning from organic materials (glass fiber, oil-absorbing cotton) to inorganic porous ceramic material. This parameter change fundamentally alters the thermal stability and combustion characteristics, making the heating element more reliable and safe.
3Quantity of substance
If porous ceramic is used as heating element, then liquid absorption amount is increased, but different expansion coefficients cause cracking and separation during fabrication
Solution Approach 1:
The patent addresses the expansion coefficient mismatch by carefully controlling the sintering temperature and duration parameters. By optimizing these fabrication parameters, the thermal expansion differences between the porous ceramic substrate and the metal resistive slurry film are minimized, preventing cracking and separation while maintaining the high liquid absorption capability of the porous ceramic.
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 prevents oxidation and fragility of the resistive slurry film, maintains liquid absorption capacity, and improves the heating element's durability and performance in electronic atomizers and humidifiers.
Implementation Method 1
a heating material piece, configured to generate heat when being powered; a liquid guiding member, configured to guide an atomizing liquid to be heated
Implementation Method 2
a liquid guiding member, configured to guide an atomizing liquid to be heated; the liquid guiding member is a member made of a microporous material
Data Source
AI summary
A heating element and method for fabricating the same includes: a heating material piece configured to generate heat when being powered. A first substrate is configured to support the heating material piece and a liquid guiding member is configured to guide an atomizing liquid to be heated. The first substrate is a substrate made of a dense material and the heating material piece is a film with a certain resistance formed by a resistive slurry fixed on a surface of the dense material substrate by at least one selected from printing, coating, soaking and spraying. Two wires are electrically connected to the first substrate to form electrodes that are respectively connected to two ends of the film with a certain resistance. The liquid guiding member is a member made of a microporous material fixed outside the first substrate and the heating material piece.