Chemically Hardened Glass Heating Elements for E-Cigarettes
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Solution Overview
Problem
Existing heating elements for e-cigarettes face challenges with mechanical stability, energy efficiency, and longevity due to the use of ceramic or plastic carrier materials, which suffer from high manufacturing costs, surface roughness, porosity, and thermal conductivity issues, leading to inefficient heat transfer and potential health risks from leaching effects.
Innovation Solution
A heating element featuring a chemically hardened glass carrier material with low thermal conductivity and specific heat capacity, combined with metallic heating conductor structures, providing targeted heat transfer and enhanced mechanical stability, allowing for compact and efficient design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic carrier materials are used, then high temperature stability and electrical insulation are achieved, but manufacturing costs increase and surface roughness deteriorates adhesion
Solution Approach 1:
The patent changes the material parameter from ceramic to chemically hardened glass, which maintains high temperature stability (glass transition temperature Tg > 400°C) while significantly reducing manufacturing costs and improving surface properties for better adhesion
Solution Approach 2:
The chemically hardened glass carrier material provides a cost-effective alternative to expensive ceramics, offering similar thermal performance at lower manufacturing cost, making the heating element more economically viable
2Reliability
If ceramic carrier materials are used, then electrical insulation is achieved, but surface roughness and porosity worsen conductive coating adhesion
Solution Approach 1:
The patent changes the surface parameters of the carrier material by using chemically hardened glass, which provides a smoother, less porous surface compared to ceramics, thereby improving the adhesion of conductive coatings while maintaining electrical insulation properties
Solution Approach 2:
The heating element uses a composite structure with chemically hardened glass carrier material and metallic heating conductor structures, where the glass provides both electrical insulation and improved surface properties for better coating adhesion
3Strength
If ceramic carrier materials are used, then mechanical stability is achieved, but thermal conductivity increases causing heat dissipation
Solution Approach 1:
The patent changes the thermal parameter of the carrier material by selecting chemically hardened glass with low thermal conductivity, which reduces heat dissipation through the carrier while maintaining mechanical stability, thereby improving energy efficiency
Solution Approach 2:
The patent converts the potential harm of heat dissipation into a benefit by using low thermal conductivity glass, which confines heat to the heating area, improving energy efficiency and allowing the use of lower heating powers
4Loss of energy
If plastic carrier materials are used, then low thermal conductivity is achieved, but temperature resistance and service life are limited
Solution Approach 1:
The patent changes the material from plastic to chemically hardened glass, which maintains low thermal conductivity similar to plastics but dramatically improves temperature resistance (Tg > 400°C) and service life, eliminating the limitations of organic materials
Solution Approach 2:
The patent replaces short-lived plastic materials with long-lasting chemically hardened glass, creating a durable carrier material that resists high temperatures and organic solvents, significantly extending the service life of the heating element
5Volume of moving object
If heating element dimensions are reduced, then compactness is achieved, but mechanical stability deteriorates
Solution Approach 1:
The patent changes the mechanical parameters of the carrier material by using chemically hardened glass with enhanced strength and stiffness, which maintains mechanical stability even when the heating element dimensions are reduced, enabling compact designs
Solution Approach 2:
The composite structure of chemically hardened glass with metallic heating conductor structures provides a mechanically stable, compact heating element suitable for modern e-cigarette designs
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 achieves high heating performance, extended service life, and reduced energy consumption, while ensuring safe and effective vaporization of substances with improved mechanical strength and adhesion of conductive coatings.
Implementation Method 1
the carrier material has a very low thermal conductivity of
Implementation Method 2
metallic heating conductor structures
Implementation Method 3
heats a vaporizable liquid so that it can be inhaled by the user
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a heating element, which is particularly suitable for use in an electronic cigarette. The heating element comprises at least a substrate material made of glass or glass-ceramic and metallic heating conductor structures, wherein the heating conductor structures are applied to the substrate material and the substrate material has a thermal conductivity < 2 W/K*m, a heat capacity < 1000 J/K*kg and a roughness Ra < 500 nm.