Laser-Graphitized Porous Carbon Core for Low-Loss Atomization
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Solution Overview
Problem
Porous carbon atomization cores exhibit high energy consumption due to a large heating area and heat diffusion from atomization areas to non-atomization areas, leading to energy waste and inefficiency.
Innovation Solution
A method involving laser processing is used to form a high conductive heating area within a porous carbon core, with controlled electrical conductivity differences between the heating and matrix areas, reducing direct contact and heat loss, and maintaining a uniform temperature field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If laser processing is used to form a high conductive heating area in the porous carbon core, then energy consumption is reduced and atomization performance is enhanced, but the device complexity increases due to the additional processing step
Solution Approach 1:
The patent applies local quality by creating a high conductive heating area with distinct electrical conductivity properties within the porous carbon core. Laser processing modifies only the specific region that requires enhanced heating, while the rest of the core maintains its original properties. This localized modification reduces overall energy consumption by concentrating electrical conductivity where needed for atomization, without requiring complete restructuring of the entire device.
Solution Approach 2:
The patent replaces traditional mechanical heating methods with laser-induced graphitization to create the heating area. Instead of using external heating elements or mechanical contact methods, the laser energy directly transforms the porous carbon material into a high conductive state through localized graphitization. This substitution eliminates the need for additional mechanical heating components, reducing device complexity while improving energy efficiency.
2Productivity
If the heating area is enlarged to improve atomization coverage, then atomization performance is enhanced, but heat diffusion to non-atomization areas increases causing energy waste
Solution Approach 1:
The patent creates distinct zones within the porous carbon core with different electrical conductivity properties. The high conductive heating area is precisely defined and localized to where atomization is needed, while surrounding areas maintain lower conductivity. This spatial differentiation of properties allows the heating area to be sufficiently large for good atomization coverage while preventing excessive heat diffusion to non-atomization regions, thus balancing productivity with energy efficiency.
Solution Approach 2:
The porous carbon matrix acts as an intermediary between the high conductive heating area and the external environment. Its inherent porous structure and thermal properties serve as a natural barrier that limits heat diffusion to non-atomization areas. This intermediary role of the porous carbon material allows the heating area to extend sufficiently for good atomization performance while the matrix itself prevents excessive energy loss through uncontrolled heat diffusion.
3Ease of manufacture
If traditional ceramic or cotton cores with metal heating bodies are used, then manufacturing is simpler, but interface problems cause liquid explosion and cracking during heating
Solution Approach 1:
The patent merges the heating function and the structural matrix into a single integrated porous carbon core. The high conductive heating area is formed within the porous carbon material itself through laser-induced graphitization, eliminating the need for separate metal heating bodies and their interfaces with ceramic or cotton components. This integration removes the interface problems that cause liquid explosion and cracking, while the porous carbon structure maintains manufacturing simplicity and inherent reliability.
4Temperature
If uniform temperature field distribution is achieved in traditional cores, then heating uniformity is improved, but local overheating and pore clogging occur
Solution Approach 1:
The patent creates non-uniform electrical conductivity distribution within the porous carbon core, with a high conductive heating area localized to where atomization is required. This intentional non-uniformity concentrates heating where needed while preventing excessive temperature rise in other regions. The porous structure is preserved in the heating area to maintain pore patency, avoiding the uniform heating approach that causes local overheating and pore clogging while still achieving adequate temperature uniformity for reliable operation.
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 significantly reduces energy consumption, enhances atomization performance, and maintains a uniform temperature distribution while minimizing energy waste and potential liquid deterioration.
Implementation Method 1
since the absorption rate of porous carbon materials to infrared lasers can reach more than 90%, the absorbed laser energy is mainly converted into internal energy
Implementation Method 2
treating the part to be treated by laser processing, so that the part to be treated absorbs the laser energy, generates local instantaneous high temperature
Implementation Method 3
heat diffuses from the atomization area to the non-atomization area
Data Source
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AI summary
A porous carbon core and a preparation method therefor, an atomization core (11), and an electronic atomizer (10). The method comprises: obtaining a porous carbon preform, the porous carbon preform comprising a porous carbon matrix (111) and a part to be treated which are integrally formed; and treating said part in a laser processing mode, so that said part is graphitized to form a high conductive heating area (112), and a porous carbon core is obtained, wherein the conductivity of the high conductive heating region (112) is greater than that of the porous carbon matrix (111). A part to be treated of a porous carbon preform is treated by adopting a laser processing method, so that said part absorbs laser energy, local instantaneous high temperature is generated, and local graphitization occurs, and thus a high conductive heating area (112) is formed in the porous carbon preform and can be used as an atomization part; electric heating can be basically carried out on the atomization part of high conductivity, the porous carbon matrix (111) of low conductive is used as a non-atomization part and mainly used for absorbing and guiding e-liquid, thereby reducing the energy consumption of the porous carbon atomization core (11).