MEMS Thermal Flow Sensor Controller for Electronic Cigarette
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Solution Overview
Problem
Current electronic cigarettes fail to replicate the immediacy response, desired resistance to draw, and consistency of traditional cigarettes, making them ineffective substitutes for habitual smokers.
Innovation Solution
A thermal flow sensor based controller with MEMS technology, comprising a resistive heater and thermopile, is integrated into an electronic cigarette to detect air flow and adjust heating current, simulating the smoking experience by responding to inhalation with low power consumption and high dynamic range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electronic cigarettes are designed with basic components (battery, atomizer, liquid reservoir), then the device structure is simple, but the device cannot provide immediacy response and consistent nicotine delivery like traditional cigarettes
Solution Approach 1:
The patent replaces conventional mechanical flow control mechanisms with a thermal flow sensor-based detection system. The sensor detects air flow through thermal principles (measuring temperature changes caused by air movement) and the controller automatically adjusts heating power based on detected flow characteristics, eliminating the need for mechanical valves or variable resistance components while achieving consistent nicotine delivery.
Solution Approach 2:
The patent implements a closed-loop feedback system where the thermal flow sensor continuously monitors air flow characteristics during user inhalation, and the controller assembly adjusts the atomizer heating power in real-time based on the detected flow rate and pattern. This feedback mechanism ensures consistent nicotine vapor delivery across different inhalation strengths and maintains immediacy response similar to traditional cigarettes.
2Speed
If the electronic cigarette uses a thermal flow sensor with MEMS technology for immediate response, then the response speed improves, but the device complexity increases
Solution Approach 1:
The patent utilizes MEMS technology to create a compact thermal flow sensor that detects air flow through changes in thermal parameters (temperature differential) rather than requiring complex mechanical or electrical measurements. The sensor's small size and low power consumption allow immediate response to inhalation without significantly increasing overall device complexity, as MEMS structures can be integrated into existing circuit boards.
Solution Approach 2:
The thermal flow sensor acts as an intermediary between the user's inhalation action and the controller's heating adjustment. Instead of requiring direct mechanical interaction or complex pressure sensing, the thermal sensor indirectly measures air flow through temperature changes, providing a simple yet effective coupling mechanism that responds immediately to inhalation while maintaining device simplicity.
3Ease of operation
If the electronic cigarette aims to replicate traditional cigarette resistance to draw, then the user experience improves, but the device requires complex flow control mechanisms
Solution Approach 1:
The patent replaces complex mechanical flow control mechanisms (such as variable restrictors or valve systems) with an electronic control approach. The thermal flow sensor detects air flow characteristics and the controller adjusts heating power to compensate for variations in draw resistance, replicating the sensation and performance of traditional cigarettes without requiring mechanical components that would increase device complexity.
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 controller provides immediate response to air flow, low power consumption, and high dynamic range, allowing for consistent nicotine delivery and realistic smoking simulation, including varying light emission and accurate nicotine measurement.
Implementation Method 1
The thermal flow sensor is fabricated using Micro-Electro-Mechanical Systems (MEMS) technologies. In a first embodiment the thermal flow sensor composes of a resistive heater and a thermopile, wherein the thermocouples of the thermopile are perpendicular to the resistive heater and the hot contacts of the thermopile and the resistive heater lie on a stack layer consisting of a porous silicon layer and an empty gap
Implementation Method 2
the thermal flow sensor composes of a resistive heater and a thermopile
Implementation Method 3
the hot contacts of the thermopile and the resistive heater lie on a stack layer consisting of a porous silicon layer and an empty gap, which recessed in a silicon substrate and provides local thermal isolation from the silicon substrate
Implementation Method 4
an atomizer consisting of a coil heater, wherein the coil heater is arranged on the outside of an atomizer
Data Source
AI summary
An electronic cigarette with a thermal flow sensor based controller is provided which comprises a housing; a battery, a controller assembly; an air inlet for allowing air to enter into the housing, a mouthpiece; a fluid reservoir; an atomizer; at least a light emitting diode; and a display. The thermal flow sensor is fabricated using micro-electro-mechanical systems (MEMS) technologies which is amenable to create the electronic cigarette with a thermal flow sensor based controller having stable evaporated liquid delivering, immediately response to smoker inhalation, like normal cigarette inhalation resistance, low power consumption, and no accidental actuation take place.