Porous Ceramic Heating Assembly for High-Wattage E-Cigarettes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heating assemblies in atomizers for electronic cigarettes, particularly those with glass fiber cores, are unsuitable for high-wattage applications as they can be damaged by high temperatures, leading to uneven heating and an unsatisfactory user experience.
Innovation Solution
A heating assembly with a substrate and micro porous ceramic liquid conducting bodies that are sintered to form an integral structure, allowing for efficient absorption and heating of tobacco liquid, and featuring a thermistor layer for temperature control to maintain stable output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass fiber core is used in heating assembly, then the structure is simple and easy to manufacture, but the glass fiber core may be burnt due to high temperature in large wattage applications
Solution Approach 1:
The patent changes the material parameter from glass fiber to high-temperature resistant materials such as ceramic foam or porous ceramic. These materials can withstand temperatures above 1000°C, solving the problem of glass fiber burning in high-wattage applications while maintaining structural integrity and reliability.
Solution Approach 2:
The patent uses composite structures combining porous ceramic materials with heating elements. The ceramic foam or porous ceramic provides both structural support and liquid absorption capabilities while resisting high temperatures, creating a reliable heating assembly for high-wattage operation.
2Power
If heating wire is wrapped around liquid conducting body, then the heating function is achieved, but the gap between heating wire and surface may be uneven causing unsatisfactory user experience
Solution Approach 1:
The patent extracts the heating wire wrapping step from the manufacturing process and replaces it with a pre-formed porous ceramic structure that has integrated heating elements. This eliminates the need for manual wrapping and ensures uniform contact between the heating element and liquid conducting body, improving both manufacturing precision and heat distribution.
Solution Approach 2:
The patent merges the heating element and liquid conducting body into a single integrated porous ceramic structure. The heating elements are embedded within or on the surface of the porous ceramic, ensuring uniform thermal contact and eliminating gaps that would occur with separate wrapped components.
3Productivity
If high wattage heating is applied, then the heating efficiency is improved, but the glass fiber core may be burnt due to high temperature
Solution Approach 1:
The patent changes the thermal resistance parameter of the liquid conducting body by using porous ceramic materials with higher melting points and better thermal stability. This allows the system to operate at high wattages (e.g., 40W or above) without the liquid conducting body degrading, thereby maintaining high heating efficiency while eliminating temperature-related damage.
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 provides a stable and efficient heating mechanism that prevents damage from high temperatures, ensuring consistent aerosol production and improved user experience by maintaining a stable temperature range.
Implementation Method 1
The liquid conducting body is made of micro porous ceramic material and is in tight contact with the substrate. The liquid conducting body is capable of conveying the tobacco liquid to the substrate.
Implementation Method 2
The heating part is configured for heating the tobacco liquid to form aerosol. The at least one heating element is electrically connected to the conductive part.
Implementation Method 3
the heating part is configured for heating the tobacco liquid to form aerosol
Implementation Method 4
featuring a thermistor layer for temperature control to maintain stable output
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An exemplary heating assembly (108) includes a substrate (1081), a heating part (1084) formed on the substrate (1081), an electrode part (1085, 1086, 1087) connected with the heating part (1084), and a liquid conducting body (1082, 1083) configured for absorbing tobacco liquid. The liquid conducting body (1082, 1083) is in tight contact with the substrate (1081). The liquid conducting body (1082, 1083) is capable of conveying the tobacco liquid to the substrate (1081).