Porous Heating Element with Integrated Electrodes for Easier Assembly
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Solution Overview
Problem
Conventional e-cigarettes face issues with unstable heating and inconvenient assembly due to the connection of electrode shrapnels to electrode contacts in the heating elements.
Innovation Solution
A heating element with a base featuring a heating section and electrode contacts fixedly connected to electrodes, utilizing silicon wafers or glass for precise hole arrangement, and a stable connection method like welding or soldering, along with an atomizing member and device design that facilitates easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode shrapnels are connected to electrode contacts in conventional heating elements, then the heating function is achieved, but the connection stability is poor and assembly is inconvenient
Solution Approach 1:
The patent merges the electrode contact and electrode into a single integrated component. The electrode contacts are directly formed as part of the heating element base structure, eliminating the need for separate electrode shrapnel connections. This integration ensures stable electrical connection while simplifying the assembly process, as the heating element can be directly installed without additional connection steps.
Solution Approach 2:
The patent extracts the connection complexity from the heating element design by removing the electrode shrapnel intermediate component. The electrode contacts are designed to directly interface with the power supply, eliminating the need for separate connection mechanisms. This extraction of the connection function from the heating element structure resolves the contradiction between connection stability and assembly convenience.
2Temperature
If conventional heating elements are used, then the basic heating function is provided, but heating uniformity is unstable
Solution Approach 1:
The patent applies local quality by designing the heating element with non-uniform hole distributions in different regions. The base structure contains multiple layers of holes with varying densities and sizes tailored to local heating requirements. This localized structural optimization ensures uniform heat distribution across the heating surface, resolving the heating uniformity issue while maintaining stable temperature control.
Solution Approach 2:
The patent utilizes porous materials by incorporating multiple layers of holes throughout the base structure. These porous features enable uniform capillary distribution of the atomizing substance across the heating element, ensuring consistent contact with the heating surface. The porous structure facilitates stable and uniform heating by preventing localized saturation or drying out, thereby improving both heating uniformity and temperature stability.
3Reliability
If complex connection structures are used to ensure stable electrode connections, then connection stability improves, but assembly complexity increases
Solution Approach 1:
The patent combines the electrode contact structure with the heating element base into a single integrated component. The electrode contacts are formed as integral parts of the base, eliminating the need for separate connection structures. This merging reduces assembly complexity while maintaining stable electrical connections, as the integrated design ensures proper alignment and contact without additional fastening or connection steps.
Solution Approach 2:
The patent segments the heating element into distinct functional zones with specialized structures. The base contains separate regions for electrode contacts, heating elements, and atomizing substance distribution, each optimized for its specific function. This segmentation allows for simplified assembly, as each segment can be independently manufactured and then assembled, reducing overall complexity while ensuring stable connections through dedicated contact interfaces.
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
Enhances the stability of electrode connections, improves heating uniformity, and simplifies assembly processes in e-cigarettes and related devices.
Implementation Method 1
a heating layer disposed on the surface of the heating section... for atomizing an atomizing substance to form an aerosol
Implementation Method 2
a plurality of holes arranged in a predetermined pattern, the plurality of holes being configured to adsorb an atomizing substance and direct the adsorbed atomizing substance to the heating layer
Data Source
AI summary
A heating element for atomizing an atomizing substance to form an aerosol, the heating element including: a base including a heating section, the heating section including a surface, a heating layer disposed on the surface, and a plurality of holes arranged in a predetermined pattern, the plurality of holes being configured to adsorb an atomizing substance and direct the adsorbed atomizing substance to the heating layer; a plurality of electrode contacts disposed on the surface of the heating section; and a plurality of electrodes being fixedly connected to the plurality of electrode contacts, respectively.