Porous Metal Atomizer for E-Cigarette Liquid Distribution

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Solution Overview

Problem

Traditional atomizing elements in electronic cigarettes have a small contact area between the resistance wire and the cigarette liquid, leading to low atomization speed, small atomization amount, and a risk of dry burning and overheating.

Innovation Solution

An atomizing element comprising a porous ceramic portion and a porous metal portion in contact with each other, where at least part of the pores of the porous ceramic portion communicate with the pores of the porous metal portion, and the porous metal portion has a thickness of not less than 30 μm, enhancing the effective atomization area and heat conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a traditional resistance wire is used for atomization, then the structure is simple, but the contact area with cigarette liquid is small leading to low atomization speed

Engineering Contradiction:

Improveatomization speedVSAvoidatomizing element structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies porous metal material as the atomizing element, which provides a large specific surface area through its porous structure. This increases the contact area between the atomizing element and cigarette liquid, thereby significantly improving atomization speed and efficiency while maintaining structural simplicity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite material structure combining porous metal and porous ceramic materials. The porous metal provides excellent electrical conductivity and heat conduction, while the porous ceramic provides high temperature resistance and chemical stability, achieving both high atomization speed and structural reliability

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If a traditional resistance wire is used, then the manufacturing is simple, but the atomization amount is small

Engineering Contradiction:

Improveatomization amountVSAvoidatomizing element fabrication

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The porous metal material inherently provides a large surface area to volume ratio, which increases the atomization amount without requiring complex multi-component structures. The manufacturing process involves forming the porous metal substrate and coating it with porous ceramic, which is relatively straightforward

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent optimizes parameters such as pore size (5-50 μm), porosity (30-70%), and thickness (30-200 μm) of the porous metal layer to maximize atomization amount. These parameter adjustments are achieved through controlled manufacturing processes without significantly increasing fabrication complexity

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a traditional atomizing element is used, then the structure is simple, but dry burning and overheating occur due to small contact area

Engineering Contradiction:

Improveprevention of dry burningVSAvoidatomizing element structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The porous structure of the metal material provides a large contact area with cigarette liquid, ensuring sufficient heat transfer and preventing local overheating and dry burning. This improves reliability while the single-integrated porous structure keeps the design relatively simple

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The composite of porous metal and porous ceramic materials provides both excellent heat conduction (preventing overheating) and high temperature resistance (preventing degradation). This enhances reliability without requiring complex active cooling or control systems

Inventive Principle:

Principle #40Composite materials

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 significantly increases the atomization speed and amount, prevents dry burning and overheating, and ensures consistent and pure smoke quality by providing a larger effective atomization area and uniform heat distribution.

Implementation Method 1

the porous metal portion having a thickness of not less than 30 μm, enhancing the effective atomization area and heat conduction

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

at least a part of pores of the porous ceramic portion communicating with pores of the porous metal portion

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20250040607A1Atomization element and electronic cigarette

Publication Date: 2025.02.06 SHENZHEN SMOORE TECH LTD

AI summary

An atomization element and an electronic cigarette. The atomization element comprises a porous ceramic portion and a porous metal portion contacting the porous ceramic portion; at least some holes of the porous ceramic portion is communicated with holes of the porous metal portion; the porous metal portion has a thickness of not less than 30 μm. The atomization element can sufficiently atomize an e-liquid, thereby improving the taste of aerosol.