Reduced Ceramic Heating Element for Smoking Systems
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Solution Overview
Problem
Existing heating elements for electrically operated smoking systems are complex and expensive to manufacture, limiting design flexibility and increasing production costs.
Innovation Solution
A heating element comprising a ceramic main body with a thin, electrically conductive path formed through reduction processes, allowing for flexible design and low-cost manufacturing, with the conductive path being less than 10µm deep and formed using techniques like electro-chemical reduction or thermal reduction in a controlled environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete metallic heating elements are used, then heating function is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the heating element structure with a single ceramic body, integrating multiple functions into one component. The ceramic body itself serves as both the structural support and the heating element, eliminating the need for separate metallic heating elements and their complex assembly.
Solution Approach 2:
The patent changes the material parameter from metallic to ceramic, and specifically creates a reduced ceramic material with altered electrical properties. By controlling the reduction process and oxygen partial pressure, the ceramic material's electrical conductivity is modified to enable heating functionality without requiring separate metal components.
2Ease of manufacture
If reduced ceramic material is used for conductive path, then manufacturing cost decreases, but electrical conductivity must be maintained
Solution Approach 1:
The patent modifies the electrical parameters of ceramic material through chemical reduction. By controlling oxygen partial pressure and reduction conditions, the ceramic material transitions from insulating to conductive state, achieving the required electrical conductivity while maintaining ceramic material advantages.
Solution Approach 2:
The patent creates a composite structure where reduced ceramic material with different electrical properties forms the conductive path within the ceramic body. The differential reduction creates zones with varying electrical conductivity, enabling both structural integrity and electrical functionality in a single material system.
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 enables the production of a simple, inexpensive heating element with adjustable resistance and design flexibility, suitable for internal use in smoking systems, allowing for efficient heat transfer and reduced system size.
Implementation Method 1
the electrically conductive path comprising a reduced form of the ceramic material
Implementation Method 2
the electrically conductive path may be formed using an electro-chemical reduction process
Implementation Method 3
The electrically conductive path can perform as a resistive heater
Data Source
Figure 1a~1b
Figure 2~3
AI summary
An electrical heating element comprising a main body (10) comprising a ceramic material and an electrically conductive path (18) formed on the main body, the electrically conductive path comprising a reduced form of the ceramic material and having first and second contact portions (20, 22) for connection to a voltage source, the main body (10) has an elongate form with the first and second contact portions (20, 22) positioned at a first end of the main body (10) and the electrically conductive path (18) extending to and from the second end of the main body (10).