Integrated Thermocouple Heating Element to Prevent Short Circuits
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Solution Overview
Problem
Existing heating elements for electronic smoking implements suffer from issues such as short-circuiting due to the close arrangement of heating wires and thermocouples, leading to complex and costly production processes.
Innovation Solution
A composite-type heating element is created by welding two different conductive materials to form a heating body that also functions as a thermocouple, eliminating the need for separate temperature measuring elements and simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating wire and thermocouple are arranged on the heating element, then temperature measurement function is achieved, but the heating element is prone to short-circuit and production process becomes complicated
Solution Approach 1:
The patent combines the heating function and temperature measurement function into a single integrated heating element. The heating wire and thermocouple are merged into one component structure, eliminating the need for separate arrangement of these elements. This integration directly resolves the short-circuit risk between closely arranged heating wire and thermocouple, while also simplifying the production process by reducing the number of components and assembly steps.
Solution Approach 2:
The integrated heating element serves multiple functions simultaneously: it acts as both a heating element and a temperature sensing element through the embedded thermocouple. This multi-functionality eliminates the need for separate heating and temperature measurement components, thereby reducing device complexity and improving reliability by removing potential short-circuit points between separate elements.
2Ease of operation
If heating wire and thermocouple are arranged closely on the heating element, then temperature control function is achieved, but the heating element is prone to short-circuit
Solution Approach 1:
The patent merges the heating wire and thermocouple into a single integrated structure where the thermocouple is embedded within or alongside the heating element body. This merging maintains the close proximity needed for effective temperature control while eliminating the risk of short-circuit between separately arranged heating wire and thermocouple, as they become part of the same component system with proper electrical isolation built into the design.
3Adaptability or versatility
If heating circuit and temperature measuring circuit are designed separately, then circuit functionality is achieved, but the overall circuit becomes complex
Solution Approach 1:
The patent integrates the heating circuit and temperature measuring circuit into a unified control system. The integrated heating element with embedded thermocouple allows both heating and temperature measurement signals to be processed through a single control circuit, eliminating the need for separate heating circuit and temperature measuring circuit designs. This reduces overall circuit complexity while maintaining full functionality through intelligent circuit design that handles both functions sequentially or simultaneously as needed.
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
This integrated design improves performance, reduces production costs, and enhances user experience by integrating heating and temperature measurement functions, while reducing complexity and improving tobacco roasting efficiency.
Implementation Method 1
The two metal or alloy materials after being welded are configured to heat up under energized conditions
Implementation Method 2
The two metal or alloy materials after being welded are configured to heat up under energized conditions, and serve as a thermocouple temperature measuring sensor for temperature measuring when not under energized conditions
Data Source
Figure 1~2
AI summary
A composite-type temperature raising and control integrated heating element (1) and a temperature control method are provided. The heating element (1) includes a heating body (4), which is integrated by welding two different conductive materials at a welding point (3). The heating element (1) is not provided with a temperature measuring element other than the heating body (4). The heating body (4) of the temperature raising and control integrated heating element (1) is formed by welding two conductive materials. When a high voltage is applied, the two conductive materials serve as the heating body (4) to generate heat. When the supply of the voltage is stopped, the two conductive materials serve as a thermocouple temperature measuring sensor to measure the temperature of the heating element (1). Compared to existing heating elements, the temperature measuring sensor is omitted, the fabrication process of the heating element (1) is simplified, the performance of the heating element (1) is improved, the roasting effect of tobacco rolls is improved, the production costs are reduced, and a better user experience is brought to consumers.