Device for transferring an active substance to a gas phase

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Solution Overview

Problem

Existing devices for converting active substances into a gas phase, such as electronic cigarettes and heat-not-burn products, face high energy consumption and low mechanical stability due to the use of wound Kanthal resistors, which require continuous heating and have limited long-term stability.

Innovation Solution

A device using a thin film heating element made of nickel-chromium alloy or refractory metal that emits thermal radiation, allowing for efficient heat transfer via thermal radiation and conduction, with a thickness ranging from 0.5 μm to 25 μm, enhancing energy efficiency and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wound Kanthal resistors are used for heating, then continuous heating can be maintained, but energy consumption increases and mechanical stability decreases

Engineering Contradiction:

Improvelong-term stabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the physical parameters of the heating element by transitioning from thick wound Kanthal resistors to thin films (0.5-25 μm) of nickel-chromium alloy or refractory metals. This parameter change reduces thermal mass and enables pulsed heating operation, thereby reducing energy consumption while maintaining reliability through controlled thermal radiation heating.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements periodic pulsed heating cycles instead of continuous heating. The thin film heating element can be rapidly heated and cooled in pulses, matching the consumer's inhalation pattern. This periodic action reduces average energy consumption while maintaining the ability to provide sufficient vapor during each pulse.

Inventive Principle:

Principle #19Periodic action

2Use of energy by moving object

If thin Kanthal meshes are used to reduce thermal mass, then energy efficiency improves, but mechanical stability deteriorates

Engineering Contradiction:

Improveenergy efficiencyVSAvoidmechanical stability

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The patent uses composite material structures where thin films of nickel-chromium alloy or refractory metals are deposited on substrates or formed as self-supporting membranes. The thin film itself (0.5-25 μm) provides both the heating function and sufficient mechanical stability, eliminating the need for thicker meshes while maintaining energy efficiency.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs thin film technology to create a heating element that is both mechanically stable and energy-efficient. The thin film (0.5-25 μm) of nickel-chromium alloy or refractory metal provides sufficient mechanical integrity while having low thermal mass, enabling rapid heating and cooling cycles without compromising structural stability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Speed

If thermal radiation heating is implemented, then heating speed increases, but device complexity increases

Engineering Contradiction:

Improveheating rateVSAvoiddevice complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent replaces conventional conductive heating mechanisms with thermal radiation heating. The thin film heating element emits infrared radiation that directly heats the consumable product and vaporizes the active substance. This substitution eliminates the need for complex thermal management systems and contact-based heating structures, simplifying the overall device while achieving rapid heating rates up to 2000 K/s.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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 thin film heating element achieves fast heating rates up to 2000 Kelvin per second with improved mechanical stability, ensuring efficient and long-term conversion of active substances into a gas phase.

Implementation Method 1

The heating element is made from a film of a nickel-chromium alloy or a refractory metal, wherein the heating element is designed to emit thermal radiation

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the heating element is designed to emit thermal radiation, and wherein the heating element is arranged with respect to the reservoir such that the active substance is heated at least by means of the thermal radiation emitted from the heating element

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250341340A1Device for transferring an active substance to a gas phase

Publication Date: 2025.11.06 INNOVATIVE SENSOR TECH IST

AI summary

A device for transferring an active substance to a gas phase, which active substance contains at least one organic component, includes: a reservoir, which is designed to receive the active substance; and a heating element, which is made from a film of a nickel-chromium alloy or a refractory metal, wherein the heating element is designed to emit thermal radiation, and wherein the heating element is arranged with respect to the reservoir such that the active substance is heated at least by the thermal radiation emitted from the heating element.