Vaporizer Heater Power Conversion for Resistance-Compensated Control
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Solution Overview
Problem
Vaporizer devices face challenges with power management, including intolerance to heater and pod contact resistance variations, reduced battery run time, faster battery aging, limited system integration, and increased component count and cost due to conventional Pulse Width Modulation (PWM) approaches for heating element control.
Innovation Solution
A direct-current to direct-current (DC-DC) converter system with a power monitor that measures current and voltage across the heating element, allowing continuous power delivery and resistance monitoring, while adjusting output voltage to maintain target power or temperature, and integrating charger and heater control circuits for improved efficiency and usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If Pulse Width Modulation (PWM) is used to control heating element power, then temperature control is achieved, but battery run time is reduced and battery aging accelerates
Solution Approach 1:
The patent changes the control parameter from PWM duty cycle to DC voltage level. The DC-DC converter regulates the voltage supplied to the heating element based on temperature feedback, replacing the PWM switching approach. This continuous voltage regulation maintains temperature control while avoiding the battery stress and run time reduction associated with PWM switching.
Solution Approach 2:
The patent substitutes the PWM mechanical/electrical switching system with a DC-DC voltage regulation system. Instead of switching the power on and off rapidly, the system uses a DC-DC converter to continuously adjust the voltage level, replacing the switching mechanism with a continuous regulation approach that reduces battery stress.
2Measurement precision
If PWM control is implemented with resistance measurement, then heating element monitoring is improved, but device complexity and component count increase
Solution Approach 1:
The DC-DC converter serves multiple functions: it provides power regulation to the heating element, performs resistance measurement during the measurement phase, and enables temperature control. By integrating these functions into a single control system, the patent reduces overall device complexity while maintaining measurement precision.
Solution Approach 2:
The system uses the heating element itself as part of the measurement circuit. During the measurement phase, the DC-DC converter applies a known voltage and measures the resulting current to calculate resistance, using the element's own electrical properties for self-diagnosis without requiring external measurement equipment.
3Power
If PWM switching is used to regulate power, then power control is achieved, but contact resistance variations cause control inaccuracies
Solution Approach 1:
The patent implements a feedback control system where the DC-DC converter continuously monitors the heating element's resistance and adjusts the output voltage accordingly. The power monitor measures actual resistance values and feeds this information back to the controller, which compensates for contact resistance variations by adjusting the voltage to maintain the desired power level.
Solution Approach 2:
The system performs a preliminary resistance measurement phase before the heating phase. During this initial phase, the DC-DC converter measures the actual resistance of the heating element and contact contacts, storing this information for use during subsequent heating operations to pre-compensate for any resistance variations.
4Adaptability or versatility
If separate charger and heater control circuits are used, then functional independence is maintained, but system integration is limited and cost increases
Solution Approach 1:
The patent merges the charger control circuit and heater control circuit into a single integrated DC-DC converter system. The same converter that regulates power to the heating element also manages battery charging, using a unified control algorithm that can distinguish between charging and heating modes. This integration reduces component count and system complexity while maintaining the functional independence of both operations.
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 solution enables longer battery run time, deeper battery discharge, improved performance at low temperatures, reduced battery stress, and cost-effective system integration with continuous heater resistance and temperature monitoring, compensating for contact resistance variations and enhancing user experience.
Implementation Method 1
The converter can be further configured to receive a first voltage from the power source and provide a second voltage to the heating element
Implementation Method 2
A vaporizer atomizer or vaporization chamber can refer to an area or volume in the vaporizer device within which a heat source (for example, a conductive, convective, and/or radiative heat source) causes heating of a vaporizable material
Implementation Method 3
heating the vaporizable material in a vaporizer atomizer or vaporization chamber to cause the vaporizable material to be converted to the gas (or vapor) phase
Data Source
AI summary
A system includes a converter configured to electrically couple to a power source and to a heating element of a vaporizer atomizer. The converter can be further configured to receive a first voltage from the power source and provide a second voltage to the heating element. The converter can be a direct-current to direct-current converter. A power monitor configured to electrically couple to the heating element, measure a current through the heating element, measure a voltage over the heating element, calculate a power and/or resistance, and output a control signal to the converter. The converter can be configured to be controlled by the control signal to vary the second voltage to maintain a target power or a target temperature over the heating element. Related apparatus, systems, techniques and articles are also described.