Patent Publication Number: US-11659864-B2

Title: Electronic cigarette burner element

Description:
FIELD OF THE INVENTION 
     The present invention is in the field of electronic cigarette burner elements. 
     DISCUSSION OF RELATED ART 
     Electronic cigarettes are electronic resistance heaters that imitate combustion based cigarettes. Electronic cigarettes can be used to quit smoking and to replace cigarettes. The e-cigarette has a built-in heating element, and the smoke oil containing nicotine is heated into a gas such as smoke or vapor through atomization, and then the user smokes from the mouthpiece. At present, the heating element of the existing electronic cigarette uses the tobacco cotton or wool to conduct oil, and then uses the heating wire to generate vape gas. The traditional electronic cigarette has a fabric wick that suffers from being easily scorched, having inconsistent wicking, and is labor-intensive to install. 
     For example, in U.S. Pat. No. 9,763,477 entitled Ceramic Heating Elements For Electronic Cigarettes by inventor Xiaochun Zhu, published Sep. 19, 2017 the abstract discloses, “An electronic cigarette having ceramic heating element with a heating rod has: (a) a hollow atomizing stem, (b) a first conductive ring sleeved at bottom of atomizing stem and airproof with atomizing stem, (c) a second conductive ring placed in and insulated from first conductive ring, (d) a conduit positioned in atomizing stem, with conduit base tightly contacting first conductive ring, (e) a liquid blocker positioned on top of atomizing stem, (f) a cigarette mouthpiece located on top of the atomizing stem and holds liquid blocker, and (g) a heating rod. The inner wall of atomizing stem, outer wall of conduit, top of first conductive ring, and bottom of liquid blocker together form a liquid storage chamber for storing e-liquid. In one embodiment, the heating rod can be a solid ceramic heating rod. In another embodiment, the heating rod can be a hollow ceramic heating rod.” 
     Also for example, in United States publication number US20190274353A1 entitled Buck Regulator With Operational Amplifier Feedback For An Aerosol Delivery Device by inventor Rajesh Sur, published Sep. 12, 2019 the abstract discloses, “An aerosol delivery device is provided that includes a heating element configured to convert electricity to heat and thereby vaporize components of an aerosol precursor composition, and a control component coupled to and configured to controllably power the heating element. The control component includes a buck regulator circuit coupled to the heating element, and an operational amplifier circuit coupled to the heating element and buck regulator circuit. The buck regulator circuit is configured to step down voltage and step up current from a power source to the heating element to thereby power the heating element. The operational amplifier circuit is configured to amplify an output voltage from the heating element to produce a higher voltage that is fed back to the buck regulator circuit, which is configured to use the higher voltage to regulate an output voltage from the buck regulator circuit to the heating element.” 
     For example, in United States publication number US20180289058A1 Electronic Cigarette and Atomizer Thereof by inventor Zhiping CHEN, published Sep. 22, 2011 the abstract discloses, “An atomizer includes a main body defining an airflow channel and a liquid storage cavity isolated from each other and an atomizing element. The atomizing element includes a porous body and a porous heating film. The porous body includes an atomizing surface and a liquid absorption surface. The atomizing surface is a plane and is substantially parallel to a direction of an air flow in the airflow channel, and the porous heating film is formed on the atomizing surface. The liquid absorption surface can absorb a liquid in the liquid storage cavity.” 
     For example, in the United States publication number US20160192710A1 Atomization Assembly And Electronic Cigarette by inventor Qiuming Liu, published Jul. 7, 2016 the abstract discloses, “An atomization assembly and an electronic cigarette are provided by the present application, the atomization assembly includes a liquid storage assembly and an atomization core assembly. The liquid storage assembly includes a liquid storage sleeve and a vapor pipe. The atomization core assembly includes an atomizing seat and an electric heating wire element. One end of the atomizing seat is covered with a cup cover, and an opening of the liquid storage chamber is covered by an end surface of the cup cover. A liquid guiding hole is provided at an area of the end surface of the cup cover, and a vapor hole is provided at an area of the end surface of the cup cover. A liquid guiding plate is provided at one side of the end surface of the cup cover. Thus, the liquid storage assembly and the atomization core assembly can be easily assembled.” 
     For example, in United States publication number US20170035119A1 Non-Porous Atomizer Chamber by inventor Desmond Gregory Otto, published Feb. 9, 2017 the abstract discloses, “A nonporous atomizer chamber atomizes a tobacco substance and is operable with a vaporizer. The chamber is fabricated from a nonporous material composition that is generally not permeable to water, gas, or other fluids. The nonporous material is effective for use with the chamber, where high temperatures create chemical reactions with the tobacco substance that cause absorption into the pores of a housing of the chamber. This creates undesirable toxic cumulates that leave aftertaste, off gas, and discolor in the housing. The housing atomizes the tobacco substance with a uniquely disposed heating coil. The heating coil takes three different possible positions, with each position creating a synergy with the nonporous material of the chamber to provide optimal atomization. A flat, coplanar position with a closed end of the housing prevents blockage of holes. A transverse disposition heats up efficiently. A longitudinal disposition occupies large volume area in the housing.” 
     SUMMARY OF THE INVENTION 
     The present invention is an improvement in the heating element for electronic cigarettes. Electronic cigarettes have an electrical resistance heated wire and generally they have a reliability and efficiency deficiency in part due to the small size construction which the present invention seeks to improve. The present invention heating element, also called burner element is self-contained. 
     An electronic cigarette heater element has a heating wire body and a stainless steel cover that covers the heating wire body. The black ceramic body can be sintered together with the stainless steel cover tube. The stainless steel cover tube is formed as a cylindrical shaped tube. The heating body is made of a ceramic matrix formed around a heating wire coil. The two materials are sintered together to form a new electronic cigarette heating body. The stainless steel cover preferably has four symmetrical circular through holes. Vape oil, also called electronic vaporizer oil, or smoke oil can enter the ceramic portion through the hole in the stainless steel cover. The oil can penetrate into the heating wire due to the porous wick nature of the ceramic. Oil near the heating wire is heated and emits a vapor that is drawn away from the ceramic heating element. A variety of different concentrations of oil can be used in conjunction with the electronic cigarette cover. The design avoids use of oil-absorbing cotton wicks which can scorch or otherwise denature under certain heat conditions. 
     The electronic cigarette burner element has a heating wire, a porous ceramic matrix, and outer cover, holes in the outer cover, and a ventilation air passage through the porous ceramic matrix. The heating wire is configured to heat and atomize vape oil. The heating wire is formed with a coil and a pair of leads including a first lead and a second lead. A porous ceramic matrix encapsulates the coil of the heating wire. A heating body is formed when the heating wire is encapsulated by the porous ceramic matrix. An outer cover can be made of metal and can fit over the heating body. A hole is formed on the outer cover to receive vape oil. The vape oil wicks through the porous ceramic matrix like a sponge receiving water. A ventilation air passage is formed along a surface of the porous ceramic matrix. The passage can be through the porous ceramic matrix, or along the side of the porous ceramic matrix. The ventilation air passage emits a vape gas when the coil heats the vape oil. The ventilation air passage is configured to receive fresh air and is configured to exhaust the gas. 
     A power supply supplies power to the first lead and the second lead. The electronic cigarette burner element optionally has a second hole, a third hole and a fourth hole formed on the sidewall of the outer cover. A number of circular holes can be formed on the outer cover. The holes could be rectangular or square. For example, the intake holes could be a dozen or more holes, or a screen configuration. The intake holes could be in the middle of the tube, or the top part of the tube and not necessarily limited to the bottom part of the tube. 
     The ventilation air passage passes through the coil of the heating wire, and also passes through the porous ceramic matrix. The ventilation air passage can be cylindrical with a ventilation air passage central axis that is coaxial to the heating wire coil central axis. Additional ventilation air passages can be formed as micro air passages that pass through the central column so that there is more than one ventilation air passage. The porous ceramic matrix has a tube shape. An upper cavity is formed above the heating body, and the upper cavity is configured to prevent user oil aspiration. The lower cavity is formed below the heating body, and can be configured to store the vape oil. The outer cover is preferably made of stainless steel. The heating body can be sintered to the outer cover for secure attachment. The heating wire may have a nickel-chromium composition. 
     The first lead and the second lead of the heating wire are arranged in parallel and connected to the power supply, which can be a low-voltage DC direct current power supply. Preferably, the porous ceramic matrix encapsulating the coil of the heating wire includes activated carbon particles mixed into the ceramic matrix. 
     Is an object of the present invention to ameliorate certain defects of the prior art. Fiber-based wicks are less uniform. When the heating wire is in a high-temperature heating state for a long time, the smoke oil in the atomizer is easily dried which results in easy scorching of the oil-absorbing cotton or wool wick. It is a further object of the present invention to provide a more stable and even heating. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a diagram showing construction of a heater unit. 
         FIG.  2    is a is a cut away diagram showing internal construction of the heater unit. 
         FIG.  3    is a diagram showing construction of the cover. 
         FIG.  4    is a cross section diagram showing the heater unit mounted in the cover. 
     
    
    
     The following call out list can be a useful guide for referencing the call out numbers of the drawings.
       36  Ceramic Matrix     37  Activated Carbon Particles     39  Outer Surface     38  Voids     20  Heater Unit     31  Upper Lead Wire Connection     22  Upper Opening     35  Heater Outside Sidewall     33  First Lead Wire     21  Lower Opening     30  Lead Wires     32  Lower Lead Wire Connection     34  Second Lead Wire     25  Coil Windings     23  First Coil Winding     24  Second Coil Winding     26  Internal Coil Cavity     27  Heater Inside Sidewall     28  First Lead Wire Tip     29  Second Lead Wire Tip     40  Cover     41  First Side Cover Opening     42  Second Side Cover Opening     100  Cover Sidewall     44  Cover Top Opening     48  Porous Material     45  Ceramic Core     43  Third Side Cover Opening     46  Second Lead Wire Connection     47  First Lead Wire Connection     81  Upper Cavity     82  Lower Cavity     83  Oil Inlet Holes     84  Vape Gas     85  Airflow     86  Vape Oil     87  Ventilation Air Passage     88  Heating Wire     89  External Power Source   

     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As seen in  FIG.  1   , a heating wire  88  has an electrical power supply  89  supplying a current to the heating wire  88 . The heating wire  88  is an electrical resistance heater that operates on direct-current low voltage. The heating wire  88  has a pair of lead wires  30  that are terminated at a tip where a coil forms the tip. The lead wires  30  includes a first lead wire  33  and a second lead wire  34 . The first lead wire  33  connects to an upper lead wire connection  31 , and the second lead wire connects to a lower lead wire connection  32 . The upper lead wire connection  33  begins the coil of the first lead wire and the lower lead wire connection  32  begins the coil of the second lead wire  34 . The coils connect to each other such that the heating wire  88  is a continuous wire with a pair of ends that are electrically powered. 
     The heater unit  20  forms a heating body and the heating wire  88  is encapsulated by a porous ceramic matrix  36 . The ceramic matrix  36  has an upper opening  22  and a lower opening  21 . The upper opening  22  communicates with the lower opening  21  to form a ventilation air passage. The ventilation air passage can be a cylindrical opening screw the ceramic matrix  36 . The heater unit  20  has a heater outside sidewall  35  with a porous outer surface  39  that is configured to receive a vape oil. Vape oil also called, vape juice or e-juice can be infused with a variety of different substances such as nicotine. The ceramic matrix  36  is a black ceramic due to the mixing of activated carbon particles with it when in a slurry form. The black ceramic has higher emissivity. 
     Preferably, activated carbon particles  37  are mixed with the ceramic slurry that forms the ceramic matrix  36 . When the ceramic matrix  36  is formed, a number of voids  38  increases the porosity of the ceramic matrix  36 . The activated carbon particles  37  can assist in absorbing impurities and can increase porosity and surface area. The activated carbon particles  37  are preferably ground as a powder for inclusion to the ceramic slurry. Activated carbon particles  37  are preferably between 2% and 20% of the total weight of the ceramic slurry. Absorption of oil  86  passes the oil along, and through the activated carbon particles  37 . 
     As seen in  FIG.  2   , coil windings  25  are formed in the heater unit  20  in the heating body. The coil windings  25  include a first coil winding  23 , and a second coil winding  24  at an upper portion near the ventilation air passage  87 . The coil windings  25  can be formed near the heater inside sidewall  27 , but are preferably not exposed.  FIG.  2    is shown in cut away view, and the internal coil cavity  26  preferably has a heater inside sidewall  27  that does not expose the coil windings  25 , but rather has the coil windings encapsulated within the ceramic matrix  36 . The first lead wire tip  28  and the second lead wire tip  29  can be secured to a socket for ease of replacement. 
     As seen in  FIG.  3   , a cover  40  is formed as a stainless steel cylinder. The cover  40  is formed as a shell having openings on a cover sidewall  100  of the cover. Openings may include a first side cover opening  41 , and a second side cover opening  42 . The heating body of the heater unit  20  can be sintered inside the stainless steel cover. Preferably, the outer shell has four circular through holes, that are sized and configured to allow oil to and absorb into the ceramic matrix  36 . Absorption is improved with higher porosity, and inclusion of activated carbon particle powder can improve porosity. 
     As seen in  FIG.  4   , an airflow  85  formed as a stream of air passes from the bottom end of the cover  40  to the top end of the cover  40 . The air flow  85  enters through the lower opening  21  and exits through the upper opening  22  of the heater unit  20 . The heater unit  20  is preferably formed as a cylindrical heating body with a tubular construction. The cover  40  has an upper cavity  81 , and a lower cavity  82 . The cover  40  has a larger diameter than the heater unit  20 , because the cover  40  covers most of the side wall of the heater unit  20 . A third side cover opening  43  can be circular and at a 90° angle to the first side cover opening  41  and the second side cover opening  42 . A fourth side cover opening can also be placed opposite the third side cover opening  43 . Preferably, the cover  40  is axially symmetrical with the right side is symmetrical to the left side, and the front side symmetrical to the backside. 
     The upper cavity  81  prevents the smoke oil from being aspirated by a user. Since the upper cavity  81  has a larger diameter than the internal coil cavity  26 , the airflow  85  slows and releases oil droplets from the airflow  85 . The lower cavity  82  can be configured for storage of the smoke oil, also called vape oil  86  or vape juice. During operation, the heating wire  88  intermittently heats and atomizes the oil  86  and the oil  86  either creates smoke or vapor, or some sort of vape gas  84  destined for user inhalation. 
     Preferably, the outer cover  40  and the ceramic matrix  36  are integrated so that the ceramic matrix  36  is adheres to the outer cover  40 . Since the ceramic matrix  36  is porous ceramic with a cornucopia of voids  38 , the oil  86  can enter the matrix  36  from the oil inlet hole of the outer cover, and then penetrate inward from the ceramic pores, so the outer cover serves to fix the ceramic and enter oil inlet holes  83 . The heater unit having  20  with the ceramic heating body acts as a wick for drawing oil  86 . Under the action of its own gravity, the oil  86  penetrates inwards from the heater outside sidewall  35  until the oil  86  contacts the coil of the heating wire  88 , and the heating wire  88  heats and atomizes the oil  86  to form vape gas  84 . 
     The heating wire  88  is preferably a nickel-chromium composition heating wire, with an and outer surface is precoated with ceramic material. The ceramic material precoat layer can improve adhesion with the ceramic matrix  36 . The construction steps can be first to form the coil on the heating wire  88 , then precoat the outer surface with a ceramic material, then mix the activated carbon particles  37  with the ceramic matrix  36  to make a slurry, then introduce the slurry and the coil windings  25  into the stainless steel cover  40  with a die and heat the slurry and coil windings to form a unitary construction. By using the stainless steel cover  40  as a mold, the ceramic matrix  36  bonds to an inside sidewall of the stainless steel cover  40 , so that it does not come loose or fall out easily during use. 
     A variety of different specifications can be varied such as the thickness of the ceramic coating, the flash point of the oil, and the thickness of the heating wire. With rudimentary analytical heat transfer calculations, undue experimentation would not be necessary for determining the construction of the electronic vaporizer. Preferably, the outer cover is made of a low-carbon stainless steel that is acid resistant and strong in oxidation resistance, moderate in hardness, strong in stability, and provides good heat dissipation. 
     The lead wires are provided at both ends of the heating wire  88 , and the lead wires are connected to the power supply through the wires. The power supply can be a battery connected to a voltage or current controller circuit. By avoiding fibers such as cotton or polyester, the present invention allows the heating wire  88  to energize and heat up quickly without much concern of overheating. Thus, it is a key feature of the present invention that no fiber wick is used in conjunction with the ceramic matrix wick. 
     Preferably, the lead wires are arranged in parallel to avoid short-circuiting. A spacer can be formed between the lead wires for maintaining the lead in a parallel configuration. The body of the heating element is extruded from ceramic material and then sintered with heat. Preferably, the pore size varies in the ceramic heater body of the heating unit to allow wicking of different viscosities of oil. As lower viscosity oil is used, greater activated carbon should be introduced into the ceramic slurry mix to provide increased microporosity.