HEATING ELEMENT WITH A BONDED THERMOCOUPLE TO ITS ELECTRICAL LEADS, AN ATOMIZER AND AN ELECTRONIC VAPORIZER HAVING A HEATING ELEMENT WITH A BONDED THERMOCOUPLE TO ITS ELECTRICAL LEADS

Abstract

A heating element for use in an electronic vaporizer includes a heating element base, a heating circuit, first and second electronic leads and first and second thermocouple wires. The electronic vaporizer includes a controller configured to sense an operating temperature of the heating element. The heating circuit is encapsulated within the heating element base and has a first terminal and a second terminal. The first electronic lead is connected to the first terminal of the heating circuit. The second electronic lead is connected to the second terminal of the heating circuit. The first thermocouple wire is coupled to the first electronic lead. The second thermocouple wire is coupled to the second electronic lead. The first and second thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application 63/419,175, filed on Oct. 25, 2022 (DRD-P0001P), the entire disclosure of which is hereby incorporated by reference and relied upon.

FIELD OF THE INVENTION

The present disclosure relates generally to electronic vaporizers for creating a vapor from an organic material, and more particularly, to heating elements with a bonded thermocouple for use in an electronic vaporizer.

BACKGROUND OF THE INVENTION

Electronic vaporizers are devices used to vaporize an organic material, for a user to inhale the produced vapor. The vaporization of the organic substance is most typically accomplished through the heating of organic compounds of a material, being either solid or liquid based. The heating results in the phase-change of (at least a portion of) the organic compounds, from their solid or liquid state to a gas state, which can then be transferred into a user through direct inhalation. The heating can also result in the alteration of the organic compounds from one species to another through the application of heat, with the new species being the compound that is to be vaporized at higher temperatures.

A desire among electronic vaporizers is the accuracy and control over the heating temperatures, with the goal that the produced vapor is at an ideal temperature where vaporization occurs, but not at too high of a temperature that would result in vapor with excessive temperatures that could be irritating to the user, or too high where the organic compounds undergoes unwanted heat-induced chemical reactions forming unwanted byproducts, or too low where the temperature is not at the critical point to cause vaporization to occur. Ideal and accurate heating temperatures are desired to achieve the optimal vapor, that is not irritating to the user, the preservation of only vaporizing the desired organic compounds, and not causing unwanted secondary reactions.

A differentiation among electronic vaporizers is the method of controlling the temperatures of the heating system, to produce vapor at the ideal temperatures. A typical electronic vaporizer is composed of the following components: A resistive heating element which converts electrical power to thermal heat and that is typically embedded into a supporting ceramic matrix, a chamber to hold the organic material that is typically in direct contact with the heating element, the electronics to power the heat source, a power supply to power the system, and several optional components that have become the norm for many electronic vaporizers such as filters, and airflow regulators. The heat source and the chamber to hold the organic material is typically combined into a single replaceable component, most commonly referred to as an atomizer. The atomizer may be composed of a system where the user directly heats the organic volatile substance off the resistive heating element, where the resistive heating element may be shaped in a way to act as a receptacle and acts as the vapor producing surface. Other common configurations include a resistive heating element that is adhered to or physically in contact with chamber that stores and heats the organic compounds from the chamber's surface. Vaporizers may also utilize different types of heating systems, such as an induction-based heating system, or infrared based heating system, yet all these systems have the same core function of converting electrical power to thermal heat.

Heating elements are devices that convert an electrical energy into thermal energy, with the most common heating elements utilizing joule or resistive heating to drive this conversion. This is done by driving an electrical current through a filament that results in heat generation caused by the electrical resistance the filament imposes on the current. These heating elements can be composed of free-floating filaments, or be filaments encapsulated in an electrically resistive material. These encapsulated heating elements allow for the heating element to be shaped in a geometry that is beneficial for the intended use and allows for the generated heat to be directed to an intended region. These encapsulate heating elements allow for easier manufacturing and assembly in devices, since the encapsulation prevents the filaments from being damaged or misoriented.

A typical heating element for a vaporizer is a ceramic heating element, where the heating filament is embedded in a ceramic structure, with two electrical leads that protrude from the heating element that allow for an electrical connection to the heating filaments. A high temperature ceramic is most commonly utilized for vaporizer heating elements due to their high strength, high temperature stability, low reactivity, good thermal conductivity, and their low-cost and ease in manufacturing. Ceramic heating elements can be manufactured in a wide range of shapes, such as plates, tubules, cups, and rods. These ceramic heating elements can include multiple heating filaments embedded within their structure. These additional filaments can be operated independently, with each having its own unique heating characteristics, or be in series as to provide the same heating to different regions of the ceramic structure. The number of electrical leads protruding from the heating element will be dependent on the number of heating filaments and their arrangement, with a minimum of two electrical leads required to complete the circuit.

Ceramic heating elements can have their produced heat be controlled by different means dependent on their structure. The simplest method of controlling the heat from a heating element is through voltage control, where the voltage applied to the heating element results in a constant heat generation rate that is tuned for specific purposes. This method of heat control is not adequate for devices that require a constant temperature output, since the heating element is designed for a controlled heat rate, with temperature dependent significantly on the operation and design of the heating system. A common method temperature control for a heating element is temperature coefficient resistance (TCR), where the heating filament's resistance is proportional to a temperature dependent on the heating filament material selection. TCR allows for adequately accurate temperature control through the use of electronics that measure the resistance between the heating elements to determine temperature and alter the applied current to the heating element to maintain the desired temperature. Inaccuracies in the TCR temperature control can arise due to manufacturing tolerances of the heating filament that can alter the relation between temperature-resistance. Another inaccuracy in TCR can arise from the compromise in selection of the heating filament material between the need for a filament material suitable for reaching certain temperatures at a certain rate and the need for accurate temperature control. This inaccuracy can be alleviated by the incorporation of multiple filaments, where one filament acts as the heating filament, where it converts electrical current into heat, while the other filament acts as a temperature sensor, utilizing TCR to determine temperature based on the resistance of the filament. While this design allows for each filament material to be tuned for its specific application, temperature inaccuracy still exists from manufacturing tolerances of the temperature sensing filament.

Electronic vaporizers are electronic devices that are used to vaporize an organic material, for the purpose of inhalation by a user. The vaporization of the organic substance is typically accomplished through the heating of organic compounds to the point where a phase change occurs from the organic compound's solid or liquid state to a gaseous state (vapor). This allows the user to inhale the resulting vapor for flavor or therapeutic purposes. This heating can also result in the activation of the organic compounds at temperatures below their vaporization temperature, resulting in a desirable change in the organic compounds' chemical structure. Too high of temperatures applied to the organic compounds can result in unwanted chemical reactions causing the vapor to not have the desired flavor or therapeutic benefits, or result in the vapor to be at too high of temperature to be comfortably inhaled by the user. A goal in vaporizer design then is the production of vapor at an accurate and controllable temperature that promotes vapor production, but not at excessive temperatures. Ideal and accurate heating is desired for an ideal flavor, volume of vapor, and to preserve the therapeutic benefits of the organic compounds.

An electronic vaporizer can come in a wide range of configurations with different components. The simplest electronic vaporizers are composed of battery that provides portable power, electronic circuitry that regulates the electric current, a heating element that converts the electric current into heat, and a reservoir or chamber that holds the organic compound where heat is being applied. Electronic vaporizers can also include additional components to improve the user's experience, or for additional secondary purposes, such as vapor filters, airflow regulators, buttons for user interface, display screens, LED lighting, charging ports, induction (wireless) charging circuitry, and electronics for wirelessly connecting to peripheral devices.

A common configuration of an electronic vaporizer includes a key component commonly referred to as the atomizer. This component is utilized for storing organic compounds and houses the heating element that converts electrical energy into heat. The atomizer is also the component where the heat is applied to the organic compound, either directly or indirectly, and the component where the vaporization occurs. This component is commonly designed to be replaceable since continuous use may result in residue build-up, and possible deterioration of heating elements. Some vaporizers are designed to be disposable, with the atomizer being built into the whole vaporizer assembly. Atomizers are typically in a configuration where a heating element is thermally bonded to a crucible that is used to store organic compounds. The crucible also acts as a heating surface, providing an easy to clean and high temperature resistance, and low reactivity surface for vapor production. Atomizers of this configuration also includes the electrical connections needed to connect the heating element's electrical connections to the circuitry of the electronic vaporizer, and the physical connections required to connect the atomizer to the electronic vaporizer. Other common configurations of an atomizer include one's where the heating element is shaped in a way to store the organic compounds and will directly heat the organic compounds, thus acting as both the crucible and the heating element.

Electronic vaporizers do come in different configurations, of which components are included or vary in how they are arranged and interconnected, but another way of distinguishing these products is in the methods the device's control the temperature being applied to the organic compounds. Different vaporizers provide unique temperature set-points with differing levels of accuracy and precision, accuracy being the degree of closeness of temperature to the target set-point, and precision being the degree of closeness of the temperature between each heating cycles. A majority of vaporizers utilize ceramic encapsulated heating elements that utilize TCR temperature control system. A TCR temperature control heating element allows for a low-cost and relatively accurate method of controlling the temperature of the heating element. The inaccuracies of the TCR system limit the precision and accuracy of the user's experience with the vaporizer. More advanced vaporizers utilize a temperature sensor system that is either built into the heating element or adhered to the heating element or crucible to provide temperature feedback signal to the vaporizer electronics. The vaporizer electronics then utilize this feedback signaling in their control algorithms to alter the voltage/current applied to the heating element and therefore adjust the temperature of the heating element. These temperature feedback systems have proven to have the highest accuracy and precision, but also increases the costs in manufacturing, complexity of the product, and reduce product lifespan with adhered thermocouples de-coupling from the intended target surface after multiple heating/cooling cycles.

Significant research of heating systems, temperature control systems, and control software have been conducted for vaporizers as a means to achieve accurate temperature, which is key to providing users with a repeatable, enjoyable experience.

The present invention is aimed at solving one or more of the problems identified above.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a heating element for use in an electronic vaporizer. The heating element includes a heating element support structure, a heating circuit, first and second electronic leads and first and second thermocouple wires. The electronic vaporizer includes a controller configured to sense an operating temperature of the heating element. The heating circuit is encapsulated within the heating element support structure and has a first terminal and a second terminal. The first electronic lead is connected to the first terminal of the heating circuit. The second electronic lead is connected to the second terminal of the heating circuit. The first thermocouple wire is coupled to the first electronic lead. The second thermocouple wire is coupled to the second electronic lead. The first and second thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

In another aspect of the present invention, an electronic vaporizer is provided. The electronic vaporizer includes a main unit, an atomizer having a heating element, and a controller. The main unit is configured to supply electrical energy. The atomizer is coupled to the main unit and is configured to receive material, convert electrical energy from the main unit into thermal energy and apply the thermal energy to the material.

The heating element includes a heating element support structure, a heating circuit, first and second electronic leads, and first and second thermocouple wires. The electronic vaporizer includes a controller configured to sense an operating temperature of the heating element. The heating circuit is encapsulated within the heating element support structure and has a first terminal and a second terminal. The first electronic lead is connected to the first terminal of the heating circuit. The second electronic lead is connected to the second terminal of the heating circuit. The first thermocouple wire is coupled to the first electronic lead. The second thermocouple wire is coupled to the second electronic lead. The first and second thermocouple wires are composed from different materials.

The controller is coupled to the heating element and has a pair of inputs. The first and second thermocouple wires are connected to the pair of inputs of the controller and form a thermocouple. The controller is configured to establish a voltage difference across the thermocouple, estimate an actual temperature associated with the heating element as a function of the voltage difference, and control an electrical current to the heating circuit to heat the heating element to a desired temperature as a function of the actual temperature.

In still another aspect, an atomizer for use in an electronic vaporizer having a controller is provided. The atomizer includes an atomizer base, a heating element, and a heating crucible. The heating crucible is thermally coupled to the heating element. The heating element includes a heating element support structure, a heating circuit, first and second electronic leads and first and second thermocouple wires. The controller is configured to sense an operating temperature of the heating element. The heating circuit is encapsulated within the heating element support structure and has a first terminal and a second terminal. The first electronic lead is connected to the first terminal of the heating circuit. The second electronic lead is connected to the second terminal of the heating circuit. The first thermocouple wire is coupled to the first electronic lead. The second thermocouple wire is coupled to the second electronic lead. The first and second thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

In another aspect of the present invention, a heating element for an electronic vaporizer has a pair of external electrical leads. The external electrical leads are bonded with dissimilar metals or semiconductors. This structure of bonding dissimilar metals or semiconductors to the electrical leads, results in the dissimilar materials acting as a thermocouple, with the heating element's heating filament, which connects these leads, acting as the thermocouple junction. Based off the Seebeck effect, when heat is applied to this junction, it results in an increase in mobility for the valence electrons near the heat source. This results in a difference in the concentration of electrons above the Fermi energy between the hot-end and the cold-end of each of the dissimilar materials. This difference in Fermi distribution results in the generation of an electrical potential between the hot-end and the cold-end, which then results in a net potential between the dissimilar metals. This net potential will then correspond to the temperature of the thermocouple junction, which can be characterized.

The use of dissimilar materials allows for the heating element to also act as a self-contained thermocouple. The voltage between the electrical leads provides electrical feedback that corresponds to the heating element's temperature. This structure has many benefits over other common heating element designs. Heating elements utilizing TCR systems have their temperature accuracy and precision dependent on the correlation between the resistance of the heating filament and temperature. This limits the material selections for the heating filament to only those that have a linear temperature vs resistance relationship. Additionally, manufacturing tolerances of the heating filament can result in deviations of the filament's resistivity which affect the perceived temperature. While the thermocouple system used in this invention relies on the Seebeck effect, which has much higher precision than TCR due to less effects the manufacturing tolerances have on the voltage between the two dissimilar metals. Heating elements that contain built in temperature sensors require additional manufacturing steps to add in secondary filaments that are utilized solely for use as a TCR based temperature sensor, with the primary filament acting as a heating filament. This solution allows for the heating and the temperature sensing filaments to be independent, so that the design and material selection of the filaments is optimized for their given function. The addition of the secondary filament does add additional manufacturing steps, with corresponding increase in costs to the heating element manufacturing and requires at least one additional electrode connection for the heating element with the electronics of the device it is connecting too. Based off the number of the heating elements' heating filaments and temperature sensing filaments, the number of electrode leads required can result in a very complex physical and electric connection between the heating element and the electronics of the device the heating element is connecting too. Additionally, the secondary filament may still operate as a TCR system and may be limited in its temperature accuracy and precision based off the manufacturing quality of the filament.

The invention described here resolves many of the aforementioned issues with traditional heating elements that utilize TCR for temperature feedback, or heating elements with built in secondary filament to act as a temperature sensor. The dissimilar metals or semiconductors can be bonded to any traditional encapsulated or non-capsulated heating element, regardless of their shape, size, or heating filament selection. The dissimilar metal/semiconductor selection is based on the operating conditions, such as the temperature measurement range, environmental conditions, required tolerance, and cost. Material selections of the dissimilar metals can be based on traditional ANSI type thermocouples, such as types J, K, T, E, etc.

The dissimilar materials can be added on post-production to the heating elements, typically through a process of welding the dissimilar metals to the electrical leads of the heating element. This welding technique allowed for a high-strength permanent bond between the added on metal/semiconductor and the heating element leads. This bond was able to withstand the high temperatures output by the heating element and resulted in consistent correlation between temperature and the measured voltage between the thermocouple leads. Dissimilar metals and semiconductors can also be adhered to the leads of the heating element through other physical and chemical methods, such as crimping, vapor deposition, electrochemical deposition, casting, etc.

Additional benefits of disclosed invention include that the addition of the dissimilar metals/semiconductors additionally do not require the addition of extra electrical leads to/from the heating element, with the added-on materials bonded to the already existing terminal leads, thus simplifying the required design for any physical or electrical connections between the heating element, and the electronic device which operates the heating element.

When the heating element is configured in an atomizer in such a way that directly applies heat to the organic compounds, and thus acts as the vaporizer surface, the controller's control software can use the resulting temperature that is determined by the difference in potential between the two thermocouple leads as the vaporizer surface temperature. When the heating element is configured in an atomizer in such a way that it is bonded to a crucible, and the crucible acts the vaporizer surface, the controller's control software must use the heating element's temperature that is determined by the difference in potential between the two thermocouple leads, along with transient based temperature vs time algorithms to determine the temperature of the crucible's surface.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:

FIG. 1A is a side view of an electronic vaporizer, according to an embodiment of the present invention.

FIG. 1B is a perspective view of the electronic vaporizer of FIG. 1A.

FIG. 1C is an internal view of the electronic vaporizer of FIG. 1A.

FIG. 1D is perspective view of a well structure of the electronic vaporizer of FIG. 1A.

FIG. 2A is a functional block diagram of the electronic vaporizer of FIG. 1A, according to an embodiment of the present invention.

FIG. 2B is a functional block diagram of a controller of the electronic vaporizer of FIG. 1A.

FIG. 2C is a simplified circuit diagram associated with the controller of FIG. 2B.

FIG. 2D is a control diagram associated with the controller of FIG. 2C, according to an embodiment of the present invention.

FIG. 3A is a perspective view of an atomizer of the electronic vaporizer of FIG. 1A, according to an embodiment of the present invention.

FIG. 3B is a side view of the atomizer of FIG. 3A.

FIG. 3C is a top view of the atomizer of FIG. 3A.

FIG. 3D is an exploded side view of the atomizer of FIG. 3A.

FIG. 3E is an exploded perspective view of the atomizer of FIG. 3A.

FIG. 4A is a perspective view of a heating element of the atomizer of FIG. 3A, according to an embodiment of the present invention.

FIG. 4B is a side view of the heating element of FIG. 4A.

FIG. 4C is an exploded perspective view of the heating element of FIG. 4A.

FIG. 4D is an exploded side view of the heating element of FIG. 4A.

FIG. 4E is top view of the heating element of FIG. 4A.

FIG. 4F is a block diagram of an exemplary heating element with first and second heating circuits, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention.

Reference throughout this specification to “one embodiment”, “an embodiment”, “one example” “an example”, or “aspect” means that a particular feature, structure or characteristic described in connection with the embodiment of example is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in an embodiment”, “one example” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and/or sub-combinations in one or more embodiments or examples. In addition, it is appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.

Referring to the FIGS, and in operation, wherein like numerals indicate like or corresponding parts throughout the several views, the present invention an provides electronic vaporizer 10 that is configured to aerosol an organic material and to provide the resultant vapor to a user to inhale. The organic material may include, but is not limited to, organic liquids and/or wax-like materials that are derived naturally or artificially made.

With reference to FIGS. 1A-1C, in one embodiment the electronic vaporizer 10 includes a main unit 20, an atomizer 60, and an inhalation unit 120. The inhalation unit 120 includes a mouthpiece 122. In the illustrated embodiment, the electronic vaporizer 10 has a central axis 12. In the illustrated embodiment, the main unit 20 and the atomizer 60 are aligned and generally centered (along with many of the components thereof) on the central axis 12. In one aspect of the present invention, the atomizer 60 includes a heating element with a bonded thermocouple (see below).

With specific reference to FIG. 1C, the main unit 20 includes a glass attachment seal 24 having a plurality of threads. In illustrated embodiment the inhalation unit 120 has internal threads (not shown) and is configured to be removably attached to the glass attachment seal 24 using the threads.

In an alternative embodiment, the mouthpiece 122 may be coupled to the vaporizer 10 via a quick connect adapter (not shown) and the main unit 20, the atomizer 60, the mouthpiece 120, and the quick connect adapter are aligned about the central axis 12. One such electronic vaporizer is disclosed in U.S. Pat. No. 11,1064,738, issued on Jul. 20, 2021, which is hereby incorporated by reference.

An exemplary mouthpiece 122 is shown in the FIGS. In general, the mouthpiece 122 allows the user to inhale creating low pressure within the mouthpiece 122 and to transfer the low pressure to the atomizer 60 via the inhalation unit 120. In the illustrated embodiment, the inhalation unit 122 is a percolating type of mouthpiece and is made from glass. However, it should be noted that that the illustrated mouthpiece is illustrative only. Any type of mouthpiece, including a non-percolating mouthpiece, may be used without departing from the spirit of the invention.

The main unit 20 includes the control electronics and user interface/controls necessary to operate the electronic vaporizer 10 and to provide power to the atomizer 60 (see below). The atomizer 60 may house a heating crucible 62 (see below) in which the organic material is inserted or loaded and a heating element which converts electrical energy into thermal energy and applies the thermal energy to the material (see below). The inhalation unit 120 collects exhausted vapor from the atomizer 60 and delivers the vapor to the user through the user's inhalation on the mouthpiece 122.

In the illustrated embodiment, the main unit 20 is a hand-held device that controls the electronic functions of the electronic vaporizer 10. The main unit 20 further acts as the hub that locks in the atomizer 60 and the inhalation unit 122. As will discussed in further detail below, the main unit 20 may include a well 22 that is configured to receive the atomizer 60. The atomizer 60 is removable from the well 22. The well 22 is configured to make electrical connections between the atomizer 60 and the circuitry in the main unit 20 (see below). As will be explained in further detail below, in one embodiment the well 22 may include pop-up pins or electrodes (such as POGO pins) to connect the circuitry of the main unit 20 with the atomizer 60. The main unit 20 may include one or more lighting features that illuminate to indicate the functionality of the electronic vaporizer 10 or to provide decorative lighting. The main unit 20 may also contain a charging port (not shown) e.g., a USB-C charging port, a port cover to protect the charging port from dust and moisture.

As shown in FIGS. 1A and 1B, a removable upper cap 24 may be provided to cover the top of the electronic vaporizer 10 and protect the heating crucible 62 and internal components of the electronic vaporizer 10. The removable upper cap 24 may be connected to a silicone seal 26 with a living hinge 28 to allow the removable upper cap 24 to be removed but remain connected to the electronic vaporizer 10 to prevent the removable cap 24 from being lost.

The main unit 20 houses the primary electronics of the device. In the illustrated embodiment, the main unit 20 includes a controller 34 (see below) that controls the functionality of the electronic vaporizer 10 (see below). The main unit 20 further includes a power cell battery 36 (see below) that provides power to the electronic vaporizer 10 and a push-button tactile switch 28 that, in the illustrated embodiment, provides the only interface between the electronic vaporizer 10 and the user. A plurality, e.g., four, of indicators 30, e.g., light emitting diodes (LED) located underneath the switch 28 in the illustrated embodiment, provide an indication of the life of the battery 36 of the electronic vaporizer 10.

The main unit 20 includes an outer housing 40. With specific reference to FIG. 1C, the main unit 20 includes a chassis 42. The battery 36 may be removably mounted to the chassis 42. A printed circuit board 44 including the controller 34 may also be mounted to the chassis.

The atomizer 60 houses the heating crucible 62, a heating element 64, and the electrical connections of the heating element 64. The heating element 64 includes a heating circuit 84 embedded therein. The heating circuit 84 converts electrical energy provided by the main unit 20 into thermal energy. As discussed in further detail below, the heating circuit 84 also acts as a temperature sensor. In the illustrated embodiment, the main unit 20 measures the voltage across the heating circuit 84 to determine the temperature of the heating element 64. The heating element 64 transfers the heat produced by the heating circuit 84 to the heating crucible 62. The heating crucible 62 holds the material that is to be vaporized.

In some embodiments of the electronic vaporizer 10, the heating element 62 converts electrical power to thermal energy through joule heating by directly heating the organic material or through thermally conduction via a material in direct contact with the organic material is in direct contact. The heating element 62 may vary in shape and size to fit the specific need of the electronic vaporizer. The electronic vaporizer 10 may include a single ceramic heating element, multiple ceramic heating elements, or multiple ceramic heating elements alongside other types of heating systems, such as induction heating, coil-based heating elements, or convective heating elements. In the illustrated embodiment, a single heating crucible 62 and a single heating element 64 are used.

Generally, the heating crucible 62 is typically made of a non-reactive material such as a quartz glass or high temperature ceramic to preserve the flavor of the produced vapor. Further, such materials resist corrosion and do not chemically react with the material loaded therein. As will be discussed in more detail below, the atomizer 60 is housed within a metallic body, and at the base has several electrode pads that connect to the pop-up pins or electrodes of the main unit 20. The atomizer 60 is located within the well 22 of the main unit 20 and may be held in place by a threaded or magnetic connection.

The inhalation unit 120 is removably coupled to the electronic vaporizer 10. In general, the mouthpiece 122 allows the user to inhale creating low pressure within the mouthpiece and to transfer the low pressure to the atomizer 60. The mouthpiece 122 may be made of glass or other suitable material. The mouthpiece 122 may be configured to hold water in a reservoir so that the vapor goes through percolation. The percolation reduces the temperature of the vapor and assists in filtering out any unwanted residue in the vapor.

With reference to FIGS. 2A-2D, an exemplary main unit 20 shown. With specific reference to FIG. 2A, a functional block diagram of an electronic vaporizer 10 according to an embodiment of the present invention is shown. As discussed above, the electronic vaporizer 10 may include the main unit 20, an atomizer 60, and the inhalation unit 120.

With specific reference to FIG. 2B, the main unit 20 includes the one or more indicators 30 to provide information and/or feedback to the user, a user input interface 32, the controller 34, and the battery 36. The battery 36 may be a lithium-ion cell, a capacitor or other suitable energy storage device. The user input interface 32 allows the user to operate the electronic vaporizer 10. Although a single switch 28 is shown in the illustrated embodiment, in other embodiments, the user input interface 32 may include additional switch and controls. In general, the user can control the electronic vaporizer by utilizing the user input interface 32 to adjust the settings. Alternatively, or in addition, the settings of the electronic vaporizer may be adjusted remotely through a wired or wireless connection, using a user device, such as cell phone or computer.

As discussed above, the atomizer 60 includes a heating element 64. As will be discussed in more detail below, the heating element 64 includes a heating circuit 84 (see below). In operation, the user may operate the main unit 20 to heat material that has been placed in the heating crucible 62 to create vapor. The controller 34 in response to user operation of the user input interface 32 senses the temperature of the heating element 64 using a temperature sensor formed by a thermocouple 68 (see below). The controller 34 responsively applies electrical current to the heating circuit 84. In one embodiment, the controller 34 measures the voltage across the heating circuit 84. The battery 36 supplies the current to the heating circuit 84 as well as powers the electronics.

The controller 34 provides the control logic to operate the main unit 20 and may include a microprocessor, programmable logic controller, an application specific logic controller, a custom controller, or other suitable controller.

With reference to FIG. 4F, as discussed above in other embodiments, a heating element may have two or more heating circuits. In the illustrated embodiment, the exemplary heating element 64 of FIG. 4F includes first and second heating circuits 84-1, 84-2.

With reference to FIGS. 3A-3E, an exemplary atomizer 60 is shown. The exemplary atomizer 60 includes an atomizer upper housing 66, an atomizer mid-housing 68, and an atomizer lower housing 70.

As shown, in the illustrated embodiment, the atomizer upper housing 66 has a central aperture 66A which is open to the interior of the atomizer 60 and an interior cavity 62A of the crucible 62. The atomizer upper housing 66 includes an outer gripping portion 66B. In the illustrated embodiment, the outer gripping portion 66B is textured to provide a better gripping surface to facilitate removal of the atomizer 60 from the electronic vaporizer 10.

The atomizer upper housing 66 of the illustrated embodiment further includes a top surface 66C and a sloped surface 66D leading to the central aperture 66A. The atomizer upper housing 66 may include a ring-shaped receptacle (not shown) for receiving a ring-shaped magnet (not shown). The magnet allows the atomizer 60 to be removably coupled to the main unit 20. The magnet may be press-fit within the receptacle or fastened therein by any suitable means.

The atomizer mid-housing 68 has a generally tubular shape within an inner cavity 68A. The atomizer upper housing 66 includes a channel (not shown) on a lower side. The channel may be configured to receive an upper edge of the atomizer mid-housing 68. In the illustrated embodiment, the atomizer upper housing 66 may be press fit onto the atomizer mid-housing 68. A seal or gasket 72 may be provided within the channel of the atomizer upper housing 66. The seal or gasket 72 may be made from silicon or other suitable material.

The atomizer lower housing 70 includes an upper portion 70A, having a receptacle 70B for receiving the heating element 82, and a lower portion 70C. The crucible 62 fits within a cavity formed by the upper portion 70A of the atomizer lower housing 70 and the inner cavity 68A of the atomizer mid-housing 68. The atomizer lower housing 70 may be screwed onto the atomizer mid-housing 68 or may be connected via a press fit.

When inserted, the crucible 62 is positioned adjacent a first side 82A of the heating element 82 (see FIGS. 4A-4E). The crucible 62 forms an interior cavity 62A and may be composed from a material such as glass. In other embodiments, the crucible 62 may be composed of a ceramic, composite, or metal material. The interior cavity 62A receives the material which is heated by the atomizer 60 to create vapor. In the illustrated embodiment, the crucible 62 is composed from quartz glass. A layer of graphene film 58 may be positioned adjacent or affixed to a top surface of the heating element 64 to protect the surface of the heating element 64.

The atomizer 60 may further include an electrode housing 74, a center electrode 76 and a ring electrode 78. In one embodiment, the center electrode 70 and the ring electrode 72 are used to connect respective inputs of the controller 34 to the heating element 64 (see below). As discussed in more detail below, the heating circuit 64 includes first and second terminal leads 64A, 64B which are electrically coupled to the electrodes 70, 72 via first and second thermocouple wires 68A, 68B. The first and second thermocouple wires 68A, 68B form a thermocouple 68 that operates as a temperature sensor.

In the illustrated embodiment, the heating element 64 includes a single heating circuit 64. The heating circuit 64 acts as a temperature sensor node for the temperature sensor formed by the thermocouple 68. However, it should be noted that in other embodiments, the heating element 64 may include more than one heating circuit, one or more heating circuits with an associated thermocouple acting as a temperature sensing circuit, one or more separate temperature sensing circuits or any combination therefore. In these other embodiments, the atomizer 60 may include additional electrodes to accommodate the additional circuits.

The atomizer lower housing 70 includes an opening for receiving the electrode housing 74. In the illustrated embodiment, the electrode housing 74 is press fit into the opening within the atomizer lower housing 70. The electrode housing 74 includes a plurality of apertures 74A through which the center electrode 76 and the ring electrode 78 are accessible. The center electrode 76 and the ring electrode 78 extend through at least part of the electrode housing 74. The first and second thermocouple wires 68A, 68B also extend through at least part of the electrode housing 74 to connect with the electrodes 70, 72.

The electrode housing 74 may be composed from a high temperature plastic. In the illustrated embodiment, the electrode housing 74 is composed of Polytetrafluoroethylene (PTFE), however, it should be noted that any suitable material may be used.

The atomizer upper housing 66, atomizer mid-house 68, and the atomizer lower housing 70 may be composed of a metal, such as stainless steel. In the illustrated embodiment, the atomizer upper housing 66, atomizer mid-house 68, and the atomizer lower housing 70 are composed from SUS303 stainless steel, however, it should be noted that any suitable material may be used. The center electrode 70 and the ring electrode 72 may be made from any suitable conductive material, such as brass. In the illustrated embodiment, the center electrode 70 and the ring electrode 72 are composed from H78 brass.

The heating crucible 62 is thermally coupled to the heating element 82. The controller 34 provides electrical power to the heating circuit 84 to controllable heat the heating element 64 and the heating crucible 62.

Returning to FIG. 1D, in the illustrated embodiment, the electronic vaporizer 10 includes a well structure 90 positioned within the main unit 20. The well structure 90 forms the well 22. As discussed above the well 22 is configured to removable receive the atomizer 90.

In the illustrated embodiment, the well structure 90 includes an upper well 92 and a lower well 94. The upper well 92 and the lower well 94 may be press fit together and mounted to an upper shell 96 which is mounted to the chassis 42. The lower well 94 is configured to receive the electrode housing 74. A plurality of pop-up pins 98 may be provided to connect the heating element 64 to the electrodes 76, 78.

Heating Element with a Bonded Thermocouple

As discussed above, the atomizer 60 is coupled to the main unit 20. The main unit 20 is configured to supply electrical energy to the atomizer 60. The atomizer 60 is configured to receive material, convert electrical energy from the main unit 20 into thermal energy and apply the thermal energy to the material. With specific reference to FIGS. 4A-4F the heating element 64 of the atomizer 60 includes a heating element support structure 88. In the illustrated embodiment, the heating element support structure 88 includes a heating element base 82. In the illustrated embodiment, the heating element base 82 may be flat disc-shaped with a circular cross-section with a relatively small height. For example, the disc-shaped heating element base 82 may have a height of in the range of 0.8 mm, with alternative height dimensions possible depending on the desired heating characteristics and structure requirements of the heating element.

Alternatively, the heating element support structure 88 may have an alternative shape. For example, the heating element support structure 88 may be shaped to receive the heating crucible 62. For example, the heating element support structure 88 could be configured to form a receptacle for receiving the heating crucible 62. In this instance, the shape of the heating element support structure 88 may be based on the shape of the heating crucible 62. For example, if the heating crucible 62 is cup-shaped with a cylinder-shaped outer surface, then, at least, the receptacle of the support structure 88 may be cylindrical to match the outer surface of the heating crucible 62. The support structure 88 may have any suitable shape, for example, a plate (with a slight height), a cup, a hollow-rod, pillar, a combination of these, or any suitable shape.

In still a further embodiment, the heating element support structure 88 and the heating crucible 62 may be combined into a single element.

The heating circuit 84 may be embedded within, or encapsulated by, the heating element support structure 88.

In the illustrated embodiment, the heating element support structure 88 includes the disc-shaped heating element base 82 and the heating circuit 82 is embedded within the heating element base 82. The heating circuit 84 may have a coil-like shape. In the illustrated embodiment, the heating element base 82 is disc shaped and has a first side 82A and a second side 82B. The heating circuit 84 is located between the first and second sides 82A, 82B.

As shown, the heating element base 82 has a predefined cross-section. In general, the heating circuit 84 is configured to provide uniform heating across the cross-section of the heating element base 82. In the illustrated embodiment, the cross-section of the heating element base 82 is generally circular and the heating circuit 84 includes series of pathways comprised of a plurality of arcuate segments.

In an alternative embodiment, the heating element support structure 88 may have a base and one or more side walls. In the alternative embodiment, the heating element support structure may have one or more heating circuit 82 in the base and/or side walls to provide a more desirable heating profile to the heating crucible 62. The heating element support structure 88 may further have a separate temperature sensing circuit (not shown) embedded therein.

The heating element base 82 may be composed from an electrically non-conductive, that is at least moderately thermally conductive, such as a ceramic. In the illustrated embodiment, the heating element base 82 is composed from an alumina ceramic. However, the heating element base 82 may be composed from, or include, any suitable ceramic material or combination thereof, including but not limited to alumina oxide ceramic, alumina nitride ceramic, zirconia carbide ceramic, tungsten carbide ceramic, and silicon nitride, etc. Alternatively, the heating element base 82 may be composed from a high temperature resistance non-ceramic material or combination thereof, including but not limited to silicon dioxide, high temperature resistance composites, and high temperature resistance polymers. The heating element 82 must be able to transfer heat to the crucible 62, but in general most materials that have high thermal conductivity, e.g., metals, also have high electrical conductivity (metals). Ceramic materials are generally electrically insulating and have at least moderate thermal conductivity. A material with less than moderate thermal conductivity would take a significant time to heat and would require considerably more power.

Further, the heating circuit 84 are composed from a slurry of metal particles printed on an internal surface of the heating element base 82. The slurry is then sintered to form the circuit 84 (or solid wires). The heating element base 82 is then re-sintered with additional alumina ceramic to encapsulate the circuit 84. It should be noted that the present invention is not limited to the process recited above. Other suitable methods of creating the heating element 64 may also be utilized. Alternatively, the heating circuit 84 may include preformed wires embedded in the heating element base 82.

The heating circuit 84 acts as a heating wire by converting electric energy into heat. The heating circuit 82 may be printed into the heating element 64, or be an embedded wire and may be composed of materials such as but not limited to: nichrome alloy, tungsten alloy, etc. . . .

As shown, the heating circuit 84 includes first and second terminals 84A, 84B. The heating element 64 includes a first electronic lead 64A connected to the first terminal 84A of the heating circuit 84 and a second electronic lead 64B connected to the second terminal 84B of the heating circuit 84.

The thermocouple 86 is formed by a first thermocouple wire 86A coupled or bonded to the first electronic lead 64A and a second thermocouple wire 86B coupled or bonded to the second electronic lead 64B. The first and second thermocouple wires 86A, 86B are composed from different or dissimilar materials (see below).

For example, the first thermocouple wire 86A may be composed from a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome or platinum. The second thermocouple wire 86B is composed from another, different one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum.

In one embodiment, the first thermocouple wire 86A is composed from a magnetic alloy composed from nickel and chromium, e.g., an alloy composed from approximately 90% nickel and 10% chromium. The second thermocouple wire 86B is composed from a magnetic alloy composed from nickel and aluminum, e.g., an alloy composed from approximately 95% nickel, 2% aluminum, 2% manganese, and 1% silicon.

The first and second thermocouple wires 86A, 86B are bonded to the respective first and second electronic leads 64A, 64B. In one embodiment, the first and second thermocouple wires 86A, 86B are welded to the respective first and second electronic leads 64A, 64B. In other embodiments, the first and second thermocouple wires 86A, 86B may be adhered to the respective first and second electronic leads 64A, 64B through other physical and chemical methods, such as crimping, vapor deposition, electrochemical deposition, casting, etc . . . .

With specific reference to FIGS. 2C-2D, the controller 34 is coupled to the heating element 64 and has a pair of inputs H+, H−. The first and second thermocouple wires 86A, 86B are connected to the pair of inputs H+, H− of the controller 34 and form a thermocouple 86. During operation, the controller 34 is configured to (1) establish a voltage difference across the thermocouple 86, (2) estimate an actual temperature associated with the heating element 64 as a function of the voltage difference, and (3) control an electrical current to the heating circuit 84 to heat the heating element 64 to a desired temperature as a function of the actual temperature.

In one embodiment, the controller 34 may implement a proportional, integral and the derivative (PID) control to adjust the electrical current supplied to the heating element 64 to maintain the desired temperature. In other embodiments, the controller 34 may implement alternative control methods, such as a time-delay model, to adjust the electrical current supplied to the heating element 64 to maintain the desired temperature.

The heating element 64 with a thermocouple 86 bonded to the electrical leads 64A, 64B generates a voltage difference between the dissimilar materials that correlates to a temperature. This voltage difference signal is typically in the millivolts range and can be processed before being analyzed by the firmware built into the vaporizer device's electronics. Signal processing can include amplification, filtering, or averaging over a time period. To convert the voltage signal into a temperature reading, a cold-junction compensation must also take place to compensate for the missing thermoelectric voltage due to the cold junction (connection back to the device electronics) not being at 0 Celsius. This cold junction reference can be accomplished through the inclusion of different hardware, such as the addition of a thermistor held at the cold junction that outputs an electrical signal that can be correlated to the cold junction temperature. Additional methods of cold junction include the use of a battery to the circuit to null the offset voltage from the reference junction, the use of an electronic ice point reference that generates a compensating voltage as a function of the temperature sensing circuit. Once this cold junction temperature is known, the temperature of the heating element, or thermocouple “hot” junction, can be known with the known Seebeck coefficient that is known for the thermocouple types. Realistically, the temperature vs signal curves for a given thermocouple may not be linear, and to obtain accurate temperature measurements, the vaporizer device may utilize linearization software to compensate the signal.

By utilizing the measured temperature of the heating element 64, the controller 34 can determine the required power output necessary to alter the temperature to meet the set-point. The applied electrical power to the heating element 64 is typically a direct current, under a variable voltage control. Other methods of power delivery can include: a direct current under a constant voltage that is switched from an on/off state for given periods of time to maintain the desired temperature, a direct current under current control, a direct current under constant current that is switched from an on/off state for given periods of time, or an alternating current.

The arrangement of the heating circuit 84 inside the heating element 64 may be a function of: the shape and/or size of the heating element 64, uniformity of desired temperature, location where temperature is to be measured, and ability in manufacturing.

In general, the electronic vaporizer 10 of the illustrated embodiment, utilizes the heating element 64 in the atomizer 60 to convert electric power into thermal energy and to measure the temperature of the heating element 64 passively through the thermocouple 86 formed by the first and second thermocouple wires 86A, 86B. The controller 34 and/or main unit 20 is electronically connected to the heating element 64 via connectors that may be controllably connected and disconnected, including, but not limited to press fittings, plugs, connection pins, pads, etc. . . . The main unit 20 powers the heating element 64 to heat the atomizer 60 and to measure the temperature of the heating element 64 by measuring the voltage across the thermocouple 86.

The heating element 64 may be replaceable or be built in and non-serviceable. In other embodiments of the invention, the heating element 64 and the heating crucible 62 may be integrated into a single module which may be replaceable or may be integrated into the electronic vaporizer 10. In other embodiments, the atomizer 60 may also be external to the main vaporizer body or be built into the main vaporizer body.

With reference to FIG. 4F, as discussed above in other embodiments, a heating element may have two or more heating circuits. In the illustrated embodiment, the exemplary heating element 64 of FIG. 2E includes first and second heating circuits 84-1, 84-2. Each heating circuit 84-1, 84-2 has a pair of respective first and second electronic leads 64A-1, 64B-1, 64A-2, 64B-2. Each pair of first and second electronic leads 64A-1, 64B-1, 64A-2, 64B-2 may be bonded or adhered to a respective pair of first and second thermocouple wires 86A-1, 86B-1, 86A-2, 86B-2.

INDUSTRIAL APPLICABILITY

With reference to the drawings, and in operation, the present invention provides an electronic vaporizer 10 that includes a main unit 20, an atomizer 60, and an inhalation unit 120 with a mouthpiece 122.

The main unit 20 houses all electronics, the user interface, and controls the power delivered to the atomizer 60. The atomizer 60 houses the heating crucible 62 where material is loaded into, and the heating element 64 which converts electrical energy into thermal energy. The inhalation unit 120 acts as the coupling between the mouthpiece 122 and the main unit 20 and controls airflow into the atomizer 60. The mouthpiece 122 collects the exhausted vapor produced from the atomizer 60 and delivers the vapor to the user as the user inhales.

The main unit 20, in the illustrated embodiment, is a hand-held device that controls the electronic functions of the electronic vaporizer 20 and acts as the hub that locks in the atomizer 60, along with the inhalation unit 120.

The main unit 20 includes a well 22 that receives the atomizer 60 and makes the electrical connections with the circuitry of the main unit 20.

The main unit 20 houses the primary electronics of the electronic vaporizer 10. In the illustrated embodiment, the main unit 20 may include a primary printed circuit board (PCB) that controls the functionality of the electronic vaporizer 10, one or more PCBs which control the indicators 30, a charging PCB which contains the USB-C Receptacle that is used to charge the electronic vaporizer 10, and a dual LiPo Power Cell 36 which provides power to the device. The primary PCB also contains a basic push-button tactile switch (switch 28) which may be the only interface the device has with the user.

The atomizer 60 houses the heating crucible 62, the heating element 64, and the electrical connections of the heating element 64. As discussed above, the heating element 64 may contain a heating circuit 82 that acts as both a heating circuit and a temperature sensing circuit.

The main unit 20 measures the resistance of the across to determine the temperature of the heating element 64. The heating element 64 transfers the heat produced by the heating coil to the heating crucible 62. The heating crucible 62 is a vessel that holds the material that is to be vaporized. The heating crucible 62 is typically made of a non-reactive material such as a quartz glass or a high temperature ceramic, a metal or a composite material to preserve the flavor of the produced vapor and to not corrode or chemically react with the material that is loaded into.

The atomizer 60 may be housed in a steel body and include several electrode pads that connect to the POGO electrodes of on the main unit 20. The atomizer 60 is placed inside, and removable from, the well 22 of the main unit 20. The atomizer 20 is held in place by a magnetic connection.

The inhalation unit 120 may act as an air intake manifold and the receptacle to secure the mouthpiece 122. The mouthpiece 122 may be made from glass and may also contain but does not require, water so that the vapor goes through percolation to reduce the temperature of the vapor and help in filtering out any unwanted residue in the vapor.

The electronic vaporizer 10 may be operated by the user by placing the atomizer 60 into the main unit 20. The user may then load the material to be vaporized into the heating crucible 62. The user can then activate the main unit 20 by different combinations of activating the switch/button 28. The user has the ability to cycle between temperature settings, choose decorative lights to be illuminated, control heating time, and control heating of the atomizer 20 using the switch/button 28.

When the user activates a heating cycle, the main unit 20 measures the voltage different across the thermocouple 86 (see above), while also delivering power to the heating circuit 84 built into the heating element 64. The main unit 20 adjusts power as the temperature begins to reach the set-point measured by the thermistor 86. Once the set-point temperature is reached, the main unit 20 will indicate this to the user by illuminating one or more of the indicators 30. The user may then inhale off the mouthpiece 122 to produce the low-pressure needed to increase vapor production. Due to the design of the electronic vaporizer 20, a low-pressure zone is created above the atomizer 60 by the fast-moving airflow, which promotes the phase-change of the liquid material into vapor. The user may then inhale the vapor through the mouthpiece 122.

To power up (or turn on) the electronic vaporizer 10, the user actuates the button/switch 28 a predetermined number of times, e.g., 5. Once powered up, the current battery level is shown using the indicators 30.

The desired temperature may also be set or cycled through a plurality of predetermined or preset temperatures, using the switch/button 28. After material has been loaded into the crucible 62, the user may press/hold the switch/button 28 to initiate heating process.

The heating element 64 with thermocouple wires 86A, 86B bonded to the electrical leads 64A 64B, provides an electronic vaporizer 10 with improved heating precision and accuracy, relatively simple design, at a low manufacturing cost. A majority of prior art vaporizers use a joule heating element to convert electrical energy into thermal energy, as to drive the vaporization of certain organic compounds. The heating element 64 described here can be utilized in any vaporizer design that includes a resistive heating element.

A vaporizer including a heating element 64 of the present invention with bonded thermocouple leads to the electrical leads can vary greatly in design. The simplest electronic vaporizer design includes the following key components: a power source, electronic circuitry that regulates the electrical current, a heating element that converts the electric current into heat, and a reservoir or chamber that stores the organic compound that is to be vaporized utilizing the heat generated from the heating element. Electronic vaporizers can also include additional components to improve the user's experience, or for additional secondary purposes, such as portable power supplies, vapor filtration devices, vapor cooling devices, airflow regulators, interactive buttons for user interface, display screens, LED lighting, charging ports, induction (wireless) charging circuitry, and electronics for wirelessly connecting the vaporizer to peripheral devices.

In some configurations of an electronic vaporizer, the heating element may be housed in an interchangeable component, commonly referred to as the atomizer. This atomizer is a replaceable part that houses the heating element, the electrical connections required for the heating element to connect to the vaporizer electronics, and the physical connections for the atomizer to connect to the main body of the vaporizer. The atomizer may operate in a way where the heating element itself is shaped in a cup-like shape so that it may act as a reservoir and directly come in contact with organic material that is to be vaporized, or it may thermally bond with a crucible that is housed in the atomizer that acts as the component that applies heat to the organic material that is to be vaporized.

Another possible configuration for a vaporizer that includes a heating element with bonded thermocouple leads to the electrical leads can include vaporizers that utilize a convection heating system, where the heating element is designed in a matter that its generated heat is applied to airflow that is then directed toward an organic material. This airflow is heated to high enough temperatures that the convective heat transfer is enough to vaporize the organic material.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing or other embodiment may be referenced and/or claimed in combination with any feature of any other drawing or embodiment.

This written description uses examples to describe embodiments of the disclosure and to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.

Claims

1. A heating element for use in an electronic vaporizer, the electronic vaporizer having a controller configured to sense an operating temperature of the heating element, comprising:

a heating element support structure;

a heating circuit encapsulated within the heating element support structure and having a first terminal and a second terminal;

a first electronic lead connected to the first terminal of the heating circuit;

a second electronic lead connected to the second terminal of the heating circuit;

a first thermocouple wire coupled to the first electronic lead; and,

a second thermocouple wire coupled to the second electronic lead, wherein the first and second thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

2. The heating element, as set forth in claim 1, wherein the first thermocouple wire is composed from one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum and the second thermocouple wire is composed from another one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum.

3. The heating element, as set forth in claim 1, wherein the first thermocouple wire is composed from a magnetic alloy composed from nickel and chromium.

4. The heating element, as set forth in claim 3, wherein the second thermocouple wire is composed from a magnetic alloy composed from nickel and aluminum.

5. The heating element, as set forth in claim 1, wherein the first and second thermocouple wires are welded to the respective first and second electronic leads.

6. The heating element, as set forth in claim 1, wherein the first thermocouple wire is composed from an alloy composed from approximately 90% nickel and 10% chromium.

7. The heating element, as set forth in claim 6, wherein the second thermocouple wire is composed from an alloy composed from approximately 95% nickel, 2% aluminum, 2% manganese, and 1% silicon.

8. The heating element, as set forth in claim 1, wherein the heating element support structure includes a heating element base.

9. The heating element, as set forth in claim 8, wherein, the heating element includes a first side and a second side, the heating circuit defines a first plane between the first and second sides of the heating element base.

10. The heating element, as set forth in claim 8, wherein the heating element base is comprised of a ceramic material.

11. The heating element, as set forth in claim 8, wherein the heating circuit is comprised of a wire embedded in the heating element base.

12. The heating element, as set forth in claim 8, wherein the heating circuit is printed into the heating element base.

13. The heating element, as set forth in claim 8, wherein the heating element base has a predefined cross-section, wherein the heating circuit is configured to provide uniform heating across the cross-section of the heating element base.

14. The heating element, as set forth in claim 13, wherein the cross-section of the heating element base is generally circular and includes series of pathways comprised of a plurality of arcuate segments.

15. The heating element, as set forth in claim 8, further comprising:

a second heating circuit encapsulated within the heating element base and having a third terminal and a fourth terminal;

a third electronic lead connected to the third terminal of the second heating circuit;

a fourth electronic lead connected to the fourth terminal of the second heating circuit;

a third thermocouple wire coupled to the third electronic lead; and,

a fourth thermocouple wire coupled to the fourth electronic lead, wherein the third and fourth thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

16. An electronic vaporizer, comprising:

a main unit configured to supply electrical energy;

an atomizer coupled to the main unit and being configured to receive material, convert electrical energy from the main unit into thermal energy and apply the thermal energy to the material, wherein the atomizer includes a heating element, the heating element including: a heating element support structure, a heating circuit encapsulated within the heating element support structure and having a first terminal and a second terminal, a first electronic lead connected to the first terminal of the heating circuit, a second electronic lead connected to the second terminal of the heating circuit, a first thermocouple wire coupled to the first electronic lead, a second thermocouple wire coupled to the second electronic lead, wherein the first and second thermocouple wires are composed from different materials; and,

a controller coupled to the heating element and having a pair of inputs, the first and second thermocouple wires connected to the pair of inputs of the controller and forming a thermocouple, the controller configured to:

establish a voltage difference across the thermocouple,

estimate an actual temperature associated with the heating element as a function of the voltage difference, and,

control an electrical current to the heating circuit to heat the heating element to a desired temperature as a function of the actual temperature.

17. The electronic vaporizer, as set forth in claim 16, wherein the first thermocouple wire is composed from one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum and the second thermocouple wire is composed from another one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum.

18. The electronic vaporizer, as set forth in claim 16, wherein the first thermocouple wire is composed from a magnetic alloy composed from nickel and chromium.

19. The electronic vaporizer, as set forth in claim 16, wherein the second thermocouple wire is composed from a magnetic alloy composed from nickel and aluminum.

20. The electronic vaporizer, as set forth in claim 16, wherein the first and second thermocouple wires are welded to the respective first and second electronic leads.

21. The electronic vaporizer, as set forth in claim 16, wherein the first thermocouple wire is composed from an alloy composed from approximately 90% nickel and 10% chromium.

22. The electronic vaporizer, as set forth in claim 21, wherein the second thermocouple wire is composed from an alloy composed from approximately 95% nickel, 2% aluminum, 2% manganese, and 1% silicon.

23. The electronic vaporizer, as set forth in claim 16, forth in claim 1, wherein the heating element support structure includes a heating element base.

24. The electronic vaporizer, as set forth in claim 23, wherein, the heating element includes a first side and a second side, the heating circuit defines a first plane between the first and second sides of the heating element base.

25. The electronic vaporizer, as set forth in claim 23, wherein the heating element base is comprised of a ceramic material.

26. The electronic vaporizer, as set forth in claim 23, wherein the heating circuit is comprised of a wire embedded in the heating element base.

27. The electronic vaporizer, as set forth in claim 23, wherein the heating circuit is printed into the heating element base.

28. The electronic vaporizer, as set forth in claim 23, wherein the heating element base has a predefined cross-section, wherein the heating circuit is configured to provide uniform heating across the cross-section of the heating element base.

29. The electronic vaporizer, as set forth in claim 28, wherein the cross-section of the heating element base is generally circular and the heating circuit includes series of pathways comprised of a plurality of arcuate segments.

30. The heating element, as set forth in claim 23, further comprising:

a second heating circuit encapsulated within the heating element base and having a third terminal and a fourth terminal;

a third electronic lead connected to the third terminal of the second heating circuit;

a fourth electronic lead connected to the fourth terminal of the second heating circuit;

a third thermocouple wire coupled to the third electronic lead; and,

a fourth thermocouple wire coupled to the fourth electronic lead, wherein the third and fourth thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

31. An atomizer for use in an electronic vaporizer having a controller, comprising:

an atomizer base;

a heating element; and,

a heating crucible thermally coupled to the heating element, the heating element including: a heating element support structure, a heating circuit encapsulated within the heating element support structure and having a first terminal and a second terminal, a first electronic lead connected to the first terminal of the heating circuit, a second electronic lead connected to the second terminal of the heating circuit, a first thermocouple wire coupled to the first electronic lead, and, a second thermocouple wire coupled to the second electronic lead, wherein the first and second thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.

32. The atomizer, as set forth in claim 31, wherein the first thermocouple wire is composed from one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum and the second thermocouple wire is composed from another one of a nickel and chromium alloy, a nickel and aluminum alloy, copper, iron, nickel, constantan, nichrome and platinum.

33. The atomizer, as set forth in claim 31, wherein the first thermocouple wire is composed from a magnetic alloy composed from nickel and chromium.

34. The atomizer, as set forth in claim 31, wherein the second thermocouple wire is composed from a magnetic alloy composed from nickel and aluminum.

35. The atomizer, as set forth in claim 31, wherein the first and second thermocouple wires are welded to the respective first and second electronic leads.

36. The atomizer, as set forth in claim 31, wherein the first thermocouple wire is composed from an alloy composed from approximately 90% nickel and 10% chromium.

37. The atomizer, as set forth in claim 36, wherein the second thermocouple wire is composed from an alloy composed from approximately 95% nickel, 2% aluminum, 2% manganese, and 1% silicon.

38. The atomizer, as set forth in claim 31, wherein the heating element support structure includes a heating element base.

39. The atomizer, as set forth in claim 38, wherein, the heating element includes a first side and a second side, the heating circuit defines a first plane between the first and second sides of the heating element base.

40. The atomizer, as set forth in claim 38, wherein the heating element base is comprised of a ceramic material.

41. The atomizer, as set forth in claim 38, wherein the heating circuit is comprised of a wire embedded in the heating element base.

42. The atomizer, as set forth in claim 38, wherein the heating circuit is printed into the heating element base.

43. The atomizer, as set forth in claim 38, wherein the heating element base has a predefined cross-section, wherein the heating circuit is configured to provide uniform heating across the cross-section of the heating element base.

44. The atomizer, as set forth in claim 43, wherein the cross-section of the heating element base is generally circular and includes series of pathways comprised of a plurality of arcuate segments.

45. The atomizer, as set forth in claim 38, further comprising:

a second heating circuit encapsulated within the heating element base and having a third terminal and a fourth terminal;

a third electronic lead connected to the third terminal of the second heating circuit;

a fourth electronic lead connected to the fourth terminal of the second heating circuit;

a third thermocouple wire coupled to the third electronic lead; and,

a fourth thermocouple wire coupled to the fourth electronic lead, wherein the third and fourth thermocouple wires are composed from different materials and configured to be connected to respective inputs of the controller.