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.

What is claimed is: 
     
         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.