Heater having a co-sintered multi-layer structure

Abstract

A method for producing a heater with a co-sintered multilayer construction for a system for providing an inhalable aerosol, including providing at least one first substrate layer, arranging at least one first insulating layer at least in areas on the first substrate layer, arranging at least one heating element at least in areas on the first insulating layer, arranging at least one second substrate layer and at least one second insulating layer at least in areas on the heating element. The second insulating layer is arranged at least in areas on the second substrate layer, and the second insulating layer is in contact at least in areas with the heating element and/or with the first insulating layer. The method includes pressing the layers and the heating element, and firing the pressed layers in order to co-sinter the layers of the multilayer construction.

Claims

1. A method for producing a heater with a co-sintered multilayer construction for a system for providing an inhalable aerosol, the method comprising: providing at least one first substrate layer; arranging at least one first insulating layer at least in areas on the first substrate layer; arranging at least one heating element at least in areas on the first insulating layer, arranging at least one second substrate layer and at least one second insulating layer at least in areas on the at least one heating element, wherein the at least one second insulating layer is arranged at least in areas on the at least one second substrate layer, and wherein the at least one second insulating layer is in contact at least in areas with the at least one heating element and/or with the at least one first insulating layer; pressing the layers and the heating element; and firing the pressed layers in order to co-sinter the layers of the multilayer construction.

2. The method according to claim 1, wherein the at least one first substrate layer and/or the at least one second substrate layer comprise(s) at least one green film comprising stabilized zirconium oxide, ZrO.sub.2.

3. The method according to claim 2, wherein the at least one green film has a thickness in a range between 0.25 mm and 0.5 mm.

4. The method according to claim 1, wherein the at least one first insulating layer and/or the at least one second insulating layer comprises a ceramic slip comprising aluminum oxide, Al.sub.2O.sub.3.

5. The method according to claim 1, wherein arranging the at least one first insulating layer and/or of the at least one second insulating layer comprises: screen-printing and/or tape casting the at least one first insulating layer on the at least one first substrate layer and/or the at least one second insulating layer on the at least one second substrate layer.

6. The method according to claim 1, wherein the at least one heating element comprises at least one resistance element comprising platinum, Pt-cermet.

7. The method according to claim 6, wherein arranging the at least one heating element comprises screen-printing of the at least one resistance element on the at least one first insulating layer.

8. The method according to claim 1, wherein arranging the at least one second substrate layer and the at least one second insulating layer comprises: arranging the at least one second insulating layer at least in areas on the at least one heating element and arranging the at least one second substrate layer at least in areas on the at least one second insulating layer, or arranging the at least one second insulating layer at least in areas on the at least one second substrate layer and arranging the at least one second insulating layer at least in areas on the at least one heating element.

9. The method according to claim 1, wherein firing of the pressed layers comprises: firing the pressed layers of the multilayer construction at a temperature of at least 1400° C. for at least 36 hours.

10. The method according to claim 1, comprising separating the heater before firing by punching out or by a laser cutting method, or separating the heater after pressing the layers and before firing.

11. The method according to claim 1, comprising introducing recesses into the at least one second insulating layer and/or into the at least one second substrate layer, by introducing recesses for exposing at least one connection means of the at least one heating element at least in areas.

12. The method according to claim 1, comprising: arranging at least one temperature sensor before the pressing of the layers between: (i) the at least one first insulating layer and the at least one first substrate layer, and/or (ii) the at least one second insulating layer and the at least one second substrate layer, and/or (iii) the at least one first insulating layer and the at least one second insulating layer.

13. Use of a heater produced by a method according to claim 1 in a system for providing an inhalable aerosol.

14. A system for providing an inhalable aerosol, comprising at least one heater produced by a method according to claim 1.

15. A heater with a co-sintered multiple layer construction for a system for providing an inhalable aerosol, comprising: at least one heating element with a first side and a second side opposite the first side, at least one first and one second insulating layer, wherein the first insulating layer is arranged at least in areas on the first side of the heating element such that there is no space between the first insulating layer and the heating element, and wherein the second insulating layer is arranged at least in areas on the second side of the heating element such that there is no space between the second insulating layer and the heating element, and at least one first substrate layer and a second substrate layer, wherein the first substrate layer is arranged at least in areas on the first insulating layer, and wherein the second substrate layer is arranged at least in areas on the second insulating layer; and at least one temperature sensor arranged between: (i) the at least one first insulating layer and the at least one first substrate layer, or (ii) the at least one second insulating layer and the at least one second substrate layer, or (iii) the at least one first insulating layer and the at least one second insulating layer.

Description

(1) In the drawings:

(2) FIG. 1 shows a schematic exploded view of a heater according to an embodiment of the invention, and

(3) FIG. 2 shows a method for producing a heater according to an embodiment of the invention.

(4) FIG. 1 shows a schematic exploded view of a heater 1 according to an embodiment of the invention.

(5) A first insulating layer 5 is arranged on a first substrate layer 3 which can be, in the embodiment shown, a green film, in particular a green film comprising stabilized ZrO2. In the embodiment shown, first insulating layer 5 can comprise a ceramic slip comprising Al2O3 and be arranged on first substrate layer 3 by screen-printing and/or tape casting. After arranging first insulating layer 5 on second substrate layer 3, the structure can be dried before further processing.

(6) A temperature sensor 9 is arranged between first substrate layer 3 and first insulating layer 5 in the embodiment shown. Temperature sensor 9 serves to determine a temperature of heater 1. In FIG. 1, temperature sensor 9 is shown only optionally since such a sensor is not essential for the invention. Also, temperature 9 or several temperature sensors (not shown) can be arranged between other layers of the multilayer construction. In embodiments not shown, the temperature sensor can also be arranged between first insulating layer 5 and a second insulating layer 5′ and/or between second insulating layer 5′ and a second substrate layer 3′.

(7) A heating element 7 is arranged on first insulating layer 5 in the embodiment shown. In FIG. 1, heating element 7 is designed as a resistance element in the form of a conductor track. In the embodiment shown, the resistance element can comprise a Pt-cermet and be arranged by a screen-printing method on first insulating layer 5. In FIG. 1 the resistance element is shown as a conductor track run in a meandering manner and with two connection contacts. In embodiments not shown, the conductor track can also have a different design. For example, the conductor track can also be designed in a helical form. The heating element can also assume the function of a temperature sensor by a suitable electronic control in an embodiment not shown.

(8) In the embodiment shown, second insulating layer 5′ is arranged on heating element 7 and is again arranged on second substrate layer 3′. The materials of first and second insulating layers 5, 5′ and of first and second substrate layers 3, 3′ can be substantially identical. Also, second insulating layer 5′ and second substrate layer 3′ can be arranged successively in a similar manner to that of first insulating layer 5 and of first substrate layer 3. As an alternative to the above, second insulating layer 5′ can also be arranged at first on second substrate layer 3′ in order to then arrange second substrate layer 3′ with second insulating layer 5′ arranged on it together on heating element 7.

(9) In the embodiment shown, recesses in the form of a shortening of second insulating layer 5′ relative to first insulating layer 5 and of second substrate layer 3′ relative to first substrate layer 3 are introduced into second insulating layer 5′ and into second substrate layer 3′ in order to expose the connection contacts of heating element 1 at least in areas. In embodiments not shown, the recesses can also be designed in the form of punched-out perforations through which the respective at least one connection conductor can be run through in order to contact the heating element 7.

(10) The layers of the multilayer construction shown in FIG. 1 are substantially planar or level. However, in embodiments not shown, these layers can also exhibit a concave or convex curvature or be bent in the form of a cylinder in order to surround the substance to be heated. For example, in this embodiment not shown, the substance to be heated can be arranged in the cylinder or pushed into it.

(11) FIG. 2 shows a method for producing a heater according to an embodiment of the invention.

(12) The method shown for producing a heater with a co-sintered multilayer construction for a system for providing an inhalable aerosol comprises the following steps: providing 1010 at least one first substrate layer, arranging 1020 at least one first insulating layer at least in areas on the first substrate layer, arranging 1030 at least one heating element at least in areas on the first insulating layer, arranging 1040 at least one second substrate layer and at least one second insulating layer at least in areas on the heating element, wherein the second insulating layer is arranged at least in areas on the second substrate layer, and wherein the second insulating layer is in contact at least in areas with the heating element and/or the first insulating layer, pressing 1050 the layers and the heating element, and firing 1060 the pressed layers for the co-sintering of the layers of the multilayer construction.

(13) The features presented in the description above, in the claims and in the figures can be essential for the invention in its different embodiments individually as well as in any combination.

LIST OF REFERENCE NUMERALS

(14) 1 Heater 3,3′ Substrate layer 5, 5′ Insulating layer 7 Heating element 9 Temperature sensor 1010 Providing the first substrate layer 1020 Arranging the first insulating layer 1030 Arranging the heating element 1040 Arranging the second substrate layer and the second insulating layer 1050 Pressing 1060 Firing