Capillary Vaporizer with Flexible Circuits for Leakage Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electronic cigarettes suffer from leakage, inconsistent dosing, and mechanical reliability issues due to their design, which leads to impaired performance, wasted liquid, and potential user safety concerns from high-temperature nichrome heating elements.
Innovation Solution
The electronic vaporizing inhaler employs capillary action to control liquid flow, uses solder-less connections and flexible circuits for improved mechanical resilience, and incorporates a microprocessor with a timer to ensure consistent dosing and safe operation, along with customizable dosing options via heat or diaphragm pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional membranes (sponge, fabric wadding) are used to hold liquid nicotine, then the device structure is simple, but liquid leakage occurs and dosing becomes inconsistent
Solution Approach 1:
The patent employs a porous PTFE membrane with specific pore size (0.03-0.1 micrometers) to achieve reliable liquid containment. The porous structure allows vapor passage while blocking liquid nicotine, resolving the contradiction between simple structure and reliable liquid containment.
Solution Approach 2:
The invention uses a composite structure combining PTFE membrane with hydrophobic coating and capillary wicking material. This composite approach enables the membrane to simultaneously repel liquid while allowing controlled vapor transmission, improving both reliability and dosing consistency.
2Temperature
If nichrome heating elements are used, then the heating element is simple and inexpensive, but the temperature reaches 900°C causing chromium leaching, user danger, and liquid burning
Solution Approach 1:
The patent changes the material parameter of the heating element from nichrome to a non-chromium alloy (such as iron-nickel or cobalt-based alloys) with controlled operating temperature. This parameter change eliminates chromium leaching while maintaining effective heating capability at safer temperatures.
Solution Approach 2:
The invention converts the harmful high-temperature operation of nichrome into a beneficial controlled-temperature system. By using alternative materials with lower operating temperatures, the system eliminates chromium release and liquid burning while still achieving effective vaporization.
3Reliability
If multiple wires with solder joints are used for electrical connections, then the electrical communication is established, but the solder joints are prone to break during drops or mechanical shock
Solution Approach 1:
The patent replaces the mechanical solder joint system with alternative electrical connection methods such as conductive adhesives, elastic contacts, or rigid-flex circuit boards. These alternatives eliminate fragile solder joints while maintaining electrical connectivity, resolving the contradiction between electrical communication and mechanical strength.
Solution Approach 2:
The invention uses flexible circuit boards or thin-film conductive layers to create electrical connections that can withstand mechanical shock. These flexible structures absorb impact forces without breaking, unlike rigid solder joints, thereby improving both reliability and strength.
4Productivity
If the heating element operates at high temperature, then the vaporization efficiency is high, but the battery life becomes shorter due to increased energy consumption
Solution Approach 1:
The patent changes the operating temperature parameter from high (900°C) to optimized moderate temperatures. By using alternative heating materials and improving heat transfer efficiency, the system achieves adequate vaporization at lower temperatures, reducing energy consumption while maintaining productivity.
Solution Approach 2:
The invention implements continuous monitoring and control of heating parameters to maintain optimal vaporization efficiency. By using feedback control and efficient heat transfer designs, the system sustains effective vaporization with minimized energy input, extending battery life while preserving productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly reduces leakage, provides consistent vapor delivery, enhances mechanical reliability, and ensures user safety by controlling temperature and energy consumption, while allowing for customizable nicotine intake.
Implementation Method 1
the liquid to be vaporized is distributed through a series of capillaries that are able to contain the vaping liquid based on the surface tension of the liquid and that allows flow of the vaping liquid in response to small changes in pressure
Implementation Method 2
the liquid to be vaporized is distributed through a series of capillaries that are able to contain the vaping liquid based on the surface tension of the liquid
Implementation Method 3
the liquid nicotine is drawn into a vaporizer where it is heated into a vapor
Implementation Method 4
the liquid nicotine is drawn into a vaporizer where it is heated into a vapor
Data Source
Figure 1~2
Figure 3A~3C
Figure 4~5
AI summary
The present invention provides an electronic vaporizing inhaler with an electrical storage device; a liquid reservoir for vaping liquid; a vaporizer with a substrate defined by a plurality of capillary apertures that provide fluid communication between the vaporizer and the liquid reservoir; a sponge; a wick; and a heating element; a microprocessor in electrical communication with the electrical storage device that directs current from the electrical storage device to the heating element in the vaporizer; a sensor configured to detect when a user draws on the electronic cigarette that activates the microprocessor when it detects that a user has drawn on the electronic cigarette; a housing having designed to contain the electrical storage device, vaporizer, microprocessor, sensor, and liquid reservoir and having a mouthpiece from which a user can inhale vapor from the vaporizer. The invention also provides a dosage control embodiment using a heat or diaphragm pump.