Coiled Heater Wire Structure for E-Vapor Devices
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Solution Overview
Problem
Existing e-vapor devices face challenges in efficiently vaporizing pre-vapor formulations due to limitations in heater structure design, leading to inconsistent vapor production and potential clogging issues.
Innovation Solution
The e-vapor device incorporates a heater structure with a base wire and a coiled heater wire, where the base wire is electrically insulated from the heater wire, allowing for efficient heat generation and vaporization. The heater structure is designed to apply a spring force against the dispensing interface, ensuring effective contact and reducing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple wire heater structure is used, then the device complexity is reduced, but the vaporization efficiency and consistency deteriorate
Solution Approach 1:
The heater structure is segmented into two distinct functional components: a base wire that provides structural support and electrical insulation, and a heater wire that generates heat through resistive heating. This segmentation allows each component to be optimized for its specific function, improving vaporization efficiency while maintaining manageable complexity
Solution Approach 2:
The heater wire is coiled around and nested upon the base wire, creating a compact integrated structure. This nesting arrangement maximizes the heater wire's contact with the pre-vapor formulation while maintaining structural integrity through the base wire, thereby improving vapor production efficiency without significantly increasing device complexity
2Manufacturing precision
If the heater wire is in direct contact with the base wire, then the manufacturing precision is improved, but electrical insulation is compromised
Solution Approach 1:
The base wire serves as an intermediary element between the heater wire and the surrounding environment. It provides electrical insulation through its material properties (such as enamel coating or inherent non-conductivity), preventing direct electrical contact between the heater wire and other conductive components while maintaining close physical proximity for efficient heat transfer
3Reliability
If the heater structure applies high spring force against the dispensing interface, then the contact effectiveness is improved, but the device complexity increases
Solution Approach 1:
The heater structure incorporates spring force, transforming it from a static rigid component to a dynamic element that can adapt to variations in the dispensing interface. This dynamic characteristic allows the heater structure to maintain consistent contact pressure and effective thermal coupling without requiring complex adjustment mechanisms, thereby improving contact effectiveness while keeping device complexity manageable
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 enhances the efficiency of vapor production, reduces the likelihood of clogging, and provides a robust heater structure that can withstand various operational conditions, leading to improved user experience and device performance.
Implementation Method 1
the wire undergoes resistive heating to vaporize the pre-vapor formulation in the wick to produce a vapor
Implementation Method 2
The anodic layer has a dielectric strength of at least 150 V/m
Data Source
AI summary
An e-vapor device may include a pre-vapor sector and a heater structure arranged in thermal contact with the pre-vapor sector. The pre-vapor sector includes a reservoir and a dispensing interface. The pre-vapor sector is configured to hold and dispense a pre-vapor formulation. The heater structure is configured to vaporize the pre-vapor formulation to generate a vapor. The heater structure includes a base wire and a heater wire coiled around the base wire. The base wire is insulated from the heater wire. As a result of the heater design, the heater structure is stiffer and more robust than other related heaters in the art, thus allowing more options for its implementation.