Curved Ultrasonic Atomization Core to Reduce Guide Cotton Burnout
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Solution Overview
Problem
Existing ultrasonic atomization cores suffer from e-liquid guide cotton burning out due to high temperatures, poor power endurance, and structural vulnerabilities, leading to high use costs and inefficient atomization.
Innovation Solution
The ultrasonic atomization core features a concave atomization sheet with a convex e-liquid guide cotton, ensuring even liquid distribution and temperature management, along with a replaceable design and elastic electrodes for uniform stress, reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a planar ultrasonic atomization sheet is used, then the structure is simple, but the temperature at the center position is high causing e-liquid guide cotton to burn out quickly
Solution Approach 1:
The patent changes the planar atomization sheet to a spherical shape. The spherical surface distributes the ultrasonic vibration energy more evenly across the surface, preventing localized overheating at the center. This curvature modification allows e-liquid to be distributed more uniformly, reducing the temperature concentration that causes the guide cotton to burn out, thereby extending its service life while maintaining structural simplicity.
2Ease of manufacture
If a planar ultrasonic atomization sheet is used, then the manufacturing is easy, but the power endurance is low due to lack of energy accumulation
Solution Approach 1:
The spherical shape of the atomization sheet creates a concave surface that acts as an energy accumulation chamber. This curvature allows ultrasonic energy and e-liquid to be concentrated and retained on the spherical surface, improving the efficiency of atomization. The spherical geometry naturally focuses the ultrasonic vibrations and e-liquid supply toward the center, enhancing energy utilization and power endurance without complicating the manufacturing process.
3Device complexity
If a cylindrical elastic electrode directly abuts against the center of the ultrasonic atomization sheet, then the connection is simple, but the atomization sheet is easily broken during assembly
Solution Approach 1:
The spherical shape of the atomization sheet distributes the contact area with the cylindrical electrode more evenly. Instead of concentrating stress at a single point on a flat surface, the curved spherical surface allows the electrode to contact along an arc, distributing the mechanical stress. This reduces the risk of breaking the atomization sheet during assembly while maintaining a simple connection structure.
4Reliability
If the atomization core is riveted into the connecting sleeve, then the connection reliability is high, but the replacement cost is high when damaged
Solution Approach 1:
The patent separates the atomization core from the connecting sleeve by removing the riveting connection. The atomization core is designed as an independent module that can be easily detached and replaced. This segmentation allows the atomization core to be maintained separately from the housing, reducing overall replacement costs when the atomization core becomes damaged, while threaded connections maintain sufficient connection reliability.
5Device complexity
If e-liquid is not guided efficiently to the center, then the structure is simple, but the e-liquid guide cotton burns through due to excessive temperature
Solution Approach 1:
The spherical surface of the atomization sheet, combined with the convex surface of the guide cotton, creates a curved contact interface that enhances capillary action and gravity-driven flow of e-liquid toward the center. This curvature geometry naturally channels e-liquid along the spherical surface to the center position, ensuring continuous cooling and preventing overheating of the guide cotton without requiring complex liquid guidance structures.
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 prolongs the lifespan of e-liquid guide cotton and ultrasonic atomization sheet, enhances atomization efficiency, reduces power consumption, and allows for cost-effective replacement of damaged components.
Implementation Method 1
an ultrasonic atomization sheet (2) and e-liquid guide cotton (3) that communicates the outside with an atomization surface
Implementation Method 2
the concave atomization surface of the ultrasonic atomization sheet has the function of focusing energy
Implementation Method 3
the e-liquid guide cotton accelerates e-liquid guide by means of the curvature of the convex surface itself on the surface in contact with the concave surface
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An ultrasonic atomization core (17), an ultrasonic atomizer, and an ultrasonic electronic cigarette, wherein the ultrasonic atomization core (17) comprises an atomization sleeve (1), an ultrasonic atomization sheet (2) and e-liquid guide cotton (3) that communicates the outside with an atomization surface of the ultrasonic atomization sheet (2) are arranged in the atomization sleeve (1), the atomization surface of the ultrasonic atomization sheet (2) is a concave surface, the e-liquid guide cotton (3) has a convex surface corresponding to the atomization surface, the curvature of the convex surface of the e-liquid guide cotton (3) is greater than or equal to the curvature of the atomization surface of the ultrasonic atomization sheet (2), and the convex surface of the e-liquid guide cotton (3) is in contact with the atomization surface of the ultrasonic atomization sheet (2). E-liquid is guided to the center of the ultrasonic atomization sheet (2) more easily, making it difficult for the e-liquid guide cotton (3) to be burnt through or be burnt out, the atomization effect is good, and the service lives of the e-liquid guide cotton (3) and the ultrasonic atomization sheet (2) are long; the ultrasonic atomization sheet (2) can effectively accumulate energy to generate smoke by means of atomization, so low working power is required, and the power endurance is strong; during assembly, the ultrasonic atomization sheet (2) is stressed uniformly and is difficult to break; the atomization core (17) can be replaced separately, which reduces the use cost; and an e-liquid passage can be cut off when e-liquid is injected into an e-liquid bin (10), which prevents e-liquid leakage and prevents the ultrasonic atomization sheet (2) from being immersed into the e-liquid.