Interference-Fit Electrode Assembly to Prevent Lead Detachment
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Solution Overview
Problem
Aerosol provision systems, such as electronic cigarettes, face issues with lead detachment causing short-circuits and liquid leakage due to the fluid transport path from the liquid reservoir into the open air channel, leading to undesirable leakage and faulty operations.
Innovation Solution
An assembly is provided with a body and electrode secured by a first interference fit, where a lead section is inserted into an aperture, and the electrode portion is inserted to secure the lead inside the aperture, reducing the need for crimping and minimizing fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lead is used to transfer power from the electrode to the heating element, then electrical connection is established, but the lead may become detached during use causing short-circuits and faulty operation
Solution Approach 1:
The lead is integrated within the electrode assembly structure, merging the electrical connection function with the structural housing. The lead passes through the electrode and is retained by the housing aperture, combining multiple functions into a unified assembly that prevents lead detachment while maintaining electrical connectivity.
2Ease of operation
If a capillary wick is used to draw liquid from reservoir to heating element, then fluid transport is enabled, but liquid leakage occurs from the cartridge
Solution Approach 1:
The harmful fluid transport path from the liquid reservoir into the open air channel is removed. The electrode assembly is designed to block this path, extracting the leakage problem from the system while preserving the necessary capillary wick function for controlled liquid delivery to the heating element.
Solution Approach 2:
The electrode assembly acts as an intermediary component between the liquid reservoir and the air channel. It provides a barrier that prevents direct fluid communication while allowing controlled liquid transport through the capillary wick, mediating between the conflicting requirements of fluid delivery and leakage prevention.
3Strength
If crimping is used to secure the lead, then mechanical attachment is achieved, but mechanical weaknesses and potential lead detachment occur
Solution Approach 1:
The crimping mechanical system is replaced with a friction-fit retention system. The lead is held in place by the interference fit between the lead outer diameter and the aperture inner diameter, eliminating the need for crimping tools and complex assembly steps while maintaining secure attachment.
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
The assembly securely attaches electrodes without crimping, reducing mechanical weaknesses and fluid leakage, ensuring stable electrical connections and reducing the risk of fluid leakage.
Implementation Method 1
a first interference fit between the body and the portion of the electrode
Data Source
AI summary
An assembly comprising a body defining an aperture, and an electrode comprising a portion within the aperture, the assembly further comprising a lead comprising a section which is secured inside the aperture by a first interference fit between the body and the portion of the electrode. The aperture may comprise a first open end and a second open end, wherein the electrode extends through the first open end, and the lead extends through the second open end. In which case, the electrode may plug the first end by a second interference fit between the body and the portion of the electrode. The portion of the electrode may comprise a tapered section against which the section of the lead is secured.