Flat Mesh Atomizer Core for Uniform Heating and Extended Life
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Solution Overview
Problem
Conventional electronic cigarette atomizers have small heating areas, low efficiency, uneven heating, and unstable operation, leading to issues like carbon deposits and uneven vape particle sizes, affecting user experience and reducing the device's lifespan.
Innovation Solution
An atomizer core with a flat mesh heating element and a porous ceramic fluid absorbing element, embedded in a cylindrical structure, providing a larger heating area and uniform heating, along with a manufacturing method that includes laser welding conductive wires and forming a tubular fluid guiding member for efficient fluid delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a conventional heating element is used, then the structure is simple, but the heating area is small and heating is uneven
Solution Approach 1:
The heating element transitions from a conventional wire or coil structure to a flat mesh structure, changing the dimensional configuration from linear to planar. This dimensional change dramatically increases the heating area while maintaining structural simplicity, allowing uniform heat distribution across the atomization surface.
Solution Approach 2:
The heating element adopts a mesh structure with inherent porosity, allowing fluid to pass through and contact the heating surface uniformly. This porous configuration increases the effective heating area while maintaining a simple flat geometry, resolving the contradiction between heating area and structural complexity.
2Productivity
If a conventional heating element is used, then the manufacturing process is simple, but the working efficiency is low
Solution Approach 1:
The flat mesh heating element is pre-formed as an integrated structure before assembly, with conductive wires already positioned and connected. This preliminary configuration of the heating pattern and electrical connections before final assembly simplifies the overall manufacturing process while achieving high working efficiency through the optimized mesh geometry.
3Reliability
If a conventional heating element is used, then the structure is simple, but the operation is unstable and carbon deposits form
Solution Approach 1:
The flat mesh heating element provides uniform heat distribution across the entire atomization surface, eliminating hot spots and cold zones. This homogeneous heating prevents localized overheating that causes carbon deposits and ensures stable, consistent operation. The simple flat mesh structure achieves this homogeneity without adding complexity.
4Reliability
If conventional atomizer structure is used, then the design is simple, but fluid leakage cannot be solved
Solution Approach 1:
The heating element and fluid absorbing element are nested within a multi-layer structure comprising a support layer, fluid guiding layer, and sealing layer. This nested configuration allows the heating component to be embedded within the fluid delivery system, creating integrated sealing paths that prevent fluid leakage while maintaining a compact overall structure.
5Duration of action of stationary object
If conventional atomizer structure is used, then the structure is simple, but the service life is short
Solution Approach 1:
The atomizer is divided into distinct functional modules: a support layer for structural integrity, a fluid guiding layer for controlled fluid delivery, a heating element for atomization, and a sealing layer for leak prevention. This segmentation allows each component to be optimized for its specific function, improving overall durability and service life while the modular nature keeps the structure manageable and not overly complex.
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 solution results in a stable, efficient heating process, reducing carbon deposits, prolonging the atomizer's lifespan, and producing uniform vape particles for improved taste and user experience, with a service life span more than four times that of conventional atomizers.
Implementation Method 1
a heating element made of a flat mesh structure
Implementation Method 2
a fluid absorbing element evenly wrapping around an outer side of the heating element for storing fluid and delivering the fluid to the heating element
Implementation Method 3
a fluid absorbing element evenly wrapping around an outer side of the heating element for storing fluid and delivering the fluid to the heating element
Data Source
AI summary
An atomizer core includes a heating element made of a flat mesh structure, a fluid absorbing element evenly wrapping around an outer side of the heating element for storing fluid and delivering the fluid to the heating element, and two conductive wires electrically extended from two sides of the heating element respectively. The atomizer core not only provides a uniform heating ability and a stable operation but also enhance the atomization rate of the fluid to maintain the real and better smoking taste. The atomizer core has a prolonged service life span and an enlarged heating area to reduce the carbon deposits of the atomizer.