Folded Heater U-Shaped Segments Vapor Output Battery Life
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Solution Overview
Problem
Existing electronic vaping devices face challenges in designing a heater that efficiently vaporizes pre-vapor formulations while maintaining optimal resistance and battery life, with current solutions often compromising on vapor output or battery endurance.
Innovation Solution
A folded heater design featuring U-shaped segments arranged in a specific configuration, with folded portions and lead portions formed from materials like Nichrome or stainless steel, which provides a balanced resistance and efficient heat transfer, ensuring consistent vapor production and extended battery life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heater design is used that increases vapor output, then vapor production is improved, but battery life deteriorates
Solution Approach 1:
The heater is divided into multiple U-shaped segments arranged in series, allowing the total heating surface area to be increased while distributing the resistance across segments. This segmentation enables optimized vapor production without requiring excessive power from the battery at any single point.
Solution Approach 2:
The heater transitions from a simple linear or planar design to a three-dimensional folded structure with U-shaped segments extending in multiple directions. This dimensional change increases the effective heating surface area within a compact volume, improving vapor output without proportionally increasing power consumption.
2Duration of action of moving object
If heater resistance is increased to extend battery life, then battery endurance is improved, but vapor output deteriorates
Solution Approach 1:
The heater resistance is optimized to a specific range (0.5 to 5.0 ohms) through careful design of the U-shaped segments' dimensions, material selection (Nichrome or stainless steel), and configuration. This parameter optimization achieves the balance between battery endurance and vapor output by ensuring efficient power utilization without excessive resistance.
3Volume of moving object
If a compact heater design is used to maintain device size, then device compactness is improved, but heating efficiency deteriorates
Solution Approach 1:
The heater utilizes a folded three-dimensional structure with U-shaped segments that maximize the heating surface area within a compact footprint. By extending the heater in multiple dimensions rather than a single linear direction, the design achieves high heating efficiency without increasing overall device volume.
Solution Approach 2:
The U-shaped segments are arranged in a nested or closely packed configuration, allowing the heater to occupy minimal space while maintaining sufficient surface area for efficient vaporization. The segments are positioned to maximize heat transfer to the pre-vapor formulation in the limited available volume.
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 folded heater design achieves a balanced resistance of 0.5 to 5.0 ohms, optimizing vapor output and battery life, providing consistent aerosol mass over multiple puffs and extended usage without compromising on device size or complexity.
Implementation Method 1
The battery is electrically connected to the heater, such that the heater heats to a temperature sufficient to convert a pre-vapor formulation to a vapor
Data Source
AI summary
A folded heater of an electronic vaping device includes a first plurality of U-shaped segments arranged in a first direction and defining a first side of the heater and a second plurality of U-shaped segments arranged in the first direction and defining a second side of the heater. The second side is substantially parallel to the first side. The heater also includes a first lead portion and a second lead portion. The first plurality of U-shaped segments, the second plurality of U-shaped segments, the first lead portion, and the second lead portion are a single integral member.