Mesh Element Vaporization in Electronic Cigarettes
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Solution Overview
Problem
Existing electronic cigarette designs suffer from short lifespan, poor atomization, nonuniform vapor production, and overheating due to direct liquid contact with the heater coil, leading to inefficiencies and reduced performance.
Innovation Solution
The electronic cigarette design features a mesh element in contact with the liquid storage, where a heater heats air that is then passed through the mesh to vaporize the liquid, eliminating direct contact between the liquid and the heater coil, and incorporating a battery, circuit board, and flow sensor for controlled vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a wire coil heater is used to directly vaporize liquid nicotine, then vaporization can be achieved, but the heater coil overheats and has short lifespan
Solution Approach 1:
The patent introduces a mesh element as an intermediary between the liquid nicotine reservoir and the heater coil. The mesh element absorbs and holds the liquid, allowing it to vaporize indirectly through heat transfer from the coil rather than direct contact. This mediator protects the heater from overheating while maintaining effective vaporization.
Solution Approach 2:
The patent employs a porous mesh element that can absorb and retain liquid nicotine on its surface and within its structure. This porous material provides large surface area for vaporization while controlling liquid flow to prevent direct contact with the heater coil, thereby extending heater lifespan while maintaining vaporization efficiency.
2Productivity
If liquid nicotine is directly contacted with the heater coil for vaporization, then heating efficiency is achieved, but poor atomization and nonuniform vapor occur
Solution Approach 1:
The porous mesh element distributes the liquid nicotine uniformly across its surface through capillary action, creating consistent liquid films that vaporize evenly. This porous structure ensures uniform atomization and vapor distribution, eliminating the nonuniform vapor problems associated with direct coil contact.
Solution Approach 2:
The mesh element undergoes thermal expansion when heated, which helps distribute heat more evenly across the liquid-nicotine-contact surface. This thermal response of the mesh structure contributes to uniform heating and consistent vapor production, improving vapor uniformity while maintaining efficiency.
3Productivity
If a wire coil heater directly contacts liquid nicotine, then vaporization occurs, but chemical changes and tar formation increase health risks
Solution Approach 1:
The mesh element serves as a protective intermediary that prevents direct contact between the heater coil and liquid nicotine. This separation reduces thermal degradation and chemical changes in the nicotine, minimizing harmful byproducts and tar formation while still enabling effective vapor generation through indirect heating.
Solution Approach 2:
The patent changes the heating parameters by using indirect heating through the mesh element rather than direct coil contact. This parameter change in the heating method reduces the temperature extremes and prolonged exposure that cause chemical degradation, thereby reducing harmful chemical changes and tar formation while maintaining vapor generation effectiveness.
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 vaporization efficiency, extends heater coil life, reduces chemical changes during vaporization, and provides uniform vapor at lower temperatures, resulting in improved performance and cost-effectiveness by avoiding direct liquid-heater contact and using corrosion-resistant materials.
Implementation Method 1
The heater heats air and the heated air is conducted through the mesh element, with the heated air vaporizing liquid on or in the mesh element
Implementation Method 2
The vaporized liquid is entrained with the heated air and may then flow through or around the liquid storage to the mouthpiece
Data Source
AI summary
In an electronic cigarette, a mesh element is in contact with liquid storage. A heater is spaced apart from the mesh element and positioned to heat air which flows through the mesh element. The heated air vaporizes the liquid in or on the mesh. The vapor is inhaled by the user. A method of vaporizing a liquid in an electronic cigarette includes conducting liquid from a liquid storage to a mesh element. Electric current is supplied to a heater, optionally in response to sensing inhalation on the outlet or mouthpiece of the electronic cigarette. The heater heats air and the heated air is conducted through the mesh element, with the heated air vaporizing liquid on or in the mesh element. The vaporized liquid is entrained with the heated air and may then flow through or around the liquid storage to the mouthpiece.