Mesh Heater Element for Electronic Cigarette Vaporization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronic cigarette heaters, typically single wire coils, face inefficiencies in heat transfer and aerosol production, with inconsistent heating and potential for hot spots, leading to suboptimal performance and user experience.
Innovation Solution
A ribbon of electrically resistive mesh material is wound around a wick, providing increased surface contact and uniform heat transfer, allowing for more efficient vaporization of liquid and consistent aerosol production, with adjustable resistivity and brazed connection regions to prevent hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single wire coil heater is used, then the device complexity is low, but the heat transfer uniformity and aerosol production efficiency are poor
Solution Approach 1:
The heater is segmented into multiple individual wires arranged in a grid pattern, where each wire acts as an independent heating element. This segmentation increases the total heating surface area and improves heat distribution uniformity across the wick, thereby enhancing aerosol production efficiency without requiring complex integrated structures
Solution Approach 2:
The heater transitions from a one-dimensional single wire coil to a two-dimensional wire grid array. This dimensional expansion increases the heating surface area in contact with the wick, improving both heat transfer uniformity and aerosol generation efficiency while maintaining structural simplicity
2Reliability
If a single wire coil heater is used, then the manufacturing is simple, but hot spots occur and heating consistency is poor
Solution Approach 1:
Dividing the heating function into multiple separate wires eliminates hot spots by distributing thermal energy across numerous contact points on the wick. The segmented wire grid ensures uniform heating consistency while remaining manufacturable through straightforward assembly processes
Solution Approach 2:
Each wire in the grid provides localized heating zones that collectively achieve uniform overall heating. This local quality approach prevents hot spots by ensuring every region of the wick receives adequate heat from adjacent wires, improving reliability without complicating manufacturing
3Area of stationary object
If a ribbon of mesh material is wound around the wick, then the heat transfer surface area increases and heating uniformity improves, but the device complexity increases
Solution Approach 1:
The heater expands from a one-dimensional ribbon wrap to a two-dimensional wire grid array, maximizing the heating surface area in contact with the wick. This dimensional approach increases heat transfer efficiency and uniformity while maintaining structural simplicity through a regular geometric pattern
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 mesh heater design enhances aerosol production efficiency, reduces current draw, and ensures consistent heating, improving user experience by providing a larger volume of aerosol with lower electrical energy consumption and minimizing the risk of overheating.
Implementation Method 1
a heater formed of a mesh material... a ribbon of electrically resistive mesh material wrapped around a wick... operative to heat the liquid material to a temperature sufficient to vaporize the liquid material
Implementation Method 2
heat the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol
Data Source
AI summary
An electronic cigarette includes a liquid supply including liquid material, a heater operable to heat the liquid material to a temperature sufficient to vaporize the liquid material and form an aerosol, and a wick in communication with the liquid material and in communication with the heater such that the wick delivers the liquid material to the heater. The heater is formed of a mesh material.