Mesh Heating Element for E-Cigarette Condensation Control

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Solution Overview

Problem

Conventional e-cigarettes face issues with aerosol condensation and blockage in the central passage due to limited heating area and spiral heating wires, leading to reduced vapor production and poor taste.

Innovation Solution

A heating element with a mesh structure and a central passage design, where the second body has a smaller outer diameter than the first body, combined with a mesh heating part, increases heating area and prevents condensate backflow, ensuring smooth airflow and improved vapor production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a spiral heating wire is used on the inner wall of the ceramic body, then the heating element can be manufactured, but the heating area is very limited resulting in low heat production

Engineering Contradiction:

Improveheating element manufacturingVSAvoidheating area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The heating element transitions from a one-dimensional spiral wire structure to a two-dimensional mesh screen structure. The mesh screen is formed by arranging multiple heating wires in a grid pattern, transforming the heating area from a line-like spiral to a surface-like mesh, thereby significantly increasing the heating area while maintaining manufacturability through standard mesh fabrication processes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Multiple heating wires are merged and integrated into a single mesh screen structure. The mesh screen combines the functions of multiple heating elements into one unified component that can be manufactured as a single piece, achieving both increased heating area and simplified manufacturing compared to using separate spiral wires.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If the heating area is limited, then the device structure remains simple, but heat production is low causing aerosol cooling or condensation before discharge

Engineering Contradiction:

Improveheating element structureVSAvoidaerosol temperature

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The heating structure evolves from a one-dimensional spiral wire to a two-dimensional mesh screen, increasing the heating area dimensionally. This dimensional transformation allows the heating element to cover a larger portion of the aerosol flow path, ensuring sufficient heat production to maintain aerosol temperature without excessive structural complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The mesh screen structure distributes heating uniformly across the entire inner wall surface where aerosol contact occurs. Each region of the mesh screen provides localized heating, ensuring consistent temperature distribution throughout the aerosol flow path, thereby preventing cooling or condensation while maintaining structural simplicity.

Inventive Principle:

Principle #3Local quality

3Productivity

If aerosols are sucked to the outlet end of the central passage, then vapor circulation is achieved, but aerosols condense and accumulate to form a viscous film blocking the central passage

Engineering Contradiction:

Improvevapor circulationVSAvoidcentral passage畅通性

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The mesh screen heating element performs preliminary heating of the aerosol as it passes through the central passage. By continuously heating the aerosol from the outset rather than relying on post-formation heating, the system prevents condensation before it can occur, thereby maintaining central passage畅通性 while ensuring adequate vapor circulation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mesh screen provides continuous heating along the entire length of the central passage, ensuring that the aerosol is continuously heated throughout its travel. This continuous heating action prevents the intermittent cooling that occurs with spiral wires, maintaining stable vapor circulation and preventing condensate accumulation that would block the passage.

Inventive Principle:

Principle #20Continuity of useful action

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 design prevents aerosol condensation, maintains vapor temperature, and enhances vapor generation, improving the overall performance and taste of electronic cigarettes.

Implementation Method 1

a heating part, the heating part being disposed on the inner wall defining the central passage and being a mesh structure

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the heating part heats and atomizes the aerosol

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250221457A1Heating element, atomization device, and electronic cigarette

Publication Date: 2025.07.10 SHENZHEN EIGATE TECH CO LTD

AI summary

A heating element, including: a main body and a heating part. The main body includes a central passage and an inner wall defining the central passage. The main body includes a first body and a second body connected to each other. The central passage extends through the first body and the second body. The second body has an outer diameter smaller than an outer diameter of the first body. The heating part is disposed on the inner wall defining the central passage and is a mesh structure.