Modular Aerosol Power Unit Assembly for Easy Recycling
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Solution Overview
Problem
Existing aerosol delivery devices, such as electronic cigarettes, face challenges in cost-effective manufacturing and recycling due to complex and non-separable designs, leading to increased capital expenditures and difficulties in disposing of used units.
Innovation Solution
A modular power unit design featuring a separable elongated shell divided into two halves, allowing for easy assembly and disassembly, which facilitates recycling and reduces manufacturing complexity by eliminating the need for soldering electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a complex non-separable design is used for aerosol delivery devices, then device functionality is maintained, but manufacturing cost increases and recycling becomes difficult
Solution Approach 1:
The device is divided into separate modular components including a power unit with battery and a cartridge section, allowing independent manufacturing and assembly of each module. This segmentation enables simplified production processes for each component while maintaining overall device functionality.
Solution Approach 2:
The modular design allows the cartridge section to be easily separated and disposed of after use, while the power unit can be recovered and reused. This facilitates recycling efforts and reduces manufacturing costs by eliminating the need to dispose of functional components.
2Ease of operation
If a non-separable design is used, then device integrity is maintained, but disassembly for recycling becomes difficult
Solution Approach 1:
The device structure is segmented into separable modules connected by simple interfaces, enabling easy manual disassembly without requiring specialized tools or complex procedures. Each module maintains structural integrity when separated.
Solution Approach 2:
The cartridge section is extracted as a removable component from the power unit, allowing users to easily separate and dispose of the consumable portion while retaining the reusable power unit. This extraction simplifies the recycling process.
3Ease of manufacture
If traditional manufacturing methods are used, then device durability is ensured, but capital expenditures increase
Solution Approach 1:
By segmenting the device into standardized modules, each component can be manufactured using simpler, more cost-effective processes. The modular architecture allows for optimized production methods for each section, reducing overall capital requirements while maintaining durability through focused quality control on critical components.
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 modular design enables the production of lower-cost disposable aerosol delivery devices that can be easily recycled, reducing waste and operational costs while maintaining device functionality.
Implementation Method 1
The power unit can include a battery
Implementation Method 2
The battery can include a lead including a projection configured for electrical connection with a terminal of the battery and including an arm extending from the projection along the length of the battery
Implementation Method 3
utilize electrical energy to vaporize or heat a volatile material
Data Source
AI summary
The present disclosure relates to an aerosol delivery device including a shell that is divided into a first half and a second half along a longitudinal axis thereof. One or more batteries may be positioned within the shell along with a battery lead that provides an electrical connection to battery terminals. A base unit may be included and may have electrical contacts for matching with a battery terminal and the battery lead. The base unit can include one or both of a printed circuit board (PCB) and a pressure sensor. The shell can attach to a cartridge housing a reservoir for an aerosol-forming composition, a heater; a liquid transport element configured for transport of the aerosol forming composition between the reservoir and the heater; and heater terminals. Such construct can provide for simplified assembly of the device.