Planar Serpentine Heating Element for Uniform Vaporization
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Solution Overview
Problem
Existing electronic vaping devices face challenges in efficiently vaporizing pre-vapor formulations due to inadequate heating element designs, which affect vapor production efficiency and uniformity.
Innovation Solution
A heater assembly featuring a heating element with a planar portion and a filament forming multiple curves, including a circuitous path with varying widths, and leads that are coplanar with the planar portion, supported by a polyetheretherketone ring, enhances heat distribution and vaporization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional heating element design is used, then the structure is simple, but the heat distribution is insufficient and vapor production efficiency is low
Solution Approach 1:
The heating element employs a serpentine (sinuous) filament configuration instead of a straight or simple coiled design. This curved, winding path increases the surface area of the heating element that contacts the pre-vapor formulation, improving heat distribution across the liquid reservoir and enhancing vapor production efficiency without requiring a completely complex structural redesign
Solution Approach 2:
The heating element transitions from a two-dimensional planar configuration to a three-dimensional serpentine structure that winds through the liquid reservoir. This dimensional change allows the heating element to better utilize the available space and improve thermal contact with the pre-vapor formulation, increasing vapor production efficiency while maintaining a relatively simple overall structure
2Temperature
If a heating element with increased surface area is used, then heat distribution improves, but the device complexity increases
Solution Approach 1:
The serpentine filament design naturally increases the surface area in contact with the pre-vapor formulation while maintaining a simple continuous structure. The curved path allows uniform heat distribution across different regions of the liquid reservoir without requiring multiple separate heating elements or complex thermal management systems
Solution Approach 2:
The heating element integrates the filament, support structure, and electrical connections into a unified assembly. The serpentine filament is supported by a simple grid or mesh structure, combining multiple functions (heating, structural support, electrical conduction) into a single integrated component that achieves uniform heat distribution without proportionally increasing device complexity
3Productivity
If the filament follows a circuitous path with varying width, then vaporization efficiency is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The serpentine filament with varying width is designed to follow a regular, predictable pattern that can be manufactured using standard wire forming or bending techniques. The curvature and width variations are implemented in a systematic manner that allows for consistent reproduction during manufacturing, maintaining reasonable precision requirements while achieving enhanced vaporization efficiency
Solution Approach 2:
The filament width is varied along the circuitous path to optimize heat distribution and vaporization efficiency. By systematically changing the width parameter along the serpentine path, the design achieves improved vaporization performance while the variations remain within manufacturable tolerances for standard heating element fabrication processes
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 described heater assembly provides improved heat distribution and vapor production efficiency, allowing for uniform heating of pre-vapor formulations and enhanced vapor quality.
Implementation Method 1
a heating element including a planar portion including a filament
Implementation Method 2
vaporize a pre-vapor formulation into a vapor
Data Source
AI summary
In an example embodiment, a heater assembly for an electronic heating device includes a heating element and a support. The heating element includes a planar portion, a first lead, and a second lead. The planar portion includes a filament. The filament defines an air channel through the planar portion. The filament includes a plurality of curves. At least one of the curves has a tip thereon. At least one of the first lead portion, the second lead portion, or both the first lead portion and the second lead portion are generally coplanar with the planar portion of the heating element. The heating element is in contact with the support such that the tip of the at least one of the curves rests thereon.