Tubular Lobe Heater Structure for E-Vaping Wick Vaporization
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Solution Overview
Problem
Existing e-vaping devices face challenges in efficiently forming a heater assembly that effectively vaporizes pre-vapor formulations with a heater design that is both efficient and easy to manufacture.
Innovation Solution
A method of forming a heater assembly for e-vaping devices involves bending a wire to create a sinuously-shaped structure with lobes, curling it to form a tubular shape around a wick, and attaching electrical leads, using nickel-chromium wire for enhanced resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional heater design is used, then the manufacturing process is simple, but the vaporization efficiency is insufficient
Solution Approach 1:
The heater wire is formed into a sinuous shape with multiple lobes and curves rather than a straight configuration. This curved geometry increases the surface area of the heater element that contacts the pre-vapor formulation, thereby improving vaporization efficiency while maintaining a manufacturable structure through wire bending processes
2Productivity
If the heater wire is curled tightly to increase surface area, then vaporization efficiency improves, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The heater is designed with distinct segmented lobes (first lobe, second lobe, third lobe, etc.) rather than a continuous tight coil. Each lobe is a discrete curved section that can be independently formed and controlled during manufacturing, making it easier to achieve consistent geometry and placement precision while still providing increased surface area for efficient vaporization
3Power
If nickel-chromium wire is used, then electrical resistivity and heating efficiency improve, but material cost increases
Solution Approach 1:
The patent specifies using nickel-chromium wire with a particular resistivity range (10-15 microhm-cm) to optimize heating efficiency. By controlling the material parameter (resistivity) within a specific range, the design achieves efficient power conversion while allowing for cost management through precise material selection rather than using exclusively expensive materials
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 allows for efficient vaporization of pre-vapor formulations while being cost-effective and straightforward to manufacture, ensuring consistent performance and longevity of the e-vaping device.
Implementation Method 1
The battery is electrically connected to the heater, such that the heater heats to a temperature sufficient to convert the pre-vapor formulation to a vapor. The wire is a nickel-chromium wire.
Implementation Method 2
a heater element which vaporizes a pre-vapor formulation to produce a 'vapor'... the heater heats to a temperature sufficient to convert the pre-vapor formulation to a vapor
Data Source
AI summary
A method of forming a heater assembly of an e-vaping device includes bending a wire to form a first lobe and bending the wire to form a second lobe. The first lobe and the second lobe form a generally sinuously-shaped heater having a first set of lobes and a second set of lobe. A first apex of the first lobe is generally opposite a second apex of the second lobe. The method may also include curling the first set of lobes towards the second set of lobes to form a heater having a substantially tubular form. The heater defines an opening there through.