Solderless Wire Bonding for E-Cigarette Cartridge Corrosion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for connecting wires between the battery and cartridge in electronic cigarettes often result in corrosion and contamination due to the reactivity of e-Liquid with certain metals, especially during the soldering process, which complicates manufacturing and affects the quality of the device.
Innovation Solution
A solderless wire bonding system using a ring, cylinder, or sleeve to connect and stabilize wires between the battery and cartridge, eliminating the need for soldering and reducing the risk of corrosion and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect wires to metal components, then electrical connection is achieved, but corrosion and contamination occur due to e-Liquid reactivity with metals
Solution Approach 1:
The patent introduces a non-metallic intermediary substance (epoxy resin or polymer coating) between the metal wire and the e-Liquid environment. This intermediary layer prevents direct contact between reactive metals and e-Liquid, eliminating corrosion and contamination while maintaining electrical connectivity through the bonding process.
Solution Approach 2:
The patent employs a disposable cartridge design where the wire bonding structure is integrated into the single-use cartridge. This eliminates the need for durable, corrosion-resistant materials in the bonding process itself, as the entire cartridge is discarded after use, preventing long-term corrosion issues.
2Ease of manufacture
If soldering process is used, then wires are connected, but manufacturing complexity increases and production costs rise
Solution Approach 1:
The patent extracts the soldering step from the manufacturing process entirely, replacing it with a simpler wire bonding method using epoxy resin or polymer coating. This eliminates the need for soldering equipment, flux materials, and complex soldering procedures, significantly simplifying manufacturing while maintaining connection reliability.
Solution Approach 2:
The patent replaces the thermal-mechanical soldering process with a chemical bonding process using epoxy resin or polymer coating. This substitution eliminates the need for heat application, flux chemicals, and precise temperature control, simplifying the manufacturing process while achieving reliable electrical connections.
3Reliability
If metal components are used in contact with e-Liquid, then electrical conductivity is achieved, but corrosion occurs reducing device lifespan
Solution Approach 1:
The patent introduces a protective intermediary layer (epoxy resin or polymer coating) that separates metal components from direct contact with e-Liquid. This intermediary barrier prevents corrosive reactions while allowing electrical functionality, thereby extending device operational lifespan without sacrificing conductivity.
Solution Approach 2:
The patent creates an inert environment by coating metal components with corrosion-resistant materials (epoxy resin, polymer coatings) that prevent reactive interactions between metals and e-Liquid. This inert barrier layer protects the metal from corrosion, extending the device's operational lifespan.
Data Source
AI summary
An electronic cigarette (“e-Cig”) may include an adapter component for connecting a battery portion of the e-Cig with the cartridge. The adapter may be configured to utilize a bonding device, such as a ring, cylinder, or sleeve component, for connecting wires without requiring soldering. The bonding device may press a wire at a contact point against a conductive material for transmission of electrical power.