Unitary Heating Element with Circuitous Filament for E-Vapor Airflow
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Solution Overview
Problem
Existing electronic vaping devices face inefficiencies in vapor production due to obstructed air channels and uneven heat distribution, which can lead to reduced vapor quality and increased power consumption.
Innovation Solution
A heating element with a planar portion and filaments that define an air channel, featuring a circuitous path and varying width, and lead portions that are bent parallel to the planar portion, allowing for efficient air flow and heat distribution, integrated into a cartridge with a porous substrate and gasket for fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional heating elements are used with obstructed air channels, then manufacturing is simpler, but vapor production efficiency decreases
Solution Approach 1:
The heating element employs a circuitous (curved) filament path instead of a straight configuration. This curvature allows the filament to define an open air channel through its non-linear arrangement, improving airflow and vapor production efficiency while maintaining structural integrity
Solution Approach 2:
The filament width varies along its circuitous path, creating a three-dimensional structure that defines an air channel. This dimensional variation allows the heating element to simultaneously provide heating surface area and create unobstructed airflow pathways, resolving the contradiction between simple structure and efficient vapor production
2Temperature
If heating elements with uniform filament width are used, then manufacturing is easier, but heat distribution becomes uneven
Solution Approach 1:
The filament width is intentionally varied at different locations along its path. Sections of the filament have different widths to create specific thermal zones and define the air channel geometry. This local variation in width allows precise control over heat distribution patterns and airflow characteristics
3Productivity
If lead portions extend perpendicular to the planar portion, then electrical connection is simpler, but air flow becomes obstructed
Solution Approach 1:
The lead portions are bent into a curved configuration that is substantially parallel to the planar portion of the heating element. This bending allows the leads to extend along the air channel path without obstructing airflow, while still providing reliable electrical connections to the filament
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 solution enables efficient vapor production with high volume and accurate temperature control, reducing power consumption and enhancing the overall performance of e-vapor devices.
Implementation Method 1
The heating element may include a planar portion including at least one filament. The filament may define an air channel through the planar portion.
Implementation Method 2
The cartridge includes a housing including a reservoir portion and a connector portion, the connector portion being configured to connect the cartridge to a power supply section. The cartridge includes a heater assembly including a heating element disposed in the housing. The heating element includes a planar portion in fluid communication with the reservoir portion.
Data Source
AI summary
A heating element for an e-vapor device includes a planar portion including at least one filament. The filament may define an air channel through the planar portion. The heating element may include first and second lead portions extending away from the planar portion. The planar portion, the first lead portion, and the second lead portion may be a unitary body.