Vaping Connector Geometry for Secure Power and Alignment
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Solution Overview
Problem
Existing electronic vaping devices face challenges in securely connecting the vaporizer assembly to the battery assembly, leading to potential misalignment and inefficient power transfer, which can affect the heating and vaporization process.
Innovation Solution
The use of a connector system comprising a male and female connector with specific geometries and materials, such as brass with nickel-silver coating, that securely and rotationally locks the vaporizer assembly to the battery assembly via an adhesive or interference fit, ensuring stable electrical coupling and efficient power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple connector design is used, then device complexity is reduced, but connection stability and alignment precision deteriorate
Solution Approach 1:
The connector employs asymmetric geometric features including a D-shaped configuration where one side is flat and the opposite side is rounded, along with asymmetric positioning of electrical contacts and alignment pins. This asymmetry prevents rotational misalignment and ensures proper orientation during connection, thereby improving connection stability without significantly increasing overall device complexity
Solution Approach 2:
The connector design incorporates nested structural elements where alignment pins are positioned within recesses, electrical contacts are housed within insulating material, and the entire connector assembly fits within the housing structure. This nesting approach organizes multiple functional elements in a compact arrangement, maintaining connection reliability while controlling device complexity
2Device complexity
If a simple connector design is used, then device complexity is reduced, but manufacturing precision requirements worsen
Solution Approach 1:
The connector incorporates pre-formed alignment pins and recesses that are manufactured as integral features of the connector body and housing. These alignment features are designed with generous tolerances and are formed during the primary manufacturing process rather than requiring subsequent precision machining or assembly operations, thereby reducing manufacturing precision requirements while maintaining connection stability
Solution Approach 2:
The alignment pins and recesses act as intermediary elements that facilitate precise alignment between the vaporizer assembly and battery assembly during connection. These intermediary features absorb manufacturing tolerances and guide the mating components into proper alignment, reducing the overall precision requirements for the connector design
3Power
If electrical contacts are exposed, then electrical conductivity is improved, but safety and insulation deteriorate
Solution Approach 1:
An insulating material is introduced as an intermediary element that surrounds and isolates the electrical contacts while allowing electrical current to pass through designated pathways. This insulating barrier prevents direct contact with exposed conductors, eliminating safety hazards such as short circuits and electrical shock, while maintaining effective electrical conductivity through controlled contact points
Solution Approach 2:
A thin insulating shell or coating is applied over the electrical contacts and connector surfaces. This thin film provides electrical insulation and safety protection while minimizing the impact on electrical conductivity and signal transmission. The insulating shell conforms to the connector geometry and is integrated into the overall connector design
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
An electronic vaping device (22) comprising: a first section having a male connector (102), the male connector (102) including: at least one flange on an outer surface of the male connector (102), at least a portion of the flange having a substantially planar first surface, a male anode portion, and a male cathode portion; and a second section having a female connector (104), the female connector (104) configured to engage the male connector (102) to connect the first section to the second section, the female connector (104) including: at least one secant flange on a surface of an internal recess, a female anode portion, and a female cathode portion.