Introduction to the composition and structure of electronic cigarettes

electronic cigarettes can be divided into core functional modules and auxiliary components, and its design revolves around the three core requirements of ‘atomising liquid smoke, delivering aerosols and controlling the use’. The following is a detailed analysis of its structure and working principle from a professional point of view, to help users understand the operating logic of the device:

1. electronic cigarettes core functional modules

Atomiser

Role: Heating and atomising the liquid smoke into aerosol, simulating the smoke effect of traditional cigarettes.

Key components:

Heating core (atomising core): Heats the liquid smoke through resistance wire (e.g. Nichrome alloy, stainless steel) or ceramic material.

Examples: Resistance wire wrapped around a cotton core structure (common in finished atomiser cores) or ceramic porous matrix (for high power devices).

Oil-conducting cotton / oil-conducting holes: Conducts the liquid from the reservoir to the core, balancing the oil-conducting speed with anti-leakage properties.

Airway design: affects the volume of smoke, the fineness of taste and suction resistance, such as straight airway (big smoke) or spiral airway (enhance taste).

Battery Components

Function: Provide power and control the operation of the device, there are two types of batteries: built-in batteries and replaceable batteries.

Key components:

Battery:

Built-in battery: mostly lithium polymer batteries (e.g. 500mAh-1500mAh), integrated into the device body, need to be charged via USB.

Replaceable batteries: common 18650/20700/21700 lithium batteries, support the user to replace their own to extend the life.

Circuit board:

Function: manage battery charging and discharging, output power regulation, short circuit protection, overcharge protection and other safety mechanisms.

Chip type: Simple devices use fixed output chips, high-end devices carry adjustable power chips (support 5W-200W power adjustment).

Charging interface: Micro-USB, Type-C or magnetic charging port, some devices support fast charging technology (such as 2A fast charging).

Cigarette cartridge/oil storage compartment

Function: store and supply the vape liquid to the atomiser, divided into two designs: open and closed.

Key components:

Oil Reservoir: Transparent or semi-transparent material (e.g. PC, glass), easy to observe the amount of liquid remaining.

Oil filling hole: open cartridges need to be manually filled with oil, while closed cartridges are disposable and can be replaced when the liquid runs out.

Seal ring: to prevent liquid leakage, need to regularly check the aging condition.

2. auxiliary components and interactive design

Mouthpiece

Role: connect the user’s mouth and airway, ergonomic design.

Common materials: plastic, metal (stainless steel, aluminium alloy), silicone or glass.

Design details:

Anti-scald design: Avoids direct contact of hot aerosols with the lips.

Condensate Recovery: Some mouthpieces have a built-in condensate tank to reduce the amount of liquid inhaled into the mouthpiece.

Air intake adjustment ring

Function: Control the air intake, adjust the suction resistance and smoke concentration.

Realisation: rotating or sliding structure, adjustment is achieved by changing the size of the airway opening.

Example: large air intake for lung (DL) devices, small air intake for mouth-to-mouth (MTL) devices.

Buttons and display (interaction module)

Buttons:

Traditional devices: mechanical keys (e.g. ignition keys, power adjustment keys).

Modern devices: touch screen or buttonless design (operated by airflow sensing or gestures).

Display:

Display parameters: remaining power, current power, number of suction ports, voltage/resistance values, etc.

Type: OLED screen (high contrast), TFT screen (colour display) or LED indicator (simplified information).

3. electronic cigarettes working principle and process

Power supply process

The battery supplies power to the atomising core through the circuit board, and the resistor wire generates heat to evaporate the smoke liquid into aerosol.

High-end devices can adjust the output power (e.g. 5W-200W), the higher the power, the greater the amount of smoke but the faster the power consumption.

Airflow and atomisation process

When the user inhales, the outside air enters the airway through the air inlet, mixes with the atomised aerosol and then outputs through the mouthpiece.

The speed of the airflow affects the temperature and taste of the smoke: fast inhalation reduces the temperature of the smoke, which is suitable for users who pursue a cool feeling.

Safety Mechanism

Short circuit protection: The circuit board automatically cuts off the power supply when the resistance of the atomiser core is abnormal (e.g. short circuit).

Overcharge protection: the battery automatically stops charging when it is full, preventing overcharging from causing bulging or explosion.

Timeout protection: when a single puff exceeds the set time (e.g. 10 seconds), the device automatically cuts off power to prevent dry burning.

4. the structural differences between different types of electronic cigarettes

Disposable electronic cigarettes

Simplified structure: Battery, atomiser and liquid are integrated into one unit, which cannot be disassembled or recharged.

Typical design: no buttons (airflow induction activation), transparent cartridges, non-adjustable air intake.

Rechargeable Electronic Cigarette

Modular design: the battery stick is separated from the cartridge, and the cartridge is closed and disposable.

Interaction optimisation: magnetic connection, LED indicator for power level, some devices support vibration feedback.

Regulator box

Highly customisable: supports replacement of battery, atomiser and cartridges, power and temperature can be freely adjusted.

Complex structure: equipped with high-end configurations such as heat dissipation fins, 510 universal interface and OLED display.

5. maintenance and use recommendations

Regular cleaning

Atomiser: Clean the heating core and airway with warm water or alcohol to remove carbon and condensation.

Atomiser: disassemble and clean weekly to prevent bacteria from growing.

Component Replacement

Atomiser: Replace in time according to the frequency of use (usually 1-2 weeks) or changes in taste.

Battery: Consider replacing the battery with a new one when the range drops significantly (especially for replaceable battery devices).

Safe use

Avoid using non-original chargers to prevent overcharging or short-circuiting.

When storing for a long period of time, keep the battery at 40%-60% to prolong life.

6.Summary

The structural design of e-cigarettes revolves around the three core elements of atomisation, power supply and interaction, and there are differences in the degree of modularity, functional complexity and user experience of different types of devices. Users need to choose the right device according to their own needs (such as portability, taste, DIY fun), and master basic maintenance knowledge to extend the service life.