What’s Inside Your Vape? A Simple Guide to Its Structure

Whether it's a disposable vape or a pod-based vape, it consists of two main parts: the atomizing chamber and the battery.

This article will disassemble them one by one.

1.Atomizing Chamber

The atomizing chamber of a vape, as the name suggests, is the place where e-liquid is atomized into an aerosol.

Its main structure includes the mouthpiece, atomizer core, oil cup, base, sealing silicone, connector, etc.

• Mouthpiece

Common materials: PCTG, PC/ABS, ceramic
Ceramic mouthpieces are widely used in CBD atomizers and are often flat or round to improve comfort in the mouth.

• Coil (Atomizer Core)

Consists of a heating coil and a wicking material.

Heating coils are available in various types, including wound coils, etched mesh, and thick-film printed metal paste.

Woolen materials include cotton and porous ceramic, resulting in ceramic and cotton coils.

Ceramic coils are known for their smooth flavor, while cotton coils are known for their strong flavor delivery and high flavor fidelity.

• E-Liquid Storage Softener

Specifically designed to store e-liquid, this is made from fibers through a heat-bonding process. It boasts advantages such as mature technology, low cost, and good e-liquid storage capacity, and is commonly used in disposable e-cigarettes.

• E-Liquid Cup (Tank)

Common materials include PCTG and glass, with PCTG being the most common.

Glass is more prevalent in CBD atomizers.

Performance requirements include chemical resistance and high-temperature resistance.

Transparent e-liquid cups are rapidly developing because they meet consumers' need for visible progress tracking.

• Other Components

• Base: typically PC/ABS

• Sealing silicone: prevents leakage

• Connector:

  • Disposable vapes: wires directly soldered to the PCB

  • Pod systems: usually spring pins

2.Battery pole

The battery module of a vape mainly provides power and also has functions such as switching on/off, power control, and temperature control.

Its structure includes the battery, PCBA solution board and microphone, body shell, indicator light, charging port, connector, etc.

• Battery

Pouch lithium batteries are common, with size depending on the type of vape. High energy density and environmental friendliness are development trends.

With the increasing emphasis on environmental protection, capacitor batteries are beginning to be used in vapes.

Combined with detachable designs, battery recycling after the vape is discarded becomes more feasible.

• PCBA (Control Board)

This solution board integrates functions such as vape switching, power management, on/off activation, power adjustment, and temperature control.

Currently, the most popular development is the integration of screens, moving towards intelligent design, which places higher demands on chips and other electronic components.

• Microphone / Airflow Sensor

The switching element of a vape, also called an airflow sensor, senses changes in airflow, causing electrical changes that ultimately start or stop the vape.

The current trend is for traditional electret capacitor microphones to move towards silicon microphones, becoming more sensitive and offering better ruggedness.

• Display (if included)

Small-sized digital tubes are relatively common, displaying only the e-liquid level and battery level. Their advantages are low cost and simple design.

TFT screens and flexible screens (especially starry sky screens) are relatively more expensive, but their cool display effects have attracted much attention in the industry.

• Casing

Disposable vapes typically have plastic casings, made of PC or PC/ABS.

Refillable cartridges are generally made of aluminum alloy, with some using zinc alloy. Common finishes include tactile paint and gradient colors. The use of environmentally friendly materials such as PLA and paper tubes still needs further optimization.

In general, the types and structures of vapes are influenced by policies, market preferences, and technological processes, while more compact, intelligent, and environmentally sustainable designs are the development direction and trend.

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