Apparatus and method for winding a substantially continuous heating element about a substantially continuous wick
The present disclosure relates to apparatuses configured to pre-form atomizers. The apparatus may include wick and heating element supplies configured to respectively provide a substantially continuous wick and a substantially continuous heating element. A winding mechanism is configured to wind the heating element about the wick. An adjustment mechanism is configured to adjust a position at which the winding mechanism winds the heating element about the wick. Additionally a synchronization mechanism synchronizes winding the heating element about the wick with adjustment of the position at which the heating element is wound about the wick such that the heating element defines a coiled heating element segment wound about the wick. This process may be repeated to produce multiple coiled heating element segments wound about the wick. A related method is also provided.
1. An apparatus configured to pre-form an atomizer, comprising:
a wick supply configured to provide a substantially continuous wick;
a heating element supply configured to provide a substantially continuous heating element;
a winding mechanism configured to wind the substantially continuous heating element about the substantially continuous wick;
an adjustment mechanism configured to adjust a position at which the winding mechanism winds the substantially continuous heating element about the substantially continuous wick; and
a synchronization mechanism configured to synchronize winding the substantially continuous heating element about the substantially continuous wick with adjustment of the position at which the substantially continuous heating element is wound about the substantially continuous wick such that the substantially continuous heating element defines a coiled heating element segment wound about the substantially continuous wick.
2. The apparatus of claim 1 , further comprising a cutting mechanism configured to cut the substantially continuous heating element to define a resistive heating element comprising the coiled heating element segment.
3. The apparatus of claim 2 , further comprising a collection reel configured to collect the substantially continuous wick with the resistive heating element wound thereon.
4. The apparatus of claim 1 , further comprising a heating element feeder configured to position the substantially continuous heating element in proximity to the substantially continuous wick.
5. The apparatus of claim 4 , wherein the heating element feeder comprises a hollow needle.
6. The apparatus of claim 4 , wherein the heating element feeder is moveable toward and away from the substantially continuous wick.
7. The apparatus of claim 1 , wherein the winding mechanism, the adjustment mechanism, and the synchronization mechanism are operably engaged with a hand crank.
8. The apparatus of claim 1 , wherein the winding mechanism, the adjustment mechanism, and the synchronization mechanism are operably engaged with a motor.
9. The apparatus of claim 1 , wherein the winding mechanism comprises a winding head configured to rotate about a rotational axis.
10. The apparatus of claim 9 , wherein the winding head defines a hole therethrough extending along the rotational axis through which the substantially continuous wick is received.
11. The apparatus of claim 9 , wherein the winding head comprises an engagement mechanism configured to releasably engage the substantially continuous heating element proximate an end thereof.
12. The apparatus of claim 11 , wherein the engagement mechanism comprises a notch defined in the winding head.
13. The apparatus of claim 1 , further comprising a tensioning mechanism configured to tension the substantially continuous wick proximate the winding mechanism.
14. The apparatus of claim 1 , wherein the adjustment mechanism comprises a sliding carriage configured for displacement with respect to the winding mechanism.
15. A method for pre-forming an atomizer, comprising:
providing a substantially continuous wick;
providing a substantially continuous heating element;
winding the substantially continuous heating element about the substantially continuous wick;
adjusting a position at which the substantially continuous heating element is wound about the substantially continuous wick; and
synchronizing winding the substantially continuous heating element about the substantially continuous wick with adjustment of the position at which the substantially continuous heating element is wound about the substantially continuous wick such that the substantially continuous heating element defines a coiled heating element segment wound about the substantially continuous wick.
16. The method of claim 15 , further comprising cutting the substantially continuous heating element to define a resistive heating element comprising the coiled heating element segment.
17. The method of claim 15 , further comprising incrementing a starting winding position on the substantially continuous wick.
18. The method of claim 17 , further comprising collecting the substantially continuous wick with the resistive heating element wound thereon on a collection reel.
19. The method of claim 15 , wherein the substantially continuous heating element is supplied at a position that is stationary with respect to the substantially continuous wick.
20. The method of claim 15 , further comprising directing the substantially continuous wick through a hole extending along a rotational axis of a winding head.
21. The method of claim 20 , wherein winding the substantially continuous heating element about the substantially continuous wick comprises releasably engaging the substantially continuous heating element proximate an end thereof with the winding head.
22. An apparatus configured to pre-form an atomizer, comprising:
a wick supply configured to provide a substantially continuous wick;
a heating element supply configured to provide a substantially continuous heating element;
a winding mechanism configured to wind the substantially continuous heating element about the substantially continuous wick;
an adjustment mechanism configured to adjust a position at which the winding mechanism winds the substantially continuous heating element about the substantially continuous wick;
a synchronization mechanism configured to synchronize winding the substantially continuous heating element about the substantially continuous wick with adjustment of the position at which the substantially continuous heating element is wound about the substantially continuous wick such that the substantially continuous heating element defines a coiled heating element segment wound about the substantially continuous wick;
a cutting mechanism configured to cut the substantially continuous heating element to define a resistive heating element comprising the coiled heating element segment; and
a collection reel configured to collect the substantially continuous wick with the resistive heating element wound thereon.
23. A method for pre-forming an atomizer, comprising:
providing a substantially continuous wick;
providing a substantially continuous heating element;
winding the substantially continuous heating element about the substantially continuous wick;
adjusting a position at which the substantially continuous heating element is wound about the substantially continuous wick; and
synchronizing winding the substantially continuous heating element about the substantially continuous wick with adjustment of the position at which the substantially continuous heating element is wound about the substantially continuous wick such that the substantially continuous heating element defines a coiled heating element segment wound about the substantially continuous wick;
cutting the substantially continuous heating element to define a resistive heating element comprising the coiled heating element segment; and
collecting the substantially continuous wick with the resistive heating element wound thereon on a collection reel.