Technical Discussion l Analysis on the problem of oil leakage of electronic cigarettes Oil leakage is a common and thorny problem in electronic cigarettes.
The concept of oil leakage is that the e-liquid flows out from abnormal channels, such as from the outside of the oil cup, the center hole, the base of the atomizer, the outside of the cigarette holder and other abnormal channels.
- Classification and causes of oil spills
- Divided by time: direct leakage and leakage Direct leakage is the rapid oil leakage in a short period of time after oil filling, and the leakage is slow leakage, which takes time or environmental changes to be reflected.
Direct leakage is generally caused by the following reasons:
Improper human operation, such as missing materials, not operating in accordance with the process sequence, and the needle is not aligned with the oil cup/absorbent cotton for oil filling;
Unreasonable machine or tool settings, such as too much oil injection, too short oil injection time, too large needle diameter, too deep needle insertion into cotton;
Poor incoming materials, such as sealing ring drape, damage, deformation, shrinkage, poor size, etc.In addition to direct leakage,
leakage is generally caused by the following reasons:
The structural design is unreasonable, for example, the air tightness is not well designed, the limit tolerance matching is unreasonable, and the material selection consideration is not rigorous;
Material factors, such as e-liquid density, dimension out of tolerance, appearance damage, deformation, etc.;
Environmental factors, such as the incompatibility of e-liquid or other components caused by the temperature difference between morning and evening, negative air transport pressure, extreme weather;
Chemical reactions, for example, some e-liquids contain fruit acid, which reacts with PC and PP plastic materials to cause cracks;
Other reasons, such as oil leakage caused by the high sensitivity of the microphone head, and the product being squeezed by external forces, etc.
- Other division methods: suction oil leakage, static oil leakage at room temperature, reliability test oil leakage
A. Suction oil leakage
The suction oil leakage is subdivided into flying oil and condensate. The flying oil is directly sucked into the mouth without atomization, which is generally caused by the oil inlet hole being too large or the cotton design being too wide. Condensate is the occasional inhalation of e-liquid from the cigarette holder into the mouth. This kind of water droplets usually formed by the condensation of “atomized steam” is a normal phenomenon, not an oil leak.
B. Oil leakage at room temperature
Oil leakage at room temperature is generally caused by human operation, improper design of oil injector parameters, improper use of tools, material problems, design defects, and increased volume caused by water absorption of e-liquid;
C, reliability test oil leakage
Reliability tests include high-altitude negative pressure, constant temperature and humidity, high temperature, low temperature, thermal shock, vibration, drop, and simulated transportation, generally caused by human operation, improper design of oiler parameters, improper use of tools, material problems, design defects, etc. .Second, the method of preventing oil leakage
Having said so much, how can we prevent oil spills? I think we can improve from the following points:
Precautions before production:
The structural design should be rigorous, the limit tolerance should be reasonable, and the material selection should be appropriate (PCTG and PETG are recommended for plastic parts in contact with e-liquid);
Strictly follow the new product introduction specifications and APQP management and control process, output files and results at each stage, and proceed to the next stage after the previous test is OK, so that the introduction of new products can be guaranteed.
Preparatory work should be done before mass production, such as documents, machinery and equipment, work fixtures, turnover trays, materials after inspection, and training of qualified operators;
Notes in production:
According to the process flow, according to the SOP operation specification, make the first piece, record the report in the test process, notify the technician to deal with the abnormality in time, and identify and isolate the products with hidden dangers;
Materials are inspected in accordance with specifications, drawings, samples, and SIP. OK products are labeled with green labels, and materials with abnormality are subject to the MRB process. MRB review is OK, and yellow labels are labeled. Returned materials are labeled with red labels, and the supplier is notified in time for processing;
The oil injection machine debugs the parameters according to the specification and SOP. After debugging, the first piece will be inspected for quality. After it is OK, it can be mass-produced. The parameters cannot be changed by the operator at will;
The introduction of tooling and fixtures should be verified with quality and production. After debugging, the first piece should be tested for quality. After OK, mass production can be performed. The operation methods and steps cannot be changed by the operator at will;
IPQC conducts the first operation with strict reference to BOM, drawings, SIP, SOP, and QCP, and pays attention to personnel flow, material replacement, abnormal machine noise, etc. during inspection, and promptly informs technicians to deal with abnormalities, and identifies and isolates products with hidden dangers;
FQC and OQC operate in strict accordance with SIP and SOP, record test problem points and data, notify technicians to deal with abnormalities in a timely manner, and identify and isolate products with hidden dangers;
Before the shift, after the shift, before pulling, and after pulling the management, the operator can leave the pulling line after closing the pulling, and the bottom cover should be pressed in time for the product after oil injection every day to prevent the taste variation caused by the volatilization of the e-liquid;
To change the taste, it needs to be cleaned, and the taste and quantity should be marked in time to prevent mixed tastes and mixed tastes;
Do a good job in batch management of e-liquid, receive and use it according to the principle of first-in, first-out, and pay attention to the matching of laser carving and e-liquid;
Defective product repairs should be marked well, and repaired products must be checked by QC before they can be pulled down, and repaired products and normal products are separated;
Pack the oil cup upside down, and paste the protective label on the outer box;
In the process of oil spilled products, joint research and development, quality, engineering, and production will be conducted for disassembly analysis, led by quality PQE, and the responsible person and completion time should be clear.
Because of my limited experience and knowledge, I will share it here. I will continue to update the latest findings or other insights in the future. If there are any inappropriate descriptions, please point out and correct them. Thank you!
atomizer / cartridge / e-liquid” / electronic cigarette / vape
MESH core / Disposable Electronic Cigarette / Refillable Electronic Cigarette
Source: Blue Hole New Consumption
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