What Is In Disposable Vapes?
Disposable vapes, also known as vape pens, disposable e-cigarettes, or puff bars, are designed for immediate use right out of the box. These convenience disposable vape devices require no assembly or maintenance, offering a straightforward and hassle-free vaping experience.Learn more about what is a disposable vape.
In the early days, disposable vapes featured a simple design, relying solely on a pre-filled e-liquid cartridge and a basic heating element. However, after more than two decades of development, modern disposable vape pens have evolved to become more sophisticated, with enhanced functionality and more complex structures. Today, 2077 Vape is here to guide you through the intricacies of the components that make up contemporary disposable puff bars.
What Is In A Disposable Vape？
Compared to pod vape kits and box vape devices, Parts inside a disposable vape is relatively simpler. Due to the use of pre-filled nicotine salt vape juice and the lack of need for device adjustments, the power requirements for heating are lower. As a result, disposable vapes typically feature a fixed design in terms of battery power, atomizer resistance, and wick configuration.
A fully-featured disposable vape typically consists of the following components:
Lithium-Ion Battery: A lithium-ion battery that powers the heating coil to vaporize the e-liquid. It’s important to note that these batteries are not the high-capacity 18650 or 21700 batteries used in more powerful devices. Given the lower power requirements, disposable vapes usually employ smaller lithium-ion batteries with capacities under 800mAh. The battery is connected to the circuit board, which manages the power supply.
Atomizer: This component houses the heating element (coil) that vaporizes the e-liquid. The resistance of these coils typically ranges from 1.5 to 2.8 ohms.
Wick: The wick is saturated with e-liquid and typically wraps around the heating coil. This design ensures that the e-liquid is evenly heated, providing optimal vaporization and enhancing the vape experience.
Intelligent Chip (Circuit Board): The circuit board controls the heating power of the device. In higher-end models, the board may also include features like liquid level sensors, power sensors, overheat protection, and voltage sensors. These features allow the device to monitor remaining liquid levels, output power, and battery life, and to implement safety measures such as cutting off power in extreme conditions. In addition to controlling the device’s operation, the circuit board is often connected to a Type-C charging port, enabling recharging for use throughout the device’s lifespan.
Display Screen: Some disposable vapes are equipped with a display screen connected to the circuit board, providing real-time information about the vape, such as remaining e-liquid, battery level, and power settings.
Pre-Filled E-Liquid: The e-liquid is fully absorbed by the wick and is vaporized through heating to produce vapor, delivering the optimal vape experience.
Composition Of An E Liquid
For users of disposable vapes, the most critical component inside a disposable vape is undoubtedly the e-liquid. The impact of e-liquid on the flavor experience of a disposable vape accounts for over 70%. When the flavor profile is fixed, the heating power and the quality of the wick mainly influence the intensity and fidelity of that flavor.
E-liquids are typically formulated using the following chemicals:
PG and VG:
- PG (Propylene Glycol): PG is produced through the hydration of propylene oxide. It is much thinner than VG and produces significantly less vapor. However, PG is known for delivering a strong throat hit, which many users find appealing.
- VG (Vegetable Glycerine): Derived from plants, VG is often perceived as a healthier option by many vape users. VG is viscous and dense, resulting in larger vapor clouds. Users who prefer VG appreciate its smoother sensation on the throat, although some might not notice any significant difference. VG tends to cause less irritation and allergic reactions compared to PG, though some users report it may lead to a phlegmy feeling in the throat.
VG is naturally sweet, which some users find advantageous as it eliminates the need for additional sweeteners in the vape juice. The sweetness in VG is not due to artificial flavor enhancers or sugars but comes from VG itself, which is generally seen as a benefit. However, some users feel that the natural sweetness of VG can overpower the intended flavor of the e-liquid.
PG and VG typically make up 80%-90% of the e-liquid composition, serving as the primary carriers for vaporization by the heating element.
Flavoring:
- Flavoring usually comprises 10%-15% of the e-liquid. These flavors are often derived from natural extracts, such as mango extract for a mango-flavored e-liquid or tobacco extract for tobacco-flavored vape juices.
- The primary function of flavoring is to impart the desired taste to the e-liquid. Whether it’s mint, fruit, or dessert tobacco flavors, the flavor can be authentically reproduced using natural or synthetic aromatic compounds.
Nicotine:
- For users transitioning from traditional cigarettes, nicotine dependency is a significant factor. Therefore, these users often opt for e-liquids with a nicotine strength ranging from 0% to 5%.
Deionized Water (0% to 5%):
- Sometimes used to thin the final e-liquid mixture because VG is relatively thick. Deionized water helps to adjust the viscosity for better performance in the device.
Ethanol (0% to 5%):
- Occasionally added to smooth out the flavor profile and enhance the vaping experience. Ethanol can also help absorb and homogenize the flavors in the e-liquid, contributing a slight softness to the taste.
How Are Disposable Vapes Made
The assembly process for a disposable vape begins with the installation of the bottom sealing silicone and fiberglass tube, which is the first step on the automatic production line. In this stage, the bottom sealing silicone and fiberglass tube are fed into the assembly line for integration. Following this, the oil reservoir tube and fiberglass tube are also loaded and assembled together. Additionally, the oil reservoir tube is paired with the oil-absorbing cotton during this step.
Once these components are assembled, the next step involves applying instant adhesive to the heating wire leads. This process ensures a secure connection between the heating wire leads and other components. To verify the integrity of the assembly, resistance testing is conducted. This measurement is crucial to ensure the vape functions properly.
After passing the resistance test, the next phase is the e-liquid injection. The purpose of this step is to ensure sufficient e-liquid is filled, which extends the device’s operational lifespan. Post-injection, each vape is weighed to confirm that it meets the standard weight specifications, ensuring product quality consistency.
Following the weighing process, the top sealing silicone is fed into the assembly line and integrated with the oil reservoir tube. Next, the oil-absorbing cotton is loaded and assembled with the reservoir tube. This step is critical to ensure that the cotton is properly connected to the reservoir tube, enabling efficient absorption of e-liquid.
After assembling the oil-absorbing cotton, the battery component is loaded and connected with the fiberglass tube leads. This step is essential to ensure a secure and reliable connection between the battery and the other components.
Subsequently, the mouthpiece is loaded and assembled with the reservoir tube assembly. This step ensures that the mouthpiece is correctly connected to the reservoir tube, allowing the vape to operate smoothly. Following the mouthpiece assembly, the vape rod is fed and assembled with the battery component, ensuring a firm connection between the rod and the battery.
Once the vape rod is assembled, the device undergoes an atomization test. This test is conducted to verify the efficiency of the atomization process. Following this, a flavor test is performed to ensure that the vape‘s flavor meets the required standards, providing an optimal user experience.
Finally, the assembled vape is discharged from the production line as a finished product, ready for packaging and distribution.
That concludes our overview of what is inside disposable vapes. Each component inside a vape serves a unique function, contributing to the overall performance and user experience. If you are interested in wholesale purchases of disposable vapes or have any technical inquiries regarding disposable vape technology, please don’t hesitate to reach out to us. At 2077 Vape, we are eager to connect with you and assist with any of your needs.