Introduction
Vaping has moved from the fringes of sub‑culture into mainstream conversation, both as a potential harm‑reduction tool for adult smokers and as a fast‑growing segment of the nicotine market. Yet, a curious question lingers at the back of many users’ minds: what actually happens inside a vape once the button is pressed? Understanding the inner workings of e‑cigarettes is essential not only for making informed purchasing decisions but also for troubleshooting performance issues, staying compliant with local regulations, and maintaining safety standards.
In this deep‑dive we’ll unpack the anatomy of modern e‑cigarettes, trace the path of energy from battery to vapor, explore the chemistry behind e‑liquids, and examine the regulatory framework that shapes product design in Australia. Along the way, we’ll spotlight two leading Australian brands—IGET and ALIBARBAR—that have built a reputation for durability, flavour variety, and compliance with the strictest quality‑control standards.
1. A Brief History of the Modern Vape
| Year | Milestone | Significance |
|---|---|---|
| 2003 | Hon Lik patents the first commercial e‑cigarette in China | Introduced a battery‑powered, liquid‑vaporizing device that mimics smoking |
| 2006‑2009 | Early “cigalike” models appear in Europe & US | First wave of disposable and rechargeable e‑cigs for adult smokers |
| 2012 | Introduction of “vaporizers” (e‑cigarette pens) | Larger batteries, replaceable coils, higher vapor production |
| 2015‑2017 | Rise of pod systems (e.g., JUUL) | Compact, high‑nicotine salt e‑liquids, youth‑appeal controversy |
| 2020+ | Growth of mod devices, mesh coils, temperature control | Customizable power, longer coil lifespans, more consistent flavour |
| 2024 | Australian market sees >30 % growth YoY, driven by premium disposable vapes | Brands like IGET and ALIBARBAR dominate with regulated, ISO‑certified products |
These milestones illustrate how engineering innovations—particularly in battery technology, coil design, and e‑liquid formulation—have driven vape evolution from simple nicotine delivery to a sophisticated, user‑centric experience.
2. Core Components of an E‑Cigarette
Every electronic cigarette, regardless of shape or price point, is built from a limited set of fundamental parts. Understanding each component helps demystify the vaping process.
2.1 Battery (Power Source)
- Type: Primarily lithium‑ion (Li‑ion) or lithium‑polymer (Li‑Po) cells, offering high energy density in a compact form factor.
- Voltage & Capacity: Measured in volts (V) and milliamp‑hours (mAh). Typical vape pens run at 3.7 V (single cell) with capacities from 350 mAh to 1500 mAh. Mods may stack cells for 2‑cell (7.4 V) or 3‑cell (11.1 V) configurations.
- Safety Features: Over‑charge, over‑discharge, short‑circuit, and temperature protection circuits are now mandatory under the Australian Therapeutic Goods Administration (TGA) guidelines for nicotine‑containing products.
2.2 Atomizer (Heated Element)
The atomizer houses the coil (resistive heating element) and wick (capillary medium). Its purpose is to transform e‑liquid into an aerosol.
- Coil Materials: Kanthal (FeCrAl), Nichrome (NiCr), Stainless Steel (SS), Nickel (Ni200), and newer mesh or cylindrical designs for larger surface area and even heating.
- Resistance Range: From ultra‑low (<0.3 Ω) “sub‑ohm” coils for high‑power cloud production, up to higher‐resistance (≥1.5 Ω) coils for mouth‑to‑lung (MTL) draws.
- Power Equation: ( P = \frac{V^2}{R} ) (where P = power in watts, V = voltage, R = resistance). This relationship determines heat generation and, consequently, vapor output.
2.3 Wick
- Material: Usually organic cotton, silica, ceramic, or low‑impedance ceramic fiber.
- Capillary Action: Pulls e‑liquid from the tank to the coil through surface tension, ensuring continuous feeding and preventing dry‑hits (overheating of the coil).
2.4 E‑Liquid (Vape Juice)
An e‑liquid typically contains:
| Ingredient | Typical Concentration | Role |
|---|---|---|
| Propylene Glycol (PG) | 30‑70 % | Thin viscosity, carries flavour, provides “throat hit”. |
| Vegetable Glycerin (VG) | 30‑70 % | Higher viscosity, produces dense vapor, sweetens flavour. |
| Nicotine (free‑base or nicotine salts) | 0‑50 mg/mL (AU limit: 20 mg/mL) | Provides pharmacologic effect. |
| Flavourings (food‑grade) | 2‑15 % | Imparts taste; regulated under ISO 11031 for safety. |
The PG/VG ratio dictates the overall vaping experience: higher PG yields a stronger throat hit, while higher VG creates smoother, thicker clouds.
2.5 Airflow System
Adjustable airflow ports or “draw‑activated” vents regulate the amount of air that mixes with the vapor. More airflow → cooler vapor, larger clouds; less airflow → tighter draw, stronger hit.
2.6 Mouthpiece
A simple silicone or plastic tip that directs the aerosol to the user’s mouth. Some models incorporate anti‑leak designs to prevent e‑liquid spillage during transport.
3. The Journey From Battery to Vapor: How an E‑Cigarette Works
Below is a step‑by‑step breakdown of the aerosolisation process:
-
Power Activation
- User inhales (draw‑activated) or presses a button (fire‑activated).
- This completes the circuit, allowing the battery to deliver voltage to the coil.
-
Electrical Energy to Heat
- Current flows through the coil’s resistive material.
- According to Joule’s Law (( Q = I^2 \times R \times t )), electrical energy converts to thermal energy, raising coil temperature typically between 150 °C–300 °C.
-
Heat Transfer to E‑Liquid
- The hot coil conductively transfers heat to the wick.
- The wick, saturated with e‑liquid, reaches its boiling point (PG ~188 °C, VG ~290 °C) and begins to vaporise.
-
Aerosol Formation
- Vaporised PG/VG carries nicotine and flavour compounds, forming a fine aerosol (sub‑micron droplets).
- The aerosol mixes with incoming air through the airflow channel, cooling slightly before reaching the mouthpiece.
-
Inhalation
- The user draws the aerosol into the lungs (deep inhalation) or holds it in the mouth (MTL style).
- Nicotine is absorbed through the pulmonary alveoli, delivering the familiar pharmacologic effect.
- Device Cooling & Cycle Reset
- After the draw, the coil temperature drops, and the wick re‑absorbs fresh e‑liquid via capillary action.
- The device is ready for the next puff.
Key Variables Influencing Vapor Quality
| Variable | Impact on Experience |
|---|---|
| Coil Resistance | Lower resistance → higher power → more vapor, but higher risk of overheating. |
| Battery Voltage | Higher voltage = higher temperature = denser clouds, but can degrade flavour if excessive. |
| PG/VG Ratio | Determines throat hit, cloud density, and flavour perception. |
| Airflow Setting | Alters temperature and vapor dilution; tight draw = hotter, tighter feel. |
| E‑Liquid Viscosity | Affects wicking speed; high VG may need a larger wick or mesh coil. |
4. Device Categories – From Cigalikes to High‑End Mods
| Category | Typical Use‑Case | Design Features | Typical Puff Count |
|---|---|---|---|
| Cigalikes | Beginner smokers seeking minimal learning curve | Disposable or rechargeable pen‑shaped, fixed coil, low‑capacity battery | 200‑800 puffs |
| Vape Pens | All‑day vapers wanting flavor variety | Replaceable tanks, replaceable coils, button‑activated, 800‑2500 mAh | 1500‑5000 puffs (depends on coil & e‑liquid) |
| Pod Systems | Nicotine‑salt users, discreet vaping | Pre‑filled or refillable pods, low‑power (≤15 W), ergonomic flat design | 500‑3000 puffs per pod |
| Mods / Advanced Personal Vaporizers (APVs) | Cloud‑chasing, DIY enthusiasts | Variable wattage/voltage, temperature control, multiple batteries, sub‑ohm coils, larger tanks (3‑10 mL) | 6000+ puffs (if using high‑capacity batteries) |
Real‑World Example: IGET Bar Plus
The IGET Bar Plus sits at the intersection of pod convenience and pen durability. Its 6000‑puff claim stems from a 1200 mAh battery coupled with a high‑efficiency mesh coil and a 4.5 mL e‑liquid reservoir. The device features an auto‑draw activation system and complies with ISO‑9001 quality management and TGO‑110 safety standards.
5. Power Regulation & Temperature Control
Modern devices employ microprocessors to manage power delivery, ensuring consistent performance and protecting the user.
5.1 Variable Wattage (VW) / Variable Voltage (VV)
- VW: User sets the wattage; the device automatically adjusts voltage based on coil resistance.
- VV: User sets the voltage; wattage varies with resistance.
Both modes allow fine‑tuning of heat output, essential for balancing flavour and cloud production.
5.2 Temperature Control (TC)
When a coil is made of Ni200, SS, or Nickel, the device can monitor resistance changes to infer temperature (R = R₀[1+α(T‑T₀)]). The microcontroller then modulates power to hold the coil at a target temperature (e.g., 215 °C), mitigating dry‑hits and reducing the formation of harmful carbonyl compounds.
5.3 Safety Algorithms
- Short‑circuit detection – instantly cuts power if resistance drops below a preset threshold.
- Over‑temperature cut‑off – shuts down the coil if it exceeds safe limits (often 350 °C).
- Low‑battery warnings – prevent deep discharge that can damage Li‑ion cells.
6. Manufacturing Standards & Australian Regulatory Landscape
6.1 ISO & TGO Certifications
| Standard | Focus | Relevance to Vapes |
|---|---|---|
| ISO 9001 | Quality Management Systems | Ensures consistent production, traceability of components (battery, coil). |
| ISO 11031 | Sensory Evaluation of Food Products | Governs the safety of flavourings used in e‑liquids. |
| TGO 110 | Australian Therapeutic Goods Order 110 (Nicotine‑containing products) | Sets maximum nicotine concentration (≤20 mg/mL), child‑resistant packaging, health warnings. |
Both IGET and ALIBARBAR report that their factories undergo regular ISO audits and that each batch of e‑liquids is tested for nicotine content, heavy metals, and microbial contamination.
6.2 Australian Competition & Consumer Commission (ACCC) Requirements
- Product Labeling: Mandatory health warnings and ingredient lists.
- Advertising Restrictions: No promotion to persons under 18; no false health claims.
- Supply Chain Traceability: Vendors must retain records for 2 years to aid recalls.
6.3 Environmental Considerations
Disposable vapes generate electronic waste. Australian law encourages producer responsibility schemes, prompting manufacturers to develop recyclable batteries and offer take‑back programmes. Brands like IGET have launched “Eco‑Return” initiatives, where customers can return used pods for proper recycling.
7. Longevity & Performance Metrics
7.1 Puff Count Estimation
A theoretical puff count can be approximated using:
[
\text{Puffs} = \frac{C{\text{battery}} \times V{\text{avg}} \times \eta{\text{eff}}}{P{\text{avg}} \times t_{\text{puff}}}
]
- ( C_{\text{battery}} ) – Battery capacity (mAh)
- ( V_{\text{avg}} ) – Average voltage during discharge (V)
- ( \eta_{\text{eff}} ) – Efficiency factor (≈0.85 for modern circuits)
- ( P_{\text{avg}} ) – Average power (W)
- ( t_{\text{puff}} ) – Average puff duration (seconds, typically 3–4 s)
For an IGET Bar Plus (1200 mAh, 3.7 V, 10 W, 3.5 s per puff), the calculation yields roughly 6,500 puffs, aligning with the manufacturer’s claim.
7.2 Coil Lifespan
- Standard Kanthal Coil: 500‑800 puffs before flavour degradation.
- Mesh Coil: 1500‑3000 puffs due to larger heating surface and lower voltage requirements.
- Temperature‑controlled Stainless Steel: Up to 5000 puffs if kept within safe temperature limits.
8. Choosing the Right Device – Practical Considerations
| User Profile | Recommended Device Type | Key Features |
|---|---|---|
| New Smoker (10‑20 cigarettes/day) | Cigalike or pod system | Low nicotine‑salt e‑liquids, discreet, auto‑draw, limited maintenance |
| Flavor‑focused Vaper | Mid‑range vape pen with replaceable tank | Adjustable airflow, moderate wattage (15‑30 W), high‑PG e‑liquids |
| Cloud‑Chaser / Competition | Sub‑ohm mod with high‑capacity battery | Variable wattage up to 200 W, mesh coil, large‑bore tank, airflow dial |
| Travel‑oriented Vaper | Disposable or compact pod | Small footprint, no coil changes, child‑proof packaging |
Fit for Australian Market: Ensure the device meets TGO‑110 standards, displays the required health warnings, and is supplied by a vendor with reputable after‑sales support (e.g., fast shipping across Sydney, Melbourne, Brisbane, Perth). Both IGET and ALIBARBAR have local fulfilment centres, ensuring same‑day dispatch for most mainland orders.
9. Maintenance & Troubleshooting
| Issue | Diagnosis | Solution |
|---|---|---|
| Dry‑hit (burnt taste) | Coil not receiving enough e‑liquid | Increase PG proportion, check wick saturation, lower power |
| Leaking tank | Over‑filled tank or loosely sealed pod | Fill to 80 % capacity, tighten connections, replace O‑rings |
| Battery drain too fast | High wattage or low‑capacity battery | Reduce wattage, switch to higher‑mAh battery, calibrate battery indicator |
| Weak throat hit | Low nicotine concentration or high VG ratio | Use higher nicotine strength (≤20 mg/mL in AU) or increase PG proportion |
| Unresponsive fire button | Battery protection mode triggered | Fully charge battery, reset device per user manual, replace battery if older than 500 cycles |
Regular coil replacement (every 2–3 weeks for daily users) and periodic cleaning of the mouthpiece prevent flavour contamination and extend device lifespan.
10. Myths & Misconceptions
| Myth | Reality |
|---|---|
| “Vaping is completely safe” | While vaping contains fewer toxicants than combustible cigarettes, it still delivers nicotine and trace chemicals. Long‑term effects are still under study. |
| “Higher VG = better clouds, always” | High VG increases viscosity, which can clog wicks and require larger‑bore coils. Balance with PG for consistent performance. |
| “Disposable vapes are cheap, so use them forever” | Disposable devices are more expensive per puff when compared with refillable systems; they also contribute to e‑waste. |
| “All flavours are FDA‑approved” | Flavourings are regulated under food‑grade standards, but not all are evaluated for inhalation safety. Trusted brands perform independent toxicology testing. |
| “Nicotine salts are less addictive” | Nicotine salts deliver nicotine efficiently, potentially increasing dependence if used excessively. |
11. Environmental Impact & Responsible Disposal
While the convenience of disposable vapes attracts many users, they pose a growing environmental challenge. Lithium‑ion batteries contain hazardous chemicals, and plastic pods contribute to landfill.
Best Practices for Australian Vapers
- Utilize Take‑Back Programs – Many retailers, including the IGET & ALIBARBAR online store, partner with certified e‑waste recyclers.
- Separate Battery from Plastic – Remove the battery (if detachable) before discarding the pod.
- Recycle Batteries – Drop off at supermarkets or dedicated recycling centres (e.g., Cleanaway, Planet Ark).
- Choose Refillable Pods – Reduces plastic waste by up to 70 % compared with single‑use disposables.
- Support Closed‑Loop Initiatives – Brands that use recycled PET for pod shells help close the material loop.
By adopting these steps, users can enjoy vaping while minimizing ecological footprints.
12. The Future of Vaping in Australia
- Regulatory Evolution: Expect tighter nicotine‑strength caps and clearer labeling requirements as health agencies gather more data.
- Technology Trends: Increased adoption of AI‑driven puff analytics, temperature‑controlled mesh coils, and bio‑compatible flavour synthesis.
- Consumer Preference: Growing demand for vegan‑friendly e‑liquids, CBD‑infused formulations (subject to legal restrictions), and zero‑nicotine “social vape” devices for flavor enjoyment alone.
Brands that invest in research, transparent supply chains, and responsible marketing—such as IGET and ALIBARBAR—are positioned to lead the market as it matures.
Conclusion
The inner mechanics of an e‑cigarette blend electrical engineering, fluid dynamics, and chemistry into a compact, user‑friendly device. From the battery’s stored energy to the coil’s precise heating of a PG/VG‑based e‑liquid, every stage determines the quality, safety, and satisfaction of the vaping experience. Understanding these processes empowers consumers to select reliable products, troubleshoot issues, and make informed choices about nicotine consumption.
In the dynamic Australian market, premium brands like IGET and ALIBARBAR stand out by delivering devices that marry performance (e.g., up to 6000 puffs on a single charge) with rigorous safety standards (ISO certifications, TGO‑110 compliance). Whether you are a newcomer seeking a discreet pod or an experienced cloud‑chaser desiring sub‑ohm power, the principles outlined above will guide you toward a device that matches your needs while respecting health and environmental responsibilities.
Frequently Asked Questions (FAQ)
1. How does a vape produce vapor without combustion?
The device uses an electric coil to heat the e‑liquid to its boiling point, turning it into a fine aerosol. No burning of plant material occurs, which eliminates many of the toxic by‑products found in cigarette smoke.
2. What is the difference between PG and VG, and which should I use?
Propylene glycol (PG) delivers a stronger throat hit and carries flavors well, while vegetable glycerin (VG) creates thicker clouds and a smoother sensation. Most vapers use a 50/50 blend; high‑cloud chasers prefer 70 % VG or more, whereas flavor enthusiasts may opt for 70 % PG.
3. Are nicotine salts safer than free‑base nicotine?
Both deliver nicotine, but nicotine salts are formulated with acids to lower the pH, allowing higher nicotine concentrations with less harshness. Safety depends on usage; higher nicotine concentrations can increase dependence.
4. How many puffs can I realistically get from an IGET Bar Plus?
Under typical use (3‑4 s draws at ~10 W), the Bar Plus is rated for up to 6000 puffs. Actual numbers vary with puff duration, e‑liquid viscosity, and battery health.
5. Is vaping legal in Australia?
Yes, vaping is legal for adults (>18 years). However, nicotine‑containing e‑liquids can only be obtained with a prescription or via legally authorized retailers, and products must comply with TGO‑110 regulations.
6. Can I use any e‑liquid in a pod system?
Most pod devices are optimized for specific viscosity ranges (typically higher PG). Using a very high‑VG liquid may cause flooding or poor wicking. Check the manufacturer’s specifications.
7. How often should I replace coils?
For regular daily vaping, replace coils every 1‑2 weeks, or sooner if you notice a burnt taste, reduced vapor production, or a change in flavour intensity.
8. What should I do if my vape leaks?
Ensure the tank is not overfilled, tighten all connections, and replace any worn O‑rings. If the leak persists, the pod or tank may be defective.
9. Are disposable vapes more cost‑effective than refillables?
While disposables require no maintenance, the cost per puff is higher than a refillable system when considering long‑term use. Refillable pods and tanks are more economical for heavy vapers.
10. How can I recycle my used vape batteries?
Remove the battery (if detachable) and bring it to a local e‑waste collection point such as a supermarket recycling bin, a dedicated battery‑recycling centre, or use the take‑back service offered by many Australian vape retailers.
11. Does vaping produce secondhand vapor that harms others?
Secondhand vapor contains significantly lower levels of harmful chemicals than secondhand smoke. Nonetheless, vaping in enclosed public spaces may be restricted by local laws; always respect non‑vapers’ preferences.
12. What are the signs of a faulty battery?
Rapid loss of charge, overheating during use, swelling, or inability to hold voltage are indicators of a compromised battery. Stop use immediately and replace with a genuine, certified battery.
13. Can I vape while pregnant?
Medical advice strongly discourages nicotine use during pregnancy, including vaping, due to potential risks to fetal development. Seek professional guidance.
14. How do temperature‑control modes protect my coil?
TC monitors resistance changes to maintain a target temperature, preventing the coil from exceeding safe limits that can produce harmful carbonyls or cause rapid coil degradation.
15. Where can I buy authentic IGET and ALIBARBAR products in Australia?
The official flagship store—IGET & ALIBARBAR E‑cigarette Australia—operates online with fulfilment hubs in Sydney, Melbourne, Brisbane, and Perth, offering fast shipping, genuine products, and local customer support.