E-Vapor Cartridge Filling With Variable-Amplitude Cam Metering
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Solution Overview
Problem
Existing methods for manufacturing e-vapor devices are labor-intensive and time-consuming, prone to inconsistencies, and lack automation in the filling of cartridges.
Innovation Solution
An apparatus for automated filling of e-vapor device cartridges, featuring a filling drum, needle assembly, and pump assembly with a variable amplitude cam system, allowing for precise control of pre-vapor formulation delivery without altering pumping start and stop times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operations are used for manufacturing e-vapor devices, then flexibility and ease of operation are maintained, but labor intensity increases and manufacturing precision decreases
Solution Approach 1:
The automated filling apparatus is divided into distinct functional modules: a filling drum for holding cartridges, a needle assembly for injection, a pump assembly for fluid delivery, and a variable amplitude cam system for control. Each module performs a specific function, allowing the complex automation task to be managed through modular components that can be independently adjusted and maintained.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated mechanical system driven by a variable amplitude cam mechanism. The cam system converts rotational motion into precise linear movements of the needle assembly and pump, eliminating manual labor while maintaining controllable complexity through mechanical means rather than electronic controls.
2Productivity
If manual filling operations are used, then device complexity is low, but productivity decreases and loss of time increases
Solution Approach 1:
The filling drum rotates continuously, allowing multiple cartridges to be filled in sequence without interruption. The variable amplitude cam system ensures that the needle assembly and pump operate continuously during the rotation, maximizing productivity by eliminating idle time between filling operations while keeping the apparatus complexity manageable through mechanical continuity.
Solution Approach 2:
The variable amplitude cam mechanism provides dynamic control over the needle assembly's movement, adjusting the amplitude of motion to optimize filling speed and precision. This dynamic adjustment capability increases productivity by adapting the filling process to different cartridge types or fluid viscosities without requiring complex electronic control systems.
3Manufacturing precision
If manual filling operations are used, then device complexity is low, but manufacturing precision and reliability decrease
Solution Approach 1:
The variable amplitude cam system changes the amplitude parameter of the needle assembly's linear motion to precisely control the fill amount. By adjusting the cam's amplitude, the system can deliver consistent, precise quantities of pre-vapor formulation to each cartridge without requiring complex electronic sensors or feedback mechanisms, maintaining reliability through mechanical parameter control.
Solution Approach 2:
The cam mechanism creates a reproducible motion pattern for the needle assembly and pump, ensuring that each filling operation is an exact copy of the previous one. This mechanical copying of the filling cycle guarantees consistent fill amounts and high manufacturing precision while keeping the system relatively simple through repeatable mechanical motion rather than complex control algorithms.
4Reliability
If automated filling is implemented, then productivity increases and manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent merges the needle assembly and pump assembly into a single integrated unit controlled by the variable amplitude cam system. This merging of functions reduces the number of separate control mechanisms needed, thereby improving reliability through coordinated operation while limiting the increase in overall system complexity by combining rather than multiplying components.
Data Source
AI summary
An apparatus for the automated filling of cartridges of e-vapor devices may include a filling drum configured to receive at least one cartridge of an e-vapor device. The apparatus may additionally include a needle assembly including at least one hypodermic needle. The needle assembly is configured to transition between a lowered state and a raised state. The lowered state is where the hypodermic needle is moved down into the cartridge, while the raised state is where the hypodermic needle is lifted up and away from the cartridge. The apparatus may further include a pump assembly configured to pump a pre-vapor formulation into the cartridge when the needle assembly is in the lowered state. The pump assembly may include a variable amplitude cam system configured to adjust an amount of the pre-vapor formulation for pumping to the cartridge without changing start and stop times for the pumping.