Pierced Capsule E-Vapor Heating Cutoff for Overheating Control

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Solution Overview

Problem

Existing e-vapor devices face issues with overheating, leading to unpleasant tastes and inefficiencies in vapor production, particularly due to the design of replaceable cartridges and reusable sections that do not adequately manage power supply and heating elements.

Innovation Solution

The e-vapor device incorporates a hermetically-sealed capsule containing a pre-vapor formulation, a puncture device with a wick and heater structure, and a vaporizer that ceases heating when current levels are below a reference point, ensuring controlled vapor production and reducing overheating risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If continuous heating is applied to vaporize the pre-vapor formulation, then vapor production is maintained, but overheating occurs leading to unpleasant tastes and inefficiencies

Engineering Contradiction:

Improvevapor productionVSAvoidoverheating

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The heating element operates in periodic cycles rather than continuously. The controller activates the heating element to vaporize the pre-vapor formulation, then pauses heating to allow the formulation to replenish the wick through capillary action. This periodic heating-vaporization-replenishment cycle prevents overheating while maintaining continuous vapor production capability.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system incorporates a controller that monitors the heating process and regulates power delivery to the heating element. The controller receives feedback about the vaporization state and adjusts heating intensity accordingly, reducing power when the wick is sufficiently saturated and preventing overheating conditions that cause unpleasant tastes.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If a replaceable cartridge design is used with threaded connections, then ease of replacement is improved, but device complexity increases due to sealing and alignment requirements

Engineering Contradiction:

Improvecartridge replacementVSAvoidthreaded connection system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The e-vapor device is divided into distinct replaceable modules: a cartridge containing the pre-vapor formulation reservoir and wick, and a separate heating element assembly. This segmentation allows each component to be optimized independently and replaced separately, simplifying the overall replacement process while managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The threaded connection system with upstream and downstream seals serves multiple functions: mechanical attachment of the cartridge, hermetic sealing to prevent formulation leakage, and alignment guidance for the heating element. This multi-functional design consolidates several requirements into a single connection interface, reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If the heating element is positioned in close thermal proximity to the wick, then vaporization efficiency is improved, but heat loss to surrounding components increases

Engineering Contradiction:

Improvevaporization efficiencyVSAvoidheat loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The heating element is positioned in close thermal proximity specifically to the wick where the pre-vapor formulation is delivered, creating a localized high-heat-zone for efficient vaporization. The upstream seal and surrounding structure act as thermal barriers, confining heat to the necessary area and reducing heat loss to other components of the cartridge assembly.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design minimizes overheating, enhances vapor quality, and optimizes the use of pre-vapor formulation by ceasing heating when necessary, thereby improving user experience and efficiency.

Implementation Method 1

the wire undergoes resistive heating to vaporize the pre-vapor formulation in the wick to produce a vapor for subsequent inhalation

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

a wick that is arranged in communication with the pre-vapor formulation

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS12472317B2E-vapor device including capsule containing pre-vapor formulation

Publication Date: 2025.11.18 ALTRIA CLIENT SERVICES LLC

AI summary

An e-vapor device may include a capsule, a mouthpiece configured to receive the capsule, and a vaporizer configured to engage with the mouthpiece to enclose the capsule therebetween. The capsule is configured to hold a pre-vapor formulation therein. The vaporizer is configured to pierce the capsule to access the pre-vapor formulation therein and to heat the pre-vapor formulation to generate a vapor. Additionally, the vaporizer may be configured to cease a heating of the pre-vapor formulation when a current in the heater structure is less than a reference level. Accordingly, the occurrence of an unpleasant taste resulting from overheating may be reduced or prevented.