Pre-Capped Cartridge Filling Through a Pierced Plug Without Heater Overfill
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Solution Overview
Problem
Existing methods for filling disposable electronic-cigarette cartridges with liquid substances are slow due to the viscous nature of the liquid and the need to impregnate a hygroscopic wad, leading to low output rates and potential issues with precise volume filling and air entrapment.
Innovation Solution
A vaping device design with a mouthpiece, plug, and enclosure that allows for efficient injection and sealing of liquid into a cavity while venting hot air through channels, using resilient materials and male-female connectors to prevent rotational movement and fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cartridge is filled with liquid substance using conventional methods, then the liquid impregnates the hygroscopic wad, but the filling process is extremely time-consuming and has low output rate
Solution Approach 1:
The filling process is segmented into two distinct phases: first, liquid is injected directly into the cartridge cavity to rapidly fill the volume; second, the liquid naturally wicks into the hygroscopic wad through capillary action. This segmentation eliminates the time-consuming manual impregnation process while maintaining precise filling control through the injection system.
Solution Approach 2:
The invention employs a hydraulic injection system using a syringe mechanism to deliver precise volumes of liquid substance into the cartridge cavity. The pneumatic/hydraulic pressure control enables accurate volume delivery and rapid filling, dramatically increasing productivity compared to conventional gravity-based or manual filling methods.
2Quantity of substance
If the cartridge is filled to the edge with liquid substance, then the liquid forms a droplet over the opening, but air entrapment and imprecise volume filling occur
Solution Approach 1:
The injection system incorporates feedback control through sensors that detect the liquid level in the cartridge cavity. When the liquid reaches a predetermined level, the sensor signals the injection system to stop, ensuring precise volume filling without overfilling or air entrapment. This closed-loop control maintains high manufacturing precision.
Solution Approach 2:
The cartridge is pre-positioned with the hygroscopic wad in place before liquid injection. The wad acts as a pre-prepared absorption matrix that immediately begins wicking liquid through capillary action as it enters the cavity, preventing air entrapment and ensuring complete liquid distribution from the start of the filling process.
3Reliability
If a second venting needle is used to evacuate air, then air can be removed from the cartridge, but the filling level must be kept low to prevent liquid blockage
Solution Approach 1:
The invention extracts and eliminates the need for a second venting needle by using the single filling needle to perform both filling and air evacuation functions. The needle is connected to a dual-mode system that can switch between injection mode (for liquid filling) and evacuation mode (for air removal), simplifying the overall system while maintaining effective air removal capability.
Solution Approach 2:
The filling needle system is made dynamic by implementing a controllable valve mechanism that can switch the needle's function between liquid injection and air evacuation. The system dynamically adjusts the needle's role based on the filling stage: initially evacuating air, then injecting liquid, and finally performing both functions simultaneously in a controlled sequence, maximizing fill volume without blockage.
4Productivity
If the cartridge is sealed immediately after filling, then the cartridge is ready for use, but overfilling the heater causes malfunction
Solution Approach 1:
The injection system uses level sensors and feedback control to monitor the liquid volume in the cartridge cavity in real-time. The system automatically stops injection when the predetermined safe level is reached, preventing overfilling of the heater. This feedback mechanism ensures reliable operation while maintaining high manufacturing speed through rapid, controlled filling.
Solution Approach 2:
The hygroscopic wad performs a self-service function by automatically absorbing excess liquid through capillary action as it is injected into the cavity. This self-regulating mechanism prevents liquid from reaching and overfilling the heater, providing inherent protection without requiring additional sensors or control systems, thus maintaining high productivity.
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
Enables high-speed filling of cartridges with precise volume control and effective air removal, improving manufacturing efficiency and reducing the risk of leakage during transportation.
Implementation Method 1
The plug (14) is formed from a silicone material to be resilient and to allow uninterrupted penetration of the needle therethrough to fill the housing (16) with the liquid substance (F)
Implementation Method 2
the extensions (40, 42) of the mouthpiece (12) are located above the pair of inlets (54, 56) forming a channel defined between the pair of inlets (54, 56) and the central opening (70) to allow heat, i.e. hot air or hot gas or heat, to escape therethrough
Implementation Method 3
The peripheral wall (84) includes a pair of adjacent semi-circular female connectors or grooves (90, 92) separated by a pair of side ribs (94, 96) extending outwardly from the peripheral wall (84) and being parallel an axis A. The side ribs (94, 96) are used to be engaged inside side grooves (98, 99) defined in the peripheral wall (24) of the mouthpiece (12) to prevent rotational movement of the mouthpiece (12) relative the housing (16) around the axis A.
Implementation Method 4
The female connectors or grooves (90, 92) are used to receive the pair of male connectors (32, 34) extending from the peripheral wall (26) of the mouthpiece (12). The method further includes the step of seal and snapping the mouthpiece (12) with the housing (16), to prevent the escape of the fluid F from the vaping device (10) during transportation.
Data Source
AI summary
A vaping device includes several components such as a mouthpiece, a plug, and an enclosure or housing. During an assembly in the factory, the plug installed on top of the enclosure. The mouthpiece is snapped to a first groove to fix it on the enclosure. During the filling process, a needle penetrates through the mouthpiece and the plug in the thinner place of the plug. When filling starts, substance pushes the air out of the enclosure through holes defined in the plug. After the filling process is complete, the mouthpiece is pushed down on the enclosure to snap on a second groove, which will close air channels in the plug with plugs from the mouthpiece. The needle is extracted thereafter.