Wick Saturation Sensing for Non-Nicotine Vape Refill Detection

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Solution Overview

Problem

Existing non-nicotine e-vaping devices lack effective methods to detect and prevent depletion of non-nicotine pre-vapor formulation, leading to potential device malfunction or user inconvenience.

Innovation Solution

Incorporation of a saturation sensor and control circuitry that measures electrical characteristics of the wick to calculate refill rates and impedance, triggering alerts or disabling the device when the formulation is low or depleted, ensuring consistent performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If no saturation sensor is used, then the device structure remains simple, but the non-nicotine pre-vapor formulation depletion cannot be detected

Engineering Contradiction:

Improvedetection of formulation depletionVSAvoidstructure with saturation sensor and control circuitry

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical or optical saturation sensors with an electrical resistance measurement system. The control circuitry measures the resistance of the wick material, which changes as it becomes saturated with pre-vapor formulation. This electrical measurement approach simplifies the device structure while achieving reliable depletion detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The wick material itself serves as the sensing element. As the wick absorbs and becomes saturated with the non-nicotine pre-vapor formulation, its electrical resistance changes naturally. The control circuitry utilizes this inherent property change to detect formulation levels, eliminating the need for separate sensing components.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If resistance measurement is used to detect saturation, then the device complexity is reduced, but the measurement precision may be insufficient

Engineering Contradiction:

Improvedetection of wick saturation levelVSAvoidcontrol circuitry for electrical measurement

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The control circuitry continuously monitors the resistance of the wick material and uses this feedback to determine saturation levels. When the resistance indicates that the wick is saturated or the formulation is depleted, the system provides feedback by alerting the user or automatically shutting down the heating element to prevent malfunction.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent utilizes the change in electrical resistance parameter of the wick material as it transitions from unsaturated to saturated state. By monitoring this parameter change, the control circuitry can precisely detect formulation levels and refill needs without requiring complex measurement systems.

Inventive Principle:

Principle #35Parameter changes

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

The solution effectively detects and prevents non-nicotine formulation depletion, maintaining device functionality and user satisfaction by providing timely alerts or disabling the device when necessary.

Implementation Method 1

a wick configured to draw non-nicotine pre-vapor formulation from the non-nicotine reservoir

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

The power supply provides power to the heater such that the heater heats to a temperature sufficient to convert the non-nicotine pre-vapor formulation to a non-nicotine vapor

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

a heating element configured to heat the non-nicotine pre-vapor formulation drawn from the non-nicotine reservoir

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 4

The saturation sensor is configured to: measure at least one electrical characteristic of the wick between the heating element and the probe wire at a first time, the at least one electrical characteristic including a resistance, a capacitance, or both a resistance and a capacitance

Methodology Applied

Scientific EffectElectrical resistance measurement: Electrical Resistance

Data Source

PatentUS20250345532A1Non-nicotine electronic vaping device

Publication Date: 2025.11.13 ALTRIA CLIENT SERVICES LLC

AI summary

In the non-nicotine electronic vaping device, a saturation sensor measures at least one electrical characteristic of the wick between the heating element and the probe wire at a first time and a second time, wherein the at least one electrical characteristic includes a resistance, a capacitance, or both a resistance and a capacitance. Control circuitry is configured to cause the non-nicotine e-vaping device to: calculate a refill rate at which the non-nicotine pre-vapor formulation flows onto the wick based on the at least one electrical characteristic at the first time and the at least one electrical characteristic at the second time; determine that the refill rate is less than a threshold refill rate; and output a low non-nicotine pre-vapor formulation alert in response to determining that the refill rate is less than the threshold refill rate.