# US 12,593,877 B2 · Vaping system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,593,877 B2 - Document ID: US12593877B2 - Status: Granted - Kind: B2 - Application number: 19/030,656 - Filed: 2025-01-17 - Published: 2025-05-22 - Granted: 2026-04-07 - Earliest claimed: 2022-09-07 - Assignees: Ayr Ltd. - Applicants: Ayr Ltd. - Inventors: Ian Murison; Stephen Jackson; Hadyn Van Der Berg; Ryan Cocking; Luv Sheth; Tom O'Callaghan - Web page: https://patentgrep.com/patent/US12593877B2 ## CPC - A24F 40/57: Temperature control - A24F 15/015: with means for refilling of liquid inhalable precursors - A24F 40/10: Devices using liquid inhalable precursors - A24F 40/42: Cartridges or containers for inhalable precursors - A24F 40/46: Shape or structure of electric heating means - A24F 40/51: Arrangement of sensors - A24F 40/53: Monitoring, e.g. fault detection - A24F 40/95: structurally associated with cases - A24F 47/00: Smokers' requisites not otherwise provided for - G05D 23/1917: {using digital means} - A24F 40/80: Testing - A24F: SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES (inhaling appliances for medical purposes, shaped like cigars, cigarettes or pipes A61M15/06) - G05D: SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES ## Abstract A vaping system includes: (a) a disposable vaping device that includes the following non user-replaceable items: (i) a heating element; (ii) a rechargeable battery, and (iii) a liquid reservoir that provides liquid to the heating element; and (b) an automatic liquid filling device, including (i) a first aperture or port configured to receive a liquid bottle or container containing atomisable liquid; (ii) a second aperture or port configured to receive the vaping device; (iii) an electronic liquid level sensing sub-system; (iv) a liquid filling sub-system configured to pump liquid from the liquid bottle or container to the liquid reservoir in the vaping device and (v) a battery charging sub-system. ## Claims ### Claim 1 A vaping device including a heating element, a power source, a pulse width modulated (PWM) system to deliver power from the power source to the heating element, and a microcontroller or chip configured with an inner closed loop temperature control algorithm configured to regulate a duty cycle of the PWM system to reach a setpoint temperature; and in which the microcontroller or chip is also configured with a second, outer closed loop power control algorithm with a power setpoint, and is configured to measure or infer power delivered to the heating element, and to automatically modify the setpoint temperature used by the inner control loop depending on the variation of the measured or inferred power from the power setpoint; and in which the microcontroller or chip is configured so that if the actual average power used is less over a single puff, or other parameter, by an amount, referred to as the power ‘error’, then the microcontroller or chip is configured to increase the temperature setpoint, in the inner temperature control loop, by a pre-set factor, Kp and the size of this Kp factor is determined based on the measured power error resulting from changes in the temperature setpoint, wherein the measured power error reflects the specific design of heating element. ### Claim 2 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured so that if the measured or inferred power is below the power setpoint, then the microcontroller or chip automatically increases the temperature setpoint used by the inner control loop. ### Claim 3 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured so that if the measured or inferred power is above the power setpoint, then the microcontroller or chip automatically decreases the temperature setpoint used by the inner control loop. ### Claim 4 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to increase the duty cycle of the PWM when the temperature setpoint is increased, and to decrease the duty cycle when the temperature setpoint is decreased. ### Claim 5 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to measure or infer the average power in a puff or other parameter, and if the measured or inferred power average is below the power setpoint, then the microcontroller or chip is configured to automatically increase the temperature setpoint used by the inner control loop, for the next puff or other parameter. ### Claim 6 (depends on 5) The vaping device of claim 5 in which the microcontroller or chip is configured so that, during the next puff or other parameter, the closed loop temperature control algorithm operates to increase the duty cycle of the PWM and the microcontroller or chip again measures or infers the average power in this next puff or other parameter and if the average power is still below the power setpoint, then the microcontroller or chip increases the temperature setpoint for the following puff or other parameter; and if the average power is now above the power setpoint, then the microcontroller or chip decreases the temperature setpoint and decreases the duty cycle of the PWM for the following puff or other parameter. ### Claim 7 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to measure or infer the average power in a puff or other parameter, and if the average power is above the power setpoint, then the microcontroller or chip is configured to automatically decrease the temperature setpoint used by the inner control loop, for the following puff. ### Claim 8 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured so that the power is an instantaneous power (V×I) a number of times for a defined period, such as for an entire single puff, or some other parameter, e.g. a part of a puff, a 16 ms cycle, or a set number of 16 ms cycles. ### Claim 9 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured so that the power setpoint is an average power per puff or other parameter, such as a part of a puff, a 16 ms cycle, or a set number of 16 ms cycles. ### Claim 10 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to limit the temperature setpoint in an acceptable range: below 280° C., to prevent burning; and above 200-220° C., to ensure that liquid is vapourised. ### Claim 11 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured with further control loops, each with a different type of setpoint. ### Claim 12 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to vary a thermal profile, namely the temperature setpoint and/or power setpoint. ### Claim 13 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile over the course of a single puff or inhalation. ### Claim 14 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile over the course of a session of puffs or inhalations. ### Claim 15 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile to optimise any one or more of the following: flavour; dose; intensity; vapour density; plume size; safety; reduction in carbonyls in inhaled vapour; reduction in metals in inhaled vapour; reduction in burning taste; consistency in nicotine delivery; improved taste; longevity of improved taste; overall experience taking into account user preferences and/or liquid supplier preferences. ### Claim 16 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile depending on the specific liquid used, taking into account one or more of the following: flavour, whether salt-based, PG/VG proportions, to deliver an optimal user experience. ### Claim 17 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile, when vaping cannabis oils, to be optimised for the specific blend of terpenes and their different activation temperatures, or the user experience that is desired, such as relaxation, pain control, appetite control, anxiety, physical performance, mental performance. ### Claim 18 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile in a way that ensures consistency of experience over the course of a vaping session. ### Claim 19 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile by lowering the temperature setpoint and/or power setpoint over the course of a session to ensure that there is no over-heating and instead a consistent level of intensity is enjoyed over the course of the entire session. ### Claim 20 (depends on 12) The vaping device of claim 12 in which the microcontroller or chip is configured to alter the thermal profile over the duration of a multi-week cessation program, gradually reducing the intensity of nicotine, CBD, THC etc (or other relevant parameter) to ease the transition away from dependency. ### Claim 21 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to enable a user to select the level of vapour output. ### Claim 22 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to automatically implement different vapour output profiles. ### Claim 23 (depends on 1) The vaping device of claim 1 in which the heating element is one of the following: a resistance based heating element with a known or measurable temperature coefficient of resistivity; a resistance based heating coil, mesh or layer; a resistance based heating coil, mesh or layer contacting a porous substance, such as a ceramic or foam; a resistance based heating flat plate or cylindrical mesh; a resistance based heating flat, stainless steel plate made of 316L stainless steel. ### Claim 24 (depends on 1) The vaping device of claim 1 which is one of the following: is a non-re-fillable, non-re-chargeable vaping device; a re-chargeable vaping device; a re-fillable and re-chargeable vaping device; an automatically re-fillable vaping device; a pod-based vaping device, where the pod is supplied to the end-user pre-filled with liquid. ### Claim 25 (depends on 1) The vaping device of claim 1 which includes a pressure drop sensor or a MEMs type pressure sensor. ### Claim 26 (depends on 1) The vaping device of claim 1 in which the microcontroller or chip is configured to deliver one or more of the following: no burning; generation of no carbonyls and no aldehydes; generation of no metals; consistent vapour production per puff; the lifetime of the heating element is extended from just a few hundred puffs to a useable life of at least 2000 puffs. ### Claim 27 (depends on 1) The vaping device of claim 1, wherein the specific design of the heating element includes thermal and/or electric response characteristics of the heating element.