Yoda! You seem to have a very good understanding of how the device works. Have you or would you consider e-mailing the company with your suggestions. I would think that they've had a lot of time to tweak the thing already just by trying it themselves and letting their friends try it.
I put a tiny rubber o-ring where the filter meets the plastic to create a seal, the blue light comes on ever time now with the smallest of puffs and it works great every time. I got the same results if I seal taped the filter to the plastic, the air flow sensor must require a certain amount of air to pass over it before the heating element engages. IMO the entire problem is the sealing of the filter to the mounting base.
I have bought 6 starter kits for friends so far and each one I modified with the o-ring is awesome. My friends love them and said they will continue to use them from now on. One lady told me its her comfort cig.
Yes, it is true that I probably overestimate the difficulty in modifying the chip, because I know nothing about it/them. To an electronics engineer it may be a breeze. I have to plead ignorance on this one.
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