Mesh Heater Resistivity Testing via Optical and Electrical Sensing
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Solution Overview
Problem
There is a lack of suitable systems for testing the appropriate characteristics of mesh-based heating systems in 'heat not burn' devices, which are integral to their function, making quality control during manufacture and assembly challenging due to structural differences with coil and wick systems.
Innovation Solution
A system and method for determining the resistivity of mesh-heater units in aerosol generating devices, utilizing a testing assembly with sensor units that can be configured for vertical displacement, allowing simultaneous testing of multiple heating systems, and featuring removable sensor units with electrical and optical capabilities to assess resistivity, integrity, and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mesh-heater units are used in heat not burn devices, then heating efficiency and aerosol generation are improved, but quality control and testing become difficult due to structural differences from traditional coil and wick systems
Solution Approach 1:
The patent uses optical copying and imaging techniques to create visual representations of the mesh-heater units and their heating patterns. Sensors capture optical images of the mesh structure and temperature distribution, allowing non-contact measurement and quality assessment without physical contact or disruption to the heating element.
Solution Approach 2:
The patent replaces traditional mechanical contact-based testing methods with optical and electrical sensing systems. Instead of physically measuring or touching the mesh-heater, the system uses optical sensors to detect thermal radiation and electrical sensors to measure resistance, enabling non-intrusive quality control.
2Ease of operation
If traditional testing methods are used for mesh-heater units, then testing simplicity is maintained, but testing accuracy and conformity assessment are insufficient due to structural differences from coil and wick systems
Solution Approach 1:
The patent introduces optical fields and electrical fields as intermediaries between the mesh-heater unit and the measurement system. Optical sensors detect thermal radiation from the mesh, and electrical sensors measure resistance through contactless or minimal-contact methods, providing accurate measurements without complex mechanical testing apparatus.
3Manufacturing precision
If multiple heating systems are tested sequentially, then testing thoroughness is ensured, but production line efficiency and speed are reduced
Solution Approach 1:
The patent combines multiple sensing modalities (optical imaging, thermal detection, electrical resistance measurement) into a single integrated testing station. Multiple mesh-heater units can be tested simultaneously using arrays of sensors, allowing parallel testing that maintains thoroughness while increasing production speed.
Solution Approach 2:
The patent enables continuous testing by implementing a testing system that operates without interrupting the production flow. The optical and electrical sensors can measure heating characteristics in real-time as mesh-heater units move through the production line, eliminating the need for stopping or sequential testing.
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 efficient and simultaneous testing of mesh-heater systems in a production line setting, ensuring conformity to specifications and reducing production line disruptions, while being adaptable to different testing requirements.
Implementation Method 1
A system for determining a resistivity of a heating system for use in an aerosol generating article
Implementation Method 2
In another example the optical sensor is configured to obtain light signals
Implementation Method 3
The resistivity of the wires/mesh foil is chosen such that a required heat output is achieved for a given supplied power to the wires/mesh foil
Data Source
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AI summary
A system and method for determining the state of a heating system for use in an aerosol generating article.