Susceptor Presence and Alignment Detection in Heated Aerosol Articles
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Solution Overview
Problem
During the manufacturing of inductively heatable aerosol-generating articles, susceptors often get lost or are not properly aligned, leading to defects that are difficult to detect using optical inspection methods since they may be fully embedded within the article.
Innovation Solution
A method and apparatus utilizing sensors responsive to the intrinsic electrical and magnetic properties of the susceptor, such as reed switches, Hall-effect sensors, or LC resonator circuits, to detect the presence or absence of a susceptor and determine its alignment, allowing for non-optical inspection and sorting of defective articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical inspection methods are used to detect susceptor presence and alignment, then the inspection process is simple and non-contact, but the detection reliability is insufficient because susceptors are fully embedded within the article and not visible from outside
Solution Approach 1:
The patent replaces optical inspection methods with electromagnetic field-based detection. Sensors responsive to electrical and magnetic properties (such as reed switches, Hall-effect sensors, or LC resonator circuits) detect the susceptor's presence and alignment by sensing its electromagnetic characteristics through the article structure, eliminating the need for direct optical visibility while improving detection reliability
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary between the inspection system and the embedded susceptor. The sensors detect changes in electromagnetic field properties (such as resonance frequency shifts or magnetic field distortions) caused by the susceptor's presence and position, enabling indirect detection through the article's structural materials
2Reliability
If sensors responsive to electrical and magnetic properties are used to detect susceptor presence, then detection reliability improves, but the device complexity increases due to additional sensor types and inspection mechanisms
Solution Approach 1:
The patent employs sensors that can detect multiple susceptor properties (electrical conductivity, magnetic susceptibility, resonance characteristics) using a unified detection platform. This multi-functional approach allows a single sensor system to identify susceptor presence, verify material properties, and determine alignment status, reducing overall system complexity compared to using separate specialized sensors for each property
Solution Approach 2:
The patent utilizes changes in electromagnetic parameters (resonance frequency, impedance, magnetic field strength) that occur when the susceptor is present or misaligned. By monitoring these parameter variations, the system reliably detects susceptor status without requiring complex sensor arrays, as each sensor type responds to characteristic parameter changes unique to the susceptor
3Manufacturing precision
If traditional optical inspection is used, then the inspection process is fast and simple, but manufacturing precision is compromised because defects cannot be reliably detected
Solution Approach 1:
The patent performs susceptor presence and alignment verification during the manufacturing process itself, rather than as a separate post-production inspection step. The sensing system is integrated into the manufacturing line, allowing real-time detection and immediate identification of defects, thereby ensuring manufacturing precision without adding significant time loss
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 reliable detection of missing or misaligned susceptors, facilitating early identification and sorting of defective articles, thereby improving manufacturing efficiency and reducing defects.
Implementation Method 1
detecting the presence or absence of a susceptor using at least one sensor that is responsive to the susceptor being at least one of electrically conductive, magnetic or magnetized
Implementation Method 2
detecting the presence or absence of a susceptor using at least one sensor that is responsive to the susceptor being at least one of electrically conductive, magnetic or magnetized
Implementation Method 3
detecting the presence or absence of a susceptor using at least one sensor that is responsive to the susceptor being at least one of electrically conductive, magnetic or magnetized
Implementation Method 4
the electric and magnetic properties of the susceptor may cause a detuning of the resonance frequency and the amplitude of an oscillating LC resonator circuit when the susceptor is near the inductor (L) of the LC resonator circuit
Implementation Method 5
the electric and magnetic properties of the susceptor may cause a detuning of the resonance frequency and the amplitude of an oscillating LC resonator circuit when the susceptor is near the inductor (L) of the LC resonator circuit
Implementation Method 6
the susceptor may be magnetized causing the article to be surrounded by a magnetic field which may be probed by a suitable sensor outside the article, for example, by a reed switch or a Hall-effect sensor or a magnetoresistance-based sensor
Implementation Method 7
the susceptor may be magnetized and subsequently passed through or nearby an induction loop or an induction coil such that the relative movement between the induction loop or the induction coil and the magnetized susceptor causes a change of the magnetic flux through the induction loop or the induction coil. According to Faraday's law of induction, the change of the magnetic flux induces an electrical current through the induction loop or the induction coil
Implementation Method 8
the susceptor is exposed to an alternating magnetic field. Depending on the magnetic and electrical properties of the susceptor, the field induces at least one of eddy currents or hysteresis losses in the susceptor which causes the susceptor to heat up
Implementation Method 9
the field induces at least one of eddy currents or hysteresis losses in the susceptor which causes the susceptor to heat up
Implementation Method 10
the field induces at least one of eddy currents or hysteresis losses in the susceptor which causes the susceptor to heat up
Data Source
AI summary
The present invention relates to method for inspecting an inductively heatable aerosol-generating article (1) for the presence of a susceptor (21) using at least one sensor (110) that is responsive to the susceptor (21) being at least one of electrically conductive, magnetic or magnetized. The invention further relates to method and apparatus for inspecting an inductively heatable aerosol-generating article for a desired article alignment at a specific article location in an article manufacturing apparatus, wherein the susceptor is provided for inductively heating an aerosol-forming substrate comprised in the article, and wherein an arrangement of the susceptor at or in the article is asymmetric with regard to a length axis of the article. The method and the apparatus comprises usage of at least a first senor which is arranged and configured to detect at a first test site of the article location a presence or absence of a susceptor, wherein the presence of the susceptor at the first test is indicative of the presence of the desired article alignment at the article location. The first sensor is responsive to the susceptor being at least one of electrically conductive, magnetic or magnetized and responsive to the presence of the susceptor at the first test site.