U.S. patent application number 17/614947 was filed with the patent office on 2022-07-28 for system and method for testing a heating system.
This patent application is currently assigned to Philip Morris Products S.A.. The applicant listed for this patent is Philip Morris Products S.A.. Invention is credited to Rui Nuno BATISTA, Lambert Wijnand BREMAN, Ricardo CALI, Andreas LOEB.
Application Number | 20220232902 17/614947 |
Document ID | / |
Family ID | 1000006302057 |
Filed Date | 2022-07-28 |
United States Patent
Application |
20220232902 |
Kind Code |
A1 |
BATISTA; Rui Nuno ; et
al. |
July 28, 2022 |
SYSTEM AND METHOD FOR TESTING A HEATING SYSTEM
Abstract
A system for determining a resistivity of a heating system for
an aerosol generating article, the system including: a receptacle
configured to receive a plurality of elements, each element
including a heating system to be tested; and a testing assembly
including: a plurality of sensors, each sensor including at least a
pair of electrical contacts configured to pass an electric current
therethrough and being configured to obtain signals related to
properties of the heating system of each of the plurality of
elements, and a processor configured to receive the signals
obtained by the sensors and determine a resistivity of the heating
system of each of the plurality of elements, the sensors being
biasedly held in the testing assembly.
Inventors: |
BATISTA; Rui Nuno; (Morges,
CH) ; CALI; Ricardo; (Mannheim, DE) ; LOEB;
Andreas; (Ludwigshafen am Rhein, DE) ; BREMAN;
Lambert Wijnand; (Ermelo, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Philip Morris Products S.A. |
Neuchatel |
|
CH |
|
|
Assignee: |
Philip Morris Products S.A.
Neuchatel
CH
|
Family ID: |
1000006302057 |
Appl. No.: |
17/614947 |
Filed: |
June 23, 2020 |
PCT Filed: |
June 23, 2020 |
PCT NO: |
PCT/EP2020/067560 |
371 Date: |
November 29, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 40/51 20200101;
A24F 40/46 20200101; A24F 40/80 20200101 |
International
Class: |
A24F 40/80 20060101
A24F040/80; A24F 40/46 20060101 A24F040/46; A24F 40/51 20060101
A24F040/51 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 28, 2019 |
EP |
19183451.4 |
Claims
1.-15. (canceled)
16. A system for determining a resistivity of a heating system for
an aerosol generating article, the system comprising: a receptacle
configured to receive a plurality of elements, each element
comprising a heating system to be tested; and a testing assembly
comprising: a plurality of sensor units, each sensor unit
comprising at least a pair of electrical contacts configured to
pass an electric current therethrough and being configured to
obtain signals related to properties of the heating system of each
of the plurality of elements, and a processor configured to receive
the signals obtained by the sensor units and determine a
resistivity of the heating system of each of the plurality of
elements, wherein the sensor units are biasedly held in the testing
assembly.
17. The system according to claim 16, wherein the signals related
to properties of the heating system of each of the plurality of
elements are obtained substantially simultaneously by the sensor
units.
18. The system according to claim 16, wherein the testing assembly
is configured to obtain the signals when the testing assembly is in
a testing configuration.
19. The system according to claim 16, wherein at least one of the
plurality of sensor units comprises at least an optical sensor.
20. The system according to claim 16, wherein the signals obtained
relate to at least one of current, voltage, or light.
21. The system according to claim 16, wherein the properties of the
heating system tested relate to at least one of resistivity of the
element, spatial location of the element, or physical condition of
the element.
22. The system according to claim 16, wherein the determined
resistivity is at least one of integrity of the heating system,
conformity of the heating system to a predetermination condition,
or functionality of the heating system.
23. The system according to claim 16, wherein the receptacle is a
plate with a plurality of cavities, each cavity being configured to
receive an element.
24. The system according to claim 16, wherein the heating system of
each element comprises a mesh foil.
25. The system according to claim 16, wherein the sensor units are
held within channels of the testing assembly under their own
weight.
26. The system according to claim 25, wherein the sensor units are
configured to be displaced from, or within, their respective
channel.
27. A method of determining a state of a heating system for an
aerosol generating article, the method comprising: providing a
system according to claim 16; populating the receptacle with a
plurality of elements, each element comprising a heating system to
be tested; actuating the plurality of sensor units to obtain
signals related to properties of the heating system of each of the
plurality of elements; and determining, with the processor, a
resistivity of the heating system of each of the plurality of
elements from the obtained signals.
28. The method according to claim 27, further comprising bringing
the testing assembly into a testing configuration.
29. The method according to claim 27, further comprising removing
the plurality of elements from the receptacle and repopulating the
receptacle with a further plurality of elements.
Description
[0001] This invention relates generally to a system and method.
More specifically, although not exclusively, this invention relates
to a system for determining a state of a heating system for use in
an aerosol generating article or an aerosol generating device and a
method of determining a state of a heating systems for use in an
aerosol generating article or an aerosol generating device.
[0002] A number of devices for generating an aerosol have been
proposed in the art. For example, devices for generating aerosols
which heat rather than combust an aerosol-generating substrate have
been proposed. Heated smoking devices in which tobacco is heated
rather than combusted, are one type of such device. An aim of such
smoking devices is to reduce the generation of unwanted and harmful
smoke constituents as produced by the combustion and pyrolytic
degradation of tobacco in conventional cigarettes. These heated
smoking devices are commonly known as `heat not burn` devices.
[0003] Known aerosol generating devices of the `heat not burn`
variety typically include a device portion comprising a battery and
control electronics, a cartridge portion comprising a supply of
liquid aerosol-generating substrate held in a liquid storage
portion, and an electrically operated heater assembly acting as a
vaporiser. The cartridge portion typically comprises not only the
supply of liquid aerosol-generating substrate and the electrically
operated heater assembly, but also a mouthpiece, through which a
user may draw aerosol into their mouth. A cartridge portion
comprising both a supply of aerosol-generating substrate held in
the liquid storage portion and a vaporiser is sometimes referred to
as a "cartomiser" or "atomiser".
[0004] The vaporiser typically comprises "coil and wick" technology
(and variants thereof) as its heating technology. That is, a coil
of heater wire is wound around an elongate wick soaked in liquid
aerosol-generating substrate. Capillary material soaked in the
aerosol-generating substrate supplies the liquid to the wick.
[0005] However, an alternative type of vaporiser is a mesh-heater
unit. Mesh-heater units generally include a plurality of wires or a
mesh foil, which define a heating surface as well as a liquid
permeable surface. A transport material is provided to transport
liquid aerosol-generating substrate to the wires or mesh foil. 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.
[0006] An example of a cartridge including mesh-heater units is
illustrated in FIG. 1. Further description of this cartridge (above
that given below) and other alternative cartridges of this type can
be found in WO 2015/117702.
[0007] The cartridge 20 of FIG. 1 comprises a generally cylindrical
housing 24 that has a size and shape selected to be received into a
cavity of a corresponding aerosol generating device. The housing
contains a capillary material 22 that is soaked in a liquid
aerosol-generating substrate. The housing has an open end to which
a heater assembly 30 is fixed. The heater assembly 30 comprises a
substrate 34 having an aperture 35 formed in it, a pair of
electrical contacts 32 fixed to the substrate and separated from
each other by a gap, and a plurality of electrically conductive
heater filaments 36 spanning the aperture and fixed to the
electrical contacts on opposite sides of the aperture 35. The
heater assembly 30 is covered by a removable cover 26. The cover
comprises a liquid impermeable plastic sheet that is glued to the
heater assembly but which can be easily peeled off. A tab is
provided on the side of the cover to allow a user to grasp the
cover when peeling it off.
[0008] Another example of a cartridge 1000 including a mesh-heater
unit is illustrated in FIG. 2. Cartridge 1000 comprises an external
housing 1050 having a mouthpiece with a mouthpiece opening 1100,
and a connection end 1150 opposite the mouthpiece. Within the
housing 1050 is a liquid storage compartment holding a liquid
aerosol-forming substrate 1310. The liquid storage compartment has
a first portion 1300 and a second portion 1350 and liquid is
contained in the liquid storage compartment by three further
components, an upper storage compartment housing 1370, a heater
mount 1340 and an end cap 1380. A heater assembly 1200 comprising a
fluid permeable heating element 1220 (i.e. a mesh heater) and a
transport material 1240 is held in the heater mount 1340. A
retention material 1360 is provided in the second portion 1350 of
the liquid storage compartment and abuts the transport material
1240 of the heater assembly 1200. The retention material 1360 is
arranged to transport liquid to the transport material 1240 of the
heater assembly 1200. The first portion 1300 of the liquid storage
compartment is larger than the second portion 1350 of the storage
compartment and occupies a space between the heater assembly 1200
and the mouthpiece opening 1100 of the cartridge 1000. Liquid in
the first portion 1300 of the storage compartment can travel to the
second portion 1350 of the liquid storage compartment through
liquid channels 1330 on either side of the heater assembly 1200.
Two channels are provided in this example to provide a symmetric
structure, although only one channel is necessary. The channels are
enclosed liquid flow paths defined between the upper storage
compartment housing 1370 and the heater mount 1340.
[0009] As the heating system is integral to the function of the
`heat not burn` devices there is a need for appropriate quality
control during manufacture and assembly. For example, the
resistivity of the mesh heating systems must conform to
specification. At present, due to the structural differences
between the mesh heating systems and the "coil and wick" systems,
there is no suitable system for testing the appropriate
characteristics of mesh-based heating systems in a manner suitable
for implementation in a larger-scale production line.
[0010] US 2018/0049478 A1 discloses systems, apparatuses, and
methods for assembling cartridges for aerosol delivery devices.
[0011] An aspect of the invention provides a system for determining
a resistivity of a heating system for use in an aerosol generating
article, the system comprising: [0012] a receptacle for receiving a
plurality of elements, each element comprising a heating system to
be tested; and [0013] a testing assembly, the testing assembly
comprising: [0014] a plurality of sensor units each sensor unit
comprising at least a pair of electrical contacts configured to
pass an electric current therethrough and being configured to
obtain signals related to properties of the heating system of one
of the plurality of elements; and [0015] a processor configured to
receive the signals obtained by the sensor units and determine a
resistivity of the heating system of each of the plurality of
elements.
[0016] In some embodiments the sensor units are held in the testing
assembly by gravity. This enables a convenient way to hold the
sensor unit but still allow displacement, for example a vertical
displacement, should a wrongly fitted element for testing be
brought into contact with the sensor unit.
[0017] In particular embodiments the sensor units are held in the
testing assembly and are configured to enable vertical
displacement. For example, vertical displacement within the testing
assembly.
[0018] Another aspect of the invention provides a system for
determining a state of a heating system for use in an aerosol
generating article, the system comprising: [0019] a receptacle for
receiving a plurality of elements, each element comprising a
heating system to be tested; and [0020] a testing assembly, the
testing assembly comprising: [0021] sensor means configured to
obtain signals related to properties of the heating system of each
of the plurality of elements; and [0022] a processor configured to
receive the signals obtained by the sensor means and determine a
state of the heating system of each of the plurality of
elements.
[0023] Aptly, the signals related to properties of the heating
system of each of the plurality of elements are obtained
substantially simultaneously by the sensor means. This allows a
testing process for heating systems as part of a production line to
be optimised in terms of speed and efficiency. That is, by testing
multiple heating systems substantially simultaneously, the testing
process is sped up.
[0024] Aptly, the testing assembly is configured to obtain the
signals when the testing assembly is in a testing configuration.
More aptly, the testing assembly is moveable relative to the
receptacle to bring the sensor means, for example the sensor units,
into the testing configuration. Having separate testing and
non-testing configurations, between which the testing assembly can
move, allows the testing assembly to be kept separate from the
receptacle when testing is not being performed. This provides
opportunity for the receptacle to be populated or repopulated
between testing operations and hence helps maintain an efficient
testing/production line. This allows another batch of elements to
be positioned for testing. This can be quickly repeated over and
over to give a continuous flow of elements to be tested.
[0025] Aptly, the sensor means comprises a plurality of sensor
units, each sensor unit being configured to obtain signals related
to properties of the heating system of one of the plurality of
elements. Providing the sensor means as a plurality of sensor
units, ensures a compact and customisable method of testing
multiple heating systems of each of the plurality of elements
simultaneously, whilst monitoring the accuracy of testing each
heating system of the individual element.
[0026] Aptly, the sensor units are removable from the testing
assembly. By configuring the sensor units to be removable from the
testing assembly, the assembly may be customised/adapted depending
on the properties that require testing or the heating systems to be
tested, or both. For example, sensor units configured to obtain
signals related to a first property may be replaced with sensor
units configured to obtain signals related to a second
property.
[0027] Aptly, at least one of the plurality of sensor units
comprises at least a pair of electrical contacts. More aptly, the
pair of electrical contacts are a pair of electrical pins. More
aptly, in the testing configuration the pair of electrical contacts
are both in contact with a portion of the heating system of the
corresponding element. Including electrical contacts within a
sensor unit allows properties related to the resistivity of the
heating system to be tested by obtaining signals related to the
voltage or current.
[0028] Aptly, the sensor unit is biasedly held in the testing
assembly. By biasing the sensor unit within the testing assembly,
the sensor unit can be configured to quickly return to a
non-testing configuration. This helps ensures a quick and efficient
production line. Alternatively, in specific embodiments the sensor
unit is biasedly held in the non-testing configuration.
[0029] Aptly, at least one of the plurality of sensor units
comprises at least an optical sensor. Using an optical sensor
allows properties related to the spatial location of the element or
the physical condition of the heating system to be tested, for
example by obtaining an image of the element/heating system.
[0030] Aptly, the at least one of the plurality of sensor units
further comprises at least one lighting element, for illuminating
the corresponding heating system to be tested. This is particularly
useful when used in combination with an optical sensor.
[0031] Aptly, the signals obtained relate to at least one of
current, voltage or light.
[0032] Aptly, the properties tested relate to at least one of
resistivity of the heating system of the element, spatial location
of the element or physical condition of the heating system of the
element.
[0033] Aptly, the determined state, for example the resistivity, is
at least one of integrity of the heating system, conformity of the
heating system to a predetermination condition, or functionality of
the heating system.
[0034] Aptly, the receptacle is a plate with a plurality of
cavities, each cavity configured to receive an element. More aptly,
the number of cavities is greater than the number of sensor units
in the sensor means.
[0035] Aptly, the receptacle is rotatable around an axis.
[0036] Aptly, the processor determines the state, for example the
resistivity, of the heating system by comparing the obtained
signals to a given set of data.
[0037] Aptly, the heating system of each element comprises a mesh
foil. [0038] Another aspect of the invention provides a method of
determining a resistivity of a heating systems for use in an
aerosol generating article, the method comprising: [0039] providing
a system comprising: [0040] a receptacle for receiving a plurality
of elements; and [0041] a testing assembly, the testing assembly
comprising: [0042] a plurality of sensor units, each sensor unit
comprising at least a pair of electrical contacts configured to
pass an electric current therethrough and being configured to
obtain signals related to properties of the heating system of one
of the plurality of elements; and [0043] a processor; [0044]
populating the receptacle with a plurality of elements, each
element comprising a heating system to be tested; [0045] actuating
the plurality of sensor units to obtain signals related to
properties of the heating system of each of the plurality of
elements; and [0046] determining, with the processor, a resistivity
of the heating system of each of the plurality of elements from the
obtained signals.
[0047] Another aspect of the invention provides a method of
determining a state of a heating systems for use in an aerosol
generating article, the method comprising: [0048] providing a
system comprising: [0049] a receptacle for receiving a plurality of
elements; and [0050] a testing assembly, the testing assembly
comprising: [0051] sensor means; and [0052] a processor; [0053]
populating the receptacle with a plurality of elements, each
element comprising a heating system to be tested; [0054] actuating
the sensor means to obtain signals related to properties of the
heating system of each of the plurality of elements; and [0055]
determining, with the processor, a state of the heating system of
each of the plurality of elements from the obtained signals.
[0056] Aptly, the method further comprises the step of bringing the
testing assembly into a testing configuration.
[0057] Aptly, the method further comprises the step of removing the
plurality of elements from the receptacle and repopulating the
receptacle with a further plurality of elements.
[0058] Aptly, the system of the second aspect of the invention is
the system of the first aspect of the invention.
[0059] Certain embodiments of the invention provide the advantage
that a system for determining a state, for example a resistivity,
of a heating system for use in an aerosol generating article is
provided that is capable of testing a plurality of elements, each
including a heating system.
[0060] Certain embodiments of the invention provide the advantage
that the system is capable of testing the heating systems in
real-time, to reduce the impact on assembly lines producing and
utilising the heating systems.
[0061] Certain embodiments of the invention provide the advantage
that the system is capable of testing a plurality of elements, each
including a heating system, simultaneously.
[0062] Certain embodiments of the invention provide the advantage
that the system is suitable for use with mesh-heater systems.
[0063] As used herein, the term `aerosol generating article refers
to an article comprising an aerosol-generating substrate that is
capable of releasing volatile compounds that can form an aerosol,
for example by heating, combustion or chemical reaction.
[0064] As used herein, the term `aerosol-generating substrate` is
used to describe a substrate capable of releasing volatile
compounds, which can form an aerosol. The aerosols generated from
the aerosol-generating substrates of aerosol generating articles
may be visible or invisible and may include vapours (for example,
fine particles of substances, which are in gaseous state, that are
ordinarily liquid or solid at room temperature) as well as gases
and liquid droplets of condensed vapours.
[0065] As used herein, the term `element` refers to a component
including a heating system to be tested (i.e. a state, for example
a resistivity, of which is to be determined). In examples, the
element is a component of an aerosol generating devices of the
`heat not burn` variety, the component incorporating the heating
system of the aerosol generating device.
[0066] As used herein, the term `heating system` refers to a system
incorporated within an element capable of providing heat. In
examples, the heating system is suitable for heating an
aerosol-generating substrate within an aerosol generating device.
In examples, the heating system includes a mesh foil for providing
heat upon flow of a current therethrough.
[0067] As used herein, the term `receptacle` refers to a component
configured to receive a plurality of elements. In examples, the
receptacle is a plate with a plurality of cavities for receiving
the plurality of elements.
[0068] As used herein, the term `testing assembly` refers to an
assembly configured to perform a testing operation to a plurality
of elements. For the testing operation, the testing assembly
utilises sensor means, for example sensor units, to obtain signals
and a processor to process the received signals.
[0069] As used herein, the term `sensor means` refers to a means,
including sensors, capable of obtaining signals related to
properties of a heating system. The sensor means may include one or
more sensors or sensor units or plurality of sensor units (for
example an electrical or optical sensor), capable of obtaining
signals related to one or more properties of a heating system. In
described examples the sensor means includes a plurality of sensor
units. As used herein, the term `sensor unit` refers to a unit
component (for example a unit that is removable from the testing
assembly), including sensors, capable of obtaining signals related
to properties of a heating system.
[0070] As used herein, the term `electrical contacts` refers to
electrical conductors configured to pass an electric current
therethrough for the purpose of obtaining electrical signals, to
measure, for example resistivity or capacitance.
[0071] As used herein, the term `optical sensor` refers to a sensor
configured to obtain light signals, for example optical images,
light intensity data, temperature spectra etc.
[0072] For the avoidance of doubt, any of the features described
herein apply equally to any aspect of the invention. Within the
scope of this application it is expressly envisaged that the
various aspects, embodiments, examples and alternatives set out in
the preceding paragraphs, in the claims or in the following
description and drawings, and in particular the individual features
thereof, may be taken independently or in any combination. Features
described in connection with one aspect or embodiment of the
invention are applicable to all aspects or embodiments, unless such
features are incompatible.
EXAMPLES
[0073] Ex1. A system for determining a state of a heating system
for use in an aerosol generating article, the system comprising:
[0074] a receptacle for receiving a plurality of elements, each
element comprising a heating system to be tested; and [0075] a
testing assembly, the testing assembly comprising: [0076] sensor
means configured to obtain signals related to properties of the
heating system of each of the plurality of elements; and [0077] a
processor configured to receive the signals obtained by the sensor
means and determine a state of the heating system of each of the
plurality of elements.
[0078] Ex2. A system according to example Ex1, wherein the signals
related to properties of the heating system of each of the
plurality of elements are obtained substantially simultaneously by
the sensor means.
[0079] Ex3. A system according to any example Ex1 or Ex2, wherein
the testing assembly is configured to obtain the signals when the
testing assembly is in a testing configuration.
[0080] Ex4. A system according to example Ex3, wherein the sensor
means comprises a plurality of sensor units, each sensor unit being
configured to obtain signals related to properties of the heating
system of one of the plurality of elements.
[0081] Ex5. A system according to example Ex4, wherein at least one
of the plurality of sensor units comprises at least a pair of
electrical contacts, wherein in the testing configuration the pair
of electrical contacts are both in contact with a portion of the
heating system of the corresponding element.
[0082] Ex6. A system according to example Ex5, wherein the sensor
unit is biasedly held in the testing assembly.
[0083] Ex7. A system according to any of examples Ex4 to Ex6,
wherein at least one of the plurality of sensor units comprises at
least an optical sensor.
[0084] Ex8. A system according to any of examples of Ex1 to Ex7,
wherein the signals obtained relate to at least one of current,
voltage or light.
[0085] Ex9. A system according to any of example Ex1 to Ex8,
wherein the properties tested relate to at least one of resistivity
of the heating system of the element, spatial location of the
element or physical condition of the heating system of the
element.
[0086] Ex10. A system according to any of examples Ex1 to Ex9,
wherein the determined state is at least one of integrity of the
heating system, conformity of the heating system to a
predetermination condition, or functionality of the heating
system.
[0087] Ex11. A system according to any of examples Ex1 to Ex10,
wherein the receptacle is a plate with a plurality of cavities,
each cavity configured to receive an element.
[0088] Ex12. A system according to any of examples Ex1 to Ex11,
wherein the heating system of each element comprises a mesh foil.
[0089] Ex13. A method of determining a state of a heating systems
for use in an aerosol generating article, the method comprising:
[0090] providing a system comprising: [0091] a receptacle for
receiving a plurality of elements; and [0092] a testing assembly,
the testing assembly comprising: [0093] sensor means; and [0094] a
processor; [0095] populating the receptacle with a plurality of
elements, each element comprising a heating system to be tested;
[0096] actuating the sensor means to obtain signals related to
properties of the heating system of each of the plurality of
elements; and [0097] determining, with the processor, a state of
the heating system of each of the plurality of elements from the
obtained signals.
[0098] Ex14. A method according to example Ex13, wherein the method
further comprises the step of bringing the testing assembly into a
testing configuration.
[0099] Ex15. A method according to example Ex13 or Ex14, wherein
the method further comprises the step of removing the plurality of
elements from the receptacle and repopulating the receptacle with a
further plurality of elements.
[0100] Embodiments of the invention will now be described by way of
example only with reference to the accompanying drawings in
which:
[0101] FIG. 1 illustrates a cartridge for use in an aerosol
generating device;
[0102] FIG. 2 illustrates another cartridge for use in an aerosol
generating device;
[0103] FIG. 3 illustrates a profile view of an example system for
determining a state of a heating system;
[0104] FIG. 4 illustrates a sensor unit for use in a system for
determining a state of a heating system; and
[0105] FIG. 5 illustrates a cutaway view of the system of FIG.
3.
[0106] Referring now to FIG. 3, a system 100 for determining a
state, for example a resistivity of a heating system is
illustrated. The system 100 includes a receptacle 102 for receiving
a plurality of elements (not shown), each element including a
heating system to be tested.
[0107] In this example, the element is a component of an aerosol
generating article or device of the `heat not burn` variety, the
component incorporating the heating system of the aerosol
generating article or device. Specifically, the element corresponds
to a cartridge for an aerosol generating device, the cartridge
being configured to be connected to the main body of an aerosol
generating device. In the described example, the heating system of
each element includes a mesh-heater unit. That is, the heating
system includes a mesh foil configured to provide a heat output in
response to a current flow therethrough. For example, the element
may be a cartridge as described in WO 2015/117702 or as otherwise
described above.
[0108] In this example, the receptacle 102 is a plate with a
plurality of cavities 104, each cavity configured to receive an
element. In the example illustrated in FIG. 3, the plate is
circular in shape, with the cavities arranged around the
circumference of the plate.
[0109] A proximal end of the cartridge (i.e. the end of the
cartridge proximal to the heating system, for example a mouthpiece
end of the cartridge) is received by the receptacle. The heating
system is exposed upwardly.
[0110] The system 100 further includes a testing assembly 106. The
testing assembly 106 includes sensor means, for example sensor
units, configured to obtain signals related to properties of the
heating system of each of the plurality of elements. The testing
assembly 106 further includes a processor configured to receive the
signals obtained by the sensor means, for example sensor units, and
determine a state, for example a resistivity, of the heating system
of each of the plurality of elements.
[0111] As a first step of a method for determining a state, for
example a resistivity, of a heating system using a system 100 in
its most general form, the receptacle 102 is populated with a
plurality of elements, each element comprising a heating system to
be tested. In embodiments, the receptacle 102 is populated by a
linear feed of elements to the receptacle. That is, the receptacle
102 is configured to be rotated, with respect to a feed point. In
this example the receptacle 102 is mounted to the shaft 120 via
mounting 150. As the receptacle is rotated, elements are introduced
into each cavity in turn. In embodiments, the elements may be
carried in pucks.
[0112] Secondly, the sensor means, for example sensor units, is
actuated to obtain signals related to properties of the heating
system of each of the plurality of elements. In embodiments, the
signals obtained relate to at least one of current, voltage or
light. In such cases, the properties tested relate to at least one
of resistivity of the heating system of the element, spatial
location of the element or physical condition of the heating system
of the element.
[0113] For example, a signal relating to a current or voltage
within the heating system may be used as an indication/measurement
of resistivity of the heating system of the element. Such a signal
may result from the application of a potential difference across
two points of the heating system.
[0114] Similarly, a signal relating to light may be used as an
indication/measurement of the spatial location of the element (or
the heating system within the element) or the physical condition of
the heating system of the element. For example, the light signal
may be used to form an image of the heating system or element, from
which the position, orientation or physical condition of the
heating system or element may be determined. In embodiments, the
measured/monitored light may be at the infra-red frequency, such
that the temperature of the heating system may be monitored (for
example, the temperature response may be measured in response to an
applied voltage), or UV frequency. Alternatively (or in addition),
the light signal may be a magnitude of light passing between two
points. As an example, a correctly positioned heating system may
prevent passage of light passing between the two points.
[0115] Thirdly, the processor determines a state, for example a
resistivity, of the heating system of each of the plurality of
elements from the obtained signals. In embodiments, the determined
state, for example the resistivity, is at least one of integrity of
the heating system of an element, conformity of the heating system
of an element to a predetermined condition, or functionality of the
heating system of an element. In other words, the determined state
may relate to the fitness of the heating system for purpose. For
example, the obtained signals may indicate that one or more
properties of the heating system of an element are symptomatic of
an abnormality or quality problem with the manufacture of the
heating system (for example, a loss of integrity, failure to
conform to resistivity performance etc).
[0116] In embodiments, the determined state may relate to the
ability of the testing assembly to test the required properties of
the heating system of an element. For example, the predetermined
condition to which the heating system must conform may be its
location within the receptacle. This may be important as if the
heating system of an element (or the element itself) is not
correctly located within receptacle, the required tests (for
example electrical tests) cannot be undertaken.
[0117] The processor may determine the state, for example the
resistivity, of the heating system of an element in any suitable
way. For example, the processor may determine the state, for
example the resistivity, of the heating system by comparing the
obtained signals to a given set of data. That is, if the signal
indicates that a property of a heating system (for example
resistivity) is above a threshold value, the processor may conclude
that the state of the heating system is a first state (for example,
the heating system conforms to a predetermined condition). In the
same manner, if the signal indicates that a property of the heating
system is below the threshold value, the processor may conclude
that the state of the heating system is a second state (for
example, the heating system does not conform to a predetermined
condition). In alternative examples, the processor may conclude
that the state of the heating system is a first state if the signal
indicates that a property is equal to a value (for example a
spatial location) and is a second state if the signal indicates
that the property is not equal to the value. The given set of data
may be provided by a server, connected within a network to the
processor.
[0118] In embodiments, the processor may determine the state, for
example the resistivity, of the heating system from signals
relating to multiple properties. For example, a state (for example
a resistivity or e.g. conformity to a predetermined condition) may
only be assigned once multiple properties of the heating system of
an element are above/below (or equal/not equal to) a predetermined
threshold.
[0119] In embodiments, the processor may manipulate the obtained
signals prior to the comparison to a given set of data. That is,
the obtained signals in their raw state may not directly correspond
to a property of the heating system of an element. In such cases,
the processor may use the obtained signals to calculate a further
metric or value, which corresponds to the desired property.
[0120] The state, for example the resistivity, of the heating
system of an element as determined by the processor may be used to
decide how the element (or the heating system thereof) is further
processed within a production line. That is, the arrangement allows
for real-time data processing and feedback within the production
line.
[0121] For example, it may be required that an element with a
heating system having a state, for example resistivity, that
indicates that the heating system is not fit for purpose (for
example the heating system has a lack of integrity, does not
conform to a pre-determined condition or does not function as
intended) should be removed from the production line. In such
examples, the processor may be configured to actuate a means for
removal of the deficient element/elements from the production line
(either directly from the receptacle or further down the production
line).
[0122] In further examples, the processor may store the state, for
example the resistivity, (or an assigned value related thereto, for
example a 1 or a 0) in a memory to allow the state, for example the
resistivity, of the element to be used in a decision-making process
further down the production line, for example removal of a
deficient element from the production line. The state, for example
the resistivity, may be stored on a server. For example, the
processor may send the state, for example resistivity, to a server,
connected within a network to the processor. In further examples,
the decision-making process may be undertaken on the server.
[0123] In a further example, the determined state, for example
resistivity, may be that the heating system is in an incorrect
position and hence other properties of the heating system cannot be
suitably tested. In such examples, the element may be rejected, or
its position within the receptacle may be corrected by a suitable
actuation means.
[0124] Once the testing operations have been completed, the
plurality of elements may then be removed from the receptacle. The
receptacle may then be repopulated with a further plurality of
elements, for which testing is required.
[0125] In this example, the testing assembly 106 is configured to
obtain the signals when the testing assembly is in a testing
configuration. That is, the testing assembly has a testing, or
active, configuration and a non-testing, or non-active,
configuration. In other words, a further step of the method may
include the step of bringing the testing assembly 106 into a
testing configuration prior to actuating the sensor means, for
example sensor units.
[0126] The testing assembly 106 is moveable relative to the
receptacle 102 to bring the sensor means, for example sensor units,
into the testing configuration. The testing configuration is a
configuration for which the sensor means, for example sensor units,
is close enough to the plurality of elements for the required
signals to be obtained. In specific embodiments, the testing
configuration may require the sensor means, for example sensor
units, to be in contact with the heating system or the element
(i.e. where contact is required for a signal to be obtained, for
example where the sensors are a pair of electrical contacts). In
alternative examples, the testing configuration may only require
that the sensor means, for example sensor units is close enough to
collect the desired signal or information to take an image or
reading of a surrounding field, in which case no contact between
the sensor means, for example sensor units, and the elements is
required.
[0127] In specific embodiments, the testing assembly 106 is
vertically moveable with respect to the receptacle 102 to bring the
testing assembly 106 into the testing configuration. In this
example, the testing assembly 106 and the receptacle 102 are
mounted on shaft 120. The testing assembly 106 is mounted on shaft
120 via a mounting assembly 122. The testing assembly 106 is
slidably mounted on the mounting assembly 122. Prior to a testing
operation, the testing assembly 106 is actuated to slide on the
mounting assembly 122 towards the receptacle 102 to bring the
testing assembly 106 into the testing configuration.
[0128] In addition, or alternatively in specific embodiments, the
testing assembly 106 may be rotatably mounted on shaft 120 to allow
relative rotation between the testing assembly 106 and the
receptacle 102 to bring the testing assembly 106 into the testing
configuration.
[0129] Once in the testing configuration, the testing assembly 106
can perform a testing operation on the heating systems received
within the receptacle 102. That is, the sensor means, for example
sensor units, can obtain signals related to the required properties
from the elements/heating systems of the elements within the
receptacle 102. In embodiments, the signals related to properties
of the heating system of each of the plurality of elements are
obtained substantially simultaneously by the sensor means, for
example sensor units.
[0130] Following the testing operation, the testing assembly 106
may then be moved out of the testing configuration, back to a
non-testing configuration. The elements may then be removed from
the receptacle and then optionally repopulated for further testing
operations.
[0131] The non-testing configuration may be defined as a relative
configuration between the testing assembly 106 and the receptacle
102 that allows the receptacle 102 to be populated, or
de-populated, with elements as required.
[0132] In the example illustrated in the Figures, the receptacle
102 is configured to receive more elements than the testing
assembly 106 can test in a given moment. That is, the number of
cavities 104 in the receptacle 102 is greater than the number of
sensor units 108 (as described below) in the sensor means for
example sensor units. In this manner, the receptacle may be fully
populated at a given moment, with more than one plurality of
elements. In other words the receptacle may be populated with one
or more testing batches of elements. The testing assembly 106 may
descend into its testing configuration, to perform a testing
operation on a first plurality of elements. The testing assembly
106 and/or the receptacle 102 may then rotate to allow the testing
assembly 106 to perform a testing operation on a second plurality
of elements. In further examples, the number of sensor units 108
within the testing assembly 106 may correspond to the elements
received within the receptacle 102. In such cases, the receptacle
contains a single plurality of elements that can be tested
simultaneously by the testing assembly.
[0133] In this example, the sensor means, for example sensor units,
includes a plurality of sensor units 108, each sensor unit 108
being configured to obtain signals related to properties of the
heating system of at least one of the plurality of elements.
[0134] FIG. 4 illustrates an example of a sensor unit 108. In this
example, the sensor unit 108 includes a housing 116. The housing
116 is configured to house at least some of the sensing components
for the sensor unit 108. In this example, the sensor unit 108
includes a shoulder portion 118.
[0135] The testing assembly 106 is configured to receive the sensor
units 108 therein. FIG. 5 illustrates a cut-away view of the
testing assembly 106 with a plurality of sensor units 108 received
therein.
[0136] In this example, the testing assembly 106 includes a plate
portion 128, covered by an optional cover portion 130. The cover
portion 130, when used, may provide protection to the hardware (for
example wiring) within the testing assembly 106. The plate portion
128 includes holes or channels arranged therethrough, each hole
configured to receive a sensor unit 108. Each hole within the plate
portion 128 includes a flange portion (not shown), which engages
with the shoulder portion 118 of the corresponding sensor unit 108,
to allow the sensor unit 108 to sit within the hole. This may
prevent the sensor unit from rotating within the corresponding hole
of the plate portion 128.
[0137] In this example, the position of holes in the plate portion
128, and hence the subsequent position of each sensor unit 108,
corresponds to the position of the elements (i.e. heating systems
to be tested) located within the receptacle 102. That is, the
sensor units 108 are positioned such that when the testing assembly
106 is brought into its testing configuration, the sensor units 108
are able to obtain signals from the corresponding element as
required.
[0138] The hardware of the sensor units 108 are coupled to the
processor by any suitable connection to allow transfer of the
obtained signals to the processor.
[0139] In the example shown in FIG. 4, the plurality of sensor
units each include at least a pair of electrical contacts 110. The
sensor unit 108 is configured such that when in the testing
configuration, the pair of electrical contacts 110 are both in
contact with a portion of the heating system of the corresponding
element. For example, for a mesh heating system, in the testing
configuration, the electrical contacts 110 may be in contact with
portions of the mesh.
[0140] In this example the electrical contacts 110 are supported by
a support structure 114 that extends from the housing 116 to
prevent damage to the contacts 110. In embodiments, the end of the
support structure 114, from which the contacts 110 extend, allows a
degree of movement of the contacts 110 (for example lateral
movement) without damage thereto.
[0141] In embodiments, the electrical contacts 110 (which in this
example are electrical pins) can obtain electrical signals from the
heating system. That is, a potential difference may be applied
between the electrical contacts 110 and the resulting current that
passes from a first of the contacts to the second of the contacts
through the heating system may be measured. In this manner
electrical properties, e.g. resistivity, of the heating system may
be determined as described previously. The electrical contacts are
coupled via connection points 132 (as shown in FIG. 5) to a wiring
system (not shown), which allows transfer of the electrical signals
to the processor.
[0142] From the electrical property, the processor can determine a
state, for example a resistivity, of the heating system, for
example, if the heating system can function as required, if the
heating system conforms to a pre-determined condition, or if the
integrity of the heating system has not been compromised. Sensor
units including electrical contacts are particularly useful for
testing mesh-heater systems, which require a given resistivity to
operate effectively.
[0143] In embodiments, the contact areas 112 of the contacts 110
may be configured with different shapes depending on the
surfaces/materials of the heating systems being tested, or the
specific properties being tested.
[0144] In other examples, each sensor unit 108 may include an
optical sensor. The optical sensor may include an imaging device,
for example a camera. The imaging device may be configured to
obtain signals related to any required frequency, for example
visual frequencies, UV or infra-red frequencies.
[0145] The optical sensor may be used to test for properties, such
as spatial location of the element or physical condition of the
heating system of the element. For example, the optical sensor may
be used to determine if the element is in a required location for
further testing. In another example, the optical sensor may be used
to check the position of the testing arrangement with respect to
the element (for example to indicate if the element is too close to
the testing arrangement). In another example, the optical sensor
may be used to check if contact was made between a part of the
testing arrangement (for example the electrical contacts of the
sensor units) and the heating system, which may be used as an
indication of a successful test operation. In such an example, the
optical sensor may be used to check if there are any marks
resulting from said contact.
[0146] The sensor units 108 may optionally include at least one
lighting element, for illuminating the corresponding heating system
to be tested. The lighting element may emit light at any required
frequency, for example UV or light of a visible wavelength to
illuminate the heating system. The signals obtained by the
corresponding optical sensor may correspond to light reflected form
the heating system.
[0147] In specific embodiments, each sensor unit 108 may be
configured to obtain signals related to one or more properties (for
example each sensor unit 108 may include a pair of electrical
contacts and/or an optical sensor and/or further sensor means, for
example sensor units, as required.
[0148] In further embodiments, the plurality of sensor units 108
may each be the same, or alternatively may be varied in their
configuration (for example the plurality of sensor units may
include at least one sensor unit configured to obtain signals
related to a first property and at least one sensor unit configured
to obtain signals related to a second property). In the alternative
example, the sensors may be arranged in any suitable way. For
example, the plurality of sensor units 108 may include two or more
different `types` of sensor unit (i.e. two or more different groups
of sensor units, each group configured to measure a different
property or set of properties). An example of this may be a group
of sensor units, each including electrical contacts, and a further
group of sensor units including an optical sensor. The groups of
sensor units may be arranged side-by-side within the testing
assembly, or the sensor units may alternate between sensor units of
each group. In each case, the testing assembly and/or the
receptacle may be rotated between testing operations to allow for
each element to be tested by a sensor unit of each group.
[0149] In specific embodiments (for example that shown in the
illustrated example), the sensor units are removable from the
testing assembly 106. That is, if required the sensor units can be
removed from the channels of the testing 106. Such removal allows
different testing operations (i.e. obtaining different signals) to
be performed, if required. For example, this may be necessary if
there is a requirement to test a batch of different elements.
[0150] Various modifications to the detailed arrangements as
described above are possible. For example, in alternative examples,
the heating system of each element may include a coil and wick
heating system.
[0151] It would be understood that the sensor means, for example
sensor units, described in the examples above is not exhaustive.
For example, the sensor means, for example sensor units, may
include temperature sensors (for example to monitor the temperature
response to an applied voltage), molecular or gas sensor means.
[0152] A single sensor unit 108 may be configured to obtain signals
from one or more of the heating systems of elements. Specifically,
a single sensor unit 108 may be located in a way that it can obtain
signals from more than one (for example two adjacent heating
systems). In such cases, the single sensor unit 108 may include
separate sets of sensors to obtain signals from the one or more
heating systems simultaneously.
[0153] The sensor units 108 may be fixed within the testing
assembly 106 prior to a testing operation. In alternative examples,
the sensor units remain free within the testing assembly 106. That
is, the sensor units 108 are held within the channels in the
testing assembly 106 under their own weight only. In this manner,
if, when brought into the testing configuration, the elements (or
heating systems thereof) are located in an incorrect position
within the receptacle 102, the testing assembly 106 may still
arrive into the testing configuration without damaging the testing
assembly 106 or the element to be tested. That is, the sensor units
108 can be displaced from (or within) their respective channels to
accommodate the incorrectly positioned element. In specific
embodiments, the shoulder portion 118 of the sensor unit 108 may
prevent rotation of the sensor unit 108 but still allow
displacement or movement from the testing assembly, for example
vertical movement. This is to prevent damage.
[0154] In embodiments, the sensor units 108 may be biasedly held
within the testing assembly 106. For example, the sensor units 108
may be spring actuated, such that the testing configuration is
achieved through movement of the sensor units 108 against the bias
of a spring, as opposed to movement of the testing assembly 106 as
a whole. In this manner, swift `reloading` of the sensor units may
be achieved (i.e. a return to a non-testing configuration) once a
testing operation is complete. This is of particular relevance for
sensor units that require contact with the heating system to obtain
a signal (for example sensor units including electrical contacts).
In the relevant embodiments, the electrical contacts 110 may be
moveable or biased in the same way.
[0155] It will also be appreciated by those skilled in the art that
any number of combinations of the aforementioned features and/or
those shown in the appended drawings provide clear advantages over
the prior art and are therefore within the scope of the invention
described herein.
[0156] The schematic drawings are not necessarily to scale and are
presented for purposes of illustration and not limitation. The
drawings depict one or more aspects described in this disclosure.
However, it will be understood that other aspects not depicted in
the drawings fall within the scope of this disclosure.
* * * * *