Aerosol-generating article material end detection by detecting differences between reel core and wound material

Abstract

A system (1) for supplying a continuous material (3) for an aerosol-generating article comprises a reel holder (5) and a reel depletion sensor (37). The reel holder (5) is configured to receive a supply reel (7) comprising a reel core (9) and a continuous material (3) wound around the reel core (9), such that the supply reel (7) is rotatable about an axis of rotation (13) for unwinding the continuous material (3). The reel depletion sensor (37) is configured to monitor a monitoring area (39) through which a circumferential surface of the supply reel (7) passes when the supply reel (7) is rotated about the axis of rotation (13). The reel depletion sensor (37) is configured to determine whether a portion of the circumferential surface of the supply reel (7) located in the monitoring area (39) is formed from the continuous material (3) or from the reel core (9).

Description

Technical Field

[0001] The present disclosure relates to supplying continuous material, particularly for aerosol-generating articles, by unwinding the continuous material from a roll core. Background Art

[0002] WO2022058079A1 discloses measuring the reduced diameter of a roll during its unwinding by means of one or more sensors. The sensors can be connected to a system capable of triggering a roll replacement or splicing when the roll diameter falls below a predetermined threshold (indicating that the roll has reached a predetermined exhaustion state).

[0003] EP3630661B1 discloses a method for unwinding a roll of rolled homogenized tobacco sheets. The method involves sensing the diameter of the roll to detect when the roll needs to be replaced. Furthermore, a roller having a rotation axis substantially parallel to the axis of rotation of the roll is in contact with the roll. As the sheet is unwound from the roll, the roller maintains contact with the outer surface of the roll.

[0004] CN110642057B discloses a material roll in which color mark positioning points are arranged at intervals on the surface layer, wherein when a radial color mark sensor detects the color mark positioning points, an automatic splicing mechanism splices a new roll to a running roll and cuts off the remaining pattern material of the running roll. Summary of the Invention

[0005] According to one aspect of the present invention, a system for supplying a continuous material for an aerosol-generating article is provided. The system includes a spool holder and a spool-end sensor. The spool holder is configured to receive a supply spool. The supply spool includes a spool core and a continuous material wound around the spool core. The spool holder is configured to receive the supply spool so that the supply spool can be rotated about a rotation axis for unwinding the continuous material. The spool-end sensor is configured to monitor a monitoring area traversed by a circumferential surface of the supply spool as the supply spool rotates about the rotation axis. The spool-end sensor is configured to determine whether a portion of the circumferential surface of the supply spool located in the monitoring area is formed by the continuous material or the spool core.

[0006] When at least one full turn of continuous material remains on the spool core, the portion of the circumferential surface of the supply spool that is located in the monitoring area is likely to be formed by the continuous material regardless of the rotation angle of the supply spool about the rotation axis. If less than one full turn of continuous material remains on the spool core, then at least at some rotation angles of the supply spool about the rotation axis, the portion of the circumferential surface of the supply spool that is located in the monitoring area is likely to be formed by the spool core.

[0007] As long as the roll end sensor determines during unwinding that the portion of the circumferential surface of the supply roll located in the monitoring area continues to be formed by continuous material, this can be considered an indication that material (in particular, at least one full turn of continuous material) remains on the roll core. If the roll end sensor determines during unwinding that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core, this can be considered an indication that less than one full turn of continuous material remains on the roll core.

[0008] The spool end sensor may be configured to determine that less than one complete turn of continuous material remains on the spool core during unwinding of the continuous material.

[0009] The spool end sensor can be configured to detect when the portion of the circumferential surface of the supply spool located in the monitoring area is no longer formed by continuous material and begins to be formed by the spool core. This can be regarded as an indication that less than a full turn of continuous material remains on the spool core.

[0010] When the portion of the circumferential surface of the supply spool located in the monitoring area ceases to be formed by the continuous material during unwinding of the continuous material and begins to be formed by the spool core, the length of the continuous material remaining on the spool core may correspond to the distance on the circumferential surface of the supply spool between the monitoring area and the point at which the continuous material left the supply spool during unwinding. When the portion of the circumferential surface of the supply spool located in the monitoring area ceases to be formed by the continuous material during unwinding and begins to be formed by the spool core, the length of the continuous material remaining on the spool core may be less than one complete turn of the continuous material on the spool core.

[0011] The spool-out sensor may be configured to determine the depletion of the supply spool with a high degree of accuracy.

[0012] The spool end sensor can be configured to determine when the length of continuous material remaining on the supply spool drops below a predetermined threshold length. The predetermined threshold length can be a length of continuous material corresponding to less than one full turn of continuous material on the spool core.

[0013] The circumferential surface of the supply spool may extend parallel to the axis of rotation.The circumferential surface of the supply spool may extend around the axis of rotation.

[0014] The system may further include a drive. The drive may be configured to unwind the continuous material from the supply spool by rotating the supply spool about the rotation axis. The drive may be part of the spool holder. The drive may be configured to engage the spool core to drive the spool core to rotate about the rotation axis.

[0015] The system may include a controller. The controller may be configured to control the drive. The controller may be configured to control the unwinding speed.

[0016] The spool end sensor may be configured to perform optical measurements of a portion of the circumferential surface of the supply spool located in the monitoring area. The spool end sensor may be configured to determine, based on the optical measurements, whether the portion of the circumferential surface of the supply spool located in the monitoring area is formed by continuous material or a spool core.

[0017] The optical measurement may be a color measurement. The roll-end sensor may be configured to determine the color of a portion of the circumferential surface of the supply roll located within the monitoring area. The roll-end sensor or the controller may be configured to determine whether the determined color corresponds to a color range of the continuous material or a color range of the roll core. One or both of the color range of the continuous material and the color range of the roll core may be preset. One or both of the color range of the continuous material and the color range of the roll core may be preset based on a single supply roll.

[0018] The color of the continuous material can be different from the color of the roll core. The roll core has a color that is sufficiently different from the color of the continuous material to facilitate the distinction between the continuous material and the roll core. For example, if the continuous material is a reconstituted tobacco material having a brown color, the roll core can have a color different from brown, such as white, for example. In particular, the roll core can comprise a plastic material, in particular a white plastic material. According to another example, the continuous material can be a reconstituted tobacco material having a brown color, and the roll core can be a different type of brown. For example, the roll core can comprise a cardboard material, in particular a brown cardboard material.

[0019] The roll end sensor may include a camera. The roll end sensor may be configured to obtain one or more photographs of the monitoring area during unwinding. The roll end sensor may be configured to obtain a video of the monitoring area during unwinding. The video may be viewed as a series of photographs. The roll end sensor may be configured to analyze the one or more photographs or videos to determine whether the portion of the circumferential surface of the supply roll located in the monitoring area is formed from continuous material or a roll core.

[0020] The roll end sensor may include a spectrophotometer.The spectrophotometer may be configured to take color measurements in the monitored area.

[0021] The system, and in particular, one or both of the controller and the driver, can be configured to slow down or stop unwinding the continuous material in response to the spool end sensor detecting that a portion of the circumferential surface of the supply spool located within the monitoring area is formed by the spool core. Slowing down or stopping the unwinding of the continuous material can prepare to replace the depleted supply spool. Slowing down or stopping the unwinding of the continuous material can prevent the end of the continuous material from being completely withdrawn from the spool core during continued operation. The system, and in particular, one or both of the controller and the driver, can be configured to stop unwinding the continuous material quickly enough so that the end of the continuous material remains on the spool core.

[0022] The system may further include a slicing unit. The splicing unit may be configured to splice the continuous material with the continuous material from the replacement supply spool. The system, and in particular the controller or the spool end sensor, may initiate splicing in response to the spool end sensor detecting that a portion of the circumferential surface of the supply spool located within a monitoring area is formed by the spool core. If splicing is initiated based on information from the spool end sensor, material waste may be reduced because less than a full turn of continuous material remains on the spool core.

[0023] The splicing unit may be provided along the conveying path of the continuous material downstream of the roll holder.

[0024] Any splicing known in the art of connecting (preferably stably connecting) two continuous materials can be used in the present invention. The splicing unit may include a first tool and a second tool. The first tool may be a lower tool. The second tool may be an upper tool. The first tool and the second tool may be configured to interact to splice the continuous material from the supply reel and the continuous material from the replacement supply reel to each other. Splicing may include pressing the continuous material from the supply reel and the continuous material from the replacement supply reel against each other in an overlapping portion. The continuous material from the supply reel and the continuous material from the replacement supply reel may overlap each other and be positioned parallel to each other between the first tool and the second tool. The continuous material from the supply reel and the continuous material from the replacement supply reel may be positioned above each other between the first tool and the second tool.

[0025] The system may be configured to convey continuous material from a supply reel through the splicing unit, in particular through a space between a first tool and a second tool of the splicing unit. The system may be configured to convey continuous material from a supply reel through the splicing unit to a processing location.

[0026] The system may include a positioning mechanism. The positioning mechanism may be configured to move a leading portion of the continuous material from the replacement supply spool into or through the splicing unit, particularly into or through a space between a first tool and a second tool of the splicing unit. The positioning mechanism may include, for example, a robotic arm.

[0027] Splicing may include wetting one or both of the continuous material of the supply roll and the continuous material of the replacement supply roll. Wetting may increase the tendency of the materials to stick together. In particular, splicing may include wetting the continuous material in the form of reconstituted tobacco material.

[0028] In some embodiments, particularly when the continuous material may include or consist of a metal material, the splicing unit may include a welding station. The welding station may include at least one welding electrode and a welding plate. The at least one welding electrode and the welding plate may be arranged at opposite upper and lower sides of the continuous material in orthogonal directions.

[0029] After splicing, the system may continue to provide a continuous flow of material, but now from a replacement supply spool.

[0030] The system may further include an opposing structure. The opposing structure may be configured to press the continuous material toward the reel core. The opposing structure may be configured to press the continuous material toward the reel core in a radial direction.

[0031] The opposing structure may be configured to press the continuous material toward the roll core after the roll end sensor has detected that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core. Pressing the continuous material toward the roll core by the opposing structure maintains tension in the continuous material. Pressing the continuous material toward the roll core by the opposing structure prevents the remaining end portion of the continuous material from detaching from the roll core. The opposing structure may be configured to press the continuous material toward the roll core during splicing. The opposing structure may be configured to press the continuous material toward the roll core to facilitate splicing.

[0032] According to an embodiment, the opposing structure may be configured to contact the supply spool only after the exhaustion sensor has determined that the portion of the circumferential surface of the supply spool located in the monitoring area is formed by the spool core or after determining that the supply spool is exhausted or nearly exhausted.

[0033] The opposing structure may be configured to press the continuous material toward the roll core during unwinding of the continuous material. The opposing structure may be configured to press the continuous material toward the roll core before the roll end sensor has detected that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core. The opposing structure may be configured to press the continuous material toward the roll core both before and after the roll end sensor has detected that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core.

[0034] The opposing structure may be configured to press the continuous material toward the roll core with a first pressing force before the roll end sensor detects that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core. The opposing structure may be configured to press the continuous material toward the roll core with a second pressing force after the roll end sensor detects that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core. The first pressing force and the second pressing force may have at least substantially the same magnitude. The second pressing force may be greater than the first pressing force. A smaller first pressing force may facilitate unwinding of the continuous material. A larger second pressing force may facilitate splicing by maintaining tension in the continuous material.

[0035] The opposing structure may be configured to clamp the continuous material against the roll core. Clamping the continuous material against the roll core may reduce or prevent relative movement between the continuous material and the roll core. The opposing structure may be configured to clamp the continuous material toward the roll core after the roll end sensor has detected that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core, or in response to the roll end sensor detecting that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core.

[0036] The opposing structure may be configured to contact the continuous material wound around the spool core. The opposing structure may be configured to maintain contact with the continuous material wound around the spool core during unwinding. The opposing structure may be configured to follow a decreasing diameter of the supply spool during unwinding. The opposing structure may be configured to follow the diameter of the supply spool by moving in a radial direction during unwinding.

[0037] The opposing structure may define a position where the continuous material is disengaged from the supply spool. The opposing structure may guide the continuous material from the supply spool during unwinding. The opposing structure may include an opposing roller. The opposing roller may have an axial direction parallel to the rotation axis. The opposing roller may have a circumferential surface parallel to the rotation axis. The opposing roller may have a circumferential surface parallel to the rotation axis. The opposing roller may be configured to engage the continuous material.

[0038] The system may further include a thickness sensor. The thickness sensor may be configured to determine the thickness of the supply spool. The thickness of the supply spool determined by the thickness sensor may indicate the length of the continuous material remaining on the spool core. The thickness of the supply spool may correspond to the diameter of the supply spool. The thickness of the supply spool may be measured in a radial direction perpendicular to the axis of rotation. The thickness sensor may provide an estimate of the length of the continuous material remaining on the spool core, even if the length is greater than one full turn of the continuous material around the spool core.

[0039] The thickness sensor and the roll end sensor can complement each other. The thickness sensor can provide a rough estimate of the length of continuous material remaining on the supply spool at any arbitrary stage of unwinding. The roll end sensor can provide a more accurate estimate of the length of continuous material remaining on the supply spool, but only when less than a full turn of continuous material remains on the supply spool.

[0040] The thickness sensor may be configured to measure a distance between the thickness sensor and a circumferential surface of the supply spool. The distance may be along a radial direction perpendicular to the axis of rotation. As the length of continuous material remaining on the supply spool decreases during unwinding, the distance between the thickness sensor and the circumferential surface of the supply spool may increase due to the decrease in the diameter of the supply spool.

[0041] The thickness sensor may be configured to determine the thickness of the supply spool based on the position of the opposing structure. The opposing structure may follow the decreasing diameter of the supply spool during unwinding. Therefore, the position of the opposing structure may indicate the thickness of the supply spool. The thickness sensor may include a distance sensor that senses the distance between the distance sensor and the opposing structure. The thickness sensor may be configured to determine the position of the opposing structure along a guide structure for the opposing structure. The guide structure may be configured to guide the opposing structure in a radial direction.

[0042] The system, and in particular, one of the controller and the drive, can optionally be configured to slow the unwinding of the continuous material in response to the thickness of the supply spool measured by the thickness sensor falling below a predetermined threshold thickness. Slowing the unwinding of the continuous material when the thickness of the supply spool falls below the predetermined threshold thickness can provide for stopping unwinding when the spool end sensor determines that the portion of the circumferential surface of the supply spool located in the monitoring area is formed by the spool core.

[0043] At a predetermined threshold thickness, a length of continuous material corresponding to at least some full turns of the continuous material around the core may remain on the core. For example, at least three full turns, or at least five full turns, or at least seven full turns, or at least ten full turns, or at least 15 full turns, or at least 20 full turns, or at least 30 full turns, or at least 50 full turns, or at least 70 full turns, or at least 100 full turns of continuous material may remain on the supply spool at the predetermined threshold thickness. Less than 1000 full turns, or less than 600 full turns, or less than 400 full turns, or less than 300 full turns, or less than 200 full turns, or less than 100 full turns, or less than 50 full turns, or less than 30 full turns, or less than ten full turns may remain on the supply spool at the predetermined threshold thickness.

[0044] In response to the thickness of the supply spool measured by the thickness sensor being below a predetermined threshold thickness, slowing the unwinding of the continuous material may include slowing the unwinding of the continuous material from an operational unwinding speed to an intermediate unwinding speed. The intermediate unwinding speed may be greater than zero. The operational unwinding speed may be, for example, between 20 m / min (meters per minute) and 400 m / min, or between 50 m / min and 400 m / min, or between 50 m / min and 300 m / min, or between 80 m / min and 300 m / min, or between 80 m / min and 250 m / min, or between 100 m / min and 250 m / min, or between 120 m / min and 200 m / min. The intermediate unwinding speed may be, for example, between 10 m / min and 200 m / min, or between 10 m / min and 150 m / min, or between 10 m / min and 100 m / min, or between 20 m / min and 80 m / min, or between 40 m / min and 60 m / min. The intermediate unwinding speed may be between 10% and 60% of the operating unwinding speed, or between 20% and 50%, or between 20% and 30%.

[0045] The system may further include a supply spool. The supply spool may be received in the spool holder.

[0046] The continuous material may be provided without a fixed connection to the reel core.

[0047] The system may include a processing station. The processing station may be positioned at the processing location. The processing station may be configured to process the continuous material. The processing station may be positioned downstream of the spool holder. The processing station may be configured to receive the continuous material unwound from the supply spool. The system may be configured to deliver the unwound continuous material to the processing station.

[0048] The processing station may, for example, include a crimping station. The crimping station may be configured to crimp a continuous material, particularly a continuous material in the form of reconstituted tobacco material. The crimping station may include one or more crimping rollers. The one or more crimping rollers may be configured to create wrinkles in the continuous material. The one or more crimping rollers may be configured to create weakened portions in the continuous material. The wrinkles or weakened portions may extend parallel to the direction of transport of the continuous material.

[0049] According to another aspect of the present invention, a method for supplying a continuous material for an aerosol-generating article to a processing location is provided. The method includes unwinding the continuous material from a supply spool. The supply spool includes a spool core and the continuous material wound around the spool core. The method includes delivering the unwound continuous material to the processing location. The method also includes detecting exhaustion of the supply spool by detecting a difference between a surface of the continuous material and a surface of the spool core.

[0050] A supply spool may be received in a spool holder.

[0051] Unwinding the continuous material from the supply spool may comprise rotating the supply spool about a rotation axis, in particular by means of a drive.

[0052] The surface of the reel core may be a circumferential surface of the reel core. The circumferential surface of the reel core may be parallel to the rotation axis.

[0053] Detecting the difference between the surface of the continuous material and the surface of the web core may be performed by a web end-of-life sensor.

[0054] Detecting the exhaustion of the supply spool may include monitoring, in particular by a spool exhaustion sensor, a monitoring area through which a circumferential surface of the supply spool passes as the supply spool rotates about the rotation axis. Detecting the exhaustion of the supply spool may include determining, in particular by the spool exhaustion sensor, whether a portion of the circumferential surface of the supply spool located in the monitoring area is formed by continuous material or by a spool core.

[0055] The supply spool may be considered exhausted if less than one full turn of continuous material remains on the spool core.

[0056] Detecting a difference between the surface of the continuous material and the surface of the winding core may include detecting that the winding core has become visible when less than a full turn of the continuous material remains on the winding core.

[0057] The method may include determining exhaustion of the supply spool when a portion of the circumferential surface of the supply spool formed from continuous material (as long as at least one full turn of continuous material remains on the supply spool) is no longer formed from continuous material but is formed from the spool core.

[0058] Detecting a difference between the surface of the continuous material and the surface of the spool core may include taking one or more pictures or one or more videos of the circumferential surface of the supply spool.

[0059] Detecting a difference between the surface of the continuous material and the surface of the spool core may include detecting a color difference between the surface of the continuous material and the surface of the spool core. The color difference may be determined by analyzing one or more photographs or one or more videos of the circumferential surface of the supply spool. The color difference may be detected based on measurements using a camera or a spectrophotometer.

[0060] Detecting depletion of the supply spool may include detecting a boundary between a portion of the circumferential surface of the spool core that is covered by the continuous material and a portion of the circumferential surface of the spool core that is not covered by the continuous material. The boundary may correspond to an end of the continuous material. The end of the continuous material may be an end of the continuous material relative to a direction of feed of the continuous material. If the entire continuous material is unwound from the spool core, the end of the continuous material may be the last portion of the continuous material to exit the spool core.

[0061] The border may extend generally parallel to the axis of rotation of the mandrel core.

[0062] The method may further include slowing or stopping, in particular slowing or stopping one or both of unwinding the continuous material and conveying the unwound continuous material via one or both of a drive or a controller, in response to detecting exhaustion of the supply spool.

[0063] The method may include starting the splicing of the continuous material with the continuous material from the replacement supply reel in response to detecting that the supply reel is exhausted. The splicing may be performed by a splicing station. The splicing may include attaching the front portion of the continuous material from the replacement supply reel to the continuous material of the supply reel. The continuous materials may be attached to each other by pressing the continuous materials together. The splicing may include wetting one or both of the continuous material from the supply reel and the continuous material from the replacement supply reel. For example, the continuous material in the form of reconstituted tobacco material from one or both of the supply reel and the replacement supply reel may be wetted to increase the tendency of the continuous material from the supply reel and the continuous material from the replacement supply reel to adhere together. The splicing may include heating one or both of the continuous material from the supply reel and the continuous material from the replacement supply reel. For example, heating a continuous material comprising metal (such as a susceptor configured to be included in an aerosol generating article) may facilitate the bonding of the continuous material of the supply reel to the continuous material from the replacement supply reel.

[0064] The method may include pressing or clamping the continuous material against or toward the roll core. The method may include pressing or clamping the continuous material toward the roll core. After exhaustion of the supply roll has been detected, the continuous material may be pressed or clamped against or toward the roll core. The continuous material may be pressed or clamped against or toward the roll core in response to detecting exhaustion of the roll core. Pressing or clamping the continuous material against or toward the roll core may maintain tension in the continuous material downstream of the supply roll, particularly to facilitate splicing.

[0065] Additionally or as an alternative to pressing or clamping the continuous material against or towards the reel core after exhaustion of the supply spool has been detected, the continuous material may be pressed or clamped towards the reel core even before exhaustion of the supply spool has been detected. In particular, the continuous material may be pressed in the direction of the reel core during the entire unwinding period.

[0066] The continuous material may be pressed or clamped against the reel core by the opposing structures.

[0067] The opposing structure may follow the decreasing diameter of the supply spool during unwinding.

[0068] The thickness of the supply spool can be determined based on the position of the opposing structure. The opposing structure can have the dual function of pressing or clamping the continuous material toward the spool core and facilitating the determination of the thickness of the supply spool. The thickness of the supply spool can be determined based on the position of the opposing structure along a guide structure that guides the opposing structure, particularly for movement of the opposing structure in a radial direction.

[0069] The opposing structure may include an opposing roller. The axial direction of the opposing roller may extend parallel to the rotation axis of the supply reel. The opposing roller may define a position at which the continuous material leaves the supply reel during unwinding.

[0070] The method may comprise determining a thickness of the supply spool during unwinding.The thickness of the supply spool may correspond to a diameter of the supply spool.

[0071] The thickness of the supply spool can be determined by a thickness sensor. The thickness sensor can measure the distance between the thickness sensor and the circumferential surface of the supply spool. As the diameter of the supply spool decreases, the distance between the thickness sensor and the circumferential surface of the supply spool can increase during unwinding.

[0072] The thickness of the supply spool may be determined based on the position of an opposing structure that contacts the continuous material wound around the spool core and follows the reduced diameter of the supply spool during unwinding.The opposing structure may be an opposing roller.

[0073] The method may comprise reducing the rotational speed of the supply spool during unwinding in response to determining, in particular in response to determining by a thickness sensor, that the thickness of the supply spool has fallen below a predetermined threshold thickness.

[0074] Reducing the rotational speed of the supply spool during unwinding in response to determining that the thickness of the supply spool has fallen below a predetermined threshold thickness may include reducing the rotational speed of the supply spool from an operational unwinding speed to an intermediate unwinding speed. The intermediate rotational speed may be greater than zero.

[0075] According to another aspect of the present invention, there is provided a use of a color measurement device for determining whether a supply spool is exhausted during unwinding of a continuous material from the supply spool.

[0076] The colour measurement device may be part of, or may form, the web end-of-life sensor.

[0077] The color measurement device may determine whether the portion of the circumferential surface of the supply spool that is located in the monitoring area, through which the circumferential surface of the supply spool passes during unwinding, is formed by continuous material or by the spool core of the supply spool.

[0078] The color measurement device may be configured to detect depletion of the supply spool by detecting a difference between a surface of the continuous material and a surface of a spool core of the supply spool.

[0079] According to another aspect of the present invention, a system for supplying a continuous material for an aerosol-generating article is provided. The system includes a spool holder, an opposing structure, and a thickness sensor. The spool holder is configured to receive a supply spool such that the supply spool is rotatable about a rotation axis. The supply spool includes a spool core and a continuous material wound around the spool core. The opposing structure is configured to contact the continuous material wound around the spool core. The opposing structure is configured to follow the decreasing diameter of the supply spool during unwinding. The thickness sensor is configured to determine the thickness of the supply spool based on the position of the opposing structure.

[0080] The system may include a drive. The drive may be configured to unwind the continuous material from the supply spool by rotating the supply spool about the rotation axis.

[0081] The system may include a controller. The controller may be configured to control the driver.

[0082] The opposing structure may be configured to follow the diameter of the supply spool by moving in a radial direction during unwinding.

[0083] The system may include a guide structure. The guide structure may be configured to guide movement of the opposed structure along a radial direction.

[0084] The thickness sensor may include a distance sensor that senses a distance between the distance sensor and the opposing structure.

[0085] The thickness sensor may be configured to measure or determine the position of the opposing structure based on a movement of the opposing structure along the radial direction guided by the guiding structure.

[0086] The opposing structure may be configured to press the continuous material towards the reel core. The opposing structure may be configured to press the continuous material towards the reel core during unwinding of the continuous material. The opposing structure may be configured to press the continuous material towards the reel core in a radial direction.

[0087] The opposing structure can define the position where the continuous material leaves the supply spool when the continuous material is unwound. The opposing structure can stabilize the continuous material during unwinding. The opposing structure can guide the continuous material off the supply spool during unwinding.

[0088] The opposing structure may be configured to clamp the continuous material against the reel core.

[0089] The opposing structure may include opposing rollers.

[0090] The system, and in particular one or both of the controller and the drive, may be configured to slow unwinding of the continuous material in response to the thickness of the supply spool determined by the thickness sensor being below a predetermined threshold thickness.

[0091] The system may include a spool end-of-life sensor.The spool end-of-life sensor may be configured to monitor a monitoring area traversed by a circumferential surface of the supply spool as the supply spool rotates about the axis of rotation.

[0092] The spool end-of-life sensor may be configured to determine whether the portion of the circumferential surface of the supply spool located in the monitoring area is formed from continuous material or a spool core.

[0093] According to another aspect of the present invention, a method for supplying a continuous material for an aerosol-generating article to a processing location is provided. The method includes unwinding the continuous material from a supply spool. The supply spool includes a spool core and the continuous material wound around the spool core. The method also includes delivering the unwound continuous material to the processing location. The method also includes determining a thickness of the supply spool based on a position of an opposing structure that contacts the continuous material wound around the spool core and follows the decreasing diameter of the supply spool during unwinding.

[0094] The continuous material may be pressed or clamped against the reel core by the opposing structure during unwinding.

[0095] The opposing structure may include opposing rollers.

[0096] The method may include reducing the rotational speed of the supply spool during the unwinding in response to determining that the thickness of the supply spool has fallen below a predetermined threshold thickness.

[0097] The method may further include detecting depletion of the supply spool by detecting a difference between a surface of the continuous material and a surface of the spool core.

[0098] According to another aspect of the invention, there is provided use of an opposing structure for pressing continuous material against a reel core and for determining the thickness of a supply reel comprising a reel core and continuous material wound around the reel core during unwinding of the continuous material from the supply reel.

[0099] According to any of the aspects described herein, the continuous material may include an aerosol-generating material. The aerosol-generating material may be configured to release an aerosol when heated. The aerosol may be an aerosol for consumption by a user. The aerosol-generating material may include tobacco. The aerosol-generating material may include reconstituted tobacco material.

[0100] In any of the aspects described herein, the continuous material can be a web material.For example, the web material can include reconstituted tobacco material.

[0101] In any aspect of the aspects described herein, the continuous material may include reconstituted tobacco material. The reconstituted tobacco material may be a cast of a slurry comprising tobacco material. The reconstituted tobacco material may include a binder. The reconstituted tobacco material may include an aerosol former. The reconstituted tobacco material may include one or more flavorings.

[0102] In any of the aspects described herein, the continuous material may include a metallic material or may consist of a metal.

[0103] In any of the aspects described herein, the continuous material may comprise metal strands.

[0104] In any of the aspects described herein, the continuous material may include a susceptor configured to be included in an aerosol-generating article. The susceptor may include or consist of a metallic material. The susceptor may be configured to be heated by induction heating. The susceptor may be configured to heat the aerosol-generating material surrounding the susceptor, causing the aerosol-generating material to release an aerosol.

[0105] In any of the aspects described herein, the aerosol-generating article may be a substantially rod-shaped or strip-shaped article. The aerosol-generating article may comprise a plurality of segments arranged one after another. The segments may be cylindrical segments arranged one after another along their longitudinal axis. The segments may be combined with one or more wrappers wrapped around the segments. The segments may comprise an aerosol-generating segment. The aerosol-generating segment may comprise an aerosol-generating material configured to release an aerosol when heated. The aerosol-generating material may comprise tobacco. The segments may comprise a filter segment. The aerosol generated by heating the aerosol-generating segment may pass through a filter segment before reaching the user's mouth. The segments may comprise a mouthpiece segment. The mouthpiece segment may be configured to be contacted by the user's mouth. Alternatively, the filter segment may be engaged by the user's mouth.

[0106] The aerosol-generating article may be configured for use with an aerosol-generating device. The aerosol-generating article may be configured to be at least partially inserted into the aerosol-generating device. The aerosol-generating device may be configured to heat the aerosol-generating article to release the aerosol from the aerosol-generating article. The aerosol-generating device may be a handheld electronic device.

[0107] The present disclosure includes various aspects, embodiments, and examples. The features, advantages, and explanations disclosed with reference to any of these aspects, embodiments, and examples may be combined with or transferred to any of the other aspects, embodiments, and examples described herein. Any of the methods or uses described herein may be performed using any of the systems described herein. Any of the systems described herein may be adapted, designed, or configured to perform any of the methods and uses described herein.

[0108] The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0109] Example Ex1: A system for supplying a continuous material for an aerosol-generating article, comprising:

[0110] a spool holder configured to receive a supply spool including a spool core and a continuous material wound around the spool core such that the supply spool is rotatable about a rotational axis for unwinding the continuous material; and

[0111] a spool end-of-life sensor configured to monitor a monitoring area traversed by a circumferential surface of the supply spool as the supply spool rotates about the rotational axis;

[0112] wherein the spool end sensor is configured to determine whether a portion of the circumferential surface of the supply spool located in the monitoring area is formed by the continuous material or the spool core.

[0113] Example Ex2: The system according to Example Ex1, further comprising:

[0114] a drive configured to unwind the continuous material from the supply spool by rotating the supply spool about the rotational axis; and

[0115] A controller is configured to control the driver.

[0116] Example Ex3: The system of example Ex1 or Ex2, wherein the spool end-of-life sensor is configured to perform an optical measurement of a portion of the circumferential surface of the supply spool located in the monitoring area.

[0117] Example Ex4: The system of example Ex3, wherein the optical measurement is a color measurement.

[0118] Example Ex5: The system of any of Examples Ex1 to Ex4, wherein the system is configured to slow or stop unwinding the continuous material in response to the spool end sensor detecting that the portion of the circumferential surface of the supply spool located in the monitoring area is formed by the spool core.

[0119] Example Ex6: A system according to any one of Examples Ex1 to Ex5, further comprising a splicing unit configured to splice the continuous material with a continuous material from a replacement supply roll, wherein the system initiates splicing in response to the roll exhaustion sensor detecting that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core.

[0120] Example Ex7: The system of any one of Examples Ex1 to Ex6, further comprising an opposing structure configured to press the continuous material toward the core.

[0121] Example Ex8: The system of example Ex7, wherein the opposing structure is configured to clamp the continuous material against the winding core.

[0122] Example Ex9: The system of example Ex7 or Ex8, wherein the opposing structure is configured to contact the continuous material wound around the spool core and to follow a decreasing diameter of the supply spool during the unwinding.

[0123] Example Ex10: The system of any of Examples Ex7 to Ex9, wherein the opposing structure is configured to follow a diameter of the supply spool by moving in a radial direction during the unwinding.

[0124] Example Ex11: The system of any one of Examples Ex7 to Ex10, wherein the opposing structures comprise opposing rollers.

[0125] Example Ex12: The system of any of Examples Ex1 to Ex11, further comprising a thickness sensor configured to determine a thickness of the supply roll based, inter alia, on a position of the opposing structure.

[0126] Example Ex13: The system of example Ex12, wherein the thickness sensor is configured to measure a distance between the thickness sensor and a circumferential surface of the supply spool.

[0127] Example Ex14: The system of example Ex12 or Ex13, wherein the system is configured to slow unwinding of the continuous material in response to a thickness of the supply spool measured by the thickness sensor being below a predetermined threshold thickness.

[0128] Example Ex15: The system according to any one of Examples Ex1 to Ex14, further comprising the supply reel.

[0129] Example Ex16: The system of any of Examples Ex1 to Ex15, wherein the supply spool is received in the spool holder.

[0130] Example Ex17: The system of any of Examples Ex1 to E16, wherein the continuous material is provided without a fixed connection to the winding core.

[0131] Example Ex18: A method of supplying a continuous material for an aerosol-generating article to a processing location, the method comprising:

[0132] - unwinding a continuous material from a supply reel, wherein the supply reel comprises a reel core and the continuous material wound around the reel core;

[0133] - conveying the unwound continuous material to a processing location; and

[0134] - Detecting depletion of the supply spool by detecting a difference between the surface of the continuous material and the surface of the spool core.

[0135] Example Ex19: The method of example Ex18, wherein the supply spool is exhausted if less than one full turn of the continuous material remains on the spool core.

[0136] Example Ex20: The method according to example Ex18 or Ex19, wherein the surface of the mandrel is a circumferential surface of the mandrel.

[0137] Example Ex21: The method of any one of Examples Ex18 to Ex20, wherein detecting a difference between a surface of the continuous material and a surface of the winding core comprises detecting a color difference between a surface of the continuous material and a surface of the winding core.

[0138] Example Ex22: A method according to any one of Examples Ex18 to Ex21, wherein detecting depletion of the supply roll includes detecting a boundary between a portion of the circumferential surface of the roll core covered by the continuous material and a portion of the circumferential surface of the roll core not covered by the continuous material.

[0139] Example Ex23: The method of example Ex22, wherein the boundary extends generally parallel to the axis of rotation of the bobbin core.

[0140] Example Ex24: The method of any of Examples Ex18 to Ex23, further comprising slowing or stopping one or both of unwinding the continuous material and conveying the unwound continuous material in response to detecting exhaustion of the supply spool.

[0141] Example Ex25: The method of any of Examples Ex18 to Ex24, further comprising initiating splicing of the continuous material with continuous material from a replacement supply spool in response to detecting exhaustion of the supply spool.

[0142] Example Ex26: The method of any one of Examples Ex18 to Ex25, further comprising pressing or clamping the continuous material against the web core.

[0143] Example Ex27: The method of any one of Examples Ex18 to Ex26, wherein the continuous material is pressed or clamped against the winding core by an opposing structure.

[0144] Example Ex28: The method of example Ex27, wherein the opposing structure follows a decreasing diameter of the supply spool during the unwinding.

[0145] Example Ex29: The method of example Ex27 or Ex28, wherein the thickness of the supply roll is determined based on the position of the opposing structures during the unwinding.

[0146] Example Ex30: The method according to any one of Examples Ex27 to Ex29, wherein the opposing structures comprise opposing rollers.

[0147] Example Ex31: The method of any of Examples Ex18 to Ex30, further comprising determining a thickness of the supply roll during the unwinding.

[0148] Example Ex32: The method of any of Examples Ex18 to Ex31, wherein the thickness of the supply spool is determined by a thickness sensor that measures the distance between the thickness sensor and a circumferential surface of the supply spool.

[0149] Example Ex33: The method of any of Examples Ex18 to Ex32, wherein the thickness of the supply spool is determined based on a position of an opposing structure that contacts the continuous material wound around the spool core and follows the reduced diameter of the supply spool during the unwinding.

[0150] Example Ex34: The method according to Example Ex33, wherein the opposed structure is the opposed structure of any one of Examples Ex27 to 30.

[0151] Example Ex35: The method of any of Examples Ex18 to Ex34, further comprising reducing a rotational speed of the supply spool during the unwinding in response to determining that a thickness of the supply spool has dropped below a predetermined threshold thickness.

[0152] Example Ex36: The method of Example Ex35, wherein reducing the rotational speed of the supply spool during the unwinding in response to determining that the thickness of the supply spool has fallen below a predetermined threshold thickness comprises reducing the rotational speed of the supply spool to a speed greater than zero.

[0153] Example Ex37: Use of a color measurement device for determining whether a supply roll is exhausted during unwinding of a continuous material from the supply roll.

[0154] Example Ex38: A system for supplying a continuous material for an aerosol-generating article, comprising:

[0155] a spool holder configured to receive a supply spool such that the supply spool is rotatable about a rotational axis, the supply spool including a spool core and a continuous material wound around the spool core;

[0156] an opposing structure configured to contact the continuous material wound around the spool core and to follow the decreasing diameter of the supply spool during the unwinding; and

[0157] A thickness sensor is configured to determine a thickness of the supply spool based on the position of the opposing structure.

[0158] Example Ex39: The system according to Example Ex38, further comprising:

[0159] a drive configured to unwind the continuous material from the supply spool by rotating the supply spool about the rotational axis; and

[0160] A controller is configured to control the driver.

[0161] Example Ex40: The system of example Ex38 or Ex39, wherein the opposing structure is configured to follow a diameter of the supply spool by moving in a radial direction during the unwinding.

[0162] Example Ex41: The system of any of Examples Ex38 to Ex40, wherein the opposing structure is configured to press the continuous material toward the web core.

[0163] Example Ex42: The system of any of Examples Ex38 to Ex41, wherein the opposing structure is configured to clamp the continuous material against the winding core.

[0164] Example Ex43: The system of any of Examples Ex38 to Ex42, wherein the opposing structures comprise opposing rollers.

[0165] Example Ex44: The system of any of Examples Ex38 to Ex43, wherein the system is configured to slow unwinding of the continuous material in response to a thickness of the supply spool determined by the thickness sensor being below a predetermined threshold thickness.

[0166] Example Ex45: The system of any of Examples Ex38 to Ex44, further comprising a spool end-of-life sensor configured to monitor a monitoring area traversed by a circumferential surface of the supply spool as the supply spool rotates about the rotation axis.

[0167] Example Ex46: The system of Example Ex45, wherein the spool end sensor is configured to determine whether the portion of the circumferential surface of the supply spool located in the monitoring area is formed by the continuous material or the spool core.

[0168] Example Ex47: A method of supplying a continuous material for an aerosol-generating article to a processing location, the method comprising:

[0169] - unwinding a continuous material from a supply reel, wherein the supply reel comprises a reel core and the continuous material wound around the reel core;

[0170] - conveying the unwound continuous material to a processing location; and

[0171] - determining the thickness of the supply spool based on the position of an opposing structure in contact with the continuous material wound around the spool core and following the reduced diameter of the supply spool during the unwinding.

[0172] Example Ex48: The method of example Ex47, wherein the continuous material is pressed or clamped against the reel core by the opposing structure during the unwinding.

[0173] Example Ex49: The method of example Ex47 or Ex48, wherein the opposing structures comprise opposing rollers.

[0174] Example Ex50: The method of any of Examples Ex47 to Ex49, further comprising reducing a rotational speed of the supply spool during the unwinding in response to determining that the thickness of the supply spool has dropped below a predetermined threshold thickness.

[0175] Example Ex51: The method of any of Examples Ex47 to Ex50, further comprising detecting depletion of the supply spool by detecting a difference between a surface of the continuous material and a surface of the spool core.

[0176] Example Ex52: Use of an opposing structure for pressing a continuous material against a reel core and for determining the thickness of a supply reel comprising a reel core and the continuous material wound around the reel core during unwinding of the continuous material from the supply reel.

[0177] Example Ex53: The system, method, or use of any one of Examples Ex1 to Ex52, wherein the continuous material comprises an aerosol-generating material.

[0178] Example Ex54: The system, method, or use of any of Examples Ex1 to Ex53, wherein the continuous material is a web material.

[0179] Example Ex55: The system, method, or use of any one of Examples Ex1 to Ex54, wherein the continuous material comprises reconstituted tobacco material.

[0180] Example Ex56: The system, method, or use of any of Examples Ex1 to Ex52, wherein the continuous material comprises a metallic material.

[0181] Example Ex57: The system, method, or use of any of Examples Ex1 to Ex52, wherein the continuous material comprises a metal strand.

[0182] Example Ex58: The system, method, or use according to any one of Examples Ex1 to Ex57, wherein the continuous material comprises a susceptor configured to be included in an aerosol-generating article. BRIEF DESCRIPTION OF THE DRAWINGS

[0183] Examples will now be further described with reference to the accompanying drawings, in which:

[0184] Figure 1 shows a schematic side view of a system for supplying a continuous material according to an embodiment;

[0185] Figure 2 a perspective schematic diagram showing a supply roller and a roll-out sensor of a system according to an embodiment;

[0186] Figure 3 shows a schematic diagram indicating unwinding speed on the vertical axis and time on the horizontal axis according to an embodiment; and

[0187] Figure 4 A series of schematic diagrams showing a supply reel and opposing structures of a system according to an embodiment are shown, wherein the diameter of the supply reel decreases throughout the series. DETAILED DESCRIPTION

[0188] Figure 1 A schematic side view of a system 1 for supplying a continuous material 3 is shown. The system 1 comprises a roll holder 5 that receives a supply roll 7. The supply roll 7 comprises a roll core 9 and a continuous material 3 wound around the roll core 9. Figure 1 In the state shown in FIG, the supply spool 7 is substantially exhausted and less than one full turn of continuous material 3 remains on the spool core 9. The spool holder 5 includes a drive 11 for rotating the supply spool 7 about an axis of rotation 13 to unwind the continuous material 3. The system 1 includes a controller 15 that controls the drive 11.

[0189] The continuous material 3 unwound from the supply reel 7 is delivered to a processing location 17. In the illustrated embodiment, the continuous material 3 is a web of reconstituted tobacco material. Furthermore, in the illustrated embodiment, a crimping station 19 is provided at the processing location 17. The crimping station 19 includes a crimping roller 21 for crimping the continuous material 3. The crimping roller 21 creates wrinkles or weakened portions in the continuous material 3 to facilitate further processing of the continuous material 3.

[0190] Between the roll holder 5 and the processing location 17, the continuous material 3 extends through a splicing station 23. Once the supply roll 7 is depleted, the splicing station 23 is configured to splice the continuous material 3 from the supply roll 7 with the continuous material 25 from the replacement supply roll 27. The splicing station 23 includes a first tool 29, in the form of a lower tool, and a second tool 31, in the form of an upper tool. The continuous material 3 from the supply roll 7 extends between the first tool 29 and the second tool 31 on its way from the supply roll 7 to the processing location 17. The system 1 includes a positioning mechanism 33, such as a robotic arm. The positioning mechanism 33 also positions the continuous material 25 from the replacement supply roll 27 between the first tool 29 and the second tool 31. Alternatively, for example, the continuous material 25 from the replacement supply roll 27 can be manually positioned between the first tool 29 and the second tool 31. To splice, the first tool 29 and the second tool 31 move toward each other to combine the continuous material 3 from the supply roll 7 with the continuous material 25 from the replacement supply roll 27. The splicing station 23 may include a moistening unit 35 that moistens one or both of the continuous material 3 from the supply reel 7 and the continuous material 25 from the replacement supply reel 27 to increase their tendency to adhere to each other.

[0191] The system 1 comprises a spool-out sensor 37 to detect depletion of the supply spool 7 . Figure 2 A spool end sensor 37 and a supply spool 7 are shown received in the spool holder 5. As the supply spool 7 rotates about the rotation axis 13, the spool end sensor 37 monitors a monitoring area 39 through which the circumferential surface of the supply spool 7 passes. The spool end sensor 37 determines whether the portion of the circumferential surface of the supply spool 7 that is located in the monitoring area 39 is formed by the continuous material 3 or the spool core 9.

[0192] During most of the unwinding period, the portion of the circumferential surface of the supply spool 7 that is located in the monitoring area 39 is formed by the continuous material 3 wound onto the spool core 9. Only when less than one full turn of continuous material 3 remains on the spool core 9 does the circumferential surface of the spool core 9 that was previously covered by the continuous material 3 become visible. Figure 2The following situation is shown: less than one full turn of continuous material 3 remains on the reel core 9, and a boundary 41 between the portion of the circumferential surface of the reel core 9 covered by the continuous material 3 and the portion of the circumferential surface of the reel core 9 not covered by the continuous material 3 is located in the monitoring area 39. At this time, the reel end sensor 37 detects the difference between the surface of the continuous material 3 and the surface of the reel core 9. When the boundary 41 moves through the monitoring area 39, the reel end sensor 37 detects that the portion of the circumferential surface of the supply reel 7 located in the monitoring area 39 is no longer formed by the continuous material 3 and begins to be formed by the reel core 9. This can be detected by the reel end sensor 37 based on color measurement, for example. In particular, the reel end sensor 37 can be configured to detect the difference between the color of the continuous material 3 and the color of the circumferential surface of the reel core 9.

[0193] The detection by the spool end sensor 37 of the portion of the circumferential surface of the supply spool 7 located in the monitoring area 39 that is no longer formed by the continuous material 3 but by the spool core 9 can be regarded as an indication that the supply spool 7 is exhausted. The supply spool 7 can be regarded as exhausted when less than one full turn of the continuous material 3 remains on the spool core 9.

[0194] like Figure 1 As shown in FIG, the system 1 includes an opposing structure 43 in the form of opposing rollers. The opposing structure 43 is guided in a guide structure 45 for movement in an axial direction toward or away from the axis of rotation 13. In the support structure 45, the opposing structure 43 is biased to move radially inward toward the axis of rotation 13. During unwinding of the continuous material 3, the opposing structure 43 contacts and maintains contact with the continuous material 3. The opposing structure 43 moves in the guide structure 45 to follow the decreasing diameter of the supply spool 7 during unwinding. The opposing structure 43 defines the position at which the continuous material 3 disengages from the supply spool 7 during unwinding.

[0195] The system 1 comprises a thickness sensor 47 which determines the thickness of the supply reel 7. The thickness of the supply reel 7 decreases during unwinding of the continuous material 3.

[0196] like Figure 1 As shown in solid lines in FIG, the thickness sensor 47 may be a distance sensor that measures the distance between the thickness sensor itself and the circumferential surface of the supply spool 7. The thickness of the supply spool 7 indicates how much continuous material 3 is left on the spool core 9.

[0197] exist Figure 1 In an alternative embodiment indicated by dashed lines, a thickness sensor 47 can determine the thickness of the supply roll 7 based on the position of the counter structure 43. In particular, the thickness sensor 47 can measure or determine the position of the counter structure 43 based on the movement of the counter structure 43 along the radial direction guided by the guide structure 45.

[0198] The measurement results from the roll end sensor 37 and the thickness sensor 47 are provided to the controller 15. The controller 15 controls the driver 11 based on the measurement results from the roll end sensor 37 and the thickness sensor 47.

[0199] In particular, the controller 15 may be configured to Figure 3 The driver 11 is controlled according to the diagram shown in FIG. Figure 3 The horizontal axis 49 in is the time axis, and Figure 3 The vertical axis 51 in FIG. 1 indicates the unwinding speed. In the first stage of unwinding, the controller 15 controls the driver 11 to unwind the continuous material 3 at the operational unwinding speed 53. Once the measurement by the thickness sensor 47 indicates that the thickness of the supply spool 7 is below the predetermined threshold thickness, the controller 15 controls the driver 11 to reduce the unwinding speed to an intermediate unwinding speed 55 that is lower than the operational unwinding speed 53 but higher than zero. When, at a later stage, the spool end sensor 37 indicates that the supply spool 7 is exhausted, i.e., less than one full turn of the continuous material 3 remains on the spool core 9, the controller 15 controls the driver 11 to stop unwinding. Thus, the unwinding speed is reduced from the intermediate unwinding speed 55 to zero.

[0200] Reducing the unwinding speed to zero occurs quickly enough so that there is still contact between the circumferential surface of the reel core 9 and the continuous material 3 when the unwinding speed reaches zero.

[0201] According to an alternative, the controller 15 controls the drive 11 to unwind the continuous material 3 at the operating unwinding speed 53 until the roll exhaustion sensor 37 indicates that the supply roll 7 is exhausted, and then controls the drive 11 to stop unwinding, without controlling the drive 11 to reduce the unwinding speed to an intermediate stage of the intermediate unwinding speed 55 that is lower than the operating unwinding speed 53 in response to the thickness of the supply roll 7 being lower than a predetermined threshold thickness.

[0202] Figure 4 shows a series of operating states during unwinding, where unwinding starts from Figure 4 The status indicated in the left part of Figure 4 The status is indicated in the right part of the . Figure 4 In the left part of , the thickness of the supply spool 7 is still above the threshold thickness and unwinding continues at the operational unwinding speed 53. Figure 3 In the middle portion of the supply roll 7, the thickness has dropped below the threshold thickness and the unwinding continues at a smaller intermediate unwinding speed 55. Figure 4 In the right portion of the drawing, unwinding has been stopped based on a signal from the spool end sensor 37. Since some continuous material 3 still exists, even though less than one full turn of continuous material 3 is on the spool core 9 after the unwinding speed has been reduced to zero, the opposing structure 43 can still clamp the continuous material 3 against the spool core 9, so that the tension of the continuous material 3 downstream of the supply spool 7 is maintained.

[0203] The controller 15 may initiate splicing by the splicing station 23 after the unwind speed has been reduced to zero.

[0204] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed herein. Therefore, in this context, the number A is understood to be A±{10%}A. Within this context, the number A can be regarded as including a numerical value within the general standard error for the measurement of the property modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentages listed above, as long as the amount of A deviation does not significantly affect the basic and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed herein.

Claims

1. A system for supplying a continuous stream of material for an aerosol-generating article, comprising: a spool holder configured to receive a supply spool including a spool core and a continuous material wound around the spool core such that the supply spool is rotatable about a rotational axis for unwinding the continuous material; as well as a spool end-of-life sensor configured to monitor a monitoring area traversed by a circumferential surface of the supply spool as the supply spool rotates about the rotational axis; wherein the spool end sensor is configured to determine whether a portion of the circumferential surface of the supply spool located in the monitoring area is formed by the continuous material or the spool core. 2 . The system of claim 1 , wherein the spool end-of-life sensor is configured to perform an optical measurement of a portion of the circumferential surface of the supply spool that is located in the monitoring area.

3. The system of claim 2, wherein the optical measurement is a color measurement.

4. A system according to any one of the preceding claims, wherein the system is configured to slow or stop unwinding the continuous material in response to the roll-out sensor detecting that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core.

5. A system according to any of the preceding claims, further comprising a splicing unit configured to splice the continuous material with continuous material from a replacement supply roll, wherein the system initiates splicing in response to the roll end sensor detecting that the portion of the circumferential surface of the supply roll located in the monitoring area is formed by the roll core.

6. The system of any one of the preceding claims, further comprising an opposing structure configured to press the continuous material toward the reel core.

7. The system according to any of the preceding claims, further comprising a thickness sensor configured to determine the thickness of the supply roll, in particular based on the position of the opposing structure.

8. The system of claim 7, wherein the system is configured to slow unwinding of the continuous material in response to the thickness of the supply spool measured by the thickness sensor being below a predetermined threshold thickness.

9. A method of supplying a continuous stream of material for an aerosol-generating article to a processing location, the method comprising: - unwinding a continuous material from a supply reel, wherein the supply reel comprises a reel core and the continuous material wound around the reel core; - conveying the unwound continuous material to a processing location; as well as - Detecting depletion of the supply spool by detecting a difference between the surface of the continuous material and the circumferential surface of the spool core.

10. The method of claim 9, wherein detecting a difference between the surface of the continuous material and the circumferential surface of the winding core comprises detecting a color difference between the surface of the continuous material and the circumferential surface of the winding core.

11. The method of claim 9 or 10, further comprising slowing or stopping one or both of unwinding the continuous material and conveying the unwound continuous material in response to detecting exhaustion of the supply spool.

12. The method of any one of claims 9 to 11, further comprising initiating splicing of the continuous material with continuous material from a replacement supply spool in response to detecting exhaustion of the supply spool.

13. The method of any one of claims 9 to 12, further comprising reducing the rotational speed of the supply spool during the unwinding in response to determining that the thickness of the supply spool has fallen below a predetermined threshold thickness.

14. Use of a color measurement device for determining whether a supply roll is exhausted during unwinding of a continuous material from the supply roll, wherein the color measurement device determines whether a portion of the circumferential surface of the supply roll located in a monitoring area is formed by the continuous material or by the roll core of the supply roll, the circumferential surface of the supply roll passing through the monitoring area during the unwinding.

15. The system, method or use of any preceding claim, wherein the continuous material comprises an aerosol generating material.

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