Components of products generated by separating aerosols to reduce cross-contamination

Abstract

A method for processing strip-shaped consumable aerosol generating articles is disclosed, each strip-shaped consumable aerosol generating article comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being enclosed in at least one circumferential package, the method comprising the steps of: i) feeding the aerosol generating article onto a vibrating screen and causing the aerosol generating article to traverse the surface of the vibrating screen; ii) after the aerosol generating article has traversed the surface of the vibrating screen, arranging it on an alignment strip comprising a plurality of transverse grooves configured to receive the aerosol generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge; i) Positioning the aerosol generating article within the transverse groove such that the first end bar portion abuts at least one of the first side edge and the opposite second side edge of the alignment strip; iv) Cutting the aerosol generating article at at least two points along its length to separate the first and second end bar portions from the aerosol generating matrix portion; v) Separating the aerosol generating matrix portion from the first and second end bar portions; vi) Separating the aerosol generating matrix portion including the metal sensor from its circumferential packaging; vii) Cutting the aerosol generating matrix portion to expose the metal sensor; viii) Applying a magnetic field to separate the metal sensor from the aerosol generating matrix portion; and ix) Collecting the aerosol generating matrix portion and the metal sensor, respectively.

Description

Technical Field

[0001] This disclosure relates to a method and system for separating components of aerosol-generated articles. Background Technology

[0002] In the manufacture of aerosol-generating articles (e.g., heated tobacco products, heated nicotine-containing products, and mixtures thereof), various components are combined to produce the aerosol-generating articles. Typically, these articles include an aerosol-generating matrix (e.g., tobacco cast leaves, other agricultural products such as clove, menthol, and guar gum, glycerin), one or more filter elements (e.g., containing cellulose-based materials), an aerosol cooling element (e.g., containing polylactic acid or acetate materials), and a metallic sensor element that, when heated, heats the aerosol-generating matrix and releases aerosols. The various components are arranged in a desired configuration and assembled into a strip-shaped article encased in an outer packaging, which may be made of paper or other materials.

[0003] There are many different designs of aerosol-generating articles, and this disclosure specifically relates to waste streams generated during the manufacture of aerosol-generating articles comprising both metallic and non-metallic materials, or to waste streams comprising used aerosol-generating articles comprising both metallic and non-metallic materials.

[0004] Referring to the manufacturing of aerosol-generated products, production lines can be set up to produce thousands, tens of thousands, or even more aerosol-generated products per hour. These products undergo quality checks, and those that do not meet quality standards are rejected and sent to a waste stream. The waste stream may include finished aerosol-generated products that do not meet quality standards, as well as partially finished products that were rejected before completion. It is desirable to separate the different components of the aerosol-generated products in the waste stream for recycling and environmentally responsible disposal.

[0005] It is also expected that components can be separated when processing used aerosol-generated articles that may have been collected from end users or testing machines.

[0006] Aerosol generating articles, available on the market in the form of consumables for use with aerosol generating devices, consist of multiple components arranged in a strip-like structure. Aerosol generating articles designed for induction heating typically include elongated metal sensors positioned longitudinally within the aerosol generating matrix.

[0007] Furthermore, such aerosol-generated articles are typically characterized by additional components, such as filtration and air management segments, arranged in a sequential manner, usually made of cellulose-based materials. During the assembly process, the various components are first aligned in a desired order and then encapsulated within an outer paper package, which is tightly applied to maintain the integrity and shape of the article.

[0008] Figure 1 An aerosol generating article 1 is shown, comprising five distinct components arranged coaxially: a front bar 10, an aerosol generating matrix strip 11 with flattened receptors 12, a hollow acetate tube (HAT) filter 13, a fine hollow acetate tube (FHAT) filter 14, and a mouthpiece filter 15. These components are arranged sequentially and tightly contained within an outer packaging 16 and a tipping paper 18 to form a cylindrical strip. The front bar 10 can be considered a first end bar portion, and the HAT filter 13, FHAT filter 14, and mouthpiece filter 15 can be considered together as a second end bar portion. Alternatively, the HAT filter 13, FHAT filter 14, and mouthpiece filter 15 can be considered together as a first end bar portion, and the front bar 10 can be considered as a second end bar portion. The aerosol generating matrix strip 11, which may comprise tobacco leaves, ground tobacco, reconstituted cast tobacco, or other suitable materials, is located between the first and second end bar portions.

[0009] Tables 1 and 2 below provide examples of materials that can be used to form various parts and examples of the dimensions of various parts. The examples are illustrative and should not be considered limiting unless the context requires otherwise.

[0010] Table 1:

[0011]

[0012] Table 2:

[0013]

[0014] When designing aerosol-generating articles, dimensions are precisely defined. However, during the manufacturing and assembly of aerosol-generating articles, deviations in component dimensions and variations in the output of assembly equipment can cause differences in the specifications of the finished product. In some cases, these variations can create gaps 17 between components. For example, when fully assembled, the aerosol-generating matrix strip 11 may not directly abut against adjacent components, but may be slightly displaced from its ideal position. Assembly equipment is typically configured to continuously monitor these process parameters and act appropriately depending on whether the aerosol-generating article is acceptable according to predefined tolerance targets. Furthermore, aerosol-generating articles may be rejected from the manufacturing process during the initial encapsulation stage due to encapsulation deformation, or immediately after the formation of the initial aerosol-generating matrix strip following the curling of the aerosol-generating matrix material.

[0015] Aerosol-generated articles that fail to meet necessary quality standards are considered defective and must be removed before the final packaging stage of the final product. To minimize waste and maximize resource utilization, it is common practice to recover high-value components (such as tobacco) from these rejected articles and reintroduce them into the production process.

[0016] For the purpose of recovering tobacco matrix from defective smoking products, such as cigarettes, existing recycling systems known as “recycling machines” are already in use. These systems typically involve crushing or tearing the product and then screening it to recover the tobacco.

[0017] A significant drawback of crushing or shredding recycling machines is the increased risk of cross-contamination during the dismantling process, particularly when multiple segments of the product are integrated. This occurs when fragments from the outer packaging or, if present, parts of the filter segments are mixed into the tobacco, resulting in reduced recycling efficiency.

[0018] Recent designs for recycling systems have attempted to address cross-contamination by incorporating a cutting device that offers a cleaner alternative to crushing. Instead, the product is fed towards cutting blades that slice its different components. After cutting, each individual component is then conveyed for further recycling.

[0019] Although recycling machines equipped with cutting devices have shown improved recycling rates compared to other types, they still encounter limitations when processing articles containing metal sensors used for induction heating. This is mainly because they cannot effectively separate the sensors from the aerosol-generating matrix.

[0020] Given the increasing emphasis on meeting higher sustainability standards, current efforts to improve manufacturing practices aim to align with these standards. Therefore, improvements to recycling processes remain necessary to enhance sustainability and overall efficiency. Summary of the Invention

[0021] According to a first aspect of the present invention, a method for processing strip-shaped consumable aerosol generating articles is provided, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being enclosed in at least one circumferential packaging material, the method comprising the following steps:

[0022] i) Feed the aerosol-generated product onto a vibrating screen and make the aerosol-generated product cross the surface of the vibrating screen;

[0023] ii) After the aerosol-generating article has traversed the surface of the vibrating screen, it is arranged on an alignment strip comprising a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge;

[0024] iii) Position the aerosol-generating article within the transverse groove such that the first end bar portion is adjacent to at least one of the first side edge and the opposite second side edge of the alignment strip;

[0025] iv) Cut the aerosol-generating article at at least two points along its length to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion;

[0026] v) Separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion;

[0027] vi) Separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging;

[0028] vii) Cutting the aerosol-generated matrix portion to expose the metal receptor;

[0029] viii) Applying a magnetic field to separate the metalloreceptor from the aerosol-generating matrix portion; and

[0030] (ix) Collect the aerosol-generating matrix portion and the metal receptor respectively.

[0031] The method of embodiments of the present invention provides several advantages over known processing methods. In particular, precisely cutting the aerosol-generating article at at least two points along its length facilitates the separation of the aerosol-generating matrix portion and the included metal receptor from other components of the aerosol-generating article. Furthermore, the steps of cutting the aerosol-generating matrix portion to expose the metal receptor and applying a magnetic field to separate the metal receptor from the aerosol-generating matrix portion enable particularly efficient separation of valuable aerosol-generating matrix (such as tobacco) from the metal receptor and other components. Additionally, the metal receptor can be reused or recycled as appropriate.

[0032] Prior to step i), the aerosol-generated articles can be collected in a collection hopper. The collection hopper can be configured to operate as a buffer, meaning that the aerosol-generated articles can be added to the collection hopper in batches in bulk form, and the collection hopper can be configured to distribute the aerosol-generated articles onto the vibrating screen in a more controlled manner. For example, the collection hopper can be configured to distribute the aerosol-generated articles onto the vibrating screen one by one. For example, the collection hopper can be configured to distribute the aerosol-generated articles in small batches (e.g., two to twenty articles or five to fifteen articles) at a time. For example, the collection hopper can be configured to receive a large batch of dozens or hundreds of aerosol-generated articles at the top and distribute the aerosol-generated articles onto the vibrating screen one by one or in small batches at the bottom. In this way, a substantially continuous flow of individualized aerosol-generated articles can be provided for use across the vibrating screen.

[0033] Aerosol-generated articles can be vibrated in a collection hopper before being controlled-wise fed into a vibrating screen. The aerosol-generated articles can be vibrated in the collection hopper by an electromechanical shaker configured to vibrate the bulk aerosol-generated articles in the hopper. Especially when conveyed in bulk and tightly packed, aerosol-generated articles can become entangled. Some aerosol-generated articles, typically with a strip-shaped profile, can become bent or twisted and become hooked onto adjacent aerosol-generated articles. This can hinder the smooth flow of aerosol-generated articles and cause processing interruptions. By vibrating the bulk aerosol-generated articles in the collection hopper, untangling of the aerosol-generated articles can be promoted, resulting in smoother flow and fewer processing interruptions.

[0034] In step i), the aerosol-generated products can be fed from a collection hopper to a vibrating screen via a vertical conveyor, said vertical conveyor including shelf sections each configured to receive and transport a batch of aerosol-generated products. Vertical conveyors can facilitate the efficient use of available space within the processing facility. Compared to corresponding horizontal conveyors, vertical conveyors can occupy less space.

[0035] In step i), the surface of the vibrating screen may include a wire mesh or grid. In step i), the vibrating screen may vibrate at a frequency of 5 Hz to 100 Hz, optionally 30 Hz to 60 Hz. In step i), the vibrating screen may vibrate at a vibration amplitude of 1 mm to 6 mm, optionally 3 mm to 4 mm. The vibrating screen can help remove unwanted components or contaminants, such as loose paper scraps or other debris, from the aerosol-generated article stream. The vibrating screen may include a mechanical or electromechanical agitator for providing controlled vibration to the aerosol-generated article. The controlled vibration may be characterized by a frequency, or amplitude, or both, used to facilitate the separation of the aerosol-generated article from unwanted waste or foreign particles. Preferably, smaller waste or foreign particles fall through holes in the vibrating screen into, for example, a waste collection container as the aerosol-generated article crosses the surface of the vibrating screen. The vibration frequency of the vibrating screen may preferably be set to a relatively high value to facilitate rapid separation of the aerosol-generated articles from each other. The vibration amplitude of the vibrating screen may be kept at a moderate value to reduce the possibility of damaging the aerosol-generated article. The direction of vibration, or the mode of vibration, or both, can be adjusted to promote a substantially uniform distribution of aerosol-generated products on the surface of the vibrating screen, thereby reducing unwanted aggregation.

[0036] After step i) and before step ii), the aerosol-generated articles may be conveyed on an auxiliary belt comprising substantially parallel tracks running at different speeds to align the aerosol-generated articles longitudinally with the direction of travel. The substantially parallel tracks may form separate longitudinal channels configured to receive the aerosol-generated articles aligned longitudinally with the direction of travel. The aerosol-generated articles may be guided into the longitudinal channels by at least one brush. At least one brush may be mounted on a motorized boom. At least one brush may be mounted on a conveyor system. At least one brush may have bristles designed to gently guide the aerosol-generated articles into the longitudinal channels. At least one brush may help ensure that the aerosol-generated articles are properly loaded into the longitudinal channels. The substantially parallel tracks running at different speeds are used to align the aerosol-generated articles with each other and with the direction of travel. In this way, randomly aligned aerosol-generated articles from the vibrating screen can be aligned with each other and with the direction of travel, which facilitates subsequent processing.

[0037] Aerosol-generated articles can be transferred from an auxiliary belt to a transfer hopper configured to collect the aerosol-generated articles, which are substantially parallel to each other. The aerosol-generated articles can be aligned with each other within the transfer hopper.

[0038] A secondary belt, running substantially perpendicular to the auxiliary belt, collects longitudinally proximal aerosol-generated articles and conveys them to a transfer hopper. In step ii), the aerosol-generated articles are temporarily held substantially parallel to each other in the transfer hopper before being distributed onto the alignment belt. Therefore, the transfer hopper can have both buffering and dispensing functions.

[0039] In step ii), the transverse groove of the alignment band may have a length greater than the length of the aerosol-generating article. This means that any given aerosol-generating article can slide along the transverse groove of the alignment band where the aerosol-generating article is located. The aerosol-generating article can move between one extreme position of the first end bar portion adjacent to one of the first side edge and the opposite second side edge, and another extreme position of the second end bar portion adjacent to the other of the first side edge and the opposite second side edge.

[0040] The alignment band may include sensors for determining the orientation of each aerosol-generating article within its respective lateral groove. The sensors may determine whether a first end bar portion faces a first side edge or a second side edge. The sensors may also determine whether a second end bar portion faces a first side edge or a second side edge. Typically, the aerosol-generating article may take one of two possible orientations within the lateral groove. In a first orientation, the first end bar portion faces the first side edge, and the second end bar portion faces the second side edge. In a second orientation, the first end bar portion faces the second side edge, and the second end bar portion faces the first side edge.

[0041] Aerosol-generating articles can be dispensed onto an alignment belt so that initially all of them have an end adjacent to or near a first side edge of the alignment belt. As will be explained below, an aerosol-generating article in one orientation can be held in a position adjacent to or near the first side edge of the alignment belt. An aerosol-generating article in another orientation can be moved along its lateral groove to be adjacent to or near a second side edge of the alignment belt.

[0042] The sensor can be an optical sensor. The sensor can be an image sensor. The sensor can be a pattern recognition sensor configured to identify a specific pattern on at least one circumferential package. The sensor can be configured to distinguish between a first end bar portion and a second end bar portion to determine the orientation of each aerosol-generating article within its respective lateral groove. By performing image analysis and pattern recognition algorithms, the sensor can accurately determine the orientation of each aerosol-generating article within its respective lateral groove by comparing the detected pattern with a stored reference pattern library.

[0043] The sensor can determine whether a first end bar portion of a given aerosol-generated article is closer to a first side edge of the alignment strip than a second end bar portion, or whether a first end bar portion is closer to a second side edge of the alignment strip than a second end bar portion.

[0044] In step iii), the aerosol generating articles can move within the transverse groove based on an orientation determined by a sensor, such that the first end bar portions abut against a corresponding first side edge or opposite second side edge of the alignment strip. In this manner, aerosol generating articles in the first orientation will be aligned with each other, all their first end bar portions abutting one of the first side and opposite second side of the alignment strip, and aerosol generating articles in the second orientation will be aligned with each other, all their first end bar portions abutting the other of the first side and opposite second side of the alignment strip. The aerosol generating articles can be moved within the transverse groove by an air jet. The aerosol generating articles can be moved within the transverse groove by an electromechanical actuator.

[0045] For example, if the sensor detects the first end bar portion, the sensor can send a signal to move the aerosol-generating article toward the first side of the alignment belt within the transverse groove. If the sensor detects the second end bar portion, the sensor can send a signal to move the aerosol-generating article toward the second side of the alignment belt within the transverse groove.

[0046] In step iv), each aerosol-generating article can be cut by a pair of rotating blades to separate the aerosol-generating matrix portion from the first end bar portion and the second end bar portion. Because the aerosol-generating articles are all aligned to the first side edges of those adjacent alignment bands in the first orientation and to the second side edges of those adjacent alignment bands in the second orientation, the rotating blades will be correctly positioned even when the first end bar portion has a different length than the second end bar portion. The rotating blades can be configured as circular or disc blades with circumferential cutting edges.

[0047] The first pair of rotating blades can be disposed adjacent to the first side of the alignment belt, and the second pair of rotating blades can be disposed adjacent to the second side of the alignment belt. This allows the aerosol generation matrix portion of the aerosol generation article adjacent to both sides of the alignment belt to be cut and separated from the first and second rod end portions.

[0048] The rotating blades can be spaced apart from each other along the axis of rotation by a distance corresponding to the length of the aerosol-generating matrix portion. The rotating blades can also be spaced apart from each other by a distance corresponding to the length of the aerosol-generating matrix portion between the first end bar portion and the second end bar portion.

[0049] The alignment belt may be provided with a recess configured to receive the cutting edge of a rotating blade, so as to allow complete cutting through the aerosol-generated article in the transverse groove. Therefore, the cutting edge of the rotating blade can extend through the alignment belt without damaging it.

[0050] The rotating blades of each pair of rotating blades can be substantially parallel to each other.

[0051] The rotating blades of each pair of rotating blades can share the same axis of rotation.

[0052] Rotary blades can have toothed cutting edges. This facilitates the cutting of aerosol-generated products.

[0053] Rotary blades can have a smooth cutting edge. This can reduce the amount of debris generated by the cutting process.

[0054] Each rotating blade may have a cutting width greater than the maximum spacing between the first end portion and the aerosol-generating matrix portion, or greater than the maximum spacing between the second end portion and the aerosol-generating matrix portion. The maximum spacing can be determined based on manufacturing tolerances of the aerosol-generating article. Imperfect abutment or alignment of the first end portion against the first or second side edge of the alignment band can be considered. For example, the maximum possible gap between segments of the aerosol-generating article (e.g., the maximum possible gap between the facing ends of the first end portion and the aerosol-generating matrix portion, or the maximum possible gap between the facing ends of the second end portion and the aerosol-generating matrix portion) can be specified as 10 micrometers. The maximum possible deviation of the aerosol-generating article from its desired position within the corresponding lateral groove of the alignment band can also be specified as 10 micrometers. In this case, each rotating blade can be specified with a cutting width of 20 micrometers. Other manufacturing tolerances can also be considered. This helps reduce cross-contamination by ensuring that the cut aerosol-generating matrix portion does not include either the first or second end portion. This can help reduce cross-contamination by ensuring that the first end portion of the cut rod does not contain any aerosol-generating matrix portion. This can also help reduce cross-contamination by ensuring that the second end portion of the cut rod does not contain any aerosol-generating matrix portion.

[0055] The spacing between the rotating blades in each pair of rotating blades can be adjusted. The spacing can be adjusted by the control unit in response to input parameters related to the type of aerosol-generating article being processed. The spacing is automatically adjusted in response to a signal from a sensing unit that determines the length of each aerosol-generating matrix portion. The spacing can also be adjusted by the control unit in response to a sensing signal that determines the respective lengths of the first rod end portion, the second rod end portion, and the aerosol-generating matrix portion. In this way, it is possible to process different types of aerosol-generating articles with different lengths of the first rod end portion, the second rod end portion, or the aerosol-generating matrix portion.

[0056] The cutting angle of the rotating blade can be adjusted. The cutting angle can be adjusted by the control unit in response to input parameters related to the type of aerosol-generated article being processed.

[0057] In step iv), the aerosol-generated article can be held in place within the transverse groove during cutting. The aerosol-generated article can be held in place by suction. The aerosol-generated article can also be held in place by clamping rollers. Holding the aerosol-generated article in place during cutting helps improve cutting accuracy. Holding the aerosol-generated article in place during cutting helps prevent it from being dislodged from the transverse groove by the rotating blade.

[0058] In step iv), debris generated from cutting aerosol articles can be removed using at least one vacuum extractor. The at least one vacuum extractor may include an adjustable nozzle. Removing the cutting debris can help reduce cross-contamination.

[0059] In step v), the first end rod portion, the second end rod portion, and the aerosol generating matrix portion can be separated from each other. The first end rod portion can be moved from the alignment belt to the first end rod portion collection container. The second end rod portion can be moved from the alignment belt to the second end rod portion collection container. The first end rod portion or the second end rod portion can be moved from the alignment belt by a pneumatic ejector. The first end rod portion or the second end rod portion, or both the first end rod portion and the second end rod portion, can be removed for recycling, subsequent treatment, or environmentally responsible disposal.

[0060] In step vi), the aerosol generating matrix portion including the metal sensor can be separated from its circumferential packaging by a pneumatic ejector that applies an air jet to longitudinally blow the aerosol generating matrix portion including the metal sensor out of its circumferential packaging.

[0061] In step vi), the aerosol generating matrix portion including the metal sensor can be separated from its circumferential packaging by cutting the circumferential packaging along the length of the aerosol generating matrix portion.

[0062] In this way, it is possible to separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging. The circumferential packaging can then be collected and removed for recycling, subsequent treatment, or environmentally responsible disposal.

[0063] In step vii), the aerosol generating matrix portion can be cut along its length to expose the metal receptor. The aerosol generating matrix portion can be cut along its length using a side cutter. This facilitates subsequent separation of the metal receptor from the aerosol generating matrix portion.

[0064] Between steps vii) and viii), the cut aerosol-generating matrix portion may traverse the vibrating surface to facilitate the unentanglement of the metal receptor with the aerosol-generating matrix portion. The vibrating surface may include a sieve.

[0065] In step viii), the aerosol generating matrix and the metal sensor of the aerosol generating matrix portion can be conveyed on a magnetic conveyor. The magnetic conveyor may include an annular drive belt with a magnetic roller at one end. The magnetic roller can hold the metal sensor on the annular belt as it passes over the magnetic roller, while allowing the aerosol generating matrix to fall into the aerosol generating matrix collection container. As the metal sensor is conveyed away from the magnetic roller, it can fall from the underside of the annular belt. The metal sensor can fall from the underside of the annular belt into the metal sensor collection container. This can facilitate the separation of the metal sensor from the non-magnetic components of the aerosol generating matrix. The magnetic roller may include at least one electromagnet. The magnetic roller may include at least one permanent magnet.

[0066] In step viii), the aerosol generating matrix and metal sensor of the aerosol generating matrix portion can be conveyed on a first conveyor, and a magnetic field can be applied by an over-band magnetic conveyor passing above the first conveyor. The over-band magnetic conveyor may include a magnet positioned above the first conveyor to lift the metal sensor away from the first conveyor and convey it away from the first conveyor on its underside. The over-band magnetic conveyor can convey the metal sensor to a metal sensor collection container. The over-band conveyor may include an electromagnet. The over-band conveyor may include a permanent magnet. In this way, the metal sensor can be effectively separated from the non-magnetic components of the aerosol generating matrix.

[0067] Both the metal sensor and the aerosol generating matrix are valuable commodities, and once separated, they can be sent for further processing or recycling.

[0068] According to a second aspect of the present invention, a system is provided for processing strip-shaped consumable aerosol generating articles, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being enclosed in at least one circumferential package, the system comprising:

[0069] i) A vibrating screen configured to receive the aerosol-generating article, the vibrating screen having a surface through which the aerosol-generating article traverses;

[0070] ii) Alignment strip, the alignment strip including a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge;

[0071] iii) An actuator configured to position the aerosol-generating article within the transverse groove such that the first end bar portion abuts at least one of a first side edge and an opposing second side edge of the alignment strip;

[0072] iv) A cutter configured to cut the aerosol-generating article at at least two points along the length of the aerosol-generating article in order to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion;

[0073] v) A first separator, configured to separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion;

[0074] vi) A second separator configured to separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging;

[0075] vii) A cutter configured to cut the aerosol-generating matrix portion to expose the metal receptor; and

[0076] viii) A magnet configured to apply a magnetic field to separate the metal receptor from the aerosol-generating matrix portion.

[0077] The system may also include a collection hopper configured to collect the aerosol-generated article before it crosses the surface of the vibrating screen. The collection hopper may be configured to vibrate the aerosol-generated article and controllably feed the aerosol-generated article into the vibrating screen.

[0078] The system may also include a vertical conveyor with shelf sections, each shelf section being configured to receive and convey a batch of aerosol-generated products, the vertical conveyor being configured to feed the aerosol-generated products from the collection hopper to the vibrating screen.

[0079] The surface of a vibrating screen may include wire mesh or grid.

[0080] The vibrating screen may be equipped with a vibrator configured to vibrate the surface at a frequency of 5 Hz to 100 Hz, optionally 30 Hz to 60 Hz.

[0081] The vibrating screen may be equipped with a vibrator configured to vibrate the surface with a vibration amplitude of 1 mm to 6 mm, optionally 3 mm to 4 mm.

[0082] The system may also include an auxiliary belt having substantially parallel tracks that operate at different speeds to align the aerosol-generating article longitudinally with the direction of travel. The substantially parallel tracks may form a separate longitudinal channel configured to receive the aerosol-generating article aligned longitudinally with the direction of travel. The system may also include at least one brush configured to guide the aerosol-generating article into the longitudinal channel.

[0083] The system may further include a transfer hopper configured to receive the aerosol-generated articles from the auxiliary belt and collect the aerosol-generated articles that are substantially parallel to each other. The system may also include a secondary belt that operates substantially perpendicular to the auxiliary belt, the secondary belt being configured to collect longitudinally proximal aerosol-generated articles and convey them to the transfer hopper, in which the aerosol-generated articles are temporarily kept substantially parallel to each other before being assigned to the alignment belt.

[0084] The lateral grooves of the alignment strip may have a length greater than the length of the aerosol-generating article. The system may also include a sensor configured to determine the orientation of each aerosol-generating article within its respective lateral groove. The sensor may be an optical sensor. The sensor may be an image sensor. The sensor may be a pattern discrimination sensor configured to identify a specific pattern on at least one circumferential package. The sensor may be configured to determine whether a first end bar portion of a given aerosol-generating article is closer to a first side edge of the alignment strip than a second end bar portion, or whether the first end bar portion is closer to a second side edge of the alignment strip than the second end bar portion.

[0085] The system may also include an air jet configured to move the aerosol-generating article within a transverse groove based on an orientation determined by a sensor, such that a portion of the first end bar abuts a corresponding first side edge or opposite second side edge of the alignment strip.

[0086] The system may also include an electromechanical actuator configured to move the aerosol-generating article within a transverse groove based on an orientation determined by a sensor, such that a portion of the first end bar abuts a corresponding first side edge or opposite second side edge of the alignment strip.

[0087] A cutter configured to cut the aerosol-generating article at at least two points along its length may include a pair of rotating blades configured to separate the aerosol-generating matrix portion from a first end bar portion and a second end bar portion. The first pair of rotating blades may be disposed adjacent to a first side of the alignment strip, and the second pair of rotating blades may be disposed adjacent to a second side of the alignment strip.

[0088] The rotating blades can be spaced apart from each other along the axis of rotation by a distance corresponding to the length of the aerosol-generating matrix portion.

[0089] The alignment belt may be provided with a recess configured to receive the cutting edge of the rotating blade so as to allow complete cutting through the aerosol generated in the transverse groove.

[0090] The rotating blades of each pair of rotating blades can be substantially parallel to each other. The rotating blades of each pair of rotating blades can share a common axis of rotation.

[0091] Rotary blades can have toothed cutting edges. Rotary blades can also have smooth cutting edges.

[0092] Each rotating blade may have a cutting width greater than the maximum distance between the first rod end portion and the aerosol generating matrix portion, or greater than the maximum distance between the second rod end portion and the aerosol generating matrix portion.

[0093] The spacing between the rotating blades in each pair of rotating blades can be adjustable. The system may also include a control unit configured to adjust the spacing in response to input parameters relating to the type of aerosol-generating article being processed. The system may also include a sensing unit configured to determine the length of each aerosol-generating matrix portion, and a control unit configured to adjust the spacing in response to the determined length of each aerosol-generating matrix portion.

[0094] The cutting angle of the rotating blade can be adjustable. The system may also include a control unit configured to adjust the cutting angle of the rotating blade in response to input parameters relating to the type of aerosol-generated article being processed.

[0095] The alignment belt can be configured to hold the aerosol-generated article in the proper position within a transverse groove during cutting. The transverse groove in the alignment belt may be provided with suction holes to hold the aerosol-generated article in the proper position within the transverse groove during cutting. The system may also include clamping rollers to hold the aerosol-generated article in the proper position within the transverse groove during cutting.

[0096] The system may also include at least one vacuum extractor configured to extract debris generated from cutting aerosol-generated articles. The at least one vacuum extractor may include an adjustable nozzle.

[0097] The first separator may be configured to separate the first end rod portion, the second end rod portion, and the aerosol generating matrix portion from each other. The alignment belt may be configured to displace the first end rod portion from the alignment belt to the first end rod portion collection container. The alignment belt may be configured to displace the second end rod portion from the alignment belt to the second end rod portion collection container. The first separator may include a pneumatic discharge device configured to displace either the first or second end rod portion from the alignment belt.

[0098] The second separator may include a pneumatic ejector configured to apply an air jet to longitudinally expel a portion of the aerosol-generating matrix, including a metal sensor, from its circumferential packaging.

[0099] The second separator may include a cutter configured to cut the circumferential package along the length of the aerosol-generating matrix portion.

[0100] The cutter in item vii) can be configured to cut the aerosol generating matrix portion along its length to expose the metal receptor. The cutter in item vii) can be a side cutter.

[0101] The system may further include, between items vii) and viii), a vibrating surface configured to promote disentanglement of the metal receptor from the aerosol-generating matrix portion. The vibrating surface may include a sieve.

[0102] A magnet may be included in a magnetic conveyor configured to transport an aerosol generating matrix portion and a metal sensor. The magnetic conveyor may include an annular drive belt with a magnetic roller at one end. The magnetic roller may be configured to hold the metal sensor on the annular belt as it passes over the magnetic roller, while allowing the aerosol generating matrix to fall into an aerosol generating matrix collection container. The magnetic roller and the annular belt may be configured to allow the metal sensor to fall from the underside of the annular belt as it is conveyed away from the magnetic roller. The system may also include a metal sensor collection container into which the metal sensor falls from the underside of the annular belt. The magnetic roller may include at least one electromagnet. The magnetic roller may include at least one permanent magnet.

[0103] The aerosol generating matrix and metal sensor can be conveyed on a first conveyor, and a magnet can be included in a suspended magnetic conveyor passing above the first conveyor. The magnet of the suspended magnetic conveyor can be positioned above the first conveyor so that the metal sensor is lifted off the first conveyor and conveyed away from the first conveyor on its underside. The suspended magnetic conveyor can be configured to convey the metal sensor to a metal sensor collection container. The magnet of the suspended magnetic conveyor may include an electromagnet. The magnet of the suspended magnetic conveyor may include a permanent magnet.

[0104] The advantages of the various optional features described with respect to the first aspect of the invention also apply to the corresponding optional features of the second aspect of the invention.

[0105] In the context of this disclosure, the term "aerosol-generating article" is intended to refer to an article comprising an aerosol-generating matrix configured for use with an aerosol-generating apparatus. The aerosol-generating matrix may include a nicotine-containing substance (e.g., tobacco). The article may include additional components (such as a mouthpiece, aerosol mixing section, a filter section, a flavoring section, etc.). The aerosol-generating article preferably has a strip-shaped or cylindrical profile. The aerosol-generating article preferably has a constant cross-section along its length, which may be circular, elliptical, or oval, but may also have other shapes, including polygonal ones.

[0106] In the context of this disclosure, the term "aerosol-generating matrix" is intended to mean a matrix capable of generating aerosols when heated. Examples of aerosol-generating matrices include tobacco cast leaves formed from pulp of ground tobacco leaves and a suitable binder, and also include mixtures of nicotine with one or more of glycerin, guar gum, menthol, cloves, other flavorings, other agricultural products, or high-retention materials with nicotine content.

[0107] In the context of this disclosure, the term "belt" is intended to mean an annular conveyor that passes over at least two rollers and is configured to convey aerosol-generated articles in a desired direction, preferably in a desired orientation.

[0108] In the context of this disclosure, the terms "first end bar portion" and "second end bar portion" are intended to refer, respectively, to a first end and a longitudinally opposed second end of an aerosol generating article comprising a filter-type element configured to allow air to pass through the aerosol generating article. An aerosol generating matrix is ​​disposed in the aerosol generating article between the first end bar portion and the second end bar portion.

[0109] In the context of this disclosure, the term "metal sensor" is intended to mean a substantially layered metal element (e.g., a substantially layered metal element in the form of a metal foil) disposed in or adjacent to an aerosol generating matrix, and which can be heated by resistive or inductive heating to cause the aerosol generating matrix to generate aerosols.

[0110] In the context of this disclosure, the terms "upstream" and "downstream" are used to describe the relative positions of components of an apparatus or steps of a method with reference to the direction of travel of the web of rolled material.

[0111] In the context of this disclosure, the term "vibrating screen" is intended to refer to a mechanical component comprising a perforated or mesh surface capable of vibrating at a desired vibration frequency and amplitude. Vibration may be substantially perpendicular to the plane of the surface. In some variations, vibration may alternatively or additionally occur in another plane, such as a plane parallel to the surface, or at an angle other than 90 degrees to the plane of the surface. The vibrating screen may be vibrated by a motor or by other suitable mechanism. The vibrating screen may be provided with raised side edges to facilitate the flow from one end of the surface to the other. Small debris or other contaminants will fall through the perforations in the perforated or mesh surface and can be collected for disposal.

[0112] The 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.

[0113] Example Ex1: A method for processing strip-shaped consumable aerosol generating articles, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being encapsulated in at least one circumferential packaging material, the method comprising the following steps:

[0114] i) Feed the aerosol-generated product onto a vibrating screen and make the aerosol-generated product cross the surface of the vibrating screen;

[0115] ii) After the aerosol-generating article has traversed the surface of the vibrating screen, it is arranged on an alignment strip comprising a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge;

[0116] iii) Position the aerosol-generating article within the transverse groove such that the first end bar portion is adjacent to at least one of the first side edge and the opposite second side edge of the alignment strip;

[0117] iv) Cut the aerosol-generating article at at least two points along its length to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion;

[0118] v) Separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion;

[0119] vi) Separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging;

[0120] vii) Cutting the aerosol-generated matrix portion to expose the metal receptor;

[0121] viii) Applying a magnetic field to separate the metalloreceptor from the aerosol-generating matrix portion; and

[0122] (ix) Collect the aerosol-generating matrix portion and the metal receptor respectively.

[0123] Example Ex2: The method of Example Ex1, wherein the aerosol-generated article is collected in a collection hopper before step i).

[0124] Example Ex3: The method of Example Ex2, wherein the aerosol-generating article is vibrated in the collection hopper before being controllably fed into the vibrating screen.

[0125] Example Ex4: The method of Example Ex2 or Ex3, wherein in step i), the aerosol-generated articles are fed from the collection hopper to the vibrating screen via a vertical conveyor, the vertical conveyor including shelf sections each configured to receive and convey a batch of aerosol-generated articles.

[0126] Example Ex5: The method of any one of Examples Ex1 to Ex4, wherein in step i), the surface of the vibrating screen comprises a wire mesh or a grid.

[0127] Example Ex6: The method of any one of Examples Ex1 to Ex5, wherein in step i), the vibrating screen vibrates at a frequency of 5 Hz to 100 Hz, optionally 30 Hz to 60 Hz.

[0128] Example Ex7: The method of any one of Examples Ex1 to Ex6, wherein in step i), the vibrating screen vibrates with a vibration amplitude of 1 mm to 6 mm, optionally 3 mm to 4 mm.

[0129] Example Ex8: The method of any one of Examples Ex1 to Ex7, wherein after step i) and before step ii), the aerosol-generating article is conveyed on an auxiliary belt comprising a substantially parallel track running at different speeds to align the aerosol-generating article longitudinally with the direction of travel.

[0130] Example Ex9: The method of Example Ex8, wherein substantially parallel running tracks form separate longitudinal channels configured to receive the aerosol-generating article longitudinally aligned with the direction of travel.

[0131] Example Ex10: The method of Example Ex9, wherein the aerosol-generating article is guided into the longitudinal channel by at least one brush.

[0132] Example Ex11: A method of any one of Examples Ex8 to Ex10, wherein the aerosol generating article is transferred from the auxiliary belt to a transfer hopper configured to collect the aerosol generating articles which are substantially parallel to each other.

[0133] Example Ex12: The method of Example Ex11, wherein a secondary belt running substantially perpendicular to the auxiliary belt collects longitudinally proximal aerosol-generated articles and conveys the aerosol-generated articles to the transfer hopper, wherein the aerosol-generated articles are temporarily held substantially parallel to each other in the transfer hopper before being assigned to the alignment belt in step ii).

[0134] Example Ex13: The method of any one of Examples Ex1 to Ex12, wherein in step ii), the transverse groove of the alignment strip has a length greater than the length of the aerosol-generated article.

[0135] Example Ex14: The method of Example Ex13, wherein the alignment band includes a sensor for determining the orientation of each aerosol-generating article within its respective lateral groove.

[0136] Example Ex15: The method of Example Ex14, wherein the sensor is an optical sensor.

[0137] Example Ex16: The method of Example Ex14 or Ex15, wherein the sensor is an image sensor.

[0138] Example Ex17: The method of any one of Examples Ex14 to Ex16, wherein the sensor is a pattern recognition sensor configured to identify a specific pattern on the at least one circumferential package.

[0139] Example Ex18: A method of any one of Examples Ex14 to Ex17, wherein the sensor determines whether a first end bar portion of a given aerosol-generated article is closer to a first side edge of the alignment strip than a second end bar portion, or whether the first end bar portion is closer to a second side edge of the alignment strip than the second end bar portion.

[0140] Example Ex19: The method of Example Ex18, wherein in step iii), the aerosol generating article moves within the transverse groove based on the orientation determined by the sensor, such that the first end bar portion abuts the corresponding first side edge or opposite second side edge of the alignment strip.

[0141] Example Ex20: The method of Example Ex19, wherein the aerosol-generating article is moved within the transverse groove by an air jet.

[0142] Example Ex21: The method of Example Ex19, wherein the aerosol generating article is moved within the transverse groove by an electromechanical actuator.

[0143] Example Ex22: The method of any one of Examples Ex1 to Ex21, wherein in step iv), each aerosol-generating article is cut by a pair of rotating blades to separate the aerosol-generating matrix portion from the first end bar portion and the second end bar portion.

[0144] Example Ex23: The method of Example Ex22, wherein a first pair of rotating blades is disposed adjacent to a first side of the alignment strip, and a second pair of rotating blades is disposed adjacent to a second side of the alignment strip.

[0145] Example Ex24: The method of Example Ex22 or Ex23, wherein the rotating blades are spaced apart from each other along the axis of rotation by a distance corresponding to the length of the aerosol generating matrix portion.

[0146] Example Ex25: A method of any one of Examples Ex22 to Ex24, wherein the alignment band is provided with a recess configured to receive the cutting edge of the rotating blade so as to allow complete cutting through the aerosol-generating article in the transverse groove.

[0147] Example Ex26: The method of any one of Examples Ex22 to Ex25, wherein the rotating blades of each pair of rotating blades are substantially parallel to each other.

[0148] Example Ex27: The method of any one of Examples Ex22 to Ex26, wherein the rotating blades of each pair of rotating blades share a common axis of rotation.

[0149] Example Ex28: The method of any one of Examples Ex22 to Ex27, wherein the rotating blade has a toothed cutting edge.

[0150] Example Ex29: The method of any one of Examples Ex22 to Ex27, wherein the rotating blade has a smooth cutting edge.

[0151] Example Ex30: The method of any one of Examples Ex22 to Ex29, wherein each rotating blade has a cutting width greater than the maximum distance between the first rod end portion and the aerosol generating matrix portion, or greater than the maximum distance between the second rod end portion and the aerosol generating matrix portion.

[0152] Example Ex31: The method of any one of Examples Ex22 to Ex30, wherein the spacing between the rotating blades in each pair of rotating blades is adjustable.

[0153] Example Ex32: The method of Example Ex31, wherein the mutual spacing is adjusted by a control unit in response to input parameters relating to the type of aerosol-generated article being processed.

[0154] Example Ex33: The method of Example Ex31, wherein the mutual spacing is automatically adjusted in response to a signal from a sensing unit that determines the length of each aerosol-generating matrix portion.

[0155] Example Ex34: The method of any one of Examples Ex22 to Ex33, wherein the cutting angle of the rotating blade is adjustable.

[0156] Example Ex35: The method of Example Ex34, wherein the cutting angle is adjusted by the control unit in response to input parameters relating to the type of aerosol-generated article being processed.

[0157] Example Ex36: The method of any one of Examples Ex1 to Ex35, wherein in step iv), the aerosol-generating article is held in the proper position in the transverse groove during cutting.

[0158] Example Ex37: The method of Example Ex36, wherein the aerosol-generating article is held in place in the transverse groove by suction.

[0159] Example Ex38: The method of Example Ex36, wherein the aerosol-generating article is held in the proper position in the transverse groove by a clamping roller.

[0160] Example Ex39: The method of any one of Examples Ex1 to Ex38, wherein in step iv), debris generated from cutting the aerosol-generated article is extracted by at least one vacuum extractor.

[0161] Example Ex40: The method of Example Ex39, wherein the at least one vacuum extractor includes an adjustable nozzle.

[0162] Example Ex41: The method of any one of Examples Ex1 to Ex39, wherein in step v), the first end rod portion, the second end rod portion and the aerosol generating matrix portion are separated from each other.

[0163] Example Ex42: The method of Example Ex41, wherein the first end bar portion is displaced from the alignment strip to the first end bar portion collection receiving portion.

[0164] Example Ex43: The method of Example Ex41 or Ex42, wherein the second end bar portion is displaced from the alignment strip to the second end bar portion collection receiving portion.

[0165] Example Ex44: The method of any one of Examples Ex41 to Ex43, wherein the first end bar portion or the second end bar portion is displaced from the alignment strip by a pneumatic ejector.

[0166] Example Ex45: A method of any one of Examples Ex1 to Ex44, wherein in step vi), the aerosol generating matrix portion including the metal sensor is separated from its circumferential packaging by a pneumatic ejector that applies an air jet to longitudinally blow the aerosol generating matrix portion including the metal sensor out of its circumferential packaging.

[0167] Example Ex46: A method of any one of Examples Ex1 to Ex44, wherein in step vi), the aerosol generating matrix portion including the metal sensor is separated from the circumferential packaging by cutting the circumferential packaging along the length of the aerosol generating matrix portion.

[0168] Example Ex47: The method of any one of Examples Ex1 to Ex46, wherein in step vii), the aerosol generating matrix portion is cut along its length to expose the metal receptor.

[0169] Example Ex48: The method of Example Ex47, wherein the aerosol generating matrix portion is cut along its length by a side cutter.

[0170] Example Ex49: The method of any one of Examples Ex1 to Ex48, wherein between steps vii) and viii), the cut aerosol generating matrix portion traverses the vibrating surface to facilitate the unentanglement of the metal receptor from the aerosol generating matrix portion of the aerosol generating matrix.

[0171] Example Ex50: The method of Example Ex49, wherein the vibrating surface includes a sieve.

[0172] Example Ex51: The method of any one of Examples Ex1 to Ex50, wherein in step viii), the aerosol generating matrix portion of the aerosol generating matrix and the metal sensor are conveyed on a magnetic conveyor.

[0173] Example Ex52: The method of Example Ex51, wherein the magnetic conveyor includes an annular drive belt having a magnetic roller at one end.

[0174] Example Ex53: The method of Example Ex52, wherein the magnetic roller holds the metal sensor on the annular belt as the annular belt passes over the magnetic roller, while allowing the aerosol generating matrix to fall into the aerosol generating matrix collection container.

[0175] Example Ex54: The method of Example Ex53, wherein the metal sensor falls off the underside of the annular belt as the metal sensor is conveyed away from the magnetic roller.

[0176] Example Ex55: The method of Example Ex54, wherein the metal sensor falls from the underside of the annular band into the metal sensor collection accommodating portion.

[0177] Example Ex56: The method of any one of Examples Ex52 to Ex55, wherein the magnetic roller comprises at least one electromagnet.

[0178] Example Ex57: The method of any one of Examples Ex52 to Ex55, wherein the magnetic roller comprises at least one permanent magnet.

[0179] Example Ex58: The method of any one of Examples Ex1 to Ex50, wherein in step viii), the aerosol generating matrix portion of the aerosol generating matrix and the metal sensor are conveyed on a first conveyor, and wherein the magnetic field is applied by a suspended belt magnetic conveyor passing above the first conveyor.

[0180] Example Ex59: The method of Example Ex58, wherein the suspended magnetic conveyor includes a magnet disposed above the first conveyor so that the metal sensor is lifted off the first conveyor and conveyed away from the first conveyor on the underside of the suspended magnetic conveyor.

[0181] Example Ex60: The method of Example Ex58 or Ex59, wherein the suspended magnetic conveyor transports the metal sensor to the metal sensor collection receiving portion.

[0182] Example Ex61: A method of any one of Examples Ex58 to Ex60, wherein the suspended belt conveyor includes an electromagnet.

[0183] Example Ex62: A method of any one of Examples Ex58 to Ex60, wherein the suspended belt conveyor includes a permanent magnet.

[0184] Example Ex63: A system for processing strip-shaped consumable aerosol generating articles, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being enclosed in at least one circumferential package, the system comprising:

[0185] i) A vibrating screen configured to receive the aerosol-generating article, the vibrating screen having a surface through which the aerosol-generating article traverses;

[0186] ii) Alignment strip, the alignment strip including a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge;

[0187] iii) An actuator configured to position the aerosol-generating article within the transverse groove such that the first end bar portion abuts at least one of a first side edge and an opposing second side edge of the alignment strip;

[0188] iv) A cutter configured to cut the aerosol-generating article at at least two points along the length of the aerosol-generating article in order to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion;

[0189] v) A first separator, configured to separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion;

[0190] vi) A second separator configured to separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging;

[0191] vii) A cutter configured to cut the aerosol-generating matrix portion to expose the metal receptor; and

[0192] viii) A magnet configured to apply a magnetic field to separate the metal receptor from the aerosol-generating matrix portion.

[0193] Example Ex64: The system of Example Ex63 further includes a collection hopper configured to collect the aerosol-generated article before it crosses the surface of the vibrating screen.

[0194] Example Ex65: The system of Example Ex64, wherein the collection hopper is configured to vibrate the aerosol-generating article and controllably feed the aerosol-generating article into the vibrating screen.

[0195] Example Ex66: The system of Example Ex64 or Ex65 further includes a vertical conveyor with shelf sections, each shelf section being configured to receive and convey a batch of aerosol-generated products, the vertical conveyor being configured to feed the aerosol-generated products from the collection hopper to the vibrating screen.

[0196] Example Ex67: A system of any one of Examples Ex63 to Ex66, wherein the surface of the vibrating screen comprises a wire mesh or a grid.

[0197] Example Ex68: A system of any one of Examples Ex63 to Ex67, wherein the vibrating screen is provided with a vibrator configured to vibrate the surface at a frequency of 5 Hz to 100 Hz, optionally 30 Hz to 60 Hz.

[0198] Example Ex69: A system of any one of Examples Ex63 to Ex68, wherein the vibrating screen is provided with a vibrator configured to vibrate the surface with a vibration amplitude of 1 mm to 6 mm, optionally 3 mm to 4 mm.

[0199] Example Ex70: The system of any one of Examples Ex63 to Ex69 further includes an auxiliary belt having a substantially parallel track that runs at different speeds to align the aerosol generating article longitudinally with the direction of travel.

[0200] Example Ex71: The system of Example Ex70, wherein substantially parallel running tracks form separate longitudinal channels configured to receive the aerosol-generating articles longitudinally aligned with the direction of travel.

[0201] Example Ex72: The system of Example Ex71 further includes at least one brush configured to guide the aerosol-generating article into the longitudinal channel.

[0202] Example Ex73: The system of any one of Examples Ex70 to Ex72 further includes a transfer hopper configured to receive the aerosol-generating article from the auxiliary belt and collect the aerosol-generating articles which are substantially parallel to each other.

[0203] Example Ex74: The system of Example Ex73 further includes a secondary belt that runs substantially perpendicular to the auxiliary belt, the secondary belt being configured to collect longitudinally proximal aerosol-generated articles and convey the aerosol-generated articles to the transfer hopper, wherein the aerosol-generated articles are temporarily kept substantially parallel to each other in the transfer hopper before being assigned to the alignment belt.

[0204] Example Ex75: A system of any one of Examples Ex63 to Ex74, wherein the transverse groove of the alignment strip has a length greater than the length of the aerosol-generating article.

[0205] Example Ex76: The system of Example Ex75 also includes a sensor configured to determine the orientation of each aerosol-generating article within its respective lateral groove.

[0206] Example Ex77: The system of Example Ex76, wherein the sensor is an optical sensor.

[0207] Example Ex78: A system of Example Ex76 or Ex77, wherein the sensor is an image sensor.

[0208] Example Ex79: A system of any one of Examples Ex76 to Ex78, wherein the sensor is a pattern recognition sensor configured to identify a specific pattern on the at least one circumferential package.

[0209] Example Ex80: A system of any one of Examples Ex76 to Ex79, wherein the sensor is configured to determine whether a first end bar portion of a given aerosol-generating article is closer to a first side edge of the alignment strip than a second end bar portion, or whether the first end bar portion is closer to a second side edge of the alignment strip than the second end bar portion.

[0210] Example Ex81: The system of Example Ex80 further includes an air jet configured to move the aerosol-generating article within the transverse groove based on the orientation determined by the sensor, such that the first end bar portion abuts a corresponding first side edge or opposite second side edge of the alignment strip.

[0211] Example Ex82: The system of Example Ex80 further includes an electromechanical actuator configured to move the aerosol generating article within the transverse groove based on the orientation determined by the sensor, such that the first end bar portion abuts a corresponding first side edge or opposite second side edge of the alignment strip.

[0212] Example Ex83: A system of any one of Examples Ex63 to Ex82, wherein the cutter configured to cut the aerosol-generating article at at least two points along the length of the aerosol-generating article includes a pair of rotating blades configured to separate the aerosol-generating matrix portion from the first end bar portion and the second end bar portion.

[0213] Example Ex84: The system of Example Ex83, wherein a first pair of rotating blades is disposed adjacent to a first side of the alignment strip, and a second pair of rotating blades is disposed adjacent to a second side of the alignment strip.

[0214] Example Ex85: A system like Example Ex83 or Ex84, wherein the rotating blades are spaced apart from each other along the axis of rotation by a distance corresponding to the length of the aerosol-generating matrix portion.

[0215] Example Ex86: A system of any one of Examples Ex83 to Ex85, wherein the alignment band is provided with a recess configured to receive the cutting edge of the rotating blade so as to allow complete cutting through the aerosol-generating article in the transverse groove.

[0216] Example Ex87: A system of any one of Examples Ex83 to Ex86, wherein the rotating blades of each pair of rotating blades are substantially parallel to each other.

[0217] Example Ex88: A system of any one of Examples Ex83 to Ex87, wherein the rotating blades of each pair of rotating blades share a common axis of rotation.

[0218] Example Ex89: A system of any one of Examples Ex83 to Ex88, wherein the rotating blade has a toothed cutting edge.

[0219] Example Ex90: A system of any one of Examples Ex83 to Ex88, wherein the rotating blade has a smooth cutting edge.

[0220] Example Ex91: A system of any one of Examples Ex83 to Ex90, wherein each rotating blade has a cutting width greater than the maximum distance between the first rod end portion and the aerosol generating matrix portion, or greater than the maximum distance between the second rod end portion and the aerosol generating matrix portion.

[0221] Example Ex92: A system of any one of Examples Ex83 to Ex91, wherein the spacing between the rotating blades in each pair of rotating blades is adjustable.

[0222] Example Ex93: The system of Example Ex92 further includes a control unit configured to adjust the mutual spacing in response to input parameters relating to the type of aerosol-generated article being processed.

[0223] Example Ex94: The system of Example Ex92 further includes a sensing unit configured to determine the length of each aerosol generating matrix portion, and a control unit configured to adjust the mutual spacing in response to the determined length of each aerosol generating matrix portion.

[0224] Example Ex95: A system of any one of Examples Ex83 to Ex94, wherein the cutting angle of the rotating blade is adjustable.

[0225] Example Ex96: The system of Example Ex95 also includes a control unit configured to adjust the cutting angle of the rotating blade in response to input parameters relating to the type of aerosol-generated article being processed.

[0226] Example Ex97: A system of any one of Examples Ex63 to Ex96, wherein the alignment band is configured to hold the aerosol-generated article in the proper position in the transverse groove during cutting.

[0227] Example Ex98: The system of Example Ex97, wherein the transverse groove in the alignment band is provided with a suction hole to hold the aerosol-generated article in the proper position in the transverse groove during cutting.

[0228] Example Ex99: The system of Example Ex97 further includes a clamping roller to hold the aerosol-generated article in the proper position within the transverse groove during cutting.

[0229] Example Ex100: The system of any one of Examples Ex63 to Ex99 further includes at least one vacuum extractor configured to extract debris generated from cutting the aerosol-generated article.

[0230] Example Ex101: The system of Example Ex100, wherein the at least one vacuum extractor includes an adjustable nozzle.

[0231] Example Ex102: A system of any one of Examples Ex63 to Ex101, wherein the first separator is configured to separate the first end bar portion, the second end bar portion and the aerosol generating matrix portion from each other.

[0232] Example Ex103: The system of Example Ex102, wherein the alignment band is configured to shift the first end bar portion from the alignment band to the first end bar portion collection receiving portion.

[0233] Example Ex104: A system of Example Ex102 or Ex103, wherein the alignment band is configured to shift the second end bar portion from the alignment band to the second end bar portion collection receiving portion.

[0234] Example Ex105: A system of any one of Examples Ex102 to Ex104, wherein the first separator includes a pneumatic ejector configured to displace the first end bar portion or the second end bar portion from the alignment band.

[0235] Example Ex106: A system of any one of Examples Ex63 to Ex105, wherein the second separator includes a pneumatic ejector configured to apply an air jet to longitudinally blow the aerosol generating matrix portion including the metal sensor out of its circumferential package.

[0236] Example Ex107: A system of any one of Examples Ex63 to Ex105, wherein the second separator includes a cutter configured to cut the circumferential package along the length of the aerosol generating matrix portion.

[0237] Example Ex108: A system of any one of Examples Ex63 to Ex107, wherein the cutter of Example vii) is configured to cut the aerosol generating matrix portion along its length to expose the metal receptor.

[0238] Example Ex109: The system of Example Ex108, wherein the cutter in item vii) is a side cutter.

[0239] Example Ex110: The system of any one of Examples Ex63 to Ex109 further includes, between items vii) and viii), a vibrating surface configured to facilitate the disentanglement of the metal sensor from the aerosol generating matrix portion of the aerosol generating matrix.

[0240] Example Ex111: The system of Example Ex110, wherein the vibrating surface includes a sieve.

[0241] Example Ex112: A system of any one of Examples Ex63 to Ex111, wherein the magnet is included in a magnetic conveyor configured to convey the aerosol generating matrix portion and the metal sensor.

[0242] Example Ex113: The system of Example Ex112, wherein the magnetic conveyor includes an annular drive belt having a magnetic roller at one end.

[0243] Example Ex114: A system of Example Ex112 or Ex113, wherein the magnetic roller is configured to hold the metal sensor on the annular belt as the annular belt passes over the magnetic roller, while allowing the aerosol generating matrix to fall into the aerosol generating matrix collection containment.

[0244] Example Ex115: The system of Example Ex114, wherein the magnetic roller and the annular belt are configured to cause the metal sensor to fall off the underside of the annular belt as the metal sensor is conveyed away from the magnetic roller.

[0245] Example Ex116: The system of Example Ex115 further includes a metal sensor collection and receiving portion, wherein the metal sensor falls from the underside of the annular band into the metal sensor collection and receiving portion.

[0246] Example Ex117: A system of any one of Examples Ex113 to Ex116, wherein the magnetic roller includes at least one electromagnet.

[0247] Example Ex118: A system of any one of Examples Ex113 to Ex117, wherein the magnetic roller comprises at least one permanent magnet.

[0248] Example Ex119: A system of any one of Examples Ex63 to Ex111, wherein the aerosol generating matrix portion of the aerosol generating matrix and the metal sensor are conveyed on a first conveyor, and wherein the magnet is included in a suspended belt magnetic conveyor passing above the first conveyor.

[0249] Example Ex120: The system of Example Ex119, wherein the magnet of the suspended belt magnetic conveyor is positioned above the first conveyor so that the metal sensor is lifted off the first conveyor and conveyed away from the first conveyor on the underside of the suspended belt magnetic conveyor.

[0250] Example Ex121: The system of Example Ex119 or Ex120, wherein the suspended magnetic conveyor is configured to transport the metal sensor to the metal sensor collection receiving portion.

[0251] Example Ex122: A system of any one of Examples Ex119 to Ex121, wherein the magnet of the suspended belt conveyor includes an electromagnet.

[0252] Example Ex123: A system of any one of Examples Ex119 to Ex121, wherein the magnet of the suspended belt conveyor comprises a permanent magnet. Attached Figure Description

[0253] The examples will now be described further with reference to the accompanying drawings, in which:

[0254] Figure 1 A longitudinal section through the aerosol-generated article is shown schematically;

[0255] Figure 2 The method for separation is illustrated in schematic form. Figure 1 The process of generating components of an article from aerosols;

[0256] Figure 3 A schematic plan view of the vibrating screen is shown.

[0257] Figure 4A schematic plan view of the auxiliary strip is shown.

[0258] Figure 5 The feeding of the aerosol-generated article onto the secondary belt is shown schematically. Figure 4 The end of the auxiliary belt;

[0259] Figure 6 The diagram illustrates the passage through the arrangement in Figure 5 A side elevation cross-sectional view of the transfer hopper between the secondary belt and the alignment belt;

[0260] Figure 7 A schematic diagram of the alignment strip is shown.

[0261] Figure 8 The rotating blade of the aerosol-generating article cutter is shown; and

[0262] Figure 9 A magnetic separator is shown schematically. Detailed Implementation

[0263] Figure 1 A longitudinal section through an exemplary aerosol-generating article 1 is shown, which includes five different components or segments arranged coaxially: a first end bar portion 10, an aerosol-generating matrix portion 11 with a metal sensor 12, a hollow acetate tube (HAT) filter 13, a fine hollow acetate tube (FHAT) filter 14, and a mouthpiece filter 15. The HAT filter 13, FHAT filter 14, and mouthpiece filter 15 may together form a second end bar portion 19. These components are arranged sequentially and tightly housed within an outer packaging 16 and a tipping paper 18 to form a cylindrical strip. In the illustrated example, the metal sensor 12 has the form of a flat strip, but other shapes and specifications may be implemented.

[0264] Exemplary dimensions and materials for the various components are listed in Tables 1 and 2 above.

[0265] The aerosol-generating article 1 is designed to adhere to precise manufacturing specifications. However, during the manufacturing and assembly process of the aerosol-generating article 1, deviations in segment dimensions and variations in the output of the assembly equipment can cause discrepancies within the specifications of the final product. In some cases, these variations can create gaps 17, such as between the front end bar portion 10 and the aerosol-generating matrix portion 11, or between the second end bar portion 19 and the aerosol-generating matrix portion 11. For example, when fully assembled, the aerosol-generating matrix portion 11 may slightly shift from its ideal position, and the assembly equipment is typically configured to continuously monitor these process parameters and take appropriate action depending on whether the finished aerosol-generating article 1 is acceptable according to predefined tolerance targets. If not, the aerosol-generating article 1 may be rejected. Furthermore, other aerosol-generating articles 1, whether finished or semi-finished, may be rejected from the manufacturing process due to encapsulation deformation during the initial encapsulation stage, or immediately after the formation of the initial aerosol-generating matrix portion 11 following the curling of the aerosol-generating matrix material.

[0266] In any case, aerosol-generated articles 1 that fail to meet the necessary quality standards are considered defective and must be removed before the final packaging stage of the final product. Subsequently, in order to minimize waste and maximize resource utilization, it is common practice to recover high-value components (especially aerosol-generating matrices containing nicotine or tobacco, or metal receptors 12, or both aerosol-generating matrices and metal receptors 12) from these rejected aerosol-generated articles 1 for recycling or reintroduction into the manufacturing process.

[0267] Various aspects of the present invention relate to a recycling process that overcomes the limitations of existing systems by implementing precise control over the separation and recycling of individual components from an aerosol-generating article 1 (e.g., a "heat-not-burn" tobacco article). The recycling process includes the following steps: vibrating a large quantity of aerosol-generating articles; aligning individualized aerosol-generating articles in a transverse direction using an alignment belt; monitoring the precise orientation of the aerosol-generating articles using a sensing unit; cutting the aerosol-generating articles into individual segments using a precision cutter; and separating the aerosol-generating matrix (e.g., a tobacco or nicotine matrix) from a metal sensor using a magnet.

[0268] In this embodiment, the process involves a conveyor system integrating multiple machines for transferring, sorting, and separating aerosol-generated articles. A vibrating screen removes unwanted components, ensuring that only clean and appropriately sized aerosol-generated articles proceed to the cutting stage. Furthermore, an alignment belt, in cooperation with a positioning device, ensures proper alignment of the aerosol-generated articles, regardless of their orientation during loading. The cutting operation is then performed by a precision cutter equipped with multiple rotating blades. The precision cutter engages the aerosol-generated articles at specific points along their length, aligning the ends of the aerosol-generating matrix portion. The cutting width of the blades can be carefully selected to prevent cross-contamination and ensure precise cutting.

[0269] To minimize cross-contamination, an extraction system can be provided to remove debris from the cutting process. A vacuum extractor can be oriented to capture debris ejected from the rotating blades, ensuring clean and efficient operation. Furthermore, the recovery process includes a magnetic separator, which effectively separates the metal sensors from the transported blend of aerosol-generated matrix and metal sensors. This step ensures proper management of each component for subsequent processing.

[0270] Embodiments of the present invention address some limitations of current systems by introducing a recycling process designed for induction-heated aerosol-generated articles using metal sensors. The risk of cross-contamination during the recycling process is reduced by incorporating a precision cutter in conjunction with the extraction mechanism. Furthermore, the inclusion of a magnetic separator enables efficient recycling of induction-heated aerosol-generated articles. Embodiments of the present invention can improve the overall efficiency of the recycling process, resulting in higher recycling rates consistent with regulatory frameworks and sustainability standards.

[0271] Figure 2 An exemplary recycling process according to an embodiment of the present invention is illustrated in schematic form. The process aims to separate the aerosol-generating article 1 into its constituent components.

[0272] During the manufacture of aerosol-generating articles, a certain amount of rejected aerosol-generating articles 1 are transferred to a facility where a recycling process 2 can be performed. (Reference) Figure 2 The recycling process 2 is performed by a conveyor system 20 that integrates multiple machines for transferring, sorting, and separating the aerosol-generated article 1 into its components. Generally, the conveyor system 20 can integrate a belt conveyor that uses a continuous loop to guide and transfer the aerosol-generated article 1 along the longitudinal processing path. Alternatively, the conveyor system 20 can integrate a roller conveyor that uses a series of cylindrical rollers to shift the aerosol-generated article 1. It should be understood that different suitable conveyors can be used for each step during the recycling process. In this sense, different modular conveyors can also be adapted to the specific requirements of each step along the processing path.

[0273] The recovery process 2 begins by feeding the bulk 21 of aerosol-generated articles 1 into the conveying system 20. In a particular embodiment, for this step, a collection hopper 22 is configured to collect and act as a buffer, dispensing small amounts of aerosol-generated articles 1 from the bulk 21. The collection hopper 22 may include a vibrator, such as an electromechanical agitator for vibrating the bulk 21. Especially when conveyed in bulk form (meaning tightly packed), the aerosol-generated articles 1 may become entangled with each other. Some aerosol-generated articles 1 may not be straight and may form a curved shape that hooks onto adjacent aerosol-generated articles 1, thereby hindering the smooth flow of individual aerosol-generated articles 1 and causing interruptions in the recovery process. By vibrating the bulk 21, the collection hopper 22 untangles the aerosol-generated articles 1, thereby ensuring that individual aerosol-generated articles 1 flow consistently and continuously along the additional processing steps of the recovery process 2.

[0274] After the bulk material 21 of the aerosol-generated product 1 is released and individually disposed of, a vibrating screen 23 downstream of the collection hopper 22 receives small batches of the aerosol-generated product 1 from the collection hopper 22 in a controlled manner. In a particular embodiment, the controlled distribution from the collection hopper 22 is supported by a vertical conveyor with shelf partitions adapted to receive output loads from the collection hopper 22. The vertical conveyor (also referred to as a lift conveyor) enables efficient utilization of available vertical space within the processing facility. The vertical conveyor unloads small batches of the aerosol-generated product 1 along the vibrating screen 23, aiming to remove unwanted components from the recycling process.

[0275] like Figure 3 As shown, the vibrating screen 23 can be configured as a wire mesh integrating a mesh structure with small openings 230.

[0276] In another preferred embodiment, the vibrating screen 23 may include a mechanical agitator for providing controlled vibration to the aerosol-generating article 1. These vibrations are characterized by being set to specific amplitudes and frequencies to ensure optimal separation of the aerosol-generating article 1 from unwanted waste or foreign particles. For example, the optimal amplitude range may be between 1 mm and 6 mm, more preferably 3 to 4 mm. For example, the optimal optical frequency may be between 5 and 100 Hz, more preferably between 30 and 60 Hz.

[0277] The amplitude (which refers to the magnitude of the vibration) and frequency (which is the vibration rate of the vibrating screen 23) can be adjusted to ensure that smaller waste materials fall into the designated waste container through the opening 230, while larger, clean, and appropriately sized aerosol-generating products 1 cannot pass through the screen.

[0278] The vibration frequency can be set to a high value to ensure rapid separation of waste, while the amplitude can be kept at a medium level to prevent damage to the aerosol-generated products. In addition, the direction and mode of vibration can be adjusted to promote uniform distribution of the aerosol-generated products on the vibrating screen 23 and prevent aggregation.

[0279] continue Figure 2 In the recycling process, prior to the cutting operation, the recycling process can be integrated with machinery used to align the aerosol-generated article 1 longitudinally with the direction of travel for conveying it to the cutting step. In a particular embodiment, such as Figure 4 As shown, the vibrating screen 23 conveys the individual aerosol-generated product 1 toward the auxiliary belt 300.

[0280] Figure 4 This is a schematic plan view of the aerosol-generated articles 1 that are substantially randomly oriented across the vibrating screen 23. The aerosol-generated articles 1 are then conveyed onto an auxiliary belt 300. The auxiliary belt 300 includes parallel running tracks that form individual channels for the aerosol-generated articles 1 received from the vibrating screen 23. In this way, each aerosol-generated article 1 loaded within the auxiliary belt is guided longitudinally along the conveying motion. For example, brushes 305 (which may be rotating brushes) may be arranged across the longitudinal direction of travel of the auxiliary belt 300. Brushes 305 can guide the aerosol-generated articles 1 into individual channels such that all aerosol-generated articles 1 are substantially parallel to each other and aligned with the longitudinal direction of travel. Brushes 305 may be used in conjunction with mechanical guides to ensure that individual aerosol-generated articles 1 are properly loaded into the channels. Brushes 305 may be mounted on a motorized boom or conveyor system, and the bristles of brushes 305 may be designed to gently guide the aerosol-generated articles 1 into the channels.

[0281] Figure 5 This is a schematic plan view of the downstream end of the auxiliary belt 300. Aerosol-generating articles 1 in a separate channel are fed onto a secondary belt 301, which has a travel direction substantially perpendicular to the travel direction of the auxiliary belt 300. It will be seen that the aerosol-generating articles 1 on the secondary belt 301 are arranged substantially parallel to each other, but now in an orientation substantially perpendicular to the travel direction. The longitudinal ends of the aerosol-generating articles 1 are also generally aligned, but it should be noted that each aerosol-generating article 1 may take one of two possible orientations—either where the first end bar portion is on the left side of the secondary belt 301 (relative to the travel direction), or where the first end bar portion is on the right side of the secondary belt 301 (relative to the travel direction).

[0282] Subsequently, a transfer hopper can be provided for parallel collection of the upcoming longitudinally aligned aerosol-generated article 1. Figure 6In the specific embodiment shown, a secondary belt 301, operating perpendicular to the auxiliary belt 300, collects the upcoming longitudinally aligned aerosol-generated article 1 and stores it in a transfer hopper 302 suitable for controlled dispensing of individual aerosol-generated articles 1. The transfer hopper 302 can provide both buffering and dispensing functions. As will be described in detail below, the transfer hopper 302 can be configured to dispense the aerosol-generated article 1 onto the alignment belt 25.

[0283] like Figure 7 As shown, as a final step in aligning the aerosol-generated article 1 for the cutting operation, the transfer hopper 302 can be adapted to load a single aerosol-generated article 1 into a specific receiving portion of the alignment belt 25. Figure 7 In the embodiment depicted, the alignment belt 25 is designed with multiple transverse slotted portions or transverse grooves 250. These portions 250 have a larger longitudinal dimension than the aerosol-generated article 1. This allows the transfer hopper to load the aerosol-generated article 1 into the portions 250 and to convey the aerosol-generated article toward the first side edge 251 of the alignment belt 25. During transfer, the aerosol-generated article 1 can be oriented in either of two ways: wherein the first end bar portion 10 faces the first side edge 251 of the alignment belt 25, or wherein the second end bar portion 19 faces the first side edge 251 of the alignment belt 25.

[0284] In a particular embodiment, the alignment belt 25 is configured to convey the aerosol-generated article flow in a conveying direction X perpendicular to the longitudinal direction of the aerosol-generated article 1, which is also a preferred direction for the cutting operation. Figure 7 As shown, shortly after the aerosol-generating article 1 is loaded, a sensing unit 31, preferably positioned on the edge of the alignment strip 25, is used to detect the precise orientation of the aerosol-generating article 1 within the receiving portion 250. This sensing unit 31 can be an optical sensor, such as an image sensor. In a preferred embodiment, the sensing unit 31 includes a pattern recognition sensor that identifies a specific pattern printed on the outer packaging of the aerosol-generating article 1. By performing image analysis and pattern recognition algorithms, the sensing unit 31 can accurately determine the orientation of the aerosol-generating article 1 by comparing the detected pattern with a stored reference pattern.

[0285] If the sensing unit 31 detects the second end bar portion 19 instead of the first end bar portion 10, the aerosol-generating article 1 is moved toward the second side edge 252 of the alignment belt 25 by the positioning mechanism 32. For example, the positioning mechanism 32 can be an air blowing device or electromechanical actuator that gently pushes the aerosol-generating article 1 toward the second side edge 252. With this alignment, the aerosol-generating article 1 can be conveyed independently of its orientation by the alignment belt 25 toward precision cutters 26A, 26B configured to cut through the aerosol-generating article 1. In an embodiment, the precision cutters 26A, 26B are positioned on both sides of the alignment belt 25, with the first precision cutter 26A for the flow of aerosol-generating article 1 traveling adjacent to the first side edge 251, and the second precision cutter 26B for the flow of aerosol-generating article 1 traveling adjacent to the second side edge 252. It should be noted that although this embodiment utilizes two precision cutters 26A, 26B on both sides of the alignment belt 25, the number of precision cutters can be varied as needed.

[0286] In a particular embodiment, each precision cutter 26A, 26B is designed to separate the aerosol generating matrix portion 11 from the first rod end portion 10 and the second rod end portion 19. To this end, the precision cutters 26A, 26B are configured to engage the aerosol generating article 1 at two different points along the length of the aerosol generating article, thereby matching the ends of the aerosol generating matrix portion 11. For this purpose, each precision cutter 26A, 26B is equipped with two parallel rotating blades 40, 41, wherein the cutting plane matches the ends of the aerosol generating matrix portion 11 in the aerosol generating article 1. To achieve complete cut-through, the alignment band 25 includes a recess 253 through which the cutting edges of the rotating blades 40, 41 protrude. Figure 8 In the exemplary embodiments shown, the rotating blades 40, 41 include circular or disc blades having a circumferential cutting edge 42 with a notch or teeth.

[0287] Furthermore, to achieve precise cutting with the greatest possible prevention of cross-contamination, the precision cutters 26A and 26B should ensure that their cutting width is always greater than the maximum possible gap 17 between segments and the maximum deviation from their center cutting position. This can be achieved by selecting the width of the cutting blades 40 and 41, taking into account the maximum gap tolerance in the manufacture of the aerosol-generating article 1 and the maximum displacement that the aerosol-generating article 1 may experience from its center position within the receiving portion 250. For example, the maximum possible gap 17 between the segments of the aerosol-generating article 1 can be specified as 10 micrometers, and the maximum deviation of the aerosol-generating article 1 from its center position within the receiving portion 250 is 10 micrometers. In this case, the blade portions 40 and 41 of the precision cutters 26A and 26B can be designed to have a cutting width of 20 micrometers. In practice, the cutting width dimension can also take into account other manufacturing tolerances of the cutting equipment or the alignment band 25.

[0288] In another embodiment, the aerosol-generating article 1 can be held in place in its receiving portion 250 by an additional device during the cutting operation. For example, shortly before reaching the rotating blades 40, 41, the clamping rollers (not shown) preceding the precision cutters 26A, 26B can press slightly against the aerosol-generating article 1 during cutting.

[0289] In this embodiment, based on predefined input parameters regarding a specific type of aerosol-generating article 1, precision cutters 26A and 26B can perform preset adjustments to perform the cutting operation more precisely. In this embodiment, precision cutters 26A and 26B are connected to a control unit adapted to receive input parameters related to the type of aerosol-generating article 1. In this way, before initiating the recovery process, the operator can input a set of parameters corresponding to the type of aerosol-generating article 1 to be processed. These parameters include the desired length of each component segment, acceptable tolerances for segment length variations, and a preferred orientation for cutting (e.g., perpendicular to the length of the aerosol-generating article 1 or at an angle). In this way, precision cutters 26A and 26B can calibrate themselves for the specific type of aerosol-generating article 1 to be cut, or the control device can instruct the operator to perform manual calibration (e.g., by replacing one precision cutter 26A or 26B with a different precision cutter 26A or 26B).

[0290] To further minimize cross-contamination, the extraction system can be configured to rapidly and efficiently remove any byproducts from the cutting process. For example, see reference... Figure 7 The vacuum extractor 51 can be oriented to capture any debris discharged from the rotating blades 40, 41 during the cutting operation. An extraction system designed for this purpose may include a nozzle that can be precisely positioned to optimize debris capture. This nozzle (which may be adjustable) is oriented towards the cutting area to ensure maximum extraction efficiency.

[0291] The recycling process continues, and after the cutting operation, the cut and segmented aerosol-generating article 1 is further sorted into different paths. In an embodiment, sorting unit 27 separates the aerosol-generating matrix portion 11 from the first end bar portion 10 and the second end bar portion 19. For example, sorting unit 27 may employ a pneumatic ejector that operates by guiding a high-speed gas flow to advance the first end bar portion 10 outward from the alignment strip 25 into a designated container 30. Similarly, the pneumatic ejector may advance the second end bar portion 19 toward another designated container 30 (e.g., including a mouthpiece filter 15, along with HAT 13 and FHAT 14). Thereafter, a mechanical actuator may be configured to move the aerosol-generating matrix portion 11 toward a blower that ejects the aerosol-generating matrix with the metal sensor 12 from the outer packaging 16.

[0292] At this stage, the aerosol generating matrix and the metal sensor 12 form a blend, which can undergo further processing 29 for unwinding. A side cutter can be used to cut the aerosol generating matrix to release or expose the core material of the metal sensor 12. An additional conveyor with a vibrating screen can be used to further unwind the metal sensor 12 from the fibers within the aerosol generating matrix.

[0293] Now for reference Figure 9 Magnetic separator 29 can be positioned to magnetically separate metal receptor 12 from the transported blend 60 of aerosol-generating matrix and metal receptor. In one embodiment, the magnetic separator is a magnetic conveyor 70. Figure 9 As shown, when the conveyed blend 60 reaches the arc portion 71 of the magnetic conveyor 70, the magnetic force from the device of the electromagnet 72 holds the metal sensor against the surface of the magnetic conveyor 70. This holding continues until the blend 60 reaches the end of the arc portion 71. At this point, the magnetic attraction from the electromagnet 72 is insufficient to hold the metal sensor, and the guide wall 73 facilitates the downstream movement of the metal sensor toward the designated container. In contrast, the aerosol-generating matrix fibers, which do not experience the attraction from the electromagnet 72, are affected by gravity and fall toward individual containers. This process effectively separates the metal sensor from the aerosol-generating matrix fibers, thereby ensuring that each component can be properly managed afterwards. In an alternative embodiment, the magnetic separator may be a suspended belt magnetic conveyor.

[0294] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein. Thus, in this context, the number A is understood to be 5% of A ± A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the property modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein.

Claims

1. A method for processing strip-shaped consumable aerosol generating articles, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being encapsulated in at least one circumferential packaging material, the method comprising the following steps: i) Feed the aerosol-generated product onto a vibrating screen and make the aerosol-generated product cross the surface of the vibrating screen; ii) After the aerosol-generating article has traversed the surface of the vibrating screen, it is arranged on an alignment strip comprising a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge; iii) Position the aerosol-generating article within the transverse groove such that the first end bar portion is adjacent to at least one of the first side edge and the opposite second side edge of the alignment strip; iv) Cut the aerosol-generating article at at least two points along its length to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion; v) Separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion; vi) Separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging; vii) Cutting the aerosol-generated matrix portion to expose the metal receptor; viii) Apply a magnetic field to separate the metal receptor from the aerosol-generating matrix portion; as well as (ix) Collect the aerosol-generating matrix portion and the metal receptor respectively.

2. The method of claim 1, wherein prior to step i), the aerosol-generating article is collected in a collection hopper, and wherein the aerosol-generating article is vibrated in the collection hopper before being controllably fed into the vibrating screen.

3. The method according to claim 1 or 2, wherein after step i) and before step ii), the aerosol-generating article is conveyed on an auxiliary belt comprising a substantially parallel track running at different speeds to align the aerosol-generating article longitudinally with the direction of travel.

4. The method of claim 3, wherein the aerosol-generating article is transferred from the auxiliary belt to a transfer hopper configured to collect the aerosol-generating articles which are substantially parallel to each other.

5. The method according to any one of claims 1 to 4, wherein in step ii), the lateral groove of the alignment band has a length greater than the length of the aerosol-generating article, and wherein the alignment band includes a sensor for determining the orientation of each aerosol-generating article within its respective lateral groove.

6. The method according to any one of claims 1 to 5, wherein in step iv), each aerosol-generating article is cut by a pair of rotating blades to separate the aerosol-generating matrix portion from the first end bar portion and the second end bar portion.

7. The method of claim 6, wherein each rotating blade has a cutting width greater than the maximum distance between the first rod end portion and the aerosol generating matrix portion, or greater than the maximum distance between the second rod end portion and the aerosol generating matrix portion.

8. The method according to any one of claims 1 to 7, wherein in step viii), the aerosol generating matrix portion and the metal sensor are conveyed on a magnetic conveyor, wherein the magnetic conveyor includes an annular drive belt having a magnetic roller at one end, and wherein the magnetic roller holds the metal sensor on the annular belt as the annular belt passes over the magnetic roller, while allowing the aerosol generating matrix to fall into the aerosol generating matrix collection container.

9. A system for processing strip-shaped consumable aerosol generating articles, each of the strip-shaped consumable aerosol generating articles comprising an aerosol generating matrix portion, the aerosol generating matrix portion including a metal sensor, the aerosol generating matrix being longitudinally disposed between a first end rod portion and a second end rod portion, the aerosol generating matrix and the first end rod portion and the second end rod portion being enclosed in at least one circumferential package, the system comprising: i) A vibrating screen configured to receive the aerosol-generating article, the vibrating screen having a surface through which the aerosol-generating article traverses; ii) Alignment strip, the alignment strip including a plurality of transverse grooves configured to receive the aerosol-generating article substantially parallel to each other, the alignment strip having a first side edge and an opposing second side edge; iii) An actuator configured to position the aerosol-generating article within the transverse groove such that the first end bar portion abuts at least one of a first side edge and an opposing second side edge of the alignment strip; iv) A cutter configured to cut the aerosol-generating article at at least two points along the length of the aerosol-generating article in order to separate the first end bar portion and the second end bar portion from the aerosol-generating matrix portion; v) A first separator, configured to separate the aerosol generating matrix portion from the first end rod portion and the second end rod portion; vi) A second separator configured to separate the aerosol-generating matrix portion, including the metal sensor, from its circumferential packaging; vii) A cutter configured to cut the aerosol-generating matrix portion in order to expose the metal receptor; as well as viii) A magnet configured to apply a magnetic field to separate the metal receptor from the aerosol-generating matrix portion.

10. The system of claim 9, further comprising a collection hopper configured to collect the aerosol-generating article before it traverses the surface of the vibrating screen, wherein the collection hopper is configured to vibrate the aerosol-generating article and controllably feed the aerosol-generating article into the vibrating screen.

11. The system of claim 9 or 10 further includes an auxiliary belt having a substantially parallel track that operates at different speeds to align the aerosol-generating article longitudinally with the direction of travel.

12. The system of claim 11, further comprising a transfer hopper configured to receive the aerosol-generated articles from the auxiliary belt and collect the aerosol-generated articles which are substantially parallel to each other.

13. The system according to any one of claims 9 to 12, wherein the lateral groove of the alignment strip has a length greater than the length of the aerosol generating article, and wherein the system further comprises a sensor configured to determine the orientation of each aerosol generating article within its respective lateral groove.

14. The system according to any one of claims 9 to 13, wherein the cutter configured to cut the aerosol-generating article at at least two points along the length of the aerosol-generating article comprises a pair of rotating blades configured to separate the aerosol-generating matrix portion from the first end bar portion and the second end bar portion.

15. The system according to any one of claims 9 to 14, wherein the magnet is included in a magnetic conveyor configured to convey the aerosol generating matrix portion and the metal sensor, wherein the magnetic conveyor includes an annular drive belt having a magnetic roller at one end, and wherein the magnetic roller is configured to hold the metal sensor on the annular belt as the annular belt passes over the magnetic roller, while allowing the aerosol generating matrix to fall into the aerosol generating matrix collection containment.

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