Apparatus and method for manufacturing consumable for aerosol provision system

Abstract

To provide an apparatus for manufacturing a consumable for an aerosol provision system that determines whether there is a defect in a sheet of aerosol-generating material.SOLUTION: An apparatus 1 includes a feeding apparatus 2 for receiving a sheet 3 of aerosol-generating material and supplying it along a conveyance path, and a sensor 5 configured to detect information indicative of defects as the sheet of aerosol-generating material passes. The apparatus further includes a consumable forming apparatus 7 configured to receive the sheet of aerosol-generating material and form it into a consumable 8; and a controller configured to determine whether there is a defect in the sheet of aerosol-generating material based on the information detected by the sensor. The invention also relates to a consumable for an aerosol provision system manufactured by the apparatus and / or method. Additionally, the invention relates to: an apparatus and method for analyzing a sheet of aerosol-generating material for a consumable for an aerosol provision system; a controller for the apparatus; and a system for manufacturing a consumable for an aerosol provision system.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an apparatus for manufacturing a consumable for an aerosol supply system and a method for manufacturing a consumable for an aerosol supply system. The present disclosure further relates to a consumable for an aerosol supply system manufactured by the apparatus and / or method disclosed herein. Additionally, the present disclosure relates to an apparatus for analyzing a sheet of an aerosol generating material for a consumable for an aerosol supply system and a controller for the apparatus for analyzing a sheet of an aerosol generating material. Furthermore, the present disclosure also relates to a system for manufacturing a consumable for an aerosol supply system.

Background Art

[0002] Certain tobacco industry products generate an aerosol that is inhaled by a consumer during use. For example, a tobacco heating device heats an aerosol generating material such as tobacco to form an aerosol by heating the material without burning it. The quality and uniformity of the aerosol generating material are important for the quality of the product and the consumer's perception when using the product.

Summary of the Invention

[0003] The present disclosure provides an apparatus for manufacturing a consumable for an aerosol supply system, the apparatus including: a supply device configured to receive a sheet of an aerosol generating material and supply the sheet of the aerosol generating material along a conveyance path; a sensor configured to detect information indicating a defect in the sheet of the aerosol generating material when the sheet of the aerosol generating material passes along the conveyance path; a consumable forming device configured to accommodate the sheet of the aerosol generating material and form the sheet of the aerosol generating material into a consumable; and a controller configured to determine the presence or absence of a defect in the sheet of the aerosol generating material based on the information detected by the sensor.

[0004] In some embodiments, the controller is configured to determine the position of a defect in a consumable based on information detected by a sensor.

[0005] In some embodiments, the position of the defect includes the axial position of the defect along the consumable.

[0006] In some embodiments, the controller is configured to determine one or more parameters of the defect, and preferably the parameters of the defect include one or more of length, width, depth, the angle of the extent of the defect with respect to the direction of the transport path, the area of the defect, the density of the sheet, the thickness of the sheet, or the porosity of the sheet.

[0007] In some embodiments, one or more defects may be present within one or more individual regions of the sheet. In other embodiments, the defects may be present throughout the sheet or substantially throughout the sheet. For example, the entire sheet may be inadvertently manufactured such that the parameters of the sheet material deviate from the desired values. The parameters may be one or more of the density / thickness / porosity of the sheet material. For example, the density of the sheet material may be less than the desired density, which makes it difficult to reduce the sheet passing through the apparatus. The sensor may be configured to detect that the density of the sheet material is low (or that some other parameter deviates from the target value or target range), and the controller may be configured to determine the presence or absence of the defect in the sheet of the aerosol generating material based on the information detected by the sensor.

[0008] In some embodiments, the controller is configured to compare the parameter of the defect with a preset value.

[0009] In some embodiments, the controller is configured to classify the defect based on a comparison of the parameter of the defect with a preset value, and preferably the classification relates to the severity of the defect.

[0010] In some embodiments, the controller is configured to evaluate the quality of the entire sheet of aerosol-generating material based on the amount or surface density of one or more defects and / or the classification of one or more defects. In some embodiments, the controller is configured to evaluate the quality of the entire sheet of aerosol-generating material based on the amount or surface density of one or more defects and / or the classification of one or more defects within a certain region. The region may include, for example, the end of the sheet material.

[0011] In some embodiments, the controller is configured to determine the presence or absence of defects in at least one individual region of the sheet of aerosol-generating material based on information detected by a sensor.

[0012] In some embodiments, the controller is configured to determine the presence or absence of defects along substantially the entire length of the sheet of aerosol-generating material based on information detected by a sensor.

[0013] In some embodiments, a defect is a deviation from a target range or value of at least one parameter of the sheet along substantially the entire length of the sheet of aerosol-generating material, and preferably the parameter is one or more of the thickness, density or porosity of the sheet.

[0014] In some embodiments, the controller is configured to evaluate the quality of a region of the sheet of aerosol-generating material based on the amount or surface density of one or more defects and / or the classification of one or more defects within the region.

[0015] In some embodiments, the quality evaluation creates quality requirements criteria, and preferably the controller is configured to store the criteria in memory, and preferably the criteria are associated with the region.

[0016] In some embodiments, that region of the sheet corresponds to an individual consumable aerosol-generating material or a batch of individual consumables formed by the device.

[0017] In some embodiments, the controller is configured to perform a specific operation based on an evaluation of the quality of the area.

[0018] In some embodiments, the operation includes sending a signal indicating that the quality of the area is below a predefined value, preferably that the entire area and / or the sheet material should be discarded and / or recycled.

[0019] In some embodiments, the operation includes sending a signal indicating that when the evaluation of the quality of the area determines that the quality is below a predefined value, preferably when it is determined that the consumable or batch of consumables including the area should be discarded and / or recycled, the consumable or batch of consumables including the area should be sorted from other consumables or batches of consumables formed by the consumable forming device.

[0020] In some embodiments, the sensor includes a signal generator and a signal receiver for detecting defects, and preferably the signal is a laser signal.

[0021] In some embodiments, the device of the present invention includes a plurality of sensors.

[0022] In some embodiments, these sensors are configured to detect an area of the sheet offset in a direction perpendicular to the direction of the transport path and / or an area of the sheet offset in a direction along the transport path.

[0023] In some embodiments, the sensor is configured to determine at least a part of the topology of the sheet of the aerosol generating material.

[0024] In some embodiments, the sensor is located above or below the sheet of the aerosol generating material.

[0025] In some embodiments, the sensor includes a camera.

[0026] In some embodiments, the apparatus of the present invention further includes a light emitter configured to direct light onto a sheet of aerosol generating material.

[0027] In some embodiments, the light emitter is located on a surface of the sheet of aerosol generating material that is distal to the camera.

[0028] In some embodiments, the light emitter is located on both sides of the sheet of aerosol generating material.

[0029] In some embodiments, the light emitter includes a filter.

[0030] In some embodiments, the camera includes a filter, preferably the filter is an optical filter.

[0031] In some embodiments, the filter of the light emitter is configured to pass electromagnetic radiation, and at least a portion thereof has the same frequency as the electromagnetic radiation passed by the filter of the camera.

[0032] In some embodiments, the camera is a three-dimensional camera configured to detect a three-dimensional image of the sheet.

[0033] In some embodiments, the defects detected by the sensor include one or more of holes, slits, non-uniformity of the sheet thickness, low-density regions, voids, tears, lumps, sheet thickness deviating from a desired range or value, sheet density deviating from a desired range or value, and sheet porosity deviating from a desired range or value.

[0034] In some embodiments, the thickness, density or porosity of the sheet may be determined by transmitting electromagnetic radiation (e.g., visible light) to one side of the sheet and measuring the amount of electromagnetic radiation (e.g., the amount of light) detected on the other side of the sheet. If the amount of electromagnetic radiation detected on the other side of the sheet is small, it has been found that the sheet material is a thin, low-density and / or highly porous sheet. In some embodiments, the thickness, density or porosity of the sheet may be detected using an X-ray or microwave sensor. In yet another embodiment, the thickness, density or porosity of the sheet may be detected using ultrasonic waves.

[0035] In some embodiments, the supply device supplies a continuous sheet of aerosol generating material, preferably the supply device includes a bobbin accommodating mechanism for accommodating a bobbin of the aerosol generating material sheet, and preferably the supply device includes a bobbin of the aerosol generating material sheet.

[0036] In some embodiments, the sheet of aerosol generating material includes tobacco.

[0037] In some embodiments, the consumable forming device includes a strip forming device configured to form a sheet of aerosol generating material into strips.

[0038] In some embodiments, the strip forming device includes a cutting device configured to cut at least a portion of the sheet of aerosol generating material into strips of aerosol generating material.

[0039] In some embodiments, the consumable forming device includes a collecting device configured to collect strips of aerosol generating material.

[0040] In some embodiments, the consumable forming device includes a winding device configured to wrap the aerosol generating material with a wrapper.

[0041] In some embodiments, the consumable forming device includes a cutting device for cutting the consumable into individual consumables.

[0042] In some embodiments, the individual consumables are consumables of a single length or a double length.

[0043] In some embodiments, the controller is configured to associate a defect with an individual consumable.

[0044] In some embodiments, the controller is configured to associate a defect with a batch of individual consumables formed by a consumable forming device.

[0045] In some embodiments, the apparatus of the present invention includes a sorting device configured to remove an individual consumable determined by the controller to include one or more defects.

[0046] In some embodiments, the consumable is a rod.

[0047] The present disclosure also provides an apparatus for analyzing a sheet of aerosol generating material formed on a consumable for an aerosol supply system. The apparatus includes a sensor configured to detect information indicating a defect in the sheet of aerosol generating material when the sheet of aerosol generating material passes along a conveyance path, and a controller configured to determine the presence or absence of a defect in the sheet of aerosol generating material based on the information detected by the sensor.

[0048] In some embodiments, the apparatus of the present invention has one or more of the features of the above-described apparatus.

[0049] The present disclosure also provides a controller for an apparatus for analyzing a sheet of aerosol generating material formed on a consumable for an aerosol supply system. The controller is configured to be connected to a sensor. The sensor is configured to detect information indicating a defect in the sheet of aerosol generating material, and the controller is configured to determine the presence or absence of a defect in the sheet of aerosol generating material based on the information detected by the sensor.

[0050] In some embodiments, the sensor is configured to detect information indicating a defect in the aerosol generating material sheet as the aerosol generating material sheet passes along the transport path.

[0051] In some embodiments, the controller has one or more of the features of the apparatus described herein.

[0052] The present disclosure also provides a method of manufacturing a consumable for an aerosol supply system, the method comprising supplying an aerosol generating material sheet along a transport path, detecting information indicating a defect in the aerosol generating material sheet as the aerosol generating material sheet passes along the transport path, forming the aerosol generating material sheet into a consumable, and determining the presence or absence of a defect in the consumable based on the detected information.

[0053] In some embodiments, the method of the present invention includes determining the location of a defect in the consumable formed based on the detected information, preferably determining the axial location of the defect.

[0054] In some embodiments, the method of the present invention includes determining one or more parameters of the defect, preferably the parameters of the defect include one or more of length, width, depth, angle of the extent of the defect with respect to the direction of the transport path, area of the defect, density of the sheet, thickness of the sheet, or porosity of the sheet.

[0055] In some embodiments, the method of the present invention includes comparing the parameters of the defect with one or more preset values, preferably classifying the defect based on the comparison of the parameters of the defect with one or more preset values.

[0056] In some embodiments, determining the presence or absence of a defect in the consumable based on the detected information includes determining the presence or absence of a defect in at least one individual region of the sheet based on the information detected by the sensor.

[0057] In some embodiments, determining the presence or absence of a defect in a consumable based on the detected information includes determining the presence or absence of a defect along substantially the entire length of the sheet based on the information detected by the sensor.

[0058] In some embodiments, a defect is a deviation from a target range or value of at least one parameter of the sheet that exists along substantially the entire length of the sheet of the aerosol generating material, preferably the parameter is one or more of the thickness, density or porosity of the sheet.

[0059] In some embodiments, the method of the present invention includes using a sensor to detect information indicating a defect, preferably the sensor includes a signal generator and a signal receiver for detecting the defect.

[0060] In some embodiments, the sensor includes a plurality of signal generators and signal receivers.

[0061] In some embodiments, these sensors are configured to detect regions of the sheet offset in a direction perpendicular to the direction of the transport path and / or regions of the sheet offset in a direction along the transport path.

[0062] In some embodiments, the sensor is located above or below the sheet of the aerosol generating material.

[0063] In some embodiments, the sensor includes a camera, preferably the camera is a 3D camera configured to detect a 3D image of the sheet.

[0064] In some embodiments, the camera includes a filter, preferably the filter is an optical filter.

[0065] In some embodiments, the method of the present invention includes illuminating the sheet of the aerosol generating material with light in the region of the sheet detected by the camera.

[0066] In some embodiments, the method of the present invention includes applying light to the sheet from a surface of the sheet distal to the camera.

[0067] In some embodiments, the method of the present invention includes applying light to both sides of the sheet of the aerosol generating material.

[0068] In some embodiments, the method of the present invention includes applying light to the sheet of the aerosol generating material through a filter configured to filter electromagnetic radiation at the same frequency as the filter of the camera.

[0069] In some embodiments, the method of the present invention includes determining at least a portion of the topology of the sheet of the aerosol generating material.

[0070] In some embodiments, the detected defects include one or more of holes, slits, non-uniformity of the sheet thickness, low density regions, voids, tears, lumps, sheet thickness deviating from a desired range or value, sheet density deviating from a desired range or value, and sheet porosity deviating from a desired range or value.

[0071] In some embodiments, supplying the sheet of the aerosol generating material along the conveyance path includes supplying a continuous sheet of the aerosol generating material, preferably the sheet is supplied from a bobbin.

[0072] In some embodiments, the sheet of the aerosol generating material includes tobacco.

[0073] In some embodiments, forming the sheet of the aerosol generating material into a consumable includes forming the sheet of the aerosol generating material into strips, preferably including cutting at least a portion of the sheet of the aerosol generating material into strips.

[0074] In some embodiments, forming the sheet of the aerosol generating material into a consumable includes collecting strips of the aerosol generating material.

[0075] In some embodiments, forming a sheet of aerosol generating material into a consumable includes wrapping the aerosol generating material in a wrapper.

[0076] In some embodiments, forming a sheet of aerosol generating material into a consumable includes cutting the consumable into individual consumables, preferably where the individual consumables are consumables of a single length or a double length.

[0077] In some embodiments, the method of the present invention includes associating a defect with an individual consumable.

[0078] In some embodiments, the method of the present invention includes sorting individual consumables determined by a controller to include one or more defects from individual consumables not determined by the controller to include one or more defects.

[0079] In some embodiments, the method of the present invention includes associating a defect with a batch of individual consumables.

[0080] In some embodiments, the consumable is a rod.

[0081] Also provided in the present disclosure are consumables for an aerosol supply system manufactured by the devices disclosed herein and / or manufactured by the methods disclosed herein.

[0082] Also provided in the present disclosure is an apparatus for analyzing a sheet of aerosol generating material for a consumable for an aerosol supply system, the apparatus including a sensor configured to detect information indicating a defect in the sheet of aerosol generating material, and a controller configured to determine the presence or absence of a defect in the sheet of aerosol generating material based on the information detected by the sensor.

[0083] The controller may be configured to determine one or more parameters of the defect, and preferably the parameters of the defect may include one or more of length, width, depth, the angle of the range of the defect with respect to the direction of the transport path, the area of the defect, the density of the sheet, the thickness of the sheet, or the porosity of the sheet.

[0084] The controller may be configured to compare the parameter of the defect with a preset value.

[0085] The controller may be configured to classify the defect based on a comparison between the parameter of the defect and a preset value, and preferably the classification relates to the severity of the defect.

[0086] In some embodiments, the controller is configured to determine the presence or absence of a defect in at least one individual region of the aerosol-generating material sheet based on information detected by the sensor.

[0087] In some embodiments, the controller is configured to determine the presence or absence of a defect along substantially the entire length of the aerosol-generating material sheet based on information detected by the sensor.

[0088] In some embodiments, the defect is a deviation from a target range or value of at least one parameter of the sheet along substantially the entire length of the aerosol-generating material sheet, and preferably the parameter is one or more of the thickness, density, or porosity of the sheet.

[0089] The controller may be configured to evaluate the quality of a region of the aerosol-generating material sheet based on the amount or surface density of one or more defects within the region and / or the classification of one or more defects within the region.

[0090] The evaluation of the quality may create quality requirements criteria, and preferably the controller may be configured to store the criteria in memory, and preferably the criteria may be associated with the region.

[0091] The area of the sheet may correspond to a batch of individual consumables formed by an aerosol generating material or device of an individual consumable.

[0092] The controller may be configured to perform a specific operation based on an evaluation of the quality of the area.

[0093] The operation may include sending a signal indicating that the quality of the area falls below a predefined value, preferably that the area and / or the entire sheet material should be discarded and / or recycled.

[0094] The sensor may include a signal generator and a signal receiver for detecting defects, and preferably the signal may be a laser signal.

[0095] The device of the present invention may include a plurality of sensors.

[0096] The sensor may be configured to determine the topology of at least a part of the sheet of the aerosol generating material.

[0097] The sensor may include a camera.

[0098] The device of the present invention may further include a light emitter configured to apply light to the sheet of the aerosol generating material.

[0099] The light emitter may be configured to be located on the surface of the sheet of the aerosol generating material distal to the camera.

[0100] The light emitter may be configured to be located on both sides of the sheet of the aerosol generating material.

[0101] The light emitter may include a filter.

[0102] The camera may include a filter, and preferably the filter may be an optical filter.

[0103] The filter of the light emitter may be configured to pass electromagnetic radiation, at least a part of which has the same frequency as the electromagnetic radiation passed by the filter of the camera.

[0104] The camera may be a three-dimensional camera configured to detect a three-dimensional image of the sheet.

[0105] The defects detected by the sensor may include one or more of holes, slits, non-uniformity of the thickness of the sheet, low-density regions, voids, cracks, lumps, the thickness of the sheet deviating from a desired range or value, the density of the sheet deviating from a desired range or value, and / or the porosity of the sheet deviating from a desired range or value.

[0106] The sheet of the aerosol generating material may include tobacco.

[0107] The present disclosure also provides an apparatus for manufacturing a consumable for an aerosol supply system, the apparatus including the apparatus disclosed herein for analyzing a sheet of an aerosol generating material, a receiving means for receiving the sheet of the aerosol generating material, a supply device configured to supply the sheet of the aerosol generating material along a conveyance path, and a consumable forming device configured to accommodate the sheet of the aerosol generating material and form the sheet of the aerosol generating material into a consumable.

[0108] The consumable forming device may include a strip forming device configured to form the sheet of the aerosol generating material into strips.

[0109] The strip forming device may include a cutting device configured to cut at least a part of the sheet of the aerosol generating material into strips of the aerosol generating material.

[0110] The consumable forming device may include a collecting device configured to collect the strips of the aerosol generating material.

[0111] The consumable forming device may include a winding device configured to wrap the aerosol generating material with a wrapper.

[0112] The consumable forming device may include a cutting device for cutting the consumable into individual consumables.

[0113] The individual consumables may be consumables of a length of one or two lengths.

[0114] The controller may be configured to associate the defect with an individual consumable.

[0115] The controller may be configured to associate the defect with a batch of individual consumables formed by the consumable forming device.

[0116] The device of the present invention may include a sorting device configured to remove an individual consumable determined by the controller to include one or more defects.

[0117] The consumable may be a rod.

[0118] The controller may be configured to determine, based on information detected by the sensor, the position of a defect in the consumable formed by the consumable forming device.

[0119] The position of the defect may include the axial position of the defect along the consumable.

[0120] The controller may be configured to perform a specific operation by evaluating the quality of the area.

[0121] In some embodiments, the operation includes sending a signal indicating that the quality of the area is below a predefined value, preferably that the area and / or the entire sheet material should be discarded and / or recycled.

[0122] In some embodiments, the operation includes sending a signal indicating that when the quality of the area is evaluated and the quality is below a predefined value, preferably when it is determined that the consumable or batch of consumables including the area should be discarded and / or recycled, the consumable or batch of consumables including the area should be sorted from other consumables or batches of consumables formed by the consumable forming device.

[0123] The sensor may be located above or below the sheet of the aerosol generating material.

[0124] The supply device may supply a continuous sheet of the aerosol generating material. Preferably, the supply device may include a bobbin accommodating mechanism for accommodating a bobbin of the sheet of the aerosol generating material. Preferably, the supply device may include a bobbin of the sheet of the aerosol generating material.

[0125] The sensor may be configured to detect information indicating a defect in the sheet of the aerosol generating material when the sheet of the aerosol generating material passes along the transport path.

[0126] The device for analyzing the sheet of the aerosol generating material may include a plurality of sensors configured to detect an area of the sheet offset in a direction perpendicular to the direction of the transport path and / or configured to detect an area of the sheet offset in a direction along the transport path.

[0127] The sensor may be configured to detect information indicating a defect in the sheet of the aerosol generating material before the supply device receives the sheet.

[0128] The present disclosure also provides a controller of an apparatus for analyzing a sheet of an aerosol generating material formed in a consumable for an aerosol supply system. The controller is configured to be connected to a sensor, and the sensor is configured to detect information indicating a defect in the sheet of the aerosol generating material. The controller is configured to determine the presence or absence of a defect in the sheet of the aerosol generating material based on the information detected by the sensor.

[0129] The sensor may be configured to detect information indicating a defect in the sheet of the aerosol generating material when the sheet of the aerosol generating material passes along a conveyance path.

[0130] The sensor may be configured to detect information indicating a defect in the sheet of the aerosol generating material before the sheet of the aerosol generating material is supplied along a conveyance path.

[0131] The apparatus / controller of the present invention may have any of the features disclosed herein.

[0132] The present disclosure also provides a method for analyzing a sheet of an aerosol generating material for a consumable of an aerosol supply system. The method includes detecting information indicating a defect in the sheet of the aerosol generating material and determining the presence or absence of a defect in the consumable based on the detected information.

[0133] The method of the present invention may include determining one or more parameters of the defect. Preferably, the parameters of the defect may include one or more of length, width, depth, angle of the range of the defect with respect to the direction of the conveyance path, area of the defect, density of the sheet, thickness of the sheet, or porosity of the sheet.

[0134] The method of the present invention may include comparing the parameters of the defect with one or more preset values, and preferably may include classifying the defect based on the comparison of the parameters of the defect with one or more preset values.

[0135] In some embodiments, determining the presence or absence of a defect in a consumable based on the detected information includes determining the presence or absence of a defect in at least one individual region of the sheet based on the information detected by the sensor.

[0136] In some embodiments, determining the presence or absence of a defect in a consumable based on the detected information includes determining the presence or absence of a defect along substantially the entire length of the sheet based on the information detected by the sensor.

[0137] In some embodiments, a defect is a deviation from a target range or value of at least one parameter of the sheet that exists along substantially the entire length of the sheet of the aerosol generating material, preferably the parameter is one or more of the thickness, density, or porosity of the sheet.

[0138] The method of the present invention may include supplying a sheet along a conveyance path and detecting information indicating a defect when the sheet is supplied along the conveyance path.

[0139] The method of the present invention may include using a sensor to detect information indicating a defect, preferably the sensor may include a signal generator and a signal receiver for detecting a defect.

[0140] The sensor may include a plurality of signal generators and signal receivers.

[0141] The sensor may include a camera, preferably the camera may be a three-dimensional camera configured to detect a three-dimensional image of the sheet.

[0142] The camera may include a filter, preferably the filter is an optical filter.

[0143] The method may include illuminating the sheet of the aerosol generating material with light in the region of the sheet detected by the camera.

[0144] The method of the present invention may include irradiating light onto a sheet from a surface of the sheet that is distal to the camera.

[0145] The method of the present invention may include irradiating light onto both surfaces of a sheet of an aerosol generating material.

[0146] The method of the present invention may include irradiating light onto a sheet of an aerosol generating material through a filter configured to filter electromagnetic radiation having the same frequency as a filter of the camera.

[0147] The method of the present invention may include determining at least a part of the topology of a sheet of an aerosol generating material.

[0148] The detected defect may include one or more of a hole, a slit, non-uniformity of the thickness of the sheet, a low density region, a void, a tear, a lump, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and a porosity of the sheet deviating from a desired range or value.

[0149] The sheet of the aerosol generating material may include tobacco.

[0150] The present disclosure also provides a method for manufacturing a consumable for an aerosol supply system, the method including analyzing a sheet of an aerosol generating material for a consumable for an aerosol supply system as described herein, and forming the sheet of the aerosol generating material into the consumable.

[0151] The method of the present invention may include supplying a sheet of an aerosol generating material along a conveyance path.

[0152] The method of the present invention may include determining a position of a defect of a consumable formed based on the detected information, preferably including determining an axial position of the defect.

[0153] The sensor may be located above or below the sheet of the aerosol generating material.

[0154] Supplying a sheet of aerosol generating material along a conveyance path may include continuously supplying the sheet of aerosol generating material, and preferably the sheet may be supplied from a bobbin.

[0155] Detecting information indicating a defect in the sheet of aerosol generating material may include detecting information indicating a defect in the sheet of aerosol generating material as the sheet passes along the conveyance path.

[0156] The method of the present invention may include using a plurality of sensors to detect information indicating a defect, and preferably these sensors are configured to detect regions of the sheet offset in a direction perpendicular to the direction of the conveyance path and / or may be configured to detect regions of the sheet offset in a direction along the conveyance path.

[0157] Supplying a sheet of aerosol generating material along a conveyance path may include detecting information indicating a defect in the sheet of aerosol generating material before the sheet is supplied along the conveyance path, preferably before the sheet is received by a supply device.

[0158] Forming the sheet of aerosol generating material into a consumable may include forming the sheet of aerosol generating material into strips, and preferably may include cutting at least a portion of the sheet of aerosol generating material into strips.

[0159] Forming the sheet of aerosol generating material into a consumable may include collecting strips of the aerosol generating material.

[0160] Forming the sheet of aerosol generating material into a consumable may include wrapping the aerosol generating material in a wrapper.

[0161] Forming the aerosol generating material sheet into a consumable may include cutting the consumable into individual consumables, and preferably the individual consumables may be consumables of a single length or a double length.

[0162] The method of the present invention may include associating a defect with an individual consumable.

[0163] The method of the present invention may include sorting individual consumables determined by the controller to include one or more defects from individual consumables not determined by the controller to include one or more defects.

[0164] The method of the present invention may include associating a defect with a batch of individual consumables.

[0165] The consumable may be a rod.

[0166] The present disclosure also provides a consumable for an aerosol supply system manufactured by the apparatus disclosed herein and / or manufactured by the method disclosed herein.

[0167] The present disclosure also provides a system for manufacturing a consumable for an aerosol supply system. The system for manufacturing a consumable includes an apparatus disclosed herein for analyzing a sheet of aerosol generating material for a consumable for an aerosol supply system, a supply apparatus for receiving the sheet of aerosol generating material and configured to supply the sheet of aerosol generating material along a conveyance path, and a consumable forming apparatus for accommodating the sheet of aerosol generating material and configured to form the sheet of aerosol generating material into a consumable.

[0168] The system of the present invention may have any of the features of the apparatus, supply apparatus, and / or consumable forming apparatus for analyzing the sheet disclosed herein.

Brief Description of the Drawings

[0169] With reference to the accompanying drawings, several embodiments will be described for illustrative purposes only.

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Embodiments for Carrying Out the Invention

[0170] FIG. 1 is a schematic diagram of an embodiment of an apparatus 1 for manufacturing a consumable used in an aerosol supply system.

[0171] In this example, the consumable is a rod made of an aerosol generating material. However, it should be noted that in other embodiments, the consumable may have a different structure, for example, it may be a strip made of an aerosol generating material.

[0172] The device 1 includes a supply device 2 configured to receive a supply of the sheet 3 of aerosol generating material and supply the sheet 3 of aerosol generating material along a transport path 4 as a continuous web.

[0173] The aerosol generating material is a tobacco material, for example, a regenerated tobacco material formed on a continuous web. However, the aerosol generating material may alternatively be a non-tobacco material.

[0174] The device 1 further includes a sensor 5 configured to detect information indicating a defect 6 in the sheet 3 of aerosol generating material as the sheet 3 of aerosol generating material passes along the transport path 4.

[0175] The device 1 also includes a consumable forming device 7 configured to receive the sheet 3 of aerosol generating material and form the sheet 3 into a consumable. In this example, the consumable forming device 7 is a rod forming device 7 configured to receive the sheet 3 of aerosol generating material and form the sheet 3 onto a rod. In this example, the rod forming device 7 is configured to form the sheet 3 onto a continuous rod 8 that is later cut into individual rods 23.

[0176] FIG. 2 schematically shows the sheet 3 of aerosol generating material formed on a consumable 8, which in this example is an individual rod 23.

[0177] The sensor 5 is configured to detect a defect 6 in the sheet 3 of aerosol generating material before the sheet 3 of aerosol generating material is formed onto the rod 8 by the rod forming device 7. In this example, the sensor 5 is located between the supply device 2 and the rod forming device 7. In other words, the rod forming device 7 is downstream of the sensor 5, and the sensor 5 is downstream of the supply device 2. The term "downstream" means the direction of the sheet 3 along the transport path 4 as the sheet 3 of aerosol generating material moves from the supply device 2 through the sensor 5 towards the rod forming device 7. This embodiment may be referred to as an "online" inspection since the sheet material 3 is inspected while it is being transported by the supply device 2 along the transport path 4.

[0178] In some embodiments, a device for detecting defects including the sensor 5 and the controller 9 is provided. In one embodiment, a device for detecting defects is provided that further selectively includes a feeding device for feeding the sheet 3 along the conveying path.

[0179] The consumable manufacturing device 1 may include a device for detecting defects. In other embodiments, the device for detecting defects may be different from the consumable manufacturing device 1, and may be used, for example, to detect defects in at least a part (e.g., the end portion of the sheet 3 or the entire sheet 3) of the sheet 3 before the sheet 3 is processed by the consumable manufacturing device 1.

[0180] In some embodiments, the aerosol generating material sheet 3 may be inspected by the sensor 5, and then, if the sheet 3 is considered to be of sufficient quality, the sheet 3 is then fed along the conveying path 4. When the sheet is considered acceptable by the controller (as will be described in detail below), the feeding device 2 can start feeding the sheet 3 along the conveying path 4 and start the rod forming process. For example, the end portion of the sheet material 3 may be inspected before the sheet material 3 is loaded into the device 1 or after the sheet material 3 is loaded into the device 1. This is sometimes referred to as an "offline" inspection because the sheet material 3 is examined before the feeding device 2 conveys the sheet material 3 along the conveying path 4.

[0181] As shown in FIG. 1, the feeding device 2 includes a housing mechanism 16 that houses a supply source 17 of the aerosol generating material sheet 3. In this example, the housing mechanism 16 is configured to house the bobbin 17 of the aerosol generating material sheet 3. The bobbin 17 supplies a continuous web of the aerosol generating material sheet 3 along the conveying path 4. In another embodiment (not shown), the feeding device 2 supplies individual aerosol generating material sheets along the conveying path 4.

[0182] The sheet 3 may be fed along the conveying path 4 by any suitable mechanism, such as a belt or a plurality of rollers.

[0183] The rod forming device 7 includes a cutting or shredding device 18 configured to cut at least a part or the entire width of the aerosol generating material sheet 3 into strips 19 of the aerosol generating material.

[0184] The rod forming device 7 also includes a collecting device 20 configured to collect the strips 19 of the aerosol generating material produced by the cutting device 18 and form them into a rod shape. In this example, the rod has a substantially circular cross-section. However, it should be noted that in other embodiments (not shown), the rod may have another shape, such as tubular, elliptical, square or hexagonal.

[0185] The collecting device 20 may include a funnel or a cone (not shown), which is configured to collect the strips 19 such that the strips 19 exit the funnel or the cone as a rod.

[0186] The rod forming device 7 further includes a winding device 21 downstream of the collecting device 20, which is configured to wrap the collected strips 19 of the aerosol generating material with a wrapper.

[0187] The winding device 21 includes a garniture (not shown) configured to receive the rod of the collected strips 19 and wrap the strips 19 with a wrapper. The wrapper is supplied as a continuous web over a garniture belt (not shown), which is configured to wrap the rod of the strips 19 as the belt, wrapper and strips 19 pass through a narrowed cone or tongue of the garniture. The wrapper may then be fixed in place using an adhesive applied to or pre-applied to the edge of the wrapper. It should be noted that in another embodiment, the winding device 21 may have another structure, for example, including a winding drum that wraps the wrapper around the rod of the strips 19.

[0188] In the example of FIG. 1, the strip 19 is collected by the collecting device 20, and then the collected strip 19 is sent to the winding device 21. However, in another embodiment (not shown), a device that combines collection and winding collects the strip 19 to form a rod and wraps the strip 19 with a wrapper. For example, it is also possible to supply the strip 19 into a garniture that collects the strip 19 to form a rod and at the same time wraps the rod with a wrapper.

[0189] The rod forming device 7 includes a cutting device 22 downstream of the winding device 21 and is configured to cut the continuous packaged rod 8 into individual rods 23 of the aerosol generating material. The individual rods 23 produced by the cutting device 22 may be of a single length or a double length rod or longer.

[0190] The device 1 includes a controller 9 (shown in FIG. 3) configured to determine the presence or absence of a defect 6 in the rod 23 formed by the rod forming device 7 based on the information detected by the sensor 5. The controller 9 is configured to associate the defect 6 with the individual rods 23 cut by the cutting device 22.

[0191] Alternatively or in addition, the controller 9 is configured to associate the defect 6 with a batch of individual rods 23 produced by the rod forming device 7. For example, if the defect 6 is detected by the sensor 5, the controller 9 determines that a batch of individual rods 23 (e.g., a batch of 2, 3, 4, 5, 6, 7, 8, 10, 20, 50, or 100 rods) contains the defect 6. Next, the entire batch containing the defect is collected or discarded, or otherwise sorted from the remaining batches of rods 23 that do not contain the defect. Additionally, the controller 9 may be configured to associate the defect 6 with the type of sheet material being supplied along the conveyance path 4. For example, the controller 9 may be configured to associate the defect 6 with a sheet material having specific characteristics such as a specific thickness / width / composition of the sheet material, or a specific brand or manufacturer of the sheet material. That is, the controller 9 may be configured to record that a particular type of sheet material is prone to receiving the defect 6. For example, sheet materials manufactured by a particular manufacturer may be more likely to have defects and / or more and / or more severe defects.

[0192] In some embodiments, if the controller 9 detects that a region of the sheet 3 does not meet one or more quality criteria (e.g., the sheet has a density, thickness, or porosity that deviates from a target value or range), the controller 9 determines that the entire length or substantially the entire length of the sheet 3 (e.g., all of the sheet 3 on the bobbin) does not meet the one or more quality criteria. Accordingly, this may be communicated to the operator such that the entire bobbin of the sheet 3 is removed. This may be done "offline" (e.g., before the sheet 3 is loaded onto the supply device 2) or "online" (e.g., as the sheet 3 is being sent along the conveyance path after being loaded onto the supply device 2). This helps prevent the device 1 from operating sub-optimally with a defective sheet material 3 that would otherwise (e.g., a sheet material with insufficient tension or a sheet material that breaks / rips within the device 1 causing the device to jam).

[0193] When a defect is detected, for example, when a defect in the rod 23 is detected, the controller 9 may remove the rod 23 from the production line and sound an alarm (for example, an audible or visual alarm) so that it can be discarded. In some embodiments, such discarding is automatic, and for example, the apparatus 1 may further include a sorting apparatus 24 as will be described in more detail below.

[0194] In some embodiments, when a defect 6 is detected, the controller 9 is configured to determine the position and / or parameters of the defect 6 in the sheet 3. The dimensions and positions of the defects in the sheet 3 can be extrapolated to determine the dimensions and positions of the defects in the formed rod. For example, the axial position of the defect 6 along the rod 8 can be determined. As used herein, the term "axial position" means the position of the defect in a direction along the longitudinal axis of the rod, that is, parallel to the transport path 4.

[0195] When the rod forming apparatus 7 is configured to produce individual rods 23 of multiple lengths, for example, rods that are 2, 3, 4, 5, 6, 7, or 8 times the length of one rod, it is particularly advantageous to determine the position of the defect 6. This is because only that portion of the individual rod 23 containing the defect 6 is removed. In some embodiments, the controller 9 is configured to determine the position of the defect 6 in the rod 8 based on the position of the defect 6 along the width and / or length of the sheet 3.

[0196] The parameters of the defect 6 determined by the controller 9 may include one or more of the length, width, depth, area, and density of the defect. Once the defect 6 is identified and measured, the controller 9 is configured to compare the parameters of the defect 6 with one or more preset values. This indicates the extent of the defect 6, and the controller 9 can determine whether the section of the rod 8 containing the defect 6 should be removed, for example, by removing the individual rod 23 having the defect 6 cut by a cutting device 22.

[0197] The controller 9 is configured to classify the defect 6 based on a comparison between the measured parameter and a preset value. This classification may indicate the severity of the defect and thus may indicate a defect that has the potential to degrade the quality of the consumable. For example, a hole is identified by the sensor 5 and the dimensions of the hole are calculated. The dimensions of the hole may be one or more of the length, width, radius, or surface area of the hole. For example, the severity of the defect 6 is classified based on the size of the detected hole, and the larger the hole, the greater the severity of the defect 6. Additionally or alternatively, the severity of the defect 6 may be classified based on the number of anomalies within a predetermined surface area, the depth of the defect 6, the density of the sheet 3, and / or the angle of a tear or crack extending in the sheet with respect to the direction of the transport path 4.

[0198] In an example where the defect is a hole, the controller 9 may compare the size of the hole 6 to a preset value of a hole classified as being large enough to be considered a defect. If the dimensions of the hole 6 meet the defect classification criteria, the individual rod 23 containing the hole 6 can be removed by the apparatus 1.

[0199] For example, one hole with dimensions exceeding a size defined by the user can be classified as a defect. Additionally, a group of holes can be classified as a defect if the total area exceeds a user-defined limit within the boundaries defined by the user.

[0200] In some embodiments, the parameters of the defect 6 determined by the controller 9 include the angle of the defect 6 extending in the direction of the transport path 4. For example, when the sensor 5 detects an abnormality such as a thin hole or a tear, the controller 9 may determine the angle at which the tear extends with respect to the direction of the transport path 4. The controller 9 may classify the tear as a defect 6 if, for example, the angle of the tear extending in the direction of the transport path 4 exceeds a predetermined value. This is advantageous because if not classified, such a tear would cause the separation of the strip 19 when the sheet 3 is processed into the strip 19 by the rod forming device 7. In some embodiments, the classification may be based on a function of the tear and the length of the tear with respect to the direction of the transport path 4. That is, if the angle or length exceeds a predetermined value, the tear is classified as a defect 6.

[0201] The controller 9 includes a memory 9A and a processor 9B. The memory 9A is configured to store instructions, and the processor 9B is configured to execute those instructions.

[0202] In some embodiments, the apparatus 1 includes a sorting device 24 for removing an individual rod 23 determined by the controller 9 to include one or more defects 6 or for removing a batch of individual rods 23, one or more of which are determined by the controller 9 to include one or more defects 6. That is, when the sensor 5 detects an abnormality of the sheet classified by the controller 9 as a defect 6 as the sheet 3 moves along the transport path 4 towards the rod forming device 7, the controller 9 determines which individual rod 23 the defect ends at based on the speed of the sheet passing through the apparatus 1. Thereby, the defects removed from the production line can be removed without stopping the apparatus 1 and without manually removing the section of the sheet 3 containing the defects.

[0203] The quality of the sheet 3 of the aerosol generating material can also be evaluated based on the number of defects 6 found in the sheet 3 and / or the classification of said defects. In some embodiments, the controller 9 is configured to evaluate the quality of the sheet 3 (e.g., a part) of the aerosol generating material by evaluating both the amount or density of the defects (e.g., surface density) and the classification of the defects. For example, a part of the sheet 3 having many low-severity defects may be evaluated as having low quality, and a part of the sheet having only one high-severity defect may also be evaluated as having low quality. In some embodiments, each defect may be assigned a weight based on the severity of the defect. Next, the controller 9 adds up all the weights of the defects detected in the sheet 3 or detected in a predetermined area of the sheet, and determines the quality of the sheet accordingly.

[0204] For example, in one embodiment, a low-severity defect is assigned a weight of 1, a medium-severity defect is assigned a weight of 2, and a high-severity defect is assigned a weight of 3. In such an example, if the controller 9 detects two high-severity defects, the sheet 3 / that part of the sheet 3 is given a quality value of 6. In contrast, if the controller 9 detects two low-severity defects and one medium-severity defect, the sheet 3 / that part of the sheet 3 is given a quality value of 4, and is thus evaluated as being of higher quality than the first example despite the presence of many defects.

[0205] In some embodiments, the controller 9 is configured to evaluate the quality of the sheet 3 (e.g., a part) of the aerosol generating material, and the evaluation of the quality is a function of both the severity of the defects and the number of defects.

[0206] In some embodiments, the controller 9 may be configured to count the number of defects 6 detected by the sensor 5 in a predetermined area or length of the sheet 3. If the number of defects 6 exceeds a predetermined value and / or a severe defect 6 is detected, that section of the sheet 3 may be removed, for example, by removing the discontinuous rod 23 including said section.

[0207] In some embodiments, if the controller 9 determines that there are defects (e.g., thickness, density, or porosity outside the target range or value) throughout the area of the sheet 3, it is to be removed. It is determined that it should be.

[0208] The sorting device 24 may include a pusher (not shown), such as a rod, configured to remove, for example, an individual rod 23 determined to have a defect 6. However, in another embodiment, the sorting device 24 may remove the defective rod 23 by other means, such as using suction or blowing compressed gas onto the defective rod 23. In some embodiments, the sorting device 24 includes a sorting drum (not shown) configured to separate the defective rod 23 from the rods 23 not determined to contain defects.

[0209] The sensor 5 is configured to detect information indicating a defect 6 in the sheet 3 of the aerosol generating material as the sheet 3 of the aerosol generating material passes along the transport path 4.

[0210] The defect 6 detected by the sensor 5 may include one or more of holes, slits, non-uniformity of the sheet thickness, low-density regions, voids, tears, and lumps. The sensor 5 is also capable of determining the topology of the sheet 3 of the aerosol generating material and thus detecting non-uniformity of the thickness of the sheet 3. Naturally, the detected defect 6 may not be in a specific area of the sheet 3, or may be a defect 6 throughout the sheet 3. For example, the sensor 5 is configured to detect a defect 6 throughout the sheet 3, such as the density, porosity, thickness, or topology of the sheet 3. In some embodiments, an area of the sheet 3 (e.g., an end region such as the first 10 or 20 centimeters of the length of the sheet 3) is inspected online or offline, and the quality of the entire sheet 3 is evaluated using the data obtained from the inspection. For example, if the end of the sheet 3 is inspected and found to be of low density, the entire sheet 3 may be removed and discarded.

[0211] The presence of a defect 6 in the aerosol generating material sheet 3 is undesirable as it degrades the consistency and / or quality of the final product. Therefore, it is advantageous to detect the defects in the aerosol generating material sheet 3 so that defective rods 23 can be removed. A defective rod is a rod that should be discarded in some embodiments based on the controller's assessment of the number of defects in the controller and / or classification of the defects in the rod, where the controller determines that the quality of the sheet material from which the rod is formed is of low quality as described above. The sensor 5 is arranged such that a defect 6 is detected before the aerosol generating material sheet 3 is formed into rods 8. This makes it possible to detect defects more accurately compared to the case where an attempt is made to detect a defect after processing the sheet 3 into a rod.

[0212] Furthermore, defects in the aerosol generating material sheet 3 can cause adverse effects on various components of the device 1. Therefore, the controller 9 may be configured to sound an alarm or stop the device 1 if a defect that can cause adverse effects to the device 1 is detected in the sheet material 3. For example, if a structural defect that causes clogging of the device 1 is detected, the alarm is activated and / or the device 1 is stopped. For example, this is the case where the width of the defect is sufficient to cause separation of the strip 19 during cutting or shredding of the sheet 3.

[0213] In another embodiment, an apparatus for detecting defects in a sheet including a controller and a sensor is provided. In some embodiments, the apparatus for detecting defects may be separate from the consumable manufacturing apparatus 1. For example, the apparatus for detecting defects may be used to detect defects in at least a part (e.g., an end of the sheet 3 or the entire sheet 3) of the sheet 3 before the sheet 3 is processed by the consumable manufacturing apparatus 1. If the sheet 3 is determined not to be of sufficient quality, the operator is informed by a display (e.g., an alarm). Therefore, the detected sheet 3 is not loaded into the consumable manufacturing apparatus.

[0214] Figures 4 and 5 illustrate an embodiment of the sensor 5. The sensor 5 includes a signal generator 10 and a signal receiver 11 for detecting a defect 6.

[0215] It should be noted that other sensors may be used, such as sensors that detect any frequency of electromagnetic radiation, such as X-rays, ultraviolet rays, visible light, infrared rays, or microwaves. In some embodiments, the sensor is an ultrasonic sensor or an electrical and / or magnetic sensor, and may include a capacitive or inductive sensor.

[0216] The sensor 5 is disposed above the region 15 of the sheet 3 of the aerosol generating material scanned by the sensor 5. When the sheet 3 of the aerosol generating material is conveyed along the conveyance path 4, the signal generator 10 emits a signal 12 that is directed at an angle toward the sheet 3 of the aerosol generating material. The signal 12 is reflected from the sheet 3 of the aerosol generating material and received by the signal receiver 11. If the signal receiver 11 does not receive the signal 12 emitted from the signal generator 10, it suggests that the sheet 3 of the aerosol generating material contains a hole. Optionally, the signal may be a laser signal.

[0217] The sensor 5 scans the sheet 3 as the sheet 3 of the aerosol generating material passes along the conveyance path 4. The sensor 5 may be digital or analog. The sensor 5 may transmit and / or receive continuous or discrete signals.

[0218] In some embodiments, there may be a plurality of sensors 5, each including a transmitter and a receiver.

[0219] In some embodiments, the plurality of sensors 5 are arranged in order, for example, in the direction of the transport path 4, and are configured to detect regions of the sheet offset in the direction along the transport path. The plurality of sensors 6 arranged in order enable scanning of a large area of the aerosol generating material sheet. Such a configuration also provides a certain degree of redundancy in the case where one of the sensors 5 fails to detect a defect, for example, due to the speed of the sheet moving along the transport path 4. If the first sensor fails to detect, a second sensor located downstream of the first sensor along the transport path can detect the defect. This configuration also makes it possible to determine the length of the defect 6 by counting the number of sensors 5 arranged in the longitudinal direction that detect the defect 6 simultaneously. However, another option for determining the length of the defect 6 is to measure how long the defect 6 is detected by a particular sensor 5 (or by the sensor 5 in an embodiment where the device 1 includes a single sensor 5).

[0220] Alternatively or in addition, in some embodiments, the plurality of sensors 5 may be offset in a direction perpendicular to the transport path 4. That is, the sensors 5 are configured to detect different regions across the width of the sheet 3 (arrow "W" in FIG. 5). This configuration is shown in FIG. 5, and each of the dashed lines R1 to R9 represents the region detected by the corresponding sensor 5. This helps to determine the size of the defect. For example, the width of the defect 6 can be determined from the number of sensors 5 that detect the defect 6 simultaneously or within a predetermined time. However, it should be noted that in another embodiment, a single sensor 5 that scans only a part of the width W of the sheet 3 or scans the entire width W of the sheet 3 may be provided.

[0221] In the above-described embodiments, the sensors 5 may be arranged in order in a line perpendicular to the transport path 4 or at an angle to the transport path.

[0222] In another embodiment, as shown in FIGS. 6 and 7, the sensor 5 includes a camera 13.

[0223] Of course, any suitable model of camera 13 can be used, for example, the Keyence(TM) CA-HL02MX camera.

[0224] The camera 13 is positioned above the sheet 3 of the aerosol generating material and is configured to image the sheet 3 of the aerosol generating material as the sheet 3 of the aerosol generating material passes along the transport path 4. Of course, the camera 13 may be positioned below the sheet 3 of the aerosol generating material, or the camera 13 may be provided on both sides of the sheet 3.

[0225] In some embodiments, the camera 13 is a three-dimensional camera. This helps the camera 13 to detect non-uniformities in the thickness of the sheet 3 of the aerosol generating material.

[0226] The camera 13 may include a filter (not shown), such as a polarizing filter, that improves the performance of the camera for detecting defects 6. In some embodiments, the filter of the camera 13 is configured to filter electromagnetic radiation of a specific frequency that is higher or lower than a predetermined value, for example. The filter may be a high-pass, low-pass, or band-pass filter.

[0227] The apparatus 1 further includes a light emitter 14 configured to direct light onto the sheet 3 of the aerosol generating material.

[0228] The light emitter 14 is configured to direct light onto a region 14A of the sheet 3. The light emitter 14 is configured to direct light onto one or both surfaces of the sheet 3 in the region 14A that is aligned with the region 15 detected by the camera 13 in the direction of the transport path 4. That is, the light emitter 14 may direct light onto the back of the sheet 3 with respect to the region 15 detected by the camera 13 and / or direct light onto the same surface of the sheet 3 as the region 15 detected by the camera 13.

[0229] In some embodiments, the region 14A of the sheet 3 onto which light is directed by the light emitter 14 overlaps the region 15 of the sheet 3 detected by the camera 13 in the direction of the transport path 4.

[0230] In some embodiments, the illuminator 14 is configured to direct light onto that portion of the length of the sheet 3 detected by the camera 13.

[0231] The illuminator 14 may include an electromagnetic radiation source, such as a light source like a bulb. The illuminator 14 may be configured to concentrate the electromagnetic radiation towards the sheet 3.

[0232] The electromagnetic radiation source may be directed such that more than 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the electromagnetic radiation emitted by the illuminator 14, or electromagnetic radiation of a specific frequency or frequency range, hits the sheet 3, preferably one or both sides of the sheet 3 in the region 15 detected by the camera 13. For example, the electromagnetic radiation source may irradiate the surface of the sheet 3 on the back of the region 15 detected by the camera 13.

[0233] In some embodiments, the illuminator 14 is disposed at a maximum distance of 3 meters, 2 meters, 1 meter, 0.75 meters, 0.5 meters, 0.25 meters or 0.15 meters or 0.1 meter from the sheet 3.

[0234] The illuminator 14 is disposed on the surface of the sheet 3 of the aerosol generating material opposite to the camera 13. This configuration has been found to be particularly effective in improving the performance of the camera for detecting defects. However, in some embodiments, the illuminator 14 may be present on both sides of the sheet 3 of the aerosol generating material, for example, above and below the sheet 3.

[0235] In the embodiment shown in FIG. 6, the camera 13 is disposed above the sheet 3 of the aerosol generating material, and the illuminator 14 is disposed below the sheet 3 of the aerosol generating material opposite to the camera 13.

[0236] The light emitter 14 may include a filter (not shown). In some embodiments, the filter is configured to filter electromagnetic radiation of a specific frequency that is higher or lower than a predetermined value, for example. The filter may be a high-pass, low-pass, or band-pass filter. At least a portion of the electromagnetic radiation that passes through the filter of the light emitter 14 passes through the filter of the camera 13. By irradiating the sheet with the filtered electromagnetic radiation, for example, the filtered light, the camera 13 can remove background light, improve the detection of the irradiation signal, and improve the detection of defects.

[0237] In some embodiments, the filter of the camera 13 and / or the filter of the light emitter 14 is a polarizing filter. Using polarizing filters together with the camera 13 and the light emitter 14 reduces interference from ambient lighting and thus improves the accuracy of the sheet analysis.

[0238] The camera 13 may be a color camera, grayscale, or black and white. In some embodiments, the camera 13 is an infrared camera.

[0239] In some embodiments, the controller 9 is configured to determine the size of the defect 6 in the sheet 3 of the aerosol generating material by counting the pixels that detect the presence or absence of the defect 6. For example, holes or other defects in the sheet 3 are of a different color and / or brighter or darker than the sheet material 3 itself. Additionally, regions of low density or thin or highly porous regions result in brighter regions compared to the rest of the sheet 3 because, for example, such regions tend to be less likely to block the light emitted from the light emitter 14. Thus, the pixels captured by the camera 13 in the region of the hole or other defect will have non-standard characteristics compared to the pixels captured in the region of the sheet 3 without such holes. The non-standard characteristics may include one or more of pixel brightness / darkness / color.

[0240] It should also be noted that the camera 13 may be used to determine the density, thickness, and / or porosity of the sheet 3 without requiring a light emitter 14. For example, the camera 13 may be used to determine density / thickness / porosity based on the color of the sheet 3 detected by the camera 13.

[0241] The controller 9 can determine the size of the defect based on the number of pixels having the non-standard characteristic, for example, the number of pixels that are darker than normal and thus indicate the presence or absence of holes. In some embodiments, the controller 9 counts the number of adjacent pixels or pixels in a predetermined region having the non-standard characteristic, for example, when the color is different from the color expected due to the presence of a damaged sheet material or when the brightness / darkness exceeds a threshold.

[0242] The controller 9 may count the number of adjacent or proximate pixels having the non-standard characteristic along the length of the sheet 3 (in the direction of the transport path 4) to determine the length of the defect 6. Additionally or alternatively, the controller 9 may count the number of adjacent or proximate pixels having the non-standard characteristic along the width W of the sheet 3 (in a direction perpendicular to the transport path 4) to determine the width of the defect 6.

[0243] In some embodiments, the controller 9 is configured to measure the surface area of the defect 6 by measuring both the length and width of the defect 6 or by counting the total number of adjacent pixels having the non-standard characteristic.

[0244] Controller 9 is configured to associate an image of a defect 6 in the sheet 3 of the aerosol generating material with one or more of a specific region of the rod 8, a specific individual rod 23, a batch of rods 23, and / or a specific sheet material 3 source. A region of the rod 8 having a defect 6, a specific individual rod 23 containing the defect 6, or a batch of individual rods 23 containing the rod 23 having the defect 6 can be removed if the defect 6 meets a specific preset removal criterion and is thus classified as a defect 6 by the controller 9. For example, if the defect 6 has a sufficient length, width, and / or surface area, or if there are a sufficient number of defects 6.

[0245] Furthermore, a color brighter / darker than normal detected by the camera 13 indicates a region of non-uniformity in the thickness of the sheet 3. For example, a bright color indicates that the sheet 3 is thinner than the standard, and a dark color indicates that the sheet is thicker than the standard. The controller 9 may be configured to determine that there is a defect 6 if any of the pixels imaged by the camera 13 exceeds or is less than a threshold brightness / darkness, or if a specific number of pixels exceeds the threshold brightness / darkness. Alternatively, if all or substantially all regions of the sheet 3 are brighter / darker than normal, this indicates that the entire sheet 3 or substantially the entire sheet has a quasi-optimal thickness, density, and / or porosity.

[0246] Referring now to FIG. 8, an embodiment of the aerosol supply system 100 is shown. In this example, the aerosol supply system 100 is a combustion-based aerosol supply system 100 such as a cigarette. However, it should be noted that the aerosol supply system 100 may be a non-combustion-based aerosol supply system 100.

[0247] The aerosol supply system 100 is a consumable 23 manufactured by the apparatus 1 of any of FIGS. 1-7. In this example, the consumable 23 is a rod.

[0248] The consumable 23 includes, for example, an aerosol generating material 23A manufactured by forming a sheet 3 of aerosol generating material into a rod shape, such as tobacco. The consumable 23 further includes a wrapper 23B surrounding the aerosol generating material 23A.

[0249] The aerosol supply system 100 further includes a member 102, which is attached to the consumable 23 by tipping paper 103 that overlaps the member 102 and a part of the consumable 23. In this example, the member 102 is a filter and includes a main body 102A made of filter material surrounded by a plug wrapper 102B.

[0250] Referring now to FIG. 9, an embodiment of a method 200 for manufacturing a member for an aerosol supply system is illustrated. The method 200 of the present invention includes supplying a sheet of aerosol generating material along a conveyance path (step S1), detecting information indicating a defect in the sheet of aerosol generating material as the sheet of aerosol generating material passes along the conveyance path (step S2), forming the sheet of aerosol generating material into a consumable (step S3), and determining the presence or absence of a defect in the consumable based on the detected information (step S4).

[0251] In another embodiment, detecting information indicating a defect (step S2) is performed before the sheet material 3 is sent along the conveyance path (for example, before the sheet material 3 is loaded into the supply device 2).

[0252] Referring now to FIG. 10, another embodiment of a method 300 for manufacturing a member for an aerosol supply system is illustrated. The method 300 of the present invention includes supplying a sheet of aerosol generating material along a conveyance path (step S1), detecting information indicating a defect in the sheet of aerosol generating material as the sheet of aerosol generating material passes along the conveyance path (step S2), forming the sheet of aerosol generating material into a consumable (step S3), and determining the presence or absence of a defect in the consumable based on the detected information (step S4). In another embodiment, detecting information indicating a defect (step S2) is performed before the sheet material 3 is sent along the conveyance path (e.g., before the sheet material 3 is loaded into the supply device 2).

[0253] Supplying a sheet of aerosol generating material along a conveyance path (step S1) may include supplying a continuous sheet of aerosol generating material (step S1A) and supplying the continuous sheet of aerosol generating material along the conveyance path (step S1B). The sheet may be supplied from a bobbin.

[0254] The step of detecting information indicating a defect in the sheet (step S2) may include irradiating the sheet of aerosol generating material with light (step S2A). In some embodiments, the sheet is irradiated with light using electromagnetic radiation that is filtered to pass only a specific frequency or region of frequencies.

[0255] The step of detecting information indicating a defect in the sheet (step S2) may include using a sensor for detecting the presence or absence of a defect (step S2B). In some embodiments, the sensor includes a signal generator and a receiver, such as a laser generator and a receiver and / or a camera. In some embodiments, the sensor is filtered to pass only a specific frequency or region of frequencies, which may be the same as or overlap with the frequencies passing through the filter described above with respect to step S2A.

[0256] In some embodiments, the step of detecting information indicating a defect in the sheet (S2) may include using a plurality of sensors. The sensors may be arranged in order in the direction of the conveyance path. Alternatively or in addition, the sensors may be offset along the width of the sheet.

[0257] The step of forming the aerosol generating material sheet into a consumable (S3) includes forming the aerosol generating material sheet into strips (step S3A). This step may include cutting at least a part of the aerosol generating material sheet into strips. In other embodiments (not shown), the sheet may be bent to become a consumable instead of being cut into strips or in addition to being cut.

[0258] The step of forming the aerosol generating material sheet into a consumable (S3) further includes collecting the strips of the aerosol generating material (step S3B).

[0259] The step of forming the aerosol generating material sheet into a consumable (S3) further includes wrapping the aerosol generating material with a wrapper (step S3C).

[0260] The step of forming the aerosol generating material sheet into a consumable (S3) further includes cutting the consumable into individual consumables (step S3D). In some embodiments, the individual consumables are consumables of a length of one or a length of two.

[0261] The step of determining the presence or absence of a defect in the consumable based on the detected information (S4) includes determining one or more parameters of the defect (step S4A). The parameters of the defect may include one or more of the length, width, depth, area, or density of the sheet. Alternatively or in addition, the parameters may include one or more of the thickness or porosity of the sheet.

[0262] The step of determining the presence or absence of a defect in the consumable (S4) further includes comparing the defect parameter with one or more preset values (step S4B), and classifying the defect based on the comparison between the defect parameter and the one or more preset values (step S4C).

[0263] The step of determining the presence or absence of a defect in the consumable (S4) further includes associating the defect with an individual consumable (step S4D). Separately or in addition to this, step S4D includes associating the defect with a batch of individual consumables.

[0264] The method 300 of the present invention further includes sorting, by the controller, individual consumables determined by the controller to include one or more defects from individual consumables determined by the controller not to include one or more defects (step S5). Any individual consumable containing a defect is removed from the device and discarded or recycled.

[0265] Of course, one or more of the steps of the method of the present invention described above may be omitted. Further, the steps of the method of the present invention may be performed simultaneously or in a different order.

[0266] In the present disclosure, "aerosol supply system" means both a combustion-based aerosol supply system and a non-combustion-based aerosol supply system.

[0267] In the present disclosure, a "non-combustion-based" aerosol supply system is a system that does not burn or ignite the constituent aerosol generating material of the aerosol supply system (or its components) in order to facilitate the delivery of at least one substance to the user.

[0268] In some embodiments, the delivery system is a non-combustion-based aerosol supply system, such as an electric non-combustion-based aerosol supply system.

[0269] In some embodiments, the non-combustion aerosol supply system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not a requirement.

[0270] In some embodiments, the non-combustion aerosol supply system is an aerosol generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0271] In some embodiments, the non-combustion aerosol supply system is a hybrid system that uses a combination of aerosol generating materials to generate an aerosol, and one or more of these materials can be heated. Each of the aerosol generating materials can be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may include, for example, tobacco or non-tobacco products.

[0272] Typically, the non-combustion aerosol supply system may include a non-combustion aerosol supply device and a consumable for use with the non-combustion aerosol supply device.

[0273] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustion aerosol supply device. These consumables are sometimes referred to as articles throughout the present disclosure.

[0274] In some embodiments, the non-combustion aerosol supply system, such as its non-combustion aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate, which is excited to distribute power in the form of heat to an aerosol generating material or a heat conducting material proximate to the heat generating power source.

[0275] In some embodiments, the non-combustion aerosol supply system may include an area for accommodating consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0276] In some embodiments, the consumables for use in the non-combustion aerosol supply system may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0277] In some embodiments, the substance to be supplied may be an aerosol generating material or a material not intended to be aerosolized. Optionally, any material may include one or more active ingredients, one or more flavoring agents, one or more aerosol forming materials, and / or one or more other functional materials.

[0278] In some embodiments, the substance to be supplied contains an active substance.

[0279] The active substance used in the present invention is a physiologically active material intended to achieve or enhance a physiological reaction. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0280] In some embodiments, the active substance contains nicotine. In some embodiments, the active substance contains caffeine, melatonin, or vitamin B12.

[0281] As described herein, the active substance may comprise one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0282] As described herein, the active substance may comprise or be derived from a plant or its components, derivatives or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from a plant such as extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Additionally, the material may contain active compounds that are naturally present in the plant or obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, camphor tree, mugwort, cocoa, cannabis, aster, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, nettles, hibiscus, laurel, licorice, matcha, mate tea, orange peel, papaya, rose, sage, green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, chrysanthemum flower, vanilla, koji, artemisia princeps, turmeric, saffron, sandalwood, silantro, bergamot, neroli, ginbai ka, blackcurrant, lithospermum erythrorhizon, pimento, mace, damiana, alchemilla, olive, lemon balm, lemon basil, chive, aster, vervain, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. Mint may be selected from the following mint species: peppermint, Moroccan mint, Egyptian mint, peppermint, odoratissimum mint, candy mint, curly mint, Kentucky colonel mint, horsemint, pineapple mint, pennyroyal mint, English spearmint and marsh pennywort.

[0283] In some embodiments, the active substance may comprise or be derived from one or more of a plant or its components, derivatives or extracts, and the plant is tobacco.

[0284] In some embodiments, the active substance may comprise or be derived from one or more of a plant or its components, derivatives or extracts, and the plant is selected from eucalyptus, camphor tree, cocoa and mugwort.

[0285] In some embodiments, it may comprise or be derived from one or more of a plant or its components, derivatives or extracts, and the plant is selected from rooibos and dandelion.

[0286] In some embodiments, the substance comprises a flavoring.

[0287] As used herein, the terms "flavoring agent" and "flavor enhancer" are permitted by local regulations and are used to produce the taste, smell or other somatic sensory stimuli desired by adult consumers.They include naturally occurring flavor materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phyllostachys pubescens leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, kojic acid, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, radish, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chat, naswar, kinma, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, neroli, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pimento, ginger, coriander, coffee, mugwort, peppermint oil from any species of the genus Mentha, eucalyptus, toshimi ki, cocoa, lemongrass, rooibos, flax, ginkgo, hashish, hibiscus, laurel, mate tea, orange peel, rose, tea such as green tea or black tea, thyme, byakushin, nasturtium flower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, chrysanthemum, curcuma, silantro, gimbai ka, blackcurrant, campanula, pimento, mace, damien, hanahakka, olive, lemon balm, lemon basil, chive, perilla, verbena, tarragon, limonene, thymol, camphene), seasonings, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, plants, or odor suppressants.They may be imitations, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0288] In some embodiments, the flavorant includes menthol, spearmint, and / or peppermint. In some embodiments, the flavorant includes flavor components of cucumber, blueberry, citrus, and / or redberry. In some embodiments, the flavorant includes eugenol. In some embodiments, the flavorant includes flavor components extracted from tobacco. In some embodiments, the flavorant includes flavor components extracted from cannabis.

[0289] In some embodiments, the flavorant may include a sensory stimulant, which is chemically induced and recognized, in addition to or instead of aroma or taste nerves, usually by stimulation of the fifth cranial nerve (trigeminal nerve). They may include agents that give a heating, cooling, tingling, or numbing sensation. Suitable heat agents include, but are not limited to, vanillyl ethyl ether, and suitable cooling agents include, but are not limited to, eucalyptol and WS-3.

[0290] The aerosol generating material is a material that can generate an aerosol when excited, for example, by heating, irradiation, or some other method. The aerosol generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and / or a flavorant. In some embodiments, the aerosol generating material may include an "amorphous solid", which is also sometimes referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that holds a fluid such as a liquid inside it. In some embodiments, the aerosol generating material includes from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of amorphous solid.

[0291] The aerosol generating material may include one or more active substances and / or flavorants, one or more aerosol forming materials, and, if necessary, one or more other functional materials.

[0292] The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0293] The one or more functional materials may include one or more of a pH regulator, a colorant, a preservative, a binder, a filler, a stabilizer and / or an antioxidant.

[0294] The forming material may be on or within a support to form a substrate. The support may be, for example, paper, cardboard, paperboard, thick paper, recycled material, plastic material, ceramic material, composite material, glass, metal or metal alloy or may include them. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded in the above materials. In some other embodiments, the susceptor is on one or both sides of the material.

[0295] A consumable is an article that includes or consists of an aerosol-generating material intended to be partially or wholly consumed by a user during use. The consumable may include one or more other components such as an aerosol-generating material storage area, aerosol-generating material transfer components, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol modifier. The consumable may also include an aerosol generator such as a heater that radiates heat so that the aerosol-generating material generates an aerosol during use. The heater may include, for example, a combustion-based material, a material heatable by electrical conduction or a susceptor.

[0296] The susceptor is a material that can be heated by the intrusion of a variable magnetic field such as an alternating magnetic field. The susceptor may be a conductive material, or may cause induction heating of the heating material by the intrusion of a variable magnetic field. The heating material may be a conductive material, or may cause magnetic hysteresis heating of the heating material by the intrusion of a variable magnetic field. The susceptor may be due to both conductivity and magnetic force, whereby the heating material can be heated by both heating mechanisms. An apparatus configured to generate a variable magnetic field is referred to herein as a magnetic field generator.

[0297] The aerosol modifier is typically located downstream of the aerosol generation region and is a substance configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component operable to selectively release the aerosol modifier.

[0298] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring agent, a coloring agent, water and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid or a gel. The aerosol modifier may be a powder, a thread or a granule. The aerosol modifier may not include a filter material.

[0299] The aerosol generator is an apparatus configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol generating material to thermal energy and release one or more volatile substances from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol generating material without heating. For example, the aerosol generator may be configured to expose the aerosol generating material to one or more of vibration, high pressure or electrostatic energy.

[0300] The various embodiments described herein are provided merely as an aid to understanding the claimed features and teachings. These embodiments are merely representative specific examples and are neither comprehensive nor exclusive. Of course, the advantages, embodiments, specific examples, functions, features, structures, and / or other aspects of the present disclosure should not be considered to limit the present disclosure to what is defined in the claims or to equivalents of the claims, but rather other embodiments may be utilized and modified without departing from the scope and / or spirit of the present disclosure. The various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, elements, features, parts, steps, means, and other combinations. The present disclosure also includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An apparatus for manufacturing a consumable for an aerosol delivery system, comprising: a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along the transport path; a consumable forming device configured to receive a sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable; and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor.

2. 10. The apparatus of claim 1, wherein the controller is configured to determine a location of a defect in a consumable formed by the consumable forming device based on information sensed by the sensor.

3. 3. The apparatus of claim 2, wherein the location of the defect comprises an axial location of the defect along the consumable.

4. 4. The apparatus of claim 1, wherein the controller is configured to determine one or more parameters of the defect, preferably the parameters of the defect include one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

5. 5. The apparatus of claim 4, wherein the controller is configured to compare a parameter of the defect to a preset value.

6. 6. Apparatus according to claim 5, characterized in that the controller is adapted to classify the defect based on a comparison of a parameter of the defect with a preset value, preferably the classification relating to the severity of the defect.

7. 7. The apparatus of claim 1, wherein the controller is configured to determine the presence or absence of defects in at least one discrete area of ​​the sheet of aerosol-generating material based on information sensed by the sensor.

8. 8. The apparatus of claim 1, wherein the controller is configured to determine the presence or absence of defects along substantially the entire length of the sheet of aerosol-generating material based on information sensed by the sensor.

9. 9. The apparatus of claim 8, wherein the defect is a deviation of at least one parameter of the sheet of aerosol-generating material from a target range or value present along substantially the entire length of the sheet of aerosol-generating material, preferably the parameter being one or more of thickness, density or porosity of the sheet.

10. 10. An apparatus as claimed in any one of claims 6 to 9, wherein the controller is configured to assess the quality of a region of a sheet of aerosol-generating material based on the amount or surface density of one or more defects in said region and / or a classification of one or more defects in said region.

11. 11. Apparatus according to claim 10, characterized in that the assessment of quality produces quality requirement criteria, preferably the controller being adapted to store said criteria in a memory, preferably said criteria being associated with said region.

12. 12. The device of claim 11, wherein the areas of the sheet correspond to individual consumable batches formed by individual consumable aerosol generating materials or devices.

13. 13. Apparatus according to any one of claims 10 to 12, characterized in that the controller is adapted to take specific actions depending on the assessment of the quality of the area.

14. 14. Apparatus according to claim 13, characterized in that the action comprises sending a signal indicating that the quality of the area falls below a predefined value, preferably indicating that the area and / or the entire sheet material should be discarded and / or recycled.

15. 15. An apparatus as claimed in claim 13 or 14, characterized in that the operation includes sending a signal indicating that the consumable or batch of consumables including the area should be sorted from other consumables or batches of consumables formed by the consumable forming device if evaluation of the quality of the area determines that the quality falls below a predefined value, preferably that the consumable or batch of consumables including the area should be discarded and / or recycled.

16. 16. Apparatus according to any one of the preceding claims, characterized in that the sensor comprises a signal generator and a signal receiver for detecting defects, preferably the signal being a laser signal.

17. 17. Apparatus according to any one of the preceding claims, characterized in that it comprises a plurality of sensors.

18. 18. Apparatus according to claim 17, characterized in that the sensors are configured to detect areas of the sheet that are offset in a direction perpendicular to the direction of the transport path and / or configured to detect areas of the sheet that are offset in a direction along the transport path.

19. 19. Apparatus according to any preceding claim, wherein the sensor is configured to determine a topology of at least a portion of the sheet of aerosol-generating material.

20. 20. Apparatus according to any one of claims 1 to 19, wherein the sensor is located above or below the sheet of aerosol-generating material.

21. 21. Apparatus according to any one of the preceding claims, characterized in that the sensor comprises a camera.

22. 22. The apparatus of claim 21, further comprising a light emitter configured to direct light onto the sheet of aerosol-generating material.

23. 23. The apparatus of claim 22, wherein the light emitter is located on a surface of the sheet of aerosol-generating material that is distal to the camera.

24. 24. Apparatus according to any one of claims 21 to 23, characterized in that the light emitters are located on both sides of the sheet of aerosol-generating material.

25. 25. Apparatus according to any one of claims 21 to 24, characterized in that the illuminator comprises a filter.

26. 26. Apparatus according to any one of claims 21 to 25, characterized in that the camera comprises a filter, preferably the filter being an optical filter.

27. 27. Apparatus according to claim 26 when dependent on claim 25, wherein the filter of the illuminator is configured to pass electromagnetic radiation, at least a portion of which has the same frequency as the electromagnetic radiation passed by the filter of the camera.

28. 28. Apparatus according to any one of claims 21 to 27, characterized in that the camera is a 3D camera arranged to detect a 3D image of the sheet.

29. 29. The apparatus of any one of claims 1 to 28, wherein the defects detected by the sensor include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

30. 30. An apparatus as claimed in any one of claims 1 to 29, wherein the supply device supplies a continuous sheet of aerosol-generating material, preferably the supply device includes a bobbin receiving mechanism for receiving a bobbin of sheets of aerosol-generating material, preferably the supply device includes a bobbin of sheets of aerosol-generating material.

31. 31. A device according to any preceding claim, wherein the sheet of aerosol-generating material comprises tobacco.

32. 32. The apparatus of any one of claims 1 to 31, wherein the consumable forming device comprises a strip forming device configured to form the sheet of aerosol-generating material into a strip.

33. 33. The apparatus of claim 32, wherein the strip-forming device comprises a cutting device configured to cut at least a portion of the sheet of aerosol-generating material into a strip of aerosol-generating material.

34. 34. The apparatus of claim 32 or 33, wherein the consumable forming device includes a collector configured to collect the strip of aerosol-generating material.

35. 35. The apparatus of any one of claims 1 to 34, wherein the consumable forming device includes a wrapping device configured to wrap the aerosol-generating material in a wrapper.

36. 36. An apparatus according to any preceding claim, wherein the consumable forming device includes a cutting device for cutting the consumable into individual consumables.

37. 37. The device of claim 36, wherein the individual consumables are single length or double length consumables.

38. 38. The apparatus of claim 36 or 37, wherein the controller is configured to associate the defects with individual consumables.

39. 39. The apparatus of any one of claims 36 to 38, wherein the controller is configured to associate defects with individual batches of consumables formed by the consumable forming device.

40. 40. The apparatus of claim 39, wherein the apparatus includes a sorting device configured to remove individual consumable items determined by the controller to contain one or more defects.

41. 41. The apparatus of any one of claims 1 to 40, wherein the consumable is a rod.

42. 1. An apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, comprising: a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along the transport path; and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor.

43. 43. Apparatus according to claim 42, characterized in that it comprises any one or more of the features of claims 1 to 41.

44. A controller for an apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, the controller configured to connect to a sensor, the sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material, and the controller configured to determine whether or not there is a defect in the sheet of aerosol-generating material based on the information detected by the sensor.

45. 45. The controller of claim 44, wherein the sensor is configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path or the sensor is configured to detect information indicative of a defect in the sheet of aerosol-generating material before the sheet of aerosol-generating material is fed along the transport path.

46. A controller according to claim 45, characterized in that the device / controller has any of the features of any of claims 1 to 43.

47. 1. A method for manufacturing a consumable for an aerosol delivery system, comprising: providing a sheet of aerosol-generating material along a conveying path; detecting information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along a transport path; forming a sheet of aerosol-generating material into a consumable; and determining whether the consumable is defective based on the sensed information.

48. 48. The method of claim 47, further comprising determining a location of the defect in the formed consumable based on the sensed information, preferably determining an axial location of the defect.

49. 49. The method of claim 47 or 48, characterized in that the method includes determining one or more parameters of the defect, preferably the parameters of the defect include one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

50. 50. The method of claim 49, further comprising comparing a parameter of the defect with one or more preset values, preferably classifying the defect based on the comparison of the parameter of the defect with the one or more preset values.

51. 51. The method of any one of claims 47 to 50, wherein determining the presence or absence of a defect in the consumable based on the detected information comprises determining the presence or absence of a defect in at least one discrete area of ​​the sheet based on information detected by a sensor.

52. 52. The method of any one of claims 47 to 51, wherein determining whether or not a consumable is defective based on the detected information comprises determining whether or not a defect exists along substantially the entire length of the sheet based on information detected by the sensor.

53. 53. The method of claim 52, wherein the defect is a deviation from a target range or value of at least one parameter of the sheet that is present along substantially the entire length of the sheet, preferably said parameter being one or more of thickness, density or porosity of the sheet.

54. 54. A method as claimed in any one of claims 47 to 53, comprising using a sensor to detect information indicative of the defect, preferably the sensor comprising a signal generator and a signal receiver for detecting the defect.

55. 55. The method of claim 54, wherein the sensor comprises a plurality of signal generators and signal receivers.

56. 56. A method according to claim 55, characterized in that the sensors are configured to detect areas of the sheet that are offset in a direction perpendicular to the direction of the transport path and / or configured to detect areas of the sheet that are offset in a direction along the transport path.

57. 57. A method according to any one of claims 54 to 56, wherein the sensor is located above or below the sheet of aerosol-generating material.

58. 58. A method according to any one of claims 54 to 57, characterized in that the sensor comprises a camera, preferably the camera being a 3D camera arranged to detect a 3D image of the sheet.

59. 60. The method of claim 58, wherein the camera includes a filter, preferably the filter is an optical filter.

60. 60. A method as claimed in claim 58 or 59, comprising shining a light on the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

61. 61. The method of claim 60, further comprising shining light onto the sheet from a side of the sheet distal from the camera.

62. 62. The method of claim 60 or 61, comprising exposing a sheet of aerosol-generating material to light on both sides.

63. 63. A method according to any one of claims 60 to 62 when dependent on claim 59, comprising directing light onto the sheet of aerosol-generating material through a filter configured to filter electromagnetic radiation of the same frequency as the camera's filter.

64. 64. A method as claimed in any one of claims 47 to 63, comprising determining a topology of at least a portion of the sheet of aerosol-generating material.

65. 65. The method of any one of claims 47 to 64, wherein the detected defects include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

66. 66. A method as claimed in any one of claims 47 to 65, wherein supplying the sheet of aerosol-generating material along the transport path comprises supplying a continuous sheet of aerosol-generating material, preferably the sheet being supplied from a bobbin.

67. 67. A method as claimed in any one of claims 47 to 66, wherein the sheet of aerosol-generating material comprises tobacco.

68. 68. A method as claimed in any one of claims 47 to 67, wherein forming the sheet of aerosol-generating material into a consumable comprises forming the sheet of aerosol-generating material into strips, preferably comprising cutting at least a portion of the sheet of aerosol-generating material into strips.

69. 70. The method of claim 68, wherein forming the sheet of aerosol-generating material into a consumable comprises collecting a strip of aerosol-generating material.

70. 70. The method of any one of claims 47 to 69, wherein forming the sheet of aerosol-generating material into a consumable product comprises enclosing the aerosol-generating material in a wrapper.

71. 71. A method as claimed in any one of claims 47 to 70, wherein forming the sheet of aerosol-generating material into a consumable comprises cutting the consumable into individual consumables, preferably individual consumables being single or double length consumables.

72. 72. The method of claim 71, further comprising associating the defect with an individual consumable.

73. 73. The method of claim 72, further comprising separating individual consumable items that are determined by the controller to contain one or more defects from individual consumable items that are not determined by the controller to contain one or more defects.

74. 74. A method according to any one of claims 71 to 73, comprising associating defects with individual batches of consumables.

75. 75. The method of any one of claims 47 to 74, wherein the consumable is a rod.

76. 1. An apparatus for analyzing a sheet of aerosol-generating material for an aerosol delivery system consumable, comprising: a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material; and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor.

77. 77. The apparatus of claim 76, wherein the controller is configured to determine one or more parameters of the defect, preferably the parameters of the defect include one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

78. 78. The apparatus of claim 77, wherein the controller is configured to compare a parameter of the defect to a preset value.

79. 80. Apparatus according to claim 78, characterized in that the controller is configured to classify the defect based on a comparison of a parameter of the defect with a preset value, preferably the classification relating to the severity of the defect.

80. 80. An apparatus as claimed in any one of claims 76 to 79, wherein the controller is configured to determine the presence or absence of defects in at least one discrete area of ​​the sheet of aerosol-generating material based on information detected by the sensor.

81. 81. The apparatus of any one of claims 76 to 80, wherein the controller is configured to determine the presence or absence of defects along substantially the entire length of the sheet of aerosol-generating material based on information sensed by the sensor.

82. 82. An apparatus as described in any one of claims 76 to 81, characterized in that the defect is a deviation of at least one parameter of the sheet of aerosol-generating material from a target range or value present along substantially the entire length of the sheet of aerosol-generating material, preferably the parameter being one or more of the thickness, density or porosity of the sheet.

83. 83. An apparatus as described in any one of claims 76 to 82, wherein the controller is configured to evaluate the quality of a region of a sheet of aerosol-generating material based on the amount or surface density of one or more defects in the region and / or a classification of one or more defects in the region.

84. 84. Apparatus according to claim 83, characterized in that the assessment of quality produces quality requirement criteria, preferably the controller being adapted to store said criteria in a memory, preferably said criteria being associated with said region.

85. 85. The device of claim 84, wherein the regions of the sheet correspond to individual consumable batches formed by individual consumable aerosol generating materials or devices.

86. 86. Apparatus according to any one of claims 83 to 85, wherein the controller is configured to take specific action depending on the assessment of the quality of the region.

87. 87. Apparatus according to claim 86, characterized in that the action comprises sending a signal indicating that the quality of the area falls below a predefined value, preferably indicating that the area and / or the entire sheet material should be discarded and / or recycled.

88. 88. Apparatus according to any one of claims 76 to 87, characterized in that the sensor comprises a signal generator and a signal receiver for detecting the defect, preferably the signal being a laser signal.

89. 89. Apparatus according to any one of claims 76 to 88, characterized in that it comprises a plurality of sensors.

90. 89. Apparatus according to any one of claims 76 to 88, wherein the sensor is configured to determine a topology of at least a portion of the sheet of aerosol-generating material.

91. 91. Apparatus according to any one of claims 76 to 90, characterized in that the sensor comprises a camera.

92. 92. The apparatus of claim 91, further comprising a light emitter configured to direct light onto the sheet of aerosol-generating material.

93. 93. The apparatus of claim 92, wherein the light emitter is configured to be located on a surface of the sheet of aerosol-generating material that is distal to the camera.

94. 94. Apparatus according to claim 92 or 93, characterized in that the light emitters are arranged to be located on both sides of the sheet of aerosol-generating material.

95. 95. Apparatus according to any one of claims 92 to 94, characterized in that the illuminator comprises a filter.

96. 96. Apparatus according to any one of claims 92 to 95, characterized in that the camera includes a filter, preferably the filter is an optical filter.

97. 97. Apparatus according to claim 96 when dependent on claim 95, wherein the filter of the illuminator is configured to pass electromagnetic radiation, at least a portion of which has the same frequency as the electromagnetic radiation passed by the filter of the camera.

98. 98. Apparatus according to any one of claims 92 to 97, characterized in that the camera is a 3D camera arranged to detect a 3D image of the sheet.

99. 99. The apparatus of any one of claims 76 to 98, wherein the defects detected by the sensor include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

100. 100. An apparatus as claimed in any one of claims 76 to 99, wherein the sheet of aerosol-generating material comprises tobacco.

101. 1. An apparatus for manufacturing a consumable for an aerosol delivery system, comprising: Apparatus for analysing a sheet of aerosol-generating material according to any one of claims 76 to 100; a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; and a consumable forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

102. 1. A method for analyzing a sheet of aerosol-generating material for an aerosol delivery system consumable, comprising: detecting information indicative of a defect in the sheet of aerosol-generating material; and determining whether the consumable is defective based on the sensed information.

103. 103. The method of claim 102, further comprising determining one or more parameters of the defect, preferably the parameters of the defect include one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

104. 104. The method of claim 103, further comprising comparing a parameter of the defect with one or more preset values, preferably classifying the defect based on a comparison of the parameter of the defect with the one or more preset values.

105. 105. The method of any one of claims 102 to 104, wherein determining the presence or absence of a defect in the consumable based on the detected information comprises determining the presence or absence of a defect in at least one discrete area of ​​the sheet based on information detected by a sensor.

106. 106. The method of any one of claims 102 to 105, wherein determining whether or not a consumable is defective based on the detected information comprises determining whether or not a defect exists along substantially the entire length of the sheet based on information detected by the sensor.

107. The method of claim 106, wherein the defect is a deviation of at least one parameter of the sheet of aerosol-generating material from a target range or value present along substantially the entire length of the sheet of aerosol-generating material, preferably the parameter is one or more of the thickness, density or porosity of the sheet.

108. 108. A method as claimed in any one of claims 102 to 107, comprising using a sensor to detect information indicative of the defect, preferably the sensor comprising a signal generator and a signal receiver for detecting the defect.

109. 109. The method of claim 108, wherein the sensor comprises a plurality of signal generators and signal receivers.

110. 110. A method according to claim 108 or 109, characterized in that the sensor comprises a camera, preferably the camera being a 3D camera arranged to detect a 3D image of the sheet.

111. 111. The method of claim 110, wherein the camera includes a filter, preferably the filter is an optical filter.

112. 112. The method of claim 110 or 111, further comprising shining a light onto the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

113. 113. The method of claim 112, further comprising shining light onto the sheet from a side of the sheet distal from the camera.

114. 114. The method of claim 112 or 113, comprising exposing a sheet of aerosol-generating material to light on both sides.

115. 115. A method according to any one of claims 112 to 114, comprising directing light onto the sheet of aerosol-generating material through a filter configured to filter out electromagnetic radiation of the same frequency as the camera's filter.

116. 116. A method as claimed in any one of claims 102 to 115, comprising determining a topology of at least a portion of the sheet of aerosol-generating material.

117. 117. The method of any one of claims 102 to 116, wherein the detected defects include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

118. 118. A method as claimed in any one of claims 102 to 117, wherein the sheet of aerosol-generating material comprises tobacco.

119. 119. A method for manufacturing a consumable for an aerosol delivery system, the method comprising analyzing a sheet of aerosol-generating material for a consumable for an aerosol delivery system by a method according to any one of claims 102 to 118, and further comprising forming the sheet of aerosol-generating material into a consumable.

120. A consumable for an aerosol delivery system manufactured by the apparatus of any one of claims 1 to 41 or claim 101 or by the method of any one of claims 47 to 75 or claim 119.

121. 1. A system for manufacturing a consumable for an aerosol delivery system, comprising: Apparatus for analyzing a sheet of aerosol-generating material for use in a consumable aerosol delivery system according to any one of claims 76 to 100; a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; and a consumable forming device configured to contain the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

122. A system according to claim 121, comprising any of the features of an apparatus according to any of claims 1 to 42.

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