Method for checking ventilation zones of aerosol-generating articles for manufacturing defects - Patents.com

Abstract

The present invention relates to a method for checking an aerosol-generating article having a ventilation zone for manufacturing defects, comprising the steps of: providing a ventilation zone in an aerosol-generating article, the ventilation zone comprising a plurality of perforations; - cutting the aerosol-generating article along a plane through the plurality of perforations, thereby creating an intersection through the plurality of perforations; - checking the intersections for manufacturing defects. Such methods for checking aerosol-generating articles for manufacturing defects may also check the shape and positioning of perforations within the article.

Description

[Technical field]

[0001] The present invention relates to a method for checking the ventilation zone of an aerosol-generating article for manufacturing defects The present invention further relates to an inspection device for checking the ventilation zone of an aerosol-generating article for manufacturing defects. [Background technology]

[0002] The aerosol-generating article comprises a substrate section that includes an aerosol-forming substrate and additionally often a ventilation zone that includes a number of perforations that allow ambient air to enter the aerosol-generating article. Methods for checking for manufacturing defects of the perforations in the ventilation zone are often limited to visual inspection of the final aerosol-generating article that includes the ventilation zone. These methods do not provide information about the path of the perforations inside the aerosol-generating article. Other methods are known that analyze the draw resistance of the aerosol-generating article and the amount of air that can be drawn through the perforations. These methods do not provide information about the geometry of the perforations or their orientation inside the article.

[0003] It would be desirable to provide a method for checking ventilation zones of aerosol-generating articles for manufacturing defects that can check the path of the perforations within the article. It would further be desirable to provide a method for checking ventilation zones of aerosol-generating articles for manufacturing defects that can provide information about the geometry of the perforations within the article. It would also be desirable to provide a method for checking for manufacturing defects that can provide information about the orientation of the perforations in the plane of the ventilation zone. It would further be desirable to provide an inspection device that can assist in checking perforations in ventilation zones for manufacturing defects. Summary of the Invention

[0004] According to one embodiment of the present invention, there is provided a method for checking an aerosol-generating article having a ventilation zone for manufacturing defects. The method may include the method steps of providing a ventilation zone in the aerosol-generating article. The ventilation zone may include a plurality of perforations. The method may include the method step of cutting the aerosol-generating article along a plane through the plurality of perforations. This may create an intersection through the plurality of perforations. The method may further include checking the intersection for manufacturing defects.

[0005] According to another embodiment of the present invention, there is provided a method for checking an aerosol-generating article having a ventilation zone for manufacturing defects, the method comprising: providing a ventilation zone in an aerosol-generating article, the ventilation zone comprising a plurality of perforations; - cutting the aerosol-generating article along a plane through the plurality of perforations, thereby creating an intersection through the plurality of perforations; - checking the intersections for manufacturing defects.

[0006] The method for checking for manufacturing defects may make it possible to check the path of the perforations in the ventilation zone through the aerosol-generating article along the intersection, which may provide further insight into the configuration of the perforations in the aerosol-generating article. The method may make it possible to check the structure of the perforations inside the aerosol-generating article for manufacturing defects, which may provide better insight into the structure and path of the perforations in the ventilation zone compared to methods of inspecting the aerosol-generating article from the outside, for example by using a visual inspection system.

[0007] The term "aerosol-generating article" is used herein to mean an article in which an aerosol-generating substrate is heated to generate an inhalable aerosol to be delivered to a consumer. The term "aerosol-forming substrate" as used herein means a substrate capable of releasing a volatile compound upon heating to generate an aerosol. The term "aerosol-generating article" also encompasses a continuous rod formed from a plurality of aerosol-generating articles. During the manufacture of aerosol-generating articles, a long rod containing up to 10 aerosol-generating articles can be formed, which can then be cut to produce smaller rods or final articles. In particular, the term "aerosol-generating article" also includes the so-called "double stick", which is two aerosol-generating articles connected together. Such a double stick can be subjected to a method for checking for manufacturing defects as described herein.

[0008] As used herein, the term "aerosol-generating device" refers to a device that includes a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0009] The aerosol-forming substrate may be a solid aerosol-forming substrate.

[0010] In certain preferred embodiments, the aerosol-forming substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0011] The term "homogenized plant material" as used herein includes any plant material formed by agglomeration of plant particles. For example, a sheet or web of homogenized tobacco material for the aerosol-forming substrate of the present invention may be formed by agglomerating particles of tobacco material obtained by grinding, crushing, or comminuting plant material and, optionally, one or more of tobacco lamina and tobacco stems. The homogenized plant material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0012] The homogenized plant material may be provided in any suitable form. For example, the homogenized plant material may be in the form of one or more sheets. The term "sheet" as used herein with respect to the present invention describes a laminar element having a width and length substantially greater than its thickness.

[0013] The homogenized plant material may be in the form of a plurality of pellets or granules.

[0014] The homogenized plant material may be in the form of multiple strands, strips, or pieces. As used herein, the term "strand" describes an elongated element of material having a length substantially greater than its width and thickness. The term "strand" should be considered to encompass strips, pieces, and any other homogenized plant material having a similar morphology. Strands of homogenized plant material may be formed from a sheet of homogenized plant material, for example, by cutting or shredding, or by other methods, such as extrusion methods.

[0015] The tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, the tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent.

[0016] The aerosol-forming substrate may further comprise one or more aerosol formers. Upon volatilization, the aerosol formers may carry other vaporized compounds, such as nicotine and flavorants in the aerosol, that are released from the aerosol-forming substrate upon heating. Aerosol formers suitable for inclusion in the homogenized plant material are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and tetradecanedioate).

[0017] The aerosol-forming substrate may have an aerosol former content of from about 5 weight percent to about 30 weight percent on a dry weight basis, or from about 10 weight percent to about 25 weight percent on a dry weight basis, or from about 15 weight percent to about 20 weight percent on a dry weight basis.

[0018] For example, where the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, the aerosol former content may preferably be from about 5 weight percent to about 30 weight percent on a dry weight basis.When the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, the aerosol former is preferably glycerol.

[0019] The aerosol-forming substrate may comprise a gel composition comprising an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. In a particularly preferred embodiment, the aerosol-forming substrate comprises a gel composition comprising nicotine.

[0020] Preferably, the gel composition comprises nicotine.

[0021] Preferably, in an aerosol-generating article according to the invention, the susceptor is arranged within the rod of the aerosol-forming substrate and is in thermal contact with the aerosol-forming substrate. The susceptor is preferably an elongated susceptor.

[0022] As used herein with respect to this specification, the term "susceptor" refers to a material capable of converting electromagnetic energy into heat. When located within a varying electromagnetic field, induced eddy currents in the susceptor cause heating of the susceptor. The elongated susceptor is located in thermal contact with an aerosol-forming substrate, which is heated by the susceptor.

[0023] The term "elongated" when used to describe a susceptor means that the susceptor has a length dimension that is greater than its width or its thickness dimension, for example, greater than twice its width or its thickness dimension.

[0024] The susceptor is preferably disposed substantially longitudinally within the rod, meaning that the length dimension of the elongated susceptor is aligned approximately parallel to the longitudinal direction of the rod, for example within ±10 degrees of parallel to the longitudinal direction of the rod. In a desirable embodiment, the elongated susceptor may be positioned at a radially central location within the rod and extends along the longitudinal axis of the rod.

[0025] Preferably, the susceptor extends all the way to the downstream end of the rod of the aerosol-generating article. In some embodiments, the susceptor may extend all the way to the upstream end of the rod of the aerosol-generating article. In particularly preferred embodiments, the susceptor has substantially the same length as the rod of the aerosol-forming substrate and extends from the upstream end of the rod to the downstream end of the rod.

[0026] The susceptor is preferably in the form of a pin, rod, strip or blade.

[0027] The length of the susceptor is preferably in the range of about 5 mm to about 15 mm (eg, about 6 mm to about 12 mm, or about 8 mm to about 10 mm).

[0028] The ratio between the length of the susceptor and the overall length of the aerosol-generating article substrate may be from about 0.2 to about 0.35.

[0029] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptors include metal or carbon.

[0030] A preferred susceptor may include or consist of a ferromagnetic material (e.g., a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel). A suitable susceptor may be or include aluminum. A preferred susceptor may be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when positioned in an electromagnetic field having similar values ​​of frequency and field strength.

[0031] Thus, the parameters of the susceptor, such as type of material, length, width, and thickness, may all be modified to provide the desired power dissipation within a known electromagnetic field. Preferred susceptors may be heated to temperatures in excess of 250 degrees Celsius.

[0032] A suitable susceptor may comprise a non-metallic core having a metal layer disposed thereon (e.g., a track of metal formed on the surface of a ceramic core). The susceptor may have a protective outer layer, such as a protective ceramic layer or a protective glass layer, that encapsulates the susceptor. The susceptor may include a protective coating formed of glass, ceramic, or an inert metal formed over a core of susceptor material.

[0033] The susceptor is arranged in thermal contact with the aerosol-forming substrate such that as the temperature of the susceptor increases, the aerosol-forming substrate is heated and an aerosol is formed. The susceptor is preferably arranged in direct physical contact with the aerosol-forming substrate, for example within the aerosol-forming substrate.

[0034] The aerosol-generating article may further comprise a downstream section located downstream of the rod of the aerosol-forming substrate. The downstream section may include an intermediate hollow section including an aerosol cooling element arranged in alignment with and downstream of the rod of the aerosol-forming substrate.

[0035] The downstream section may further include one or more downstream elements above the aerosol cooling element. By way of example, the intermediate hollow section may further comprise a support element positioned immediately downstream of the rod of the aerosol-forming substrate, and the aerosol cooling element may be located between the support element and the downstream end (or mouth end) of the aerosol-generating article. More specifically, the aerosol cooling element may be positioned immediately downstream of the support element. In some preferred embodiments, the aerosol cooling element may abut the support element. As described below, the downstream section may further include one or more elements above the intermediate hollow section at a position downstream of the intermediate hollow section.

[0036] The aerosol cooling element may comprise a hollow tubular segment defining a cavity extending all the way from an upstream end of the aerosol cooling element to a downstream end of the aerosol cooling element, and ventilation zones may be provided at locations along the hollow tubular segment.

[0037] As used herein, the term "hollow tubular segment" is used generally to mean an elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term "tubular" is used hereinafter with reference to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. However, it will be appreciated that alternative shapes (e.g., alternative cross-sectional shapes) of the tubular element may be possible.

[0038] In the context of the present invention, the hollow tubular segment provides an unrestricted flow channel. This means that the hollow tubular segment provides a negligible level of resistance to withdrawal (RTD). Thus, the flow channel should not include any components that would impede the longitudinal air flow. Preferably, the flow channel is substantially empty.

[0039] The term "elongated" when used to describe an aerosol cooling element means that the aerosol cooling element has a length dimension that is greater than its width dimension or its diameter dimension, e.g., more than twice its width dimension or its diameter dimension.

[0040] The term "longitudinal" as used herein refers to a direction corresponding to a major longitudinal axis of the aerosol-generating article extending between the upstream and downstream ends of the aerosol-generating article. The terms "upstream" and "downstream" as used herein describe the relative positions of an element (or portion of an element) of the aerosol-generating article with respect to the direction in which aerosol is transported through the aerosol-generating article during use.

[0041] The plurality of perforations in the ventilation zone may include at least two perforations. The plurality of perforations in the ventilation zone may include at least four, preferably at least six perforations. More preferably, the plurality of perforations may include up to 15, preferably up to 11 perforations in the ventilation zone.

[0042] The aerosol-generating article may have a central longitudinal axis. Cutting the aerosol-generating article along a plane through the plurality of perforations may include cutting the aerosol-generating article within the ventilation zone in a plane transverse to the central longitudinal axis. Preferably, the aerosol-generating article is cut within its ventilation zone in a direction perpendicular to the central longitudinal axis.

[0043] This may provide a cross-section of multiple perforations within the ventilation zone, which may allow checking the width and length of the perforations within the ventilation zone for manufacturing defects.

[0044] Cutting the aerosol-generating article along a plane through the multiple perforations can provide a cut portion of the aerosol-generating article, one end of which forms an intersection through the ventilation zone, which cut portion of the aerosol-generating article having an intersection can then be used in a method to check for manufacturing defects.

[0045] The method may provide a cross-section of all perforations in the ventilation zone. It may therefore be possible to check all perforations in the ventilation zone by inspecting the intersections for manufacturing defects.

[0046] The perforation may comprise a hole extending from the exterior of the aerosol-generating article to the interior of the aerosol-generating article. Thus, the cross-sectional cut of the perforation may comprise an elongated shape, preferably a rectangular shape.

[0047] The aerosol-generating article may be cut through a hollow segment that includes the ventilation zone. Checking for manufacturing defects may then include checking whether at least one cross-section cut of the perforation extends from the interior of the hollow segment to the exterior of the aerosol-generating article. Checking for manufacturing defects may include rejecting an aerosol-generating article whose cross-section cut does not extend from the interior of the hollow segment to the exterior of the aerosol-generating article.

[0048] The number of cross-sections of the perforations that extend from the interior of the hollow segment to the exterior of the aerosol-generating article may be determined, and the aerosol-generating article may be rejected if less than two-thirds of its cross-sections extend from the interior of the hollow segment to the exterior of the aerosol-generating article.

[0049] At least one cross-section of the perforation within the intersection may be checked for manufacturing defects, preferably at least two or at least three cross-sections are checked for manufacturing defects, and most preferably all cross-sections of the perforation are checked for manufacturing defects.

[0050] This may allow for quick checking of intersections by only checking a percentage of the cross-sections of multiple perforations, which may speed up the process of checking for manufacturing defects. Alternatively, it may be possible to check all cross-sections of the perforations for manufacturing defects. This method may provide a very accurate assessment of manufacturing defects.

[0051] A tubular sacrificial element may be used during cutting of the aerosol-generating article. The tubular sacrificial element may have a slightly larger diameter than the aerosol-generating article. The tubular sacrificial element may be placed over the aerosol-generating article prior to cutting the article.

[0052] The tubular sacrificial element may include a plastic tube or shell. The tubular sacrificial element may include an indicator that indicates an expected location of the perforation in the vent zone. The indicator may include a marking on the tubular sacrificial element.

[0053] After placing the tubular sacrificial element over the aerosol-generating article, the tubular sacrificial element containing the aerosol-generating article may be cut. Preferably, the aerosol-generating article may be cut through an indicator on the tubular sacrificial element.

[0054] This may make it easier to position the cutting device in the correct way. The tubular sacrificial element may mechanically stabilize the aerosol-generating article during the cutting procedure. This may avoid deformation of the aerosol-generating article, especially in the region of the intersection formed by the cutting process.

[0055] The aerosol-generating article may be cut using a cutting device, which may be, for example, a rotary knife or a filter cutting machine.

[0056] A reference image of the cross-section of the perforations may be provided. The reference image may be superimposed on the cross-section of the perforations at the intersection of the aerosol-generating article. This may allow a visual check for manufacturing defects. Preferably, one or both of the width or orientation of the cross-section cut within the intersection may be checked using the reference image.

[0057] The use of the reference image may allow for a quicker and easier visual inspection of the perforations for manufacturing defects. In particular, the width of the reference image may be compared with the width of at least a portion of the cross-section of the perforations at the intersection. This may allow for an easy check for width-related manufacturing defects. The reference image may show the correct position of the cross-section of the perforations in the intersection. Thus, the reference image may allow for an easy check for potential manufacturing defects related to the orientation of the perforations in the ventilation zone.

[0058] The reference image may be positioned above the intersection to visually check for manufacturing defects. The reference image and the intersection of the cut aerosol-generating article may be rotatably disposed relative to one another. The reference image may be superimposed onto at least one cross-sectional cut of the perforations via rotation.

[0059] Rotating the reference image relative to the cross-section of the drill hole may provide a simple way to overlay the reference image onto the cross-section.

[0060] In one embodiment of a method for checking for manufacturing defects, the reference image may be continuously superimposed with at least a portion of the cross-section cut of the drill hole to check for manufacturing defects by rotating the reference image relative to the cross-section cut.

[0061] The aerosol-generating article may have a central longitudinal axis. The rotation of the reference images and the cross-section cut relative to each other may be performed about the central longitudinal axis of the aerosol-generating article. In particular, the rotational movement may be about the central longitudinal axis of the cut aerosol-generating article. This may provide a simple way of superimposing the reference image onto at least a portion of the cross-section cut of the perforation.

[0062] The inclination of the cross-section cut of the perforations relative to the plane of the cut may be determined. In particular, due to the inclination of the perforations relative to the plane of the cut, the cross-section cut of the perforations at the intersection may not extend continuously from the exterior of the aerosol-generating article to the interior of the article. As a result, partial cross-section cuts that do not extend from the exterior to the interior of the aerosol-generating article at the intersection may be considered as manufacturing defects. As a result, aerosol-generating articles that include these partial cross-section cuts at the intersection may be rejected in the method for checking for manufacturing defects. Thus, the method for checking for manufacturing defects of the present invention may also determine whether the perforations in the ventilation zone have the correct orientation in the plane of the ventilation zone.

[0063] The reference image may be an image of a correctly positioned and correctly shaped cross-section. Additionally, the reference image may have the correct width.

[0064] The area of ​​the reference image that can be superimposed on the area of ​​the cross-section of the perforations can be determined. This can enable a person skilled in the art to determine the percentage of overlap between the area of ​​the reference image and the area of ​​the cross-section of the perforations. A low percentage of the superimposable area of ​​the reference image can indicate a large deviation between the reference image and the cross-section of the perforations at the intersection of the aerosol-generating article. The aerosol-generating article can be rejected if the deviation between the cross-section of the perforations at the intersection and the reference image is too large. The aerosol-generating article can be rejected if less than 80 percent, preferably less than 85 percent, more preferably less than 90 percent of the area of ​​the reference image can be superimposed on the area of ​​the cross-section of the perforations.

[0065] The aerosol-generating article may further be rejected if less than 80 percent, preferably less than 85 percent, and more preferably less than 90 percent of the total number of cross-sections of the perforations at the intersection can be superimposed, as described above, to the extent that at least 80 percent of the area of ​​the reference image can be superimposed on the area of ​​each cross-section.

[0066] Thus, small deviations of up to 20 percent, preferably up to 10 percent, between the area of ​​the reference image and the area of ​​the cross-section cut may be tolerated, which may still allow sufficient resistance to drawing and allow sufficient temperature conditioning of the aerosol in the ventilation zone of the aerosol-generating article due to ambient air entering the aerosol-generating article through the perforations.

[0067] The percentage of overlap between the area of ​​the reference image and the area of ​​the cross-section of the perforation at the intersection can be determined by using a CT scan. Some method steps or the complete method of checking the ventilation zone of an aerosol-generating article for manufacturing defects can include a computer-implemented method. The reference image can be a computer-generated image or can be implemented in an inspection tool, as described further below.

[0068] An aerosol-generating article may be rejected if the central axis of the cross-section of the perforations at the intersection of the aerosol-generating article has an inclination angle of more than 10 degrees, preferably more than 5 degrees, relative to the reference image.

[0069] Such a large tilt angle indicates that the perforation is very tilted compared to the reference image and the aerosol-generating article should be rejected.

[0070] A drill hole passes the method for checking for manufacturing defects if the central axis of the cross-section cut lies completely within the reference image.

[0071] The tilt angle between the central axis of the cross-sectional cut and the reference image may be determined as the cut angle between the central axis of the cut and the reference image.

[0072] In particular, an aerosol-generating article may be rejected if the reference image cannot be superimposed on a cross-section of the perforations at the intersection, which may indicate that the perforations are offset from the reference image to such an extent that the aerosol-generating article should be rejected.

[0073] The reference image is - a line indicating the width and position of a correctly positioned and correctly shaped cross-section cut, or a circular arc indicating the area within which the central axis of the cross-sectional cut of the perforation should be located.

[0074] A reference image containing lines indicating the width and location of a correctly positioned and correctly shaped cross-section cut may be used to determine the degree of overlap between an area of ​​the reference image and an area of ​​the cross-section cut.

[0075] To determine the above-mentioned tilt angle between the central axis of the cross-section and the reference image, a reference image including a circular arc may be used.

[0076] Inspection tools can be used to check for manufacturing defects. a cavity for receiving a cut portion of an aerosol-generating article, the cut portion including an intersection; and a reference image of a cross-section of the perforation; - means for rotating the reference image and the cut aerosol-generating article relative to each other in order to superimpose the reference image onto the cross-sectional cut of the perforation in the intersection.

[0077] Such a tool may be conveniently used to easily overlay a reference image onto a cross-sectional cut of the perforation. In particular, a cut portion of the aerosol-generating article that includes the intersection may be accommodated within the cavity.

[0078] The bottom of the cavity may comprise a transparent material, which may allow a user to see the intersection of the cut portions of the aerosol-generating article when placed within the cavity.

[0079] The reference image may be located adjacent the bottom of the cavity, which may allow a user of the inspection tool to simply overlay the reference image onto a cross-sectional cut of a perforation located within the intersection of the cut portion of the aerosol-generating article.

[0080] The reference image may be contained within a transparent reference element of the inspection tool, which may be configured to be rotatable relative to the cavity, in particular relative to a transparent bottom of the cavity of the inspection tool.

[0081] The inspection tool may be configured for a user to view the intersection of the cut portions of the aerosol-generating article through the transparent reference element and the transparent bottom of the cavity.

[0082] This may allow the user to easily visually check the cross-section of the perforations within the intersection by superimposing a reference image onto the cross-section via rotational movement of the transparent reference element relative to the transparent bottom of the cavity.

[0083] The inspection tool may further comprise a light source for illuminating the intersection and the reference image, which may facilitate visual checking of the intersection for manufacturing defects.

[0084] The inspection tool may further comprise a magnifying means configured to provide a magnified image of the intersection of the cut portion of the aerosol-generating article including the cross-section of the perforation. The magnifying means may facilitate visual checking of the intersection for manufacturing defects. The magnifying means may include or consist of a magnifying lens.

[0085] The magnifying means may facilitate manual visual inspection for manufacturing defects.

[0086] When magnification is used, the reference image is - a line indicating the width and position of the enlarged cross-section cut, correctly positioned and correctly shaped, or a circular arc indicating the area within which the central axis of the enlarged cross-sectional cut of the perforation should be located.

[0087] In particular, the reference image may be adapted to indicate the width and position of a correctly positioned and correctly shaped cross-section cut enlarged by the magnifying means, or may include a circular arc indicating the area within which the central axis of the cross-section cut of the perforation enlarged by the magnifying means should be located.

[0088] The reference image may be located on a magnifying means, which may facilitate superimposing the reference image on a magnified cross-sectional cut of the intersection of the cut portion of the aerosol-generating article.

[0089] The magnification means may facilitate manual visual inspection of manufacturing defects by a user of the inspection tool.

[0090] The bottom of the cavity of the inspection tool may be located within the focal length of the magnification means, which may allow sufficient magnification of the intersection of the cut portions of the article.

[0091] The magnification means may provide a magnification factor of 1.5-10, preferably 2-6.

[0092] The plurality of perforations in the ventilation zone of the aerosol-generating article may extend radially from a central longitudinal axis of the article.

[0093] Checking for manufacturing defects at the intersection may then include checking whether the cross-section of the perforation is angled relative to its radial extension from the central longitudinal axis.

[0094] An aerosol-generating article may be rejected if the cross-sections of the perforations at the intersections of the article are inclined at more than 20 degrees, preferably more than 5 degrees, to their radial extension.

[0095] The intersections of the cut portions of the aerosol-generating article may be dyed to increase the contrast between the perforations and the wall of the aerosol-generating article.

[0096] This may facilitate visual inspection of the cross-section of the perforation.

[0097] Dyeing may be accomplished by contacting the intersections with a dye, such as ink.

[0098] The aerosol-generating article may be tubular and the perforations may be arranged circumferentially around the tubular aerosol-generating article.

[0099] The intersections of such aerosol-generating articles can be easily checked for manufacturing errors using the methods described herein, particularly those involving a reference image, which can be easily superimposed onto at least a portion of the cross-section cut of the perforations by rotating the reference image relative to the cross-section cut.

[0100] The method step of checking an intersection for manufacturing defects may include two separate check steps. In a first initial check step, the number of complete cross-sections of perforations at an intersection of the aerosol-generating article extending from the exterior of the article to the interior of the article may be determined. If the number of complete cross-sections is above a threshold, one or more of the location of the cross-section cut within the intersection, the shape of the cross-section cut, and the angle of the cross-section cut relative to the radial extension of the perforations may be checked in a second check step. The threshold may represent a minimum percentage of complete cross-section cuts relative to the total number of cross-section cuts located at an intersection of the aerosol-generating article.

[0101] In a first initial step, the number of cross-sections of the perforations of the intersection of the aerosol-generating article that extend from the exterior of the article to the interior of the article may be determined. Partial cross-sections of perforations that do not extend from the exterior of the article to the interior of the article may be considered manufacturing defects and may not be counted as complete cross-sections. The aerosol-generating article may be rejected and not undergo further check steps for manufacturing defects if less than 40 percent, preferably less than 30 percent, more preferably less than 25 percent of the expected number of cross-sections extend completely from the exterior of the article to the interior of the article. This percentage value may represent a threshold value for the first initial check step. For example, if the total number of perforations that should be present in the ventilation zone of the aerosol-generating article is 11 and less than two perforations extend completely from the exterior to the interior of the article, the aerosol-generating article may be rejected and no further check steps may be performed on the article. If there are at least three perforations that extend completely from the exterior to the interior of the article, further inspection steps, in particular the second check step, may be used.

[0102] The invention further provides an inspection tool for checking for manufacturing defects in a ventilation zone of an aerosol-generating article, the ventilation zone including a plurality of perforations. The inspection tool may comprise a cavity for receiving the aerosol-generating article, and the aerosol-generating article is cut along a plane through the ventilation zone to generate an intersection through the plurality of perforations. The inspection tool may include a reference image of the cross-section cut of the perforations. The inspection tool may comprise means for rotating the reference image and the intersection of the cut aerosol-generating article relative to one another to superimpose the reference image on the cross-section cut of the perforations within the intersection.

[0103] Another embodiment of the present invention provides an inspection tool for checking for manufacturing defects in a ventilation zone of an aerosol-generating article, the ventilation zone including a plurality of perforations. The inspection tool comprises: a cavity for receiving an aerosol-generating article, the aerosol-generating article being cut along a plane through the ventilation zone to create an intersection through a plurality of perforations; and a reference image of a cross-section of the perforation; - means for rotating the reference image and the cut aerosol-generating article relative to each other in order to superimpose the reference image on a cross-sectional cut of the perforation in the intersection.

[0104] Such an inspection tool may facilitate visual inspection of the intersections for manufacturing defects.

[0105] The inspection tool may further comprise a light source for removing the intersection and the reference image.

[0106] The light source may further facilitate visual inspection of the intersection.

[0107] The reference image may be contained within a transparent, rotatable portion of the tool, which may facilitate overlaying the reference image onto a cross-sectional cut of the borehole within the intersection.

[0108] The transparent rotatable portion of the tool may include a magnifying means, such as a magnifying lens.

[0109] The inspection tool may include further features as described above with respect to methods of using the inspection tool. EXAMPLES

[0110] The following provides a non-exhaustive list of non-limiting examples, any one or more of the features of which may be combined with any one or more features of the other examples, embodiments, or aspects described herein.

[0111] Example A: 1. A method for checking an aerosol-generating article having a ventilation zone for manufacturing defects, comprising: providing a ventilation zone in an aerosol-generating article, the ventilation zone comprising a plurality of perforations; - cutting the aerosol-generating article along a plane through the plurality of perforations, thereby creating an intersection through the plurality of perforations; - checking the intersections for manufacturing defects. Example B: A method according to embodiment A, wherein at least one cross-section of the perforations within the intersection is checked for manufacturing defects, preferably at least two or three, and more preferably all, cross-sections of the perforations are checked for manufacturing defects. Example C: A method according to embodiment A or B, in which the inclination of a cross-section of the perforation relative to a plane is determined. Example D: A method according to any of Examples A to C, in which a reference image of a cross-section of the perforations is provided, the reference image being superimposed on the cross-section of the perforations at an intersection of the aerosol-generating article to visually check for manufacturing defects, preferably one or both of the width or orientation of the cross-section cut within the intersection being checked using the reference image, more preferably an area of ​​the reference image that can be superimposed on the cross-section of one of the perforations is determined. Example E: A method according to embodiments A to D, in which a reference image is positioned on the intersection, the reference image and the intersection are rotatably arranged relative to each other, and the reference image is superimposed on one cross-sectional cut of the perforation via the rotation. Example F: A method according to either embodiment D or E, wherein the aerosol-generating article is rejected if less than 80 percent, preferably less than 90 percent, of the area of ​​the reference image is superimposed over the area of ​​the cross-section of the perforations at the intersection of the aerosol-generating article. Example G: A method according to any of embodiments D to F, wherein the aerosol-generating article is rejected if the central axis of the cross-section of the perforations at the intersection of the aerosol-generating article has an inclination angle of more than 10 degrees, preferably more than 5 degrees, relative to the reference image. Example H: The method according to embodiments D-G, wherein the aerosol-generating article is rejected if the reference image cannot be superimposed on the cross-section of the perforations at the intersection. Example I: The reference image is - a line indicating the width and position of a correctly positioned and correctly shaped cross-section cut, or -A circular arc indicating the area within which the central axis of the cross-sectional cut of the perforation should be located. Example J: Inspection tools are used to check for manufacturing defects, the inspection tools a cavity for receiving a cut portion of an aerosol-generating article, the cut portion including an intersection; and a reference image of a cross-section of the perforation; A method according to embodiments D to I, comprising: a means for rotating the reference image and the cut aerosol-generating article relative to each other to superimpose the reference image on a cross-sectional cut of the perforation in the intersection. Example K: The method according to embodiments A-J, wherein the inspection tool further comprises a light source for illuminating the intersection and the reference image. Example L: A method according to any of embodiments A-K, wherein the aerosol-generating article is cut through a hollow segment including a ventilation zone and checking for manufacturing defects includes checking whether at least one cross-section of the perforation extends from the interior of the hollow segment to the exterior of the article, preferably wherein the number of cross-sections of the perforations extending from the interior to the exterior of the hollow segment is determined. Example M: The method according to any one of claims AL, wherein the aerosol-generating article is rejected if at least one cross-section of the perforation does not extend from the interior to the exterior of the article. Example N: A method according to any of Examples A-M, wherein the aerosol-generating article comprises a central longitudinal axis and the aerosol-generating article is cut in a direction transverse to the longitudinal axis, thereby generating an intersection, preferably the aerosol-generating article is cut in a direction perpendicular to the longitudinal axis. Example O: The method according to claim 14 , wherein the plurality of perforations extend radially from the central longitudinal axis. Example P: The method according to any of Examples A-O, wherein the intersection is dyed to increase the contrast between the perforations and the wall of the aerosol-generating article. Example Q: The method according to any of embodiments AP, wherein the aerosol-generating article is tubular and the perforations are circumferentially disposed around the tubular aerosol-generating article. Example R: 1. An inspection tool for checking for manufacturing defects in a ventilation zone of an aerosol-generating article, the ventilation zone including a plurality of perforations, the inspection tool comprising: a cavity for receiving an aerosol-generating article, the aerosol-generating article being cut along a plane through the ventilation zone to create an intersection through a plurality of perforations; and a reference image of a cross-section of the perforation; - a means for rotating the reference image and the cut aerosol-generating article relative to each other to overlay the reference image on a cross-sectional cut of the perforation in the intersection. Example S: An inspection tool according to any one of embodiments A-R, wherein the inspection tool further comprises a light source for illuminating the intersection and the reference image. Example T: An inspection tool according to any of embodiments R or S, wherein the reference image is contained within a transparent, rotatable portion of the tool.

[0112] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0113] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0114] [Figure 1] FIG. 1 shows a cross-sectional view of an aerosol-generating article that includes a ventilation zone. [Diagram 2] FIG. 2 illustrates a schematic perspective view of an inspection tool that accommodates a cut portion of an aerosol-generating article having an intersection. [Figure 3A-3B] Figure 3A shows cross-sectional views of an aerosol-generating article having different perforations, and Figure 3B shows cross-sectional views of the aerosol-generating article of Figure 3A with a complete cross-section and a partial cross-section. [Figure 4A-4B] 4A and 4B show close-up views of intersections of cut sections of an aerosol-generating article, also illustrating the lines as a reference image for checking the intersections for manufacturing defects. [Figure 5A-5B] 5A and 5B show close-up views of an intersection of a cut portion of an aerosol-generating article, also including a circular arc as a reference image for checking the intersection for manufacturing defects. [Figure 6] FIG. 6 shows an intersection of a cut portion of an aerosol-generating article, with the reference image overlaid on the cross-section of the perforation as outlined to determine the percentage of overlap between the area of ​​the reference image and the area of ​​the cross-section. [Figure 7A-7C] 7A-7C show a sequence for severing a ventilation zone in an aerosol-generating article using a tubular sacrificial element. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0115] In the following, like elements are designated with like reference numerals throughout all figures.

[0116] FIG. 1 shows a cross-sectional view of an aerosol-generating article 10. The aerosol-generating article 10 includes an aerosol-forming substrate 22 having a susceptor element 24. Such an aerosol-generating article 10 can be inserted into an aerosol-generating device that includes, for example, a heating coil as a heating element. The heating coil can heat the susceptor element via a magnetic field that is altered by induction heating. The aerosol-generating article 10 also includes a hollow aerosol-cooling element 17 that includes hollow tubular elements 34 and 20. The aerosol-cooling element 17 functions to cool the aerosol and further facilitate the formation of the aerosol from the aerosol-forming substrate. The aerosol-cooling element 17 also includes a ventilation zone 14 having perforations 12. The perforations are often formed in the aerosol-generating article by a laser device. When a user inhales on the mouthpiece filter 30 of the aerosol-generating article 10, ambient air from outside the article can enter the aerosol-cooling element 17 through the perforations 12 and into the interior of the article. This can facilitate the cooling and formation of the aerosol. The location of the perforations 12 in the ventilation zone 14 is important to provide a sufficient cooling effect that also promotes the formation of aerosol. Therefore, periodically checking the correct location and shape of the perforations in the ventilation zone 14 is important to provide a reliable smoking experience to the user. The aerosol-generating article 10 also includes a front plug 32. At the upstream portion of the aerosol-generating article, there is an outer wrapping paper 26 that surrounds the aerosol-forming substrate. The downstream portion of the aerosol-generating article, including the ventilation zone 14 and the mouthpiece filter 30, is covered by a tipping paper 28. The aerosol-generating article has a tubular shape and includes a central longitudinal axis 18. The ventilation zone 14, including the perforations, can be cut along a plane 16. The plane 16 preferably extends perpendicular to the central longitudinal axis 18 of the aerosol-generating article. Cutting the ventilation zone 14 along the plane 16 creates a cross-sectional cut of the perforations at the intersection, which can be further checked for manufacturing defects.

[0117] FIG. 2 shows a schematic perspective view of an inspection tool 40 including a cut portion 10A of an aerosol-generating article in its cavity 38. Due to the cutting of the ventilation zone along the plane 16 shown in FIG. 1, a cut portion 10A of the aerosol-generating article is provided, which includes an intersection 36 through the ventilation zone. The inspection tool 40 includes a magnifying means 42, e.g., a magnifying lens, which produces a magnified view 44 of the intersection 36 of the cut portion of the aerosol-generating article. Checking the magnified view 44 for manufacturing defects greatly facilitates the detection of the defects. The magnifying means 42 also includes a reference image 46 in the form of a line. This reference image 46 shows the correct position and shape of the cross-section cut of the perforation. Furthermore, the area of ​​the reference image 46 within the fine hollow acetate tube 20 may also show the area of ​​the cross-section cut of the perforation that is correctly oriented and correctly shaped. The magnifying means can be rotated about the central longitudinal axis 18 of the cut portion 10A of the aerosol-generating article, as indicated by the arrow 48. This allows a user of the inspection tool 40 to superimpose the reference image 46 onto the various cross-section cuts 12A of the magnification 44 of the intersection 36. The material of the fine hollow acetate tube 20 may be dyed with a dye, such as an ink, to increase the contrast between the cellulose acetate material of the fine hollow acetate tube 20 and the cross-section cuts 12A. The reference image 46 may be superimposed onto successive cross-section cuts 12A by rotating the magnification means. This may allow a user to visually inspect at least some or all of the cross-section cuts 12A for manufacturing defects. There may be a light source 50 to illuminate the intersection or the magnification 44 of the intersection. This may facilitate visual inspection for manufacturing defects.

[0118] FIG. 3A illustrates a cross-sectional view of a portion of an aerosol-generating article 10 having fine hollow acetate tubing 20 in the ventilation zone. Two separate perforations 12 are present in the ventilation zone. The perforation 12 on the left side of the fine hollow acetate tube 20 is a perforation with the correct shape and orientation that is also correctly positioned in the pane 16. In contrast, the perforation 12' on the right side of the fine hollow acetate tube 20 exhibits an inclination with respect to the plane 16. The perforation 12' exhibits an inclination indicated by the inclination angle 12D of the central axis 12C of the perforation with respect to the plane 16 for cutting the article. This inclination causes air to enter the interior of the aerosol-generating article at a position more downstream of the aerosol cooling element of the article compared to the air that enters the interior of the article through the perforation 12. This can have a detrimental effect on the cooling and formation of the aerosol. Therefore, the formation of such perforations 12' with a large inclination with respect to the plane 16 should be avoided.

[0119] Figure 3B illustrates a cross-sectional view of the aerosol-generating article 10 shown in Figure 3A along the plane 16. Cutting the aerosol-generating article 10 of Figure 3A along the plane 16 results in the intersection 36 of the article shown in Figure 3B. The perforation 16 of Figure 3A with the correct orientation and shape with its central axis coinciding with the plane 16 provides the cross-sectional cut 12A shown in Figure 3B, which is a complete cross-sectional cut extending from the exterior 13 of the aerosol-generating article to the hollow interior 15. In contrast, the perforation 12' shown in Figure 3A with an inclination relative to the plane 16 provides, after cutting, a partial cross-sectional cut 12B that does not extend from the exterior to the interior of the aerosol-generating article. Thus, cutting the aerosol-generating article 10 along the plane 16 in the ventilation zone and through the perforations 12, 12' also provides information about the potential inclination of these perforations 12, 12' relative to the plane 16, making it possible to identify perforations 12' that exhibit an undesirable inclination relative to the plane 16. Identifying those perforations 12' that exhibit undesirable high tilt does not require the use of the reference images described herein.

[0120] FIG. 4A illustrates a close-up 44 of an intersection 36 through the ventilation zone of an aerosol-generating article, where the cellulose acetate material of the fine hollow acetate tube has been stained with ink to increase contrast. The perforations in the ventilation zone result in a perfect cross-section 12A that runs from the exterior to the interior of the article. A reference image 46 in the form of a line can be used to evaluate potential manufacturing defects. This reference image 46 can be easily superimposed on the cross-section cut 12A shown in FIG. 4A, showing that the cross-section cut 12A has the desired correct positioning and shape. Furthermore, the cross-section cut 12A is a perfect cross-section cut, and therefore also shows that the respective perforations do not exhibit significant inclination of their central axis relative to the plane 16 for cutting the article. Thus, an aerosol-generating article exhibiting such an intersection can pass the method for checking the ventilation zone for manufacturing defects, as indicated by the check mark in the upper right corner of FIG. 4A.

[0121] Figure 4B illustrates a close-up 44 of an intersection of a different aerosol-generating article after cutting the article. The intersection presents a partial cross-section 12B of the perforations that shows a significant inclination of the central axis of each of the perforations relative to the plane 16. Furthermore, the positioning of the partial cross-section 12B with respect to the reference image 46 shown in the circle illustrated in Figure 4B is also offset. Thus, a sufficiently large area of ​​the reference image 46 cannot be superimposed on the area of ​​the cross-section cut. As a result, an aerosol-generating article that presents such an intersection after cutting is rejected by the method for checking for manufacturing defects, as indicated by the cross mark in the top right corner of Figure 4B.

[0122] FIG. 5A shows a close-up 44 of another intersection of an aerosol-generating article after cutting the article. There is a reference image 46 in the form of a circular arc. This arc indicates the correct position of the cross-section cut within the intersection. In particular, the central axis 12E of the cross-section cut should be located within the circular arc in order for each perforation to pass the method for checking for manufacturing defects. In FIG. 5, the central axis 12E of one cross-section cut is perfectly located within the arc of the reference image, indicating that each perforation has a correct positioning and shape. Furthermore, there are multiple cross-section cuts 12A extending from the exterior to the interior of the article, which also indicates that each perforation is correctly located within the plane 16 of the ventilation zone. Thus, an aerosol-generating article exhibiting such an intersection can pass the method for checking the ventilation zone for manufacturing defects, as indicated by the check mark in the top right corner of FIG. 5A.

[0123] Figure 5B shows a close-up view of a further intersection of the aerosol-generating article after the article has been cut. In this case, arc 46 does not cover central axis 12E of the cross-section cut. Rather, a tilt angle or cut angle 12F exists between central axis 12E of the cross-section cut and arc 46. If this tilt angle 12F is too large, particularly greater than 10 degrees, and preferably greater than 5 degrees, the aerosol-generating article will be rejected, as indicated by the cross mark in the top right corner of Figure 5B.

[0124] FIG. 6 shows another intersection of the ventilation zone of an aerosol-generating article. In this case, the perforations and their respective cross-section cuts 12A also extend radially from the central longitudinal axis 18 of the article. A reference image 46 in the form of a line, shown by a dashed line in FIG. 6, can be used to superimpose an area of ​​the reference image 46 onto an area of ​​the cross-section cut 12A. If the reference image 46 is a long line that also extends into the interior of the intersection, as shown in FIG. 6, only the area of ​​the reference image located within the cellulose acetate tube 20 is taken into account when calculating the percentage of overlap between the area of ​​the reference image and the area of ​​the respective cross-section 12A. The cross-section cut is slightly inclined with respect to the reference image, so that the complete area of ​​the reference image cannot be superimposed onto the area of ​​the cross-section cut. However, as mentioned above, small deviations of up to 20 percent, preferably up to 10 percent, can be tolerated. Thus, an aerosol-generating device exhibiting an intersection as shown in FIG. 6 can also pass the method for checking for manufacturing defects.

[0125] 7A-7C illustrate a sequence of method steps for cutting an aerosol-generating article along a plane 16 through perforations 12 in the ventilation zone. FIG. 7A illustrates a schematic representation of an aerosol-generating article 10 having perforations 12. The article can be placed into a tubular sacrificial element 52, as shown in FIG. 7B. The tubular sacrificial element 52 can be, for example, a plastic tube that also includes an opening 54 that allows the tubular sacrificial element 52 to be fitted over the aerosol-generating article 10. The ventilation zone of the article 10 can then be cut along the plane 16 using cutting means 56, as shown in FIG. 7C. This method allows for easy cutting of the ventilation zone through the perforations 12 without causing significant deformation of the resulting intersections, although such deformation of the intersections should be avoided as it can interfere with methods for checking for manufacturing defects.

Claims

1. A method for checking for manufacturing defects in aerosol-generating articles having ventilation zones, - To provide a ventilation zone in an aerosol-generating article, wherein the ventilation zone includes a plurality of perforations. - The aerosol-generating article is cut along a plane through the multiple perforations, thereby creating intersections through the multiple perforations, A method comprising checking the intersection for manufacturing defects, wherein a reference image of a cross-sectional view of the perforation is provided, and the reference image is superimposed on the cross-sectional view of the perforation at the intersection of the aerosol-generating article for visual checking for manufacturing defects.

2. The method according to claim 1, wherein at least one cross-sectional cut of the perforation within the intersection is checked for manufacturing defects, preferably at least two or three cross-sectional cuts of the perforation, more preferably all cross-sectional cuts are checked for manufacturing defects.

3. The method according to claim 1 or 2, wherein the inclination of the cross-sectional cutting of the drilling in the plane is determined.

4. The method according to claim 1, wherein one or both of the width and orientation of the cross-sectional cuts within the intersection are checked by using the reference image, and more preferably, an area of ​​the reference image that can be superimposed on one of the cross-sectional cuts of the perforation is determined.

5. The method according to claim 1, wherein the reference image is positioned on the intersection, the reference image and the intersection are rotatably arranged relative to each other, and the reference image is superimposed on one cross-sectional section of the hole via rotation.

6. The method according to claim 1, wherein the aerosol-generating article is rejected if less than 80 percent, preferably less than 90 percent, of the area of ​​the reference image overlaps with the area of ​​the cross-sectional cutting of the perforation at the intersection of the aerosol-generating article.

7. The method according to claim 1, wherein the aerosol-generating article is rejected if the central axis of the cross-sectional cutting of the perforation at the intersection of the aerosol-generating article has an inclination angle of more than 10 degrees, preferably more than 5 degrees, with respect to the reference image.

8. The method according to claim 1, wherein an aerosol-generating article is rejected if the reference image cannot be superimposed on the cross-sectional view of the perforation at the intersection.

9. The aforementioned reference image is - Lines indicating the width and position of a correctly positioned and correctly formed cross-section, or The method according to claim 1, comprising one of the following: an arc indicating the region in which the central axis of the cross-sectional cutting of the perforation should be located.

10. The inspection tool is used to check for manufacturing defects, and the inspection tool is - A cavity for receiving the cut portion of the aerosol-generating article, wherein the cut portion includes the intersection, - The aforementioned reference image of the cross-section of the perforation, The method according to claim 1, further comprising means for rotating the reference image and the cut aerosol-generating article relative to each other in order to superimpose the reference image onto the cross-sectional cut of the perforation in the intersection.

11. The method according to claim 1, wherein the inspection tool further comprises a light source for illuminating the intersection and the reference image.

12. The method according to claim 1, wherein the aerosol-generating article is cut through a hollow segment including the ventilation zone, and checking for manufacturing defects includes checking whether at least one cross-sectional cut of the perforation extends from the inside of the hollow segment to the outside of the article, preferably determining the number of cross-sectional cuts of the perforation extending from the inside of the hollow segment to the outside.

13. The method according to claim 1, wherein an aerosol-generating article is rejected if at least one cross-sectional cut of the perforation does not extend from the inside to the outside of the article.

14. The method according to claim 1, wherein the aerosol generating article includes a central longitudinal axis, the aerosol generating article is cut transversely to the longitudinal axis, thereby generating the intersection, and preferably the aerosol generating article is cut in a direction perpendicular to the longitudinal axis.

15. An inspection tool for checking for manufacturing defects in the ventilation zone of an aerosol-generating article, wherein the ventilation zone includes a plurality of perforations, and the inspection tool is - A cavity for receiving the aerosol-generating article, the cavity being cut along a plane passing through the ventilation zone in order to generate intersections through the plurality of perforations, - Reference image of cross-section of perforation, - An inspection tool comprising means for rotating the reference image and the cut aerosol-generating article relative to each other in order to superimpose the reference image onto a cross-sectional cut of the perforation within the intersection.

Images