Closed-loop system and method for controlling the position of susceptors within aerosol-generating articles

Abstract

A closed-loop system for controlling the position of susceptors within aerosol-generating articles, the system comprising a source for a continuous sheet material, a source for continuous susceptors, a winding device for winding the continuous sheet material, and a forming device for gathering the continuous sheet material and forming the continuous sheet material having inserted continuous susceptors into a continuous rod. The system also comprises a cutting device for cutting the continuous rod into aerosol-generating articles, and a control unit comprising output control for detecting the state of the susceptors within the aerosol-generating articles and comparing the detected state to quality specifications. The system further comprises a positioning device or a winding depth adjuster for manipulating the position of the continuous susceptors, and the control unit is adapted to trigger the positioning device to adjust the position of the continuous susceptors or trigger the winding depth adjuster to adjust the winding depth of the sheet material within the winding device when the detected state does not meet the quality specifications.

Description

Technical Field

[0001] The present disclosure relates to a closed-loop system and method for controlling the position of susceptors within aerosol-generating articles, particularly within rod-shaped aerosol-generating articles. In particular, the present disclosure relates to such systems and methods in the manufacturing process of aerosol-generating articles.

Background Art

[0002] For inductively heated tobacco consumables, it is necessary to provide an inductively heatable susceptor within the aerosol-forming substrate. The susceptor should be assigned to the center of the rod-shaped article and should not be damaged or deformed. Both the position and integrity of the susceptor in the consumable can change the heating efficiency, temperature distribution, or lead to a lack of consistency in the performance of the consumable. By improving the quality of the manufactured consumables, waste reduction can also be achieved.

[0003] Therefore, there is a need for systems and methods for manufacturing aerosol-generating articles that enable consistent positioning of susceptors within aerosol-generating articles, particularly at high production volumes.

Summary of the Invention

[0004] According to one aspect of the present invention, a closed-loop system for controlling the position of susceptors within an aerosol-generating article is provided. The system comprises a source for a continuous sheet material, a source for continuous susceptors, a winding device for winding the continuous sheet material, a forming device for gathering the continuous sheet material and forming the continuous sheet material having the inserted continuous susceptors into a continuous rod, a cutting device for cutting the continuous rod into aerosol-generating articles, A control unit for detecting the state of a susceptor within an aerosol-generating article and providing output control for comparing the detected state with quality specifications. The system further includes a positioning device for manipulating the position of successive susceptors. The control unit is adapted to trigger the positioning device to adjust the position of successive susceptors or to trigger a crimp depth adjuster to adjust the crimp depth of the sheet material within the crimping device when the detected state does not meet the quality specifications.

[0005] The closed-loop system according to the present invention preferably measures, in real time, the state of a susceptor within a manufactured aerosol-generating article. This information is used to adjust manufacturing parameters to hold the susceptor at a predetermined position within the manufactured article. The predetermined position of the susceptor preferably corresponds to the central position of the article.

[0006] Adjustable manufacturing parameters include the positioning of successive susceptors when successive susceptors are inserted into successive sheet material during rod formation, or the adjustment of the crimp depth of the successive sheet material. The adjustable manufacturing parameters may include both the positioning of successive susceptors when successive susceptors are inserted into successive sheet material during rod formation and the adjustment of the crimp depth of the successive sheet material.

[0007] Accordingly, at least one, preferably several, physical characteristics of the manufactured article are measured or determined and used to adjust other manufacturing parameters to maintain the susceptor at a predetermined position.

[0008] Output control may, for example, detect the absolute position of the susceptor within the article. For example, output control may detect the displacement of the susceptor in the direction around a rod-shaped article that is offset from the center of the article. Output control may also detect the form of the susceptor, for example, if the susceptor has a deformed (e.g., bent) shape. These parameters need to be within certain predetermined thresholds in order to be respectively permitted and accepted by the output control or within the control unit. If the predetermined threshold is exceeded, the article is detected as not meeting the predetermined quality specifications. Depending on the allowable deviation from the threshold, e.g., the proportion of articles exceeding the predetermined threshold, an adjustment signal may be given to the positioning unit or the crimp depth adjuster, and the position of the susceptor is adapted. As another method, if the threshold is exceeded, the article may be excluded as waste.

[0009] Preferably, the output control comprises an exclusion system for excluding defective articles including a state of the susceptor that does not meet at least a minimum quality specification.

[0010] Preferably, the output control is adapted to exclude the aerosol-generating article as waste when the detected state of the susceptor exceeds a predetermined waste threshold. Therefore, the waste threshold may correspond to the minimum quality specification that the article must meet to be acceptable.

[0011] The detected state of the aerosol-generating article may include any one or more of the position of the susceptor within the aerosol-generating article, the form of the susceptor within the aerosol-generating article, the eccentricity of the susceptor within the aerosol-generating article, or the shape of the assembly of the sheet material surrounding the susceptor. The absolute displacement of the susceptor from the center of the article to a more radial position within the rod, the deformation of the susceptor, particularly the deformation of the cross-section of the susceptor, or the bending of the susceptor band, or the non-uniform distribution of the assembly of the sheet material around the susceptor may lead to non-uniform heating of the aerosol-forming substrate of the article.

[0012] Therefore, the output control is preferably adapted to capture information on the cross-section of the aerosol-generating article.

[0013] The output control is preferably adapted to capture information on the cross-section of at least one end of the aerosol-generating article. The output control may also be adapted to capture information on the cross-sections of both ends of the aerosol-generating article.

[0014] To detect the state of the susceptor within the article, the output control may comprise any detection system suitable for capturing information on the state of the susceptor within the article, in particular the position of the susceptor within the article, for example the cross-section of the susceptor within the article. The output control may comprise, for example, an optical system, an infrared system, an X-ray system, or an inductive detection system.

[0015] The output control preferably comprises one or several cameras.

[0016] The output control may comprise a detection system for determining the orientation of the susceptor within the article for positioning the article controlled by the output control at a defined control position. Information regarding the orientation of the susceptor within the article may be used as a correction factor for the output control when determining the state of the susceptor within the article. Alternatively, information regarding the orientation of the susceptor may be used, for example, to align the article before capturing information on the cross-section of the end of the article.

[0017] For example, a visual system can detect the overlap of wrappers that package rod-shaped aerosol-generating articles. In the manufacturing process of continuous rods of an aerosol-forming substrate containing a continuous susceptor, the relative positions of the continuous packaging material with respect to its content remain substantially constant. Thus, by visually detecting the overlap, approximate information regarding the position of the susceptor within the article can be obtained. This may be used to adapt the detection system to the orientation of the susceptor within the article and perform output control. The orientation of the susceptor within the article may also be obtained by other means, such as induction means, infrared means, or similar. Thus, a closed-loop system, particularly a control unit, may preferably comprise article rotation means for rotating the article in order to align everything in the same orientation for passing through the output control.

[0018] Furthermore, a defined and consistent position of the susceptor, or particularly the susceptor band, for all shaped articles may be advantageous, or even essential, for articles that have to be cut or processed in another way, such that a specific relative position of the susceptor band with respect to other segments is desired or required, for example, for assembly with other segments. It has been found that a random orientation of the susceptor band within the article can lead to irregular cutting, deformation of the susceptor, or even a reduction in the lifetime of the cutting knife. The relative position of the susceptor band with respect to the cutting knife has been found to have a great influence on the quality of the cut.

[0019] Thus, the defined position of the article corresponds to an optimized cutting angle of the susceptor band with respect to the cutting device. Thus, it may be beneficial to provide an optimized rotational positioning of the article for output control, but it may also be beneficial before cutting the article or otherwise further processing the article.

[0020] As described above, the position of the continuous susceptor within the sheet material may be adjusted by a positioning device or by a crimp depth adjuster. In some embodiments of the closed-loop system, the system comprises a positioning device and a crimp depth adjuster. Thus, in these embodiments, the control unit is adapted to trigger the positioning device to adjust the position of the continuous susceptor and, if the detected conditions do not meet the quality specifications, to trigger the crimp depth adjuster to adjust the crimp depth of the sheet material within the crimper.

[0021] The closed-loop system may comprise a positioning device that directly manipulates the position of the continuous susceptor when the susceptor is combined with the continuous sheet material. For example, the position of the continuous susceptor may be adjusted as the continuous susceptor is inserted into the partially assembled sheet material. The insertion and positioning of the continuous susceptor preferably occur within the forming device during or upstream of the rod forming process.

[0022] The continuous susceptor is preferably guided by a positioning device. The position of the continuous susceptor is preferably adjusted by moving the positioning device.

[0023] The positioning device may be movably arranged to be movable, for example, along the x-axis and the y-axis in at least two directions perpendicular to each other.

[0024] The positioning device is preferably movable relative to the supply direction of the continuous susceptor. Thus, the x-axis may correspond to the conveyance direction of the continuous material along the production line. Thereby, the insertion position of the continuous susceptor into the partially assembled sheet material can be changed. Adjusting the position where the continuous susceptor is inserted into the sheet material may result in the insertion of the continuous susceptor into the sheet material assembled at a higher density at a position more upstream or more downstream along the rod forming process. Thereby, the insertion depth of the sheet material may be adjusted, or the insertion resistance may be reduced. By reducing the insertion resistance, the risk that the continuous susceptor is damaged during insertion into the sheet material can also be reduced.

[0025] The positioning device is preferably movable in three mutually perpendicular directions. Thereby, it becomes possible to adjust the position of the continuous susceptor in all three dimensions.

[0026] In order to combine rod forming and adjustment of the position of the continuous susceptor, it is preferable that the forming device and the positioning device are combined.

[0027] The positioning device is preferably disposed movably within the forming device.

[0028] The positioning device may also include rotation means for rotating the continuous susceptor along the major axis direction of the continuous susceptor.

[0029] The positioning device is rotatable, and thereby it is preferable to rotate the continuous susceptor. For example, the positioning device may include an opening through which the continuous susceptor passes. The opening of the positioning device may have a shape corresponding to the cross-sectional shape of the continuous susceptor. When the positioning device rotates or is displaced laterally, the continuous susceptor automatically follows the movement of the positioning device.

[0030] The positioning device preferably has a conical shape.

[0031] The forming device preferably has a conical shape, for example, embodied as a garniture tongue.

[0032] The positioning device is preferably disposed within the cone of the forming device.

[0033] To simplify the insertion of the continuous susceptor into the sheet material or to reduce the insertion resistance, the forming device may comprise a channel former for forming a channel in the partially assembled continuous sheet material. Next, the continuous susceptor may be inserted into the channel.

[0034] The curling device may provide a sheet material having various types of curls. Preferred curls extend in the longitudinal or transverse direction of the curled sheet material. Since the curling of the sheet material is often used to support the subsequent assembly of the sheet material, the sheet material is preferably curled in the longitudinal or transport direction.

[0035] The curling device is preferably adapted to provide a longitudinally continuous curl to the continuous sheet material. The longitudinally running curl is disposed in the transport direction of the sheet material. A downstream assembly process disposed further downstream that mainly assembles the flat sheet material from both sides may follow along the curl, resulting in a more defined assembly and, accordingly, a homogeneously assembled rod.

[0036] The curling device may comprise two interacting curling elements. The curling elements are arranged such that the continuous sheet material can pass between the two interacting curling elements, thereby enabling the continuous sheet material to be curled.

[0037] The curl depth adjuster is preferably adapted to vary the distance between the two interacting curling elements. A short distance between the curling elements increases the curl depth of the sheet material, and a long distance decreases the curl depth of the sheet material.

[0038] The two interacting curling elements are preferably curling plates or curling rollers.

[0039] The curling elements are preferably interlocking curling elements, which preferably include an interlocking curling structure.

[0040] The control unit preferably further comprises a moisture sensor for measuring the moisture of the continuous sheet material. It has been found that several parameters can affect the depth of curling of the sheet material. The sheet thickness has only a slight effect on the depth of curling, but the water content of the sheet material may significantly affect the depth of curling. The control unit may be adapted to trigger a curling depth adjuster to adjust the depth of curling of the sheet material in the curling device according to the water content of the continuous sheet material.

[0041] The control unit may comprise reference data stored within the control unit. The reference data may include information regarding the curling behavior of several types of sheet materials. For example, the reference data may include information regarding the physical characteristics of a specific composition of the sheet material, such as a tobacco blend, used with the sheet material at different water contents.

[0042] The moisture sensor may be disposed at different positions along the production line. The moisture sensor is preferably disposed upstream or downstream of the curling device.

[0043] The closed-loop system may further comprise a substance introduction device for introducing a substance into the continuous sheet material.

[0044] The substance introduction device is preferably a liquid introduction device.

[0045] The substance introduced into the continuous sheet material may be a flavorant such as, for example, menthol, fruit flavorant, or tobacco flavorant. The substance may also be, for example, water, nicotine, or an aerosol former such as, for example, glycerin. Using a substance introduction device, the sheet material can be adapted to the consumable to be formed. In particular, the original properties of the sheet material may be changed or adapted to the desired product. For example, by adding humidity, the manufacturing process of aerosol forming articles such as, for example, the crimping process or the susceptor positioning process, may be affected. Articles containing different flavorants may be manufactured from the same basic sheet material. Even further, the original non-aerosol forming sheet material may be changed into an aerosol forming sheet material by adding an aerosol forming substance. Tobacco-derived materials already contain an aerosol forming substance, while sheet materials made from, for example, cellulose-based materials do not.

[0046] The closed-loop system may comprise a packaging device for packaging a continuous rod with a wrapper. The wrapper may be made of a packaging material well-known in the art, such as, for example, wrapping paper or wrapping plastic.

[0047] To further improve the manufacturing process, the closed-loop system may comprise various control devices, such as, for example, control sensors. In particular, the control system may comprise a measuring device for measuring sheet material parameters before or after the sheet material is crimped, susceptor parameters before the susceptor is inserted into the sheet material, such as, for example, device parameters of the crimping device or the liquid insertion device, or parameters of the formed rod-shaped article.

[0048] For example, the control unit the thickness or width of the continuous sheet material, and the displacement of the continuous sheet material relative to a predetermined transport position, and the continuous sheet material, in particular defects such as holes and slits, and the crimping depth of the continuous sheet material, and the thickness of the continuous susceptor, and the width of the continuous susceptor, Discoloration of a continuous sheet material, The material flow in the material introduction device, The position of the crimping element, For example, as part of the output control, the electrical specifications of the susceptor, particularly the resistance or impedance, The resistance of susceptor insertion into the partially assembled continuous sheet material, The susceptor splice portion, The flow of the adhesive in the adhesive application device of the wrapping device, The specifications of the aerosol generating article, particularly the diameter or ellipticity of the article, the presence or absence of a susceptor, the porosity of the article, and fragmentation of the assembled and crimped sheet materials within the article, and at least one additional measuring device for measuring or detecting any one of them may be provided.

[0049] According to another aspect of the present invention, Providing a continuous sheet material, Crimping the continuous sheet material, Providing a continuous susceptor, Assembling the continuous sheet material and inserting the continuous susceptor into the continuous sheet material to thereby form a continuous rod, Cutting the continuous rod to form an aerosol generating article, Performing output control to thereby detect the state of the susceptor in the aerosol generating article and compare the detected state with the quality specifications, and thereby, if the detected state does not meet the quality specifications of the aerosol generating article, Adjusting the position of the continuous susceptor, or Adjusting the crimping depth of the continuous sheet material, to provide a method for controlling the position of the susceptor in the aerosol generating article.

[0050] In some embodiments of the method, the method includes adjusting the position of the continuous susceptor and adjusting the crimp depth of the continuous sheet material when the detected condition does not meet the quality specification. One of the two measurements may be sufficient to adjust the position of the susceptor within the article, but both measurements may provide even more accurate results. In particular, adjusting the depth of the crimp may improve the stability of the susceptor within the article and may maintain the central position of the susceptor within the article.

[0051] The advantages and features of this method have been considered in relation to a closed-loop system and are also applicable to this method.

[0052] The method according to the present invention enables the position of the susceptor to be adjusted in real time. Therefore, the manufacture of aerosol-generating articles can be optimized or corrected continuously and in-line.

[0053] The method may include discarding the aerosol-generating article as waste when the detected condition of the susceptor within the aerosol-generating article exceeds a predetermined waste threshold.

[0054] Detecting the condition of the susceptor within the aerosol-generating article preferably includes detecting the position of the susceptor within the aerosol-generating article, the shape of the susceptor within the aerosol-generating article, the eccentricity of the susceptor within the aerosol-generating article, or the shape of the assembly of the sheet material surrounding the susceptor.

[0055] The method preferably includes capturing information about the cross-section of the aerosol-generating article. In particular, the method may include capturing information about the cross-section of at least one end of the aerosol-generating article. The method preferably includes capturing information about the cross-sections of both ends of the aerosol-generating article.

[0056] The method may include detecting the condition of the susceptor within the aerosol-generating article by visual inspection of the article, by infrared measurement of the article, by X-ray measurement of the article, or by permittivity measurement of the article.

[0057] The method preferably includes detecting the state of the susceptor in the aerosol-generating article by optical means, in particular using a camera.

[0058] The method according to the invention may include adjusting the position of the continuous susceptor before the continuous rod is formed. For example, the method may include adjusting the position while gathering the continuous sheet material.

[0059] The method preferably includes adjusting the position of the continuous susceptor by moving the continuous susceptor along at least two directions that are perpendicular to each other.

[0060] More preferably, the method includes adjusting the position of the continuous susceptor by moving the continuous susceptor along three directions that are perpendicular to each other.

[0061] The method may include adjusting the position of the continuous susceptor by guiding the continuous susceptor within and along a movable positioning device.

[0062] The method may include adjusting the position of the continuous susceptor by rotating the continuous susceptor along the longitudinal axis of the continuous susceptor.

[0063] The curling of the continuous sheet material is preferably carried out in the longitudinal or transverse direction of the sheet material, and thus in the conveying direction, or at right angles to the conveying direction of the sheet material. The method according to the invention preferably includes providing curling of the continuous sheet material in the conveying direction of the continuous sheet material.

[0064] The method preferably includes gathering the continuous sheet material along the curl formed in the continuous sheet material.

[0065] The method may include forming channels in a partially assembled continuous sheet material and inserting a continuous susceptor into the channels.

[0066] The method preferably includes inserting a continuous susceptor between the folds of a continuous sheet material.

[0067] The method may include curling a continuous sheet material by guiding the continuous sheet material between curling elements. For example, the method may thereby include guiding the continuous sheet material between curling rollers or curling plates.

[0068] Adjusting the depth of curling is preferably carried out by changing the distance between the curling elements.

[0069] The method may further include measuring the water content of the continuous sheet material and adjusting the curling depth according to the water content of the continuous sheet material. Measuring the water content of the continuous sheet material may be carried out, for example, before or after curling, or before and after curling.

[0070] The method according to the present invention may further include winding a continuous rod with a wrapper. The wrapper is preferably a continuous paper sheet or a continuous plastic sheet.

[0071] The method according to the present invention may further include adding a substance to the continuous sheet material.

[0072] The fluid is preferably a liquid.

[0073] The substance preferably includes a flavoring agent, nicotine, or an aerosol former.

[0074] The continuous susceptor may be, for example, a continuous band, a continuous filament, or a wire. The continuous susceptor is preferably a continuous band.

[0075] The continuous susceptor may include, for example, a metal, a magnetic material, or a magnetic metal. For example, the susceptor material is stainless steel, in particular, ferritic stainless steel, or aluminum.

[0076] The continuous sheet material is a substantially flat sheet, which is curled and then assembled into a rod shape. In an embodiment where a positioning device is used to adjust the position of the continuous susceptor within the sheet material, the already curled sheet material may be supplied for the rod manufacturing process.

[0077] The continuous sheet material may be provided as a non-aerosol forming sheet material or as an aerosol forming sheet material.

[0078] The method may include changing a non-aerosol forming sheet material to an aerosol forming sheet material by adding an aerosol forming substance to the non-aerosol forming sheet material before forming the continuous rod.

[0079] The continuous sheet material may be, for example, a tobacco material containing the sheet material, a plant-based sheet material, a cellulose-based sheet material, a fibrous material containing the sheet material, or a combination of these materials.

[0080] The method according to the present invention the thickness or width of the continuous sheet material, the displacement of the continuous sheet material relative to a predetermined conveying position, the continuous sheet material, in particular defects such as holes and slits, the curling depth of the continuous sheet material, the thickness of the continuous susceptor, the width of the continuous susceptor, the discoloration of the continuous sheet material, the material flow within the material introduction device, the position of the curling element, the electrical specifications of the susceptor, in particular the resistance or impedance, The resistance to susceptor insertion into a partially assembled continuous sheet material, and the susceptor splice portion, and the flow of adhesive within the adhesive applicator of the wrapping apparatus, and the specifications of the aerosol generating article, in particular the diameter or ellipticity of the article, the presence or absence of a susceptor, the porosity of the article, and fragmentation of the assembled and crimped sheet materials within the article, may be provided with additional measuring devices for measuring or detecting any of these.

[0081] The electrical specifications of the susceptor, in particular the resistance or impedance, are preferably measured or detected as part of detecting the state of the susceptor within the aerosol generating article. In particular, such measurement of resistance or impedance may be part of the output control. The measurement of the electrical specifications of the susceptor may also be carried out on a continuous susceptor as a quality check before the continuous susceptor is used in the manufacturing process of the aerosol forming article.

[0082] The method may further include detecting the susceptor splice portion within the continuous susceptor or within the aerosol generating article. Articles containing splice portions should be removed as they do not meet the quality specifications.

[0083] The splice portions may be detected before the continuous susceptor is inserted into the continuous sheet material. These may be detected when the continuous susceptor is within the continuous rod. Alternatively or additionally, these may be detected when the susceptor is within the aerosol forming article, for example as part of the output control.

[0084] The continuous sheet material is a continuous aerosol forming sheet material when formed into a continuous rod. The continuous sheet may be an aerosol forming sheet material when supplied to the manufacturing process, or may be deformed into an aerosol forming sheet material before or during assembly into the rod.

[0085] The continuous sheet material forms an aerosol-forming substrate within the article.

[0086] The continuous sheet material is preferably a tobacco sheet, particularly a sheet of homogenized tobacco material.

[0087] The tobacco sheet forming the aerosol-forming substrate may also contain tobacco particles, fiber particles, aerosol formers, binders, and, for example, flavorants.

[0088] The tobacco sheet is preferably a cast leaf. A cast leaf is a form of reconstituted tobacco formed from a slurry containing tobacco particles, fiber particles, aerosol formers such as glycerol or propylene glycol, binders, and, for example, flavorants.

[0089] The aerosol-forming tobacco sheet preferably contains volatile tobacco flavorant compounds that are released from the tobacco substrate when heated. The aerosol-forming tobacco substrate may contain or consist of blended tobacco cut filler, or may contain homogenized tobacco material. The homogenized tobacco material may be formed by aggregating particulate tobacco. The aerosol-forming substrate may consist of or further contain non-tobacco-containing materials, for example, plant-based homogenized materials other than tobacco.

[0090] The fiber particles can include tobacco stem material, stalks, or other tobacco plant materials, and other cellulose-based fibers (such as wood fibers with a low lignin content). The fiber particles may be selected based on the desire to produce sufficient tensile strength in the cast leaf at a low content, for example, a content of about 2 percent to 15 percent. Alternatively, fibers such as plant fibers may be used with or instead of the above-described fiber particles, including hemp and bamboo.

[0091] The aerosol former included in the slurry forming the cast leaf, or the aerosol former used in other aerosol forming substrates, may be selected based on one or more properties. Functionally, the aerosol former provides a mechanism that, when heated above a specific volatilization temperature of the aerosol former, causes the aerosol former to volatilize and enables the aerosol former to carry nicotine or flavorant or both in the form of an aerosol. Different aerosol formers typically vaporize at different temperatures. The aerosol former can be any suitable known compound or mixture of compounds that promotes the formation of a dense and stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the induction heating device used with the inductively heated tobacco substrate. The aerosol former may be selected based on its ability to remain stable, for example, at or near room temperature, but to volatilize at higher temperatures, for example, from 40°C to 450°C.

[0092] The aerosol former may also have a wetting agent type property that helps maintain a desirable amount of moisture in the aerosol forming substrate, especially when the substrate consists of tobacco-derived products, particularly when it contains tobacco particles, although not necessarily. In particular, some aerosol formers are water-absorbing materials that function as wetting agents, i.e., materials that help keep a substrate containing the wetting agent in a moist state.

[0093] One or more aerosol formers may be combined to utilize one or more properties of the combined aerosol formers. For example, triacetin may be combined with glycerin and water to utilize the ability of triacetin to carry the active ingredient and the wetting agent properties of glycerin.

[0094] The aerosol-forming matrix may be selected from polyols, glycol ethers, polyol esters, esters, and fatty acids, and may contain one or more of the following compounds, namely glycerin, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso-erythritol, diacetin mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene glycol.

[0095] The aerosol-forming substrate may contain other additives and components such as flavorants. The aerosol-forming substrate preferably contains nicotine and at least one aerosol-forming matrix.

[0096] The crimped sheet material, specifically the crimped aerosol-forming sheet material, more specifically the crimped tobacco sheet, such as Castileaf, may have a range between about 0.5 millimeters and about 2 millimeters, preferably between about 0.8 millimeters and about 1.5 millimeters, and a thickness of, for example, 1 millimeter. A deviation in thickness of up to about 30 percent may occur due to manufacturing tolerances.

[0097] As used herein, the term " susceptor " refers to a material having the ability to convert electromagnetic energy into heat. When located within an alternating electromagnetic field, eddy currents are typically induced within the susceptor and hysteresis losses occur, causing heating of the susceptor. Since the susceptor is located in thermal contact with or in close thermal proximity to the aerosol-forming matrix, the aerosol-forming matrix is heated by the susceptor, thereby forming an aerosol. The susceptor is preferably disposed in direct physical contact with the aerosol-forming matrix.

[0098] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to release material from the aerosol-forming substrate. Preferred susceptors include metal or carbon. Preferred susceptors may include or consist of iron materials or ferromagnetic materials (such as ferromagnetic alloys like ferrite iron, ferromagnetic steel, etc., stainless steel, or aluminum), or may be made of these. The susceptor preferably contains more than 5 percent, preferably more than 20 percent, preferably more than 50 percent or 90 percent of ferromagnetic or paramagnetic material. Preferred susceptors may be heated to a temperature of about 150 degrees Celsius to about 300 degrees Celsius. Preferably, the susceptor may be heated to a temperature of about 200 degrees Celsius to about 270 degrees Celsius, for example 235 degrees Celsius.

[0099] The susceptor is preferably a metal such as stainless steel, especially ferromagnetic stainless steel or aluminum. The susceptor is preferably a magnetic material or contains a magnetic material.

[0100] The continuous susceptor is preferably a filament, rod, sheet, or band. If the susceptor has a constant cross-section, for example a circular cross-section, the profile has a preferred width or diameter of about 1 millimeter to about 5 millimeters.

[0101] The susceptor is preferably a metal band.

[0102] The susceptor is preferably a stainless steel band. However, the susceptor material may also include or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloy (austenitic nickel-chromium superalloy), metallized film, ceramic (such as zirconia, etc.), transition metal (such as iron, cobalt, nickel, etc.), or semimetal components (such as boron, carbon, silicon, phosphorus, aluminum, etc.).

[0103] The susceptor band in the article preferably has a basic rectangular shape with a width of about 2 millimeters to about 8 millimeters, more preferably about 3 millimeters to about 5 millimeters, for example 4 millimeters.

[0104] The width of the susceptor band is smaller than the width or diameter of the rod-shaped aerosol-generating article in which the susceptor band is disposed.

[0105] The thickness of the susceptor material is preferably about 0.03 millimeters to about 1 millimeter, more preferably about 0.05 millimeters to about 0.5 millimeters, for example about 0.07 millimeters to about 0.2 millimeters.

[0106] In principle, whenever the term "about" is used throughout this specification in relation to a particular value, it is understood that the value following the term "about" need not be that particular value which is precisely exact due to technical considerations. However, the term "about" used in relation to a particular value is always understood to include the particular value following the term "about" and to be explicitly disclosed. The aerosol-generating article preferably has the form of a rod with a rod diameter preferably in the range of about 3 millimeters to about 12 millimeters, more preferably in the range of about 4 millimeters to about 8 millimeters, for example 7 millimeters. The rod preferably has a circular or elliptical cross-section. However, the rod may also have a rectangular or polygonal cross-section.

[0107] The aerosol-forming article is preferably a rod-shaped article and preferably has a circular cross-section.

[0108] An aerosol-generating article comprises an aerosol-forming substrate having the ability to form an aerosol. The aerosol-forming substrate is solid and may comprise a tobacco-containing material containing a volatile tobacco flavorant compound released from the substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may further comprise an aerosol former. Examples of suitable aerosol formers are glycerin and propylene glycol. The aerosol-forming substrate is formed from a continuous sheet material.

[0109] The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more of the features of these examples may be combined with any one or more of the features of any other example, embodiment, or aspect described herein.

[0110] Example 1: A closed-loop system for controlling the position of a susceptor within an aerosol-generating article, the system comprising a source for a continuous sheet material, a source for a continuous susceptor, a winding device for winding the continuous sheet material, a forming device for gathering the continuous sheet material and forming the continuous sheet material having the inserted continuous susceptor into a continuous rod, a cutting device for cutting the continuous rod into aerosol-generating articles, a control unit comprising an output control for detecting the state of the susceptor within the aerosol-generating article and comparing the detected state with quality specifications, the system further comprising a positioning device for manipulating the position of the continuous susceptor, or a winding depth adjuster, and the control unit being adapted to trigger the positioning device to adjust the position of the continuous susceptor or, when the detected state does not meet the quality specifications, to trigger the winding depth adjuster to adjust the winding depth of the sheet material within the winding device.

[0111] Example 2: The closed-loop system according to Example 1, wherein the output control is adapted to exclude the aerosol-generating article as waste when the detected state of the susceptor exceeds a predetermined waste threshold.

[0112] Example 3: The detected state of the aerosol-generating article is the position of the susceptor within the aerosol-generating article, the form of the susceptor within the aerosol-generating article, the eccentricity of the susceptor within the aerosol-generating article, or the shape of the assembly of the sheet material surrounding the susceptor, and is the closed-loop system according to any one of the preceding embodiments.

[0113] Example 4: The closed-loop system according to any one of the preceding embodiments, wherein the output control is adapted to capture information on the cross-section of the aerosol-generating article.

[0114] Example 5: The closed-loop system according to Example 4, wherein the output control is adapted to capture information on the cross-section of at least one end of the aerosol-generating article.

[0115] Example 6: The closed-loop system according to any one of Examples 4 to 5, wherein the output control is adapted to capture information on the cross-sections of both ends of the aerosol-generating article.

[0116] Example 7: The closed-loop system according to any one of the preceding embodiments, wherein the output control comprises an optical system, an infrared system, an X-ray system, or an inductive detection system.

[0117] Example 8: The closed-loop system according to Example 7, wherein the output control includes a camera.

[0118] Example 9: A closed-loop system according to any one of the preceding embodiments, wherein the system comprises a positioning device and a crimp depth adjuster, and the control unit triggers the positioning device to adjust the position of the continuous susceptor and triggers the crimp depth adjuster to adjust the crimp depth of the sheet material in the crimping device when the detected conditions do not meet the quality specifications.

[0119] Example 10: A closed-loop system according to any one of the preceding embodiments, wherein the positioning device is movably arranged so as to be movable in at least two directions perpendicular to each other.

[0120] Example 11: The closed-loop system according to Example 10, wherein the positioning device is movable in the supply direction of the continuous susceptor.

[0121] Example 12: The closed-loop system according to any one of Examples 10 to 11, wherein the positioning device is movable in three directions perpendicular to each other.

[0122] Example 13: The closed-loop system according to any one of Examples 10 to 12, wherein the positioning device is movably arranged within the forming device.

[0123] Example 14: A closed-loop system according to any one of the preceding embodiments, wherein the positioning device includes rotating means for rotating the continuous susceptor along the major axis direction of the continuous susceptor.

[0124] Example 15: The closed-loop system according to Example 14, wherein the positioning device is rotatable, thereby rotating the continuous susceptor.

[0125] Example 16: The closed-loop system according to any one of Examples 10 to 15, wherein the positioning device has a conical shape.

[0126] Example 17: A closed-loop system according to any one of the preceding embodiments, wherein the forming device has a conical shape.

[0127] Example 18: The closed-loop system according to Example 17, wherein the positioning device is disposed within the cone of the forming device.

[0128] Example 19: The closed-loop system according to any one of the preceding examples, wherein the forming device comprises a channel former for forming channels in a partially assembled continuous sheet material.

[0129] Example 20: The closed-loop system according to any one of the preceding examples, wherein the crimping device is adapted to provide a crimp continuous in the longitudinal axis to the continuous sheet material.

[0130] Example 21: The closed-loop system according to any one of the preceding examples, wherein the crimping device comprises two interacting crimping elements arranged such that the continuous sheet material can pass between the two interacting crimping elements, thereby crimping the continuous sheet material.

[0131] Example 22: The closed-loop system according to Example 21, wherein the crimp depth adjuster is adapted to vary the distance between the two interacting crimping elements.

[0132] Example 23: The closed-loop system according to any one of Examples 21 to 22, wherein the two interacting crimping elements are crimp plates or crimp rollers.

[0133] Example 24: The closed-loop system according to any one of the preceding examples, wherein the control unit further comprises a moisture sensor for measuring the moisture content of the continuous sheet material.

[0134] Example 25: The closed-loop system according to Example 24, wherein the control unit is adapted to trigger the crimp depth adjuster to adjust the crimp depth of the sheet material within the crimping device according to the moisture content of the continuous sheet material.

[0135] Example 26: A closed-loop system according to any one of Examples 24 to 25, wherein the moisture sensor is disposed upstream or downstream of the crimping device.

[0136] Example 27: A closed-loop system according to any one of the preceding examples, further comprising a substance introduction device for introducing a substance into a continuous sheet material.

[0137] Example 28: A closed-loop system according to Example 27, wherein the substance introduction device is a liquid introduction device.

[0138] Example 29: A closed-loop system according to any one of the preceding examples, further comprising a packaging device for packaging a continuous rod with a wrapper.

[0139] Example 30: The control unit is the thickness or width of the continuous sheet material, the displacement of the continuous sheet material relative to a predetermined transport position, the continuous sheet material, in particular defects such as holes and slits, the crimp depth of the continuous sheet material, the thickness of the continuous susceptor, the width of the continuous susceptor, the discoloration of the continuous sheet material, the substance flow in the substance introduction device, the position of the crimping element, the electrical specifications of the susceptor, in particular the resistance or impedance, the resistance of the susceptor insertion into the partially assembled continuous sheet material, the susceptor splice portion, the flow of the adhesive in the adhesive application device of the wrapping device, the specifications of the aerosol-generating article, in particular at least one additional measuring device for measuring or detecting any one of the diameter or ellipticity of the article, the presence or absence of a susceptor, the porosity of the article, the fragmentation of the assembled sheet material and the crimped sheet material within the article, of a closed-loop system according to any one of the preceding examples.

[0140] Example 31: A method for controlling the position of a susceptor in an aerosol-generating article, comprising: providing a continuous sheet material; winding the continuous sheet material; providing a continuous susceptor; assembling the continuous sheet material and inserting the continuous susceptor into the continuous sheet material to thereby form a continuous rod; cutting the continuous rod to form an aerosol-generating article; performing output control to thereby detect the state of the susceptor in the aerosol-generating article and compare the detected state with quality specifications, and thereby, if the detected state does not meet the quality specifications of the aerosol-generating article, adjusting the position of the continuous susceptor or adjusting the winding depth of the continuous sheet material.

[0141] Example 32: The method according to Example 31, comprising adjusting the position of the continuous susceptor and adjusting the winding depth of the continuous sheet material when the detected condition does not meet the quality specifications.

[0142] Example 33: The method according to any one of Examples 31 to 32, wherein when the state detected for the susceptor in the aerosol-generating article exceeds a predetermined waste threshold, the aerosol-generating article is excluded as waste.

[0143] Example 34: The method according to any one of Examples 31 to 33, wherein detecting the state of the susceptor in the aerosol-generating article comprises detecting the position of the susceptor in the aerosol-generating article, the form of the susceptor in the aerosol-generating article, the eccentricity of the susceptor in the aerosol-generating article, or the shape of the assembly of the sheet material surrounding the susceptor.

[0144] Example 35: The method according to any one of Examples 31 to 34, wherein information on the cross-section of the aerosol-generating article is captured.

[0145] Example 36: The method according to Example 35, which captures information on the cross-section of at least one end of the aerosol-generating article.

[0146] Example 37: The method according to any one of Examples 35 to 36, which captures information on the cross-sections of both ends of the aerosol-generating article.

[0147] Example 38: The method according to any one of Examples 31 to 37, which detects the state of the susceptor within the aerosol-generating article by visual inspection of the article, by infrared measurement of the article, by X-ray measurement of the article, or by permittivity measurement of the article.

[0148] Example 39: The method according to Example 38, wherein the state of the susceptor in the aerosol-generating article is detected by optical means, in particular by a camera.

[0149] Example 40: The method according to any one of Examples 31 to 39, which includes adjusting the position of the continuous susceptor before the continuous rod is formed.

[0150] Example 41: The method according to Example 40, which includes adjusting the position while assembling the continuous sheet material.

[0151] Example 42: The method according to any one of Examples 31 to 41, which includes adjusting the position of the continuous susceptor by moving the continuous susceptor along at least two directions perpendicular to each other.

[0152] Example 43: The method according to Example 42, which adjusts the position of the continuous susceptor by moving the continuous susceptor along three directions perpendicular to each other.

[0153] Example 44: The method according to any one of Examples 31 to 43, which includes adjusting the position of the continuous susceptor by guiding the continuous susceptor within and along a movable positioning device.

[0154] Example 45: The method according to any one of Examples 31 to 44, comprising adjusting the position of a continuous susceptor by rotating the continuous susceptor along the major axis direction of the continuous susceptor.

[0155] Example 46: The method according to any one of Examples 31 to 45, wherein a continuous sheet material is wound in the major axis direction.

[0156] Example 47: The method according to Example 46, comprising gathering a continuous sheet material along a curl formed in the continuous sheet material.

[0157] Example 48: The method according to any one of Examples 31 to 47, comprising forming a channel in a partially gathered continuous sheet material and inserting a continuous susceptor into the channel.

[0158] Example 49: The method according to any one of Examples 31 to 48, comprising inserting a continuous susceptor between the folds of a continuous sheet material.

[0159] Example 50: The method according to any one of Examples 31 to 49, comprising winding a continuous sheet material by guiding the continuous sheet material between curling elements.

[0160] Example 51: The method according to Example 50, thereby guiding a continuous sheet material between a curling roller or a curling plate.

[0161] Example 52: The method according to any one of Examples 50 to 51, wherein adjusting the winding depth is performed by changing the distance between the curling elements.

[0162] Example 53: The method according to any one of Examples 31 to 52, comprising measuring the water content of a continuous sheet material and adjusting the winding depth according to the water content of the continuous sheet material.

[0163] Example 54: The method according to Example 53, wherein the water content of the continuous sheet material is measured before or after curling, or before and after curling.

[0164] Example 55: The method according to any one of Examples 31 to 54, further comprising winding a continuous rod with a wrapper.

[0165] Example 56: The method according to Example 55, wherein the wrapper is a continuous paper sheet or a continuous plastic sheet.

[0166] Example 57: The method according to any one of Examples 31 to 56, further comprising adding a substance to the continuous sheet material.

[0167] Example 58: The method according to Example 57, wherein the substance is a liquid.

[0168] Example 59: The method according to any one of Examples 56 to 58, wherein the substance comprises a flavoring agent, nicotine, or an aerosol former.

[0169] Example 60: The method according to any one of Examples 31 to 59, wherein the continuous susceptor is a continuous band, a continuous filament, or a wire.

[0170] Example 61: The method according to any one of Examples 31 to 60, wherein the continuous susceptor comprises a metal, a magnetic material, or a magnetic metal.

[0171] Example 62: The method according to Example 61, wherein the susceptor material is stainless steel, particularly ferromagnetic stainless steel, or aluminum.

[0172] Example 63: The method according to any one of Examples 31 to 62, wherein the continuous sheet material is a substantially flat sheet, which is curled and then assembled into a rod shape.

[0173] Example 64: The method according to any one of Examples 31 to 63, wherein a continuous sheet material is provided as a non-aerosol-forming sheet material or as an aerosol-forming sheet material.

[0174] Example 65: The method according to Example 64, wherein the non-aerosol-forming sheet material is changed to an aerosol-forming sheet material by adding an aerosol-forming substance to the non-aerosol-forming sheet material before forming a continuous rod.

[0175] Example 66: The method according to any one of Examples 31 to 65, wherein the continuous sheet material is a tobacco material containing a sheet material, a plant-based sheet material, a cellulose-based sheet material, a fibrous material containing a sheet material, or a combination of these materials.

[0176] Example 67: The thickness or width of the continuous sheet material, and The displacement of the continuous sheet material relative to a predetermined conveying position, and The continuous sheet material, in particular defects such as holes and slits, and The curling depth of the continuous sheet material, and The thickness of the continuous susceptor, and The width of the continuous susceptor, and The discoloration of the continuous sheet material, and The material flow in the material introduction device, and The position of the curling element, and The electrical specifications of the susceptor, in particular the resistance or impedance, and The resistance to susceptor insertion into the partially assembled continuous sheet material, and The susceptor splice portion, and The flow of the adhesive in the adhesive application device of the wrapping device, and The method according to any one of Examples 31 to 66, further comprising at least one additional measuring device for measuring or detecting any one of the specifications of the aerosol-generating article, in particular the diameter or ellipticity of the article, the presence or absence of a susceptor, the porosity of the article, and the fragmentation of the sheet material assembled and curled within the article.

[0177] Example 68: The method according to Example 67, wherein the electrical specifications of the susceptor, particularly the resistance or impedance, are measured or detected as part of detecting the state of the susceptor within the aerosol-generating article.

[0178] Example 69: The method according to any one of Examples 67 to 68, for detecting a splice portion of the susceptor within the continuous susceptor or within the aerosol-generating article.

[0179] Here, the examples will be further described with reference to the drawings.

Brief Description of the Drawings

[0180]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0181] Figure 1 shows a manufacturing line for an aerosol-generating article and a closed control loop system for position control of a susceptor within a wound sheet material assembly forming the aerosol-generating article.

[0182] In FIG. 1, the black arrow 77 indicates the physical flow of the product. The dotted arrow 88 indicates the flow of information from various measuring devices 81, 82, 83, 84, 85, 86, 89 including sensors to the control unit 8. The two dashed arrows 99 indicate the flow of information from the control unit 8 to the actuator of the coiling device 4 or to the positioning device 6 within the forming device 5 which can be embodied as a conical forming module.

[0183] In the supply unit 7, a continuous sheet material, such as a tobacco-containing sheet material, in particular a cast leaf, is unwound from a bobbin. In an optional flavor module 78, not only flavors, but also nicotine, aerosol formers, or other substances can be applied to the continuous sheet material. For example, the original non-aerosol-forming sheet material can be changed to an aerosol-forming sheet material and consequently to an aerosol-forming substrate using the flavor module 78.

[0184] The sheet material is further conveyed to a coiling device 4 where the sheet material is coiled. It is preferred that the sheet material is provided with a longitudinal coiling along the length and the conveying direction of the sheet material. Further downstream on the production line, a susceptor band insertion module 76 is arranged. The susceptor band insertion module 76 is preferably incorporated into the forming device 5 which also includes a positioning device 6 for the susceptor band within the partially assembled sheet material. The positioning device 6 can be used to adjust the position of the continuous susceptor relative to the sheet material. In the forming device 5, the aerosol-forming sheet material is mainly coiled and assembled along the aerosol-forming sheet material, the susceptor is formed into a continuous rod, and the continuous rod is further cut into individual rod-shaped articles within a cutting device 79 downstream. The articles can be, for example, single or double rods of aerosol-generating articles and can therefore have single or double lengths.

[0185] The cut rod receives output control 86. Output control 86 is preferably a visual inspection of the cross-section of the rod. Output control 86 preferably controls the state of the susceptor in the rod-shaped article mainly by controlling the position of the susceptor within the article. The measurements of the susceptor and the determined conditions are compared with the quality specifications in output control 86 or in control unit 8.

[0186] The information of output control 86 is supplied to control unit 8. Control unit 8 transmits a corresponding signal to positioning device 6 or winding device 4, or both positioning device 6 and winding device 4, in order to adjust the continuous susceptor position on the sheet material during rod formation or to adjust the winding depth of the sheet material in winding device 4 according to the results of quality control.

[0187] Next to output control 86, various measuring devices 81, 82, 83, 84, 85, 89 arranged along the production line can provide an input to control unit 8. This information can be used to adjust the individual devices 7, 78, 4, 5, 6, 76, 79 arranged along the production line. The various measuring devices 81, 82, 83, 84, 85, 89 are - Measuring device 81 for detecting the moving position of the sheet material, such as a left or right deviation from the central conveying direction. The deviation of the moving position of the sheet material may be corrected by repositioning the sheet material in a more central conveying direction. The information on the deviation of the moving position of the sheet material may also be input to other further downstream devices, such as flavorant module 78, for example. - Measuring device 82 for measuring the width and thickness of the sheet material. This information may be used, for example, in winding device 4 and susceptor chip insertion module 76. Exemplary values for the cast leaf are a width of 125 mm and a thickness of 200 μm. - For example, discoloration measuring device 83 following flavorant module 78, - A measuring device for measuring the curling depth 84 and a moisture sensor 87 for measuring the water content of the sheet material. The humidity information of the sheet material can significantly affect the curling process, while the information regarding the depth of curling can be directly used to adjust the distance of the curling elements within the curling device 4. An exemplary value for the curling depth of the cast leaf is 250 μm (average peak, thickness 200 μm) at a water content of 8%. - An impedance measuring device 89 may be provided to control the susceptor before it is inserted into the sheet material. By this means, it can be avoided that a defective susceptor or a susceptor of inappropriate quality is used in the manufacture of the article. Exemplary values for the impedance and resistance of the metal susceptor sheet are 600 milliohms.

[0188] A resistance measuring device 85 is provided at the position of the susceptor chip insertion module 76. The resistance measuring device 85 measures the insertion resistance of the susceptor into the sheet material. A high insertion resistance may deform the susceptor during the insertion process or result in a susceptor with an insufficient insertion depth into the sheet material. For example, adjusting the position where the susceptor is inserted into the sheet material may reduce the risk since the sheet material is gathered more or less densely at a more upstream or more downstream position.

[0189] The system shown in FIG. 1 includes several measuring devices arranged along the manufacturing line of aerosol-generating articles. These devices may be present to enhance the accuracy and reliability of the system, but they may also be optional and may be positioned at other process stages of the manufacturing line or control system, or multiple devices may be arranged to be available, for example, at other process stages of the manufacturing line. By way of mere example, the moisture sensor 87 may be provided before or during the supply of the sheet material, immediately before the sheet material is wound, or after the sheet material is wound but before rod formation. The moisture sensor may also be provided at some or all of these locations. Also, it has been found that the width and thickness of the sheet material have little effect on the winding process of the sheet material, and it is also possible to omit the measuring device 82. Further, for example, the insertion module 76 for susceptor insertion also includes a positioning device. It is preferable that a deviation from a reference within a range of about 0.2 millimeters from the reference movement distance is detected.

[0190] FIG. 2 is a schematic view of the forming device 5 in the form of a forming cone 51. In the forming cone 51, a continuous wound sheet material 70 is assembled, and a continuous susceptor 72 is inserted into the partially assembled continuous sheet material 70. Both materials are formed into a continuous rod 71. The continuous susceptor 72 is preferably arranged at the center of the rod 71 along the central longitudinal axis direction of the rod and is completely surrounded by the sheet material 70. The continuous susceptor 72 is preferably arranged between the windings or folds of the partially assembled aerosol-forming sheet material 70.

[0191] The continuous wound sheet material 70 may be, for example, an aerosol-forming sheet such as a homogenized tobacco material and a cast leaf containing an aerosol-forming body. The continuous susceptor 72 may be a continuous metal band, for example, a ferromagnetic stainless steel band.

[0192] The positioning device 6 in the form of a movable cone 61 is arranged within the forming cone 51. The outlet 52 of the forming cone 51 of the forming device 5 is arranged concentrically with the outlet 63 of the movable cone 61 of the positioning device 6. The two outlets 52, 63 may be arranged at the same position along the X-axis, but usually they are not arranged in such a way. The X-axis corresponds to the moving direction of the sheet material 70 and the susceptor 72 in FIG. 2. Generally, the outlet 63 of the movable cone 61 is arranged upstream of the outlet 52 of the forming cone 52.

[0193] The movable cone 61 guides the continuous susceptor 72 during the insertion of the susceptor 72 into the sheet material 70, thereby defining the position of the susceptor within the rod 71.

[0194] The positioning device 6 preferably comprises a linear guide that enables adjustment of the position of the movable cone 61 along the X, Y, and Z directions, and these axes are perpendicular to each other. By adjusting the position of the movable cone 61, it is preferable that the direction and orientation of the susceptor can change in real time. For example, the outlet 63 of the movable cone 61 has a shape corresponding to the shape of the cross-section of the continuous susceptor. Thereby, the susceptor is precisely guided, and any movement of the movable cone is directly transmitted to the continuous susceptor.

[0195] The positioning device 6 is movable along the X direction and it is also possible to change the inclination angle 62 between the positioning device 6 and the forming device 5.

[0196] The positioning device 6, particularly the movable cone 61, may also preferably be rotatable about the intermediate axis in the major axis direction of the cone 61.

[0197] In FIG. 2, the X direction is parallel to the moving direction of the sheet material 70. The Y direction is directed transverse to the moving direction of the sheet material 70 and is perpendicular to the moving direction. The Z direction is directed in the upward / downward direction compared to the moving direction of the sheet material and is perpendicular to the moving direction.

[0198] Figure 3 shows an example of a control loop for the curling process of a continuous sheet material 70. The same reference numbers are used for elements that are the same as or similar to those in Figure 1.

[0199] Before the sheet material 70 is curled, measurements of humidity, and optionally width and thickness, are carried out with appropriate measuring devices indicated by the humidity sensor 87.

[0200] Next, the sheet material 70 is curled in the curling device 4 by passing between two curling rollers 41. The distance 40 between the curling rollers 41 is measured and may be adjusted to adjust the curling depth 42 of the sheet material 70.

[0201] The information from the humidity sensor 87 is compared with reference data stored in the control unit 8. The reference data includes the settings of the curling device 4, i.e., the curling roller distance 40 for a specific composition of the sheet material, such as a tobacco blend for a tobacco material containing a sheet material with a specific water content.

[0202] The graph shown in the upper right square of Figure 3, indicated as the control unit 8, shows the curling depth value d against the water content M. For example, a low, medium, or high water content M corresponds to a target curling depth value 43 of 0.20 millimeters to 0.23 millimeters. A low water content refers to a water moisture M of less than 7.6 percent, and a high water content refers to a value M of water in the sheet material, such as case leaf, exceeding 8.5 percent.

[0203] Downstream of the curling device 4, a curling depth measuring device 84, such as a depth profiler, measures the curling depth 42. The target curling depth 43 is compared with the measured curling depth 42. Information on the deviation 44 of these values is provided to the control unit 8, and this control unit 8 may accordingly give a signal 99 to the actuator of the curling device 4 to adjust the distance 40 of the curling rollers 41. The distance 40 of the curling rollers 41 may be measured, for example, with a laser sensor.

[0204] In the illustrated embodiment, the measured water content M gives a target crimp depth value 43 of 0.204 millimeters. The measured crimp depth 42 within the measuring device 84 gives a measured crimp depth 42 of 0.173 millimeters. Thus, using this information, the distance 40 of the crimp roller 41 within the crimper 4 may be set to 0.2 millimeters.

[0205] In the output control 86, the cross-section of the assembled rod is also measured. Next, information regarding the position of the susceptor within the rod and also information regarding the assembly of the sheet material can be determined. For example, a homogeneous or non-homogeneous assembly across the cross-section of the rod may be detected. In the exemplary drawing shown to the left of the square indicating the output control 86, an acceptable result 91 showing a uniform assembly of the sheet material across the cross-section of the rod is seen. In the exemplary drawing shown in the center of the square indicating the output control 86, an unacceptable result 92 is shown. The unacceptable result shows a cross-section of the article including a region 921 without sheet material. Articles delivering an unacceptable result 92 may be rejected. The rejection may be actuated by a suitable signal from the control unit 8 that actuates a rejection device (not shown). Information regarding the acceptable or unacceptable results 91, 92 is also used in the control unit 8 for the depth adjustment of the crimp.

[0206] Figure 4 shows an example of the output control 86 including an image sensor 2, for example, a camera. The camera takes a photograph of the cross-section of the end 730 of the rod-shaped article 73, for example, a double rod of an aerosol-forming article. Thereby, the position of the susceptor 74 within the double rod can be measured and compared with the quality specifications to detect or determine the state of the susceptor.

[0207] In FIG. 4, it is preferable that the rod-shaped article 73 is conveyed in the circular groove of the conveyor drum 30 with circular grooves and continuously passes through the camera for position measurement. The article 73 may be accurately positioned on the conveyor drum 30 such that the susceptor 74 in the article 73 has a specific predetermined orientation on the conveyor drum 30 when passing through the camera. Thereby, quality control can be simplified. In particular, this can enhance the speed of comparison between the measurement and the quality specifications, particularly the predetermined threshold for acceptance or rejection of the article 73. A predetermined and consistent orientation of the susceptor within the article can also be advantageous for further processes further downstream in the production line, such as, for example, cutting of the article, or assembly of an article having additional segments of an aerosol-generating article or device.

[0208] In FIGS. 5 and 6, examples of different measured values of the state of the susceptor 74 in the rod-shaped article 73 are shown.

[0209] In FIGS. 5 and 6, photographs of cross-sections of a rod-shaped aerosol-forming article 73 are shown, which comprises a susceptor strip 74 surrounded by a crimped and assembled aerosol-forming sheet material 75, for example a cast leaf. The susceptor strip 74 is not completely straight and is not exactly on the central longitudinal axis of the article 73. In FIG. 5, two rectangles 201, 202 indicate the limits with respect to the quality specifications. The two rectangles 201, 202 are arranged symmetrically around the central axis of the rod and indicate the boundary distances of the susceptor strip positions within the article 73.

[0210] The inner rectangle 201 may indicate a warning threshold that includes, for example, the susceptor position outside the inner rectangle 201 for the measured article 73. These articles are still considered acceptable. However, if a certain percentage of the articles 73, for example, 5 percent to 20 percent, are outside the inner rectangle 201 and thus exceed the warning threshold, the control unit 8 may activate the positioning device 5 to adjust the position of the susceptor 74 during insertion into the sheet material 75. Alternatively or additionally, the control unit 8 may activate the curling device 4 to adjust the curling depth 40 of the sheet material 75 before continuous insertion of the susceptor band into the sheet material 75.

[0211] The outer rectangle 200 may be, for example, a waste threshold. If a controlled article provides a susceptor position outside the outer rectangle 200 and thus exceeds the waste threshold, the article 73 is excluded.

[0212] It is preferred that the position of the susceptor 73 is adjusted or the curling depth 40 is adjusted before the waste threshold increases.

[0213] In FIG. 6, the susceptor strip 74 is curved and offset from the central axis of the article 73.

[0214] The output control 8 may include an eccentricity measurement or a deformation measurement of the susceptor 74. For example, the center 202 and the lateral ends 203 (lateral with respect to the cross-sectional view) of the susceptor 74 may be detected. From these measurements, the general displacement and bending range of the susceptor 74 may be detected and compared with the acceptable range of a given quality specification. Several measurements along the susceptor 74 may enhance the accuracy of the susceptor position across the cross-section of the article.

[0215] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc. are to be understood as being modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, as well as any intermediate ranges therebetween, whether or not specifically enumerated herein. Thus, in this context, the number A is understood as A ± 5%. Within this context, the number A may be considered to include numerical values within the general standard error of the measurement of the property being modified by the number A. The number A may deviate by the percentages listed above in some instances as used in the appended claims, provided that the amount by which A deviates does not substantially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, as well as any intermediate ranges therebetween, whether or not specifically enumerated herein.

Claims

1. A closed-loop system for controlling the position of a susceptor within an aerosol generating article, wherein the system A supply source for continuous sheet material, A supply source for continuous susceptors, A crimping device for crimping the aforementioned continuous sheet material, A molding apparatus for assembling the continuous sheet material and forming the continuous sheet material, which has inserted continuous susceptors, into a continuous rod, A cutting device for cutting the continuous rod to produce the aerosol generating article, The system comprises a control unit that detects the state of the susceptor in the aerosol generating article and has output control for comparing the detected state with quality specifications, and the system A positioning device or crimping depth adjuster for manipulating the position of the continuous susceptor, The positioning device is movable in the direction of continuous susceptor supply, The positioning device is movably arranged so as to be movable in at least three directions perpendicular to each other, The positioning device further comprises a positioning device or a crimping depth adjuster, which includes a rotating means for rotating the continuous susceptor along the long axis direction. A closed-loop system in which the control unit is adapted to trigger the positioning device to adjust the position of the continuous susceptor, or to trigger the crimp depth adjuster to adjust the crimp depth of the sheet material in the crimping device when the detected condition does not meet quality specifications.

2. The detected state of the aerosol-generating article is, The closed-loop system according to claim 1, comprising: the position of the susceptor within the aerosol generating article; the shape of the susceptor within the aerosol generating article; the eccentricity of the susceptor within the aerosol generating article; or the shape of the collection of sheet materials surrounding the susceptor.

3. The closed-loop system according to any one of claims 1 to 2, wherein the output control is adapted to capture information of the cross-section of at least one end of the aerosol-generating article.

4. The closed-loop system according to claim 1, wherein the positioning device is movably arranged within the molding apparatus.

5. The closed-loop system according to claim 1, wherein the positioning device has a conical shape.

6. The closed-loop system according to claim 1, wherein the crimping depth adjuster is adapted to change the distance between two interacting crimping elements of the crimping device.

7. The closed-loop system according to claim 1, wherein the control unit further comprises a moisture sensor for measuring the moisture content of the continuous sheet material, and the control unit is adapted to trigger the crimp depth adjuster in accordance with the measured moisture content of the continuous sheet material to adjust the crimp depth of the sheet material in the crimping device.

8. A method for controlling the position of a susceptor within an aerosol generating article, To provide a continuous sheet material, The process of crimping the aforementioned continuous sheet material, To provide a continuous susceptor, The process involves assembling the continuous sheet material, inserting the continuous susceptor into the continuous sheet material, thereby forming a continuous rod. The continuous rod is cut to create an aerosol generating article, Output control is performed to detect the state of the susceptor in the aerosol generating article, and the detected state is compared with the quality specifications. If the detected state does not meet the quality specifications of the aerosol generating article, The position of the continuous susceptor is adjusted by moving the continuous susceptor along three directions perpendicular to each other, and / or by rotating the continuous susceptor along the long axis of the continuous susceptor, or A method comprising adjusting the crimping depth of the continuous sheet material.

9. The method according to claim 8, which captures information about the cross-section of the aerosol-generating article.

10. The method according to any one of claims 8 to 9, comprising adjusting the position of the continuous susceptor while assembling the continuous sheet material.

11. The method of claim 8, comprising adjusting the position of the continuous susceptor by guiding the continuous susceptor within and along a movable positioning device.

12. The method according to claim 8, wherein the water content of the continuous sheet material is measured, and the crimping depth is adjusted according to the water content of the continuous sheet material.

13. The method according to claim 8, wherein an aerosol-forming substance is added to the non-aerosol-forming sheet material before forming the continuous rod, thereby providing a continuous sheet material in the form of a non-aerosol-forming sheet material and transforming the non-aerosol-forming sheet material into an aerosol-forming sheet material.

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