Apparatus and method for manufacturing consumables for aerosol delivery systems - Patents.com

Abstract

The present disclosure relates to an apparatus for manufacturing consumables for an aerosol delivery system. The apparatus includes a feeding device configured to receive a sheet of aerosol-generating material and feed the sheet of aerosol-generating material along a transport path, and a sensor configured to detect information indicative of defects in the sheet of aerosol-generating material as the sheet passes along the transport path. The apparatus also includes a consumables forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable product, and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor. The present disclosure also relates to consumables for an aerosol delivery system manufactured by the apparatus and / or method disclosed herein. Additionally, the present disclosure relates to an apparatus and method for analyzing a sheet of aerosol-generating material for use in consumables for an aerosol delivery system, as well as a controller for an apparatus for analyzing a sheet of aerosol-generating material. The present disclosure also relates to a system for manufacturing consumables for an aerosol delivery system.

Description

[Technical field]

[0001] The present disclosure relates to an apparatus for manufacturing consumables for an aerosol delivery system and a method for manufacturing consumables for an aerosol delivery system. The present disclosure further relates to consumables for an aerosol delivery system manufactured by the apparatus and / or methods disclosed herein. Additionally, the present disclosure relates to an apparatus for analyzing a sheet of aerosol-generating material for consumables for an aerosol delivery system and a controller for an apparatus for analyzing a sheet of aerosol-generating material. Additionally, the present disclosure also relates to a system for manufacturing consumables for an aerosol delivery system. [Background technology]

[0002] Certain tobacco industry products, when used, generate an aerosol that is inhaled by the consumer. For example, tobacco heating devices heat an aerosol-generating material, such as tobacco, to heat the substrate without burning it and form an aerosol. The quality and uniformity of the aerosol-generating material is important to the quality of the product and the consumer's experience when using that product. Summary of the Invention

[0003] The present disclosure provides an apparatus for manufacturing a consumable for an aerosol delivery system, the apparatus including a feeder configured to receive a sheet of aerosol-generating material and feed the sheet of aerosol-generating material along a transport path, a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path, a consumable forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable, and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor.

[0004] In some embodiments, the controller is configured to determine a location of a defect in a consumable product formed by the consumable product forming device based on information sensed by the sensor.

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

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

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

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

[0009] In some embodiments, the controller is configured to classify the defect based on a comparison of a parameter of the defect to a pre-defined value, preferably the classification relating to a severity of the defect.

[0010] In some embodiments, the controller is configured to assess the quality of the entire sheet of aerosol-generating material based on the amount or surface density of the one or more defects and / or the classification of the one or more defects. In some embodiments, the controller is configured to assess the quality of the entire sheet of aerosol-generating material based on the amount or surface density of the one or more defects and / or the classification of the one or more defects within an area, which could include, for example, an edge of the sheet of material.

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

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

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

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

[0015] In some embodiments the quality assessment produces quality requirement criteria, and preferably the controller is configured to store the criteria in a memory, preferably the criteria being associated with said region.

[0016] In some embodiments, the areas of the sheet correspond to individual consumable batches formed by individual consumable aerosol generating materials or devices.

[0017] In some embodiments, the controller is configured to take a particular action depending on the assessment of the quality of the region.

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

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

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

[0021] In some embodiments, the devices of the present invention include a plurality of sensors.

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

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

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

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

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

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

[0028] In some embodiments, the light emitters are located on both sides of the sheet of aerosol-generating material.

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

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

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

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

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

[0034] In some embodiments, the thickness, density, or porosity of a sheet may be determined by transmitting electromagnetic radiation (e.g., visible light) to one side of the sheet and measuring the amount of electromagnetic radiation (e.g., the amount of light) detected on the other side of the sheet. It has been found that a lower amount of electromagnetic radiation detected on the other side of the sheet indicates a thin, less dense, and / or more porous sheet material. In some embodiments, the thickness, density, or porosity of a sheet may be detected using an x-ray or microwave sensor. In yet other embodiments, the thickness, density, or porosity of a sheet may be detected using ultrasound.

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

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

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

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

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

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

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

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

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

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

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

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

[0047] The present disclosure also provides an apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, the apparatus including a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along a transport path, and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor.

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

[0049] The present disclosure also provides a controller for an apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, the controller configured to connect to a sensor, the sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material, and the controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor.

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

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

[0052] The disclosure also provides a method for manufacturing a consumable for an aerosol delivery system, the method including: supplying a sheet of aerosol-generating material along a transport path; detecting information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path; forming the sheet of aerosol-generating material into a consumable; and determining whether or not the consumable is defective based on the detected information.

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

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

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

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

[0057] In some embodiments, determining whether a consumable is defective based on the sensed information includes determining whether a defect exists along substantially the entire length of the sheet based on the information sensed by the sensor.

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

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

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

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

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

[0063] In some embodiments the sensor comprises a camera, preferably the camera is a three-dimensional camera configured to detect a three-dimensional image of the sheeting.

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

[0065] In some embodiments, the method includes shining a light on the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

[0066] In some embodiments, the method includes shining light onto the sheeting from a side of the sheeting distal from the camera.

[0067] In some embodiments, the methods of the present invention include exposing a sheet of aerosol-generating material to light on both sides.

[0068] In some embodiments, the methods of the present invention include shining a light on the sheet of aerosol-generating material through a filter configured to filter electromagnetic radiation of the same frequency as the camera's filter.

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

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

[0071] In some embodiments, providing the sheet of aerosol-generating material along the transport path comprises providing a continuous sheet of aerosol-generating material, preferably the sheet is provided from a bobbin.

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

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

[0074] In some embodiments, forming the sheet of aerosol-generating material into a consumable comprises collecting a strip of aerosol-generating material.

[0075] In some embodiments, forming the sheet of aerosol-generating material into a consumable product comprises encasing the aerosol-generating material in a wrapper.

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

[0077] In some embodiments, the method includes associating the defect with an individual consumable item.

[0078] In some embodiments, the method includes sorting individual consumable items that are determined by the controller to include one or more defects from individual consumable items that are not determined by the controller to include one or more defects.

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

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

[0081] The present disclosure also provides consumables for the aerosol delivery systems manufactured by the apparatus disclosed herein and / or by the methods disclosed herein.

[0082] The present disclosure also provides an apparatus for analyzing a sheet of aerosol-generating material for a consumable for an aerosol delivery system, the apparatus including a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material, and a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor.

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

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

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

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

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

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

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

[0090] The quality assessment produces quality requirement criteria, and preferably the controller may be configured to store the criteria in a memory, which criteria may preferably be associated with said region.

[0091] The areas of the sheet may correspond to individual consumable aerosol generating materials or individual consumable batches formed by the device.

[0092] The controller may be configured to take certain actions depending on the assessment of the quality of the region.

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

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

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

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

[0097] The sensor may include a camera.

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

[0099] The light emitter may be arranged to be located on a surface of the sheet of aerosol-generating material that is distal to the camera.

[0100] The light emitters may be arranged to be located on both sides of the sheet of aerosol-generating material.

[0101] The illuminator may include a filter.

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

[0103] The illuminator's filter may be configured to pass electromagnetic radiation, at least a portion of which has the same frequency as the electromagnetic radiation passed by the camera's filter.

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

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

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

[0107] The present disclosure also provides an apparatus for manufacturing a consumable for an aerosol delivery system, the apparatus including an apparatus as disclosed herein for analyzing a sheet of aerosol-generating material, a feeding device for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path, and a consumable forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

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

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

[0110] The consumable forming device may include a collector configured to collect the strip of aerosol-generating material.

[0111] The consumable forming device may include a wrapping device configured to wrap the aerosol-generating material in a wrapper.

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

[0113] The individual consumables may be single or double length consumables.

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

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

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

[0117] The consumable may be a rod.

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

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

[0120] The controller may be configured to take certain actions depending on the assessment of the quality of the region.

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

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

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

[0124] The supply device may supply a continuous sheet of aerosol-generating material, and preferably the supply device may include a bobbin receiving mechanism for receiving a bobbin of the sheet of aerosol-generating material, and preferably the supply device may include a bobbin of the sheet of aerosol-generating material.

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

[0126] An apparatus for analyzing a sheet of aerosol-generating material may include a plurality of sensors configured to detect areas of the sheet that are offset in a direction perpendicular to the direction of the transport path and / or configured to detect areas of the sheet that are offset in a direction along the transport path.

[0127] The sensor may be configured to detect information indicative of a defect in the sheet of aerosol-generating material before the sheet is received by the dispensing device.

[0128] The present disclosure also provides a controller for an apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, the controller configured to connect to a sensor, the sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material, and the controller configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor.

[0129] The sensor may be configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along the transport path.

[0130] The sensor may be configured to detect information indicative of a defect in the sheet of aerosol-generating material before the sheet of aerosol-generating material is fed along the transport path.

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

[0132] The present disclosure also provides a method for analyzing a sheet of aerosol-generating material for a consumable for an aerosol delivery system, the method including detecting information indicative of a defect in the sheet of aerosol-generating material and determining whether or not the consumable is defective based on the detected information.

[0133] The method of the present invention may include determining one or more parameters of the defect, preferably the parameters of the defect may include one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

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

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

[0136] In some embodiments, determining whether a consumable is defective based on the sensed information includes determining whether a defect exists along substantially the entire length of the sheet based on the information sensed by the sensor.

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

[0138] The method may include feeding a sheet along a transport path and detecting information indicative of a defect as the sheet is fed along the transport path.

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

[0140] The sensor may include multiple signal generators and signal receivers.

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

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

[0143] This may include shining a light onto the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

[0144] The method may include shining light onto the sheet from a side of the sheet that is distal from the camera.

[0145] The method of the present invention may include exposing a sheet of aerosol-generating material to light on both sides.

[0146] The method of the present invention may include shining a light on the sheet of aerosol-generating material through a filter configured to filter electromagnetic radiation of the same frequency as the camera's filter.

[0147] The method may include determining the topology of at least a portion of the sheet of aerosol-generating material.

[0148] The detected defects may include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

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

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

[0151] The method may include feeding a sheet of aerosol-generating material along a transport path.

[0152] The method of the present invention may include determining a location of the defect in the formed consumable based on the sensed information, and preferably may include determining an axial location of the defect.

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

[0154] Supplying the sheet of aerosol-generating material along the transport path may include supplying a continuous sheet of aerosol-generating material, preferably the sheet may be supplied from a bobbin.

[0155] Sensing information indicative of a defect in the sheet of aerosol-generating material may include detecting information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path.

[0156] The method of the present invention may include using a plurality of sensors to detect information indicative of defects, preferably configured to detect areas of the sheet that are offset in a direction perpendicular to the direction of the transport path and / or configured to detect areas of the sheet that are offset in a direction along the transport path.

[0157] Feeding the sheet of aerosol-generating material along the transport path may include detecting information indicative of a defect in the sheet of aerosol-generating material before the sheet is fed along the transport path, preferably before the sheet is received by the feeding device.

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

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

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

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

[0162] The method may include associating the defect with an individual consumable item.

[0163] The method may include separating individual consumable items that are determined by the controller to include one or more defects from individual consumable items that are not determined by the controller to include one or more defects.

[0164] The method may include associating the defects with individual batches of consumables.

[0165] The consumable may be a rod.

[0166] The present disclosure also provides consumables for the aerosol delivery systems manufactured by the apparatus disclosed herein and / or by the methods disclosed herein.

[0167] The present disclosure also provides a system for manufacturing a consumable for an aerosol delivery system, the system for manufacturing the consumable including an apparatus as disclosed herein for analyzing a sheet of aerosol-generating material for a consumable for an aerosol delivery system, a supply device for receiving the sheet of aerosol-generating material and configured to supply the sheet of aerosol-generating material along a transport path, and a consumable forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

[0168] The systems of the present invention may have any of the features of the apparatus for analyzing sheets, the feeding apparatus and / or the consumable forming apparatus disclosed herein. [Brief description of the drawings]

[0169] Several embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a schematic diagram of an embodiment of an apparatus for producing consumables for an aerosol delivery system. [Diagram 2] 1 is a schematic representation of a sheet material being formed into a consumable. [Diagram 3] 2 is a schematic diagram of a sensor and controller of the device of FIG. 1. [Figure 4] 1 is a schematic representation of sheet material passing through an embodiment of a sensor. [Diagram 5] 5 is a schematic top view of a portion of sheet material in which defects are detected by the sensor of FIG. 4; [Figure 6] 11 is a schematic diagram of sheet material passing through another embodiment of a sensor. [Figure 7] 7 is a schematic top view of a portion of sheet material in which defects are detected by the sensor of FIG. 6; [Figure 8] 2 is a schematic cross-sectional view of an aerosol delivery system including a consumable product produced by the apparatus of FIG. 1. [Figure 9] FIG. 1 is a flow diagram of an embodiment of a method for manufacturing a consumable for an aerosol delivery system. [Figure 10] FIG. 1 is a flow diagram of another embodiment of a method for manufacturing a consumable for an aerosol delivery system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0170] FIG. 1 is a schematic diagram of an embodiment of an apparatus 1 for producing consumables for use in an aerosol delivery system.

[0171] In this example, the consumable is a rod of aerosol-generating material, however, it should be noted that in alternative embodiments, the consumable may have a different configuration, such as a strip of aerosol-generating material.

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

[0173] The aerosol-generating material is a tobacco material, for example a reconstituted tobacco material formed into a continuous web, however, the aerosol-generating material may alternatively be a non-tobacco material.

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

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

[0176] FIG. 2 shows diagrammatically a sheet 3 of aerosol-generating material that is formed into consumables 8, in this example individual rods 23.

[0177] The sensor 5 is configured to detect defects 6 in the sheet of aerosol-generating material 3 before the sheet of aerosol-generating material 3 is formed into a rod 8 by the rod forming apparatus 7. In this example, the sensor 5 is located between the feeder 2 and the rod forming apparatus 7. In other words, the rod forming apparatus 7 is downstream of the sensor 5, which is downstream of the feeder 2. The term "downstream" refers to the direction of the sheet of aerosol-generating material 3 along the transport path 4 as it moves from the feeder 2, past the sensor 5 and towards the rod forming apparatus 7. This embodiment is sometimes referred to as an "online" inspection, as the sheet of material 3 is examined while it is being transported by the feeder 2 along the transport path 4.

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

[0179] The consumable manufacturing apparatus 1 may include a defect detection device. In other embodiments, the defect detection device may be separate and distinct from the consumable manufacturing apparatus 1 and may be used, for example, to detect defects in at least a portion of the sheet 3 (e.g., an edge of the sheet 3 or the entire sheet 3) before the sheet 3 is processed by the consumable manufacturing apparatus 1.

[0180] In some embodiments, the sheet 3 of aerosol-generating material may be inspected by sensor 5 after which, if the sheet 3 is deemed to be of sufficient quality, the sheet 3 is then fed along transport path 4. Once the sheet is deemed acceptable by the controller (as described in more detail below), feeder 2 can begin feeding the sheet 3 along transport path 4 and the rod forming process can begin. For example, the edges of the sheet material 3 may be inspected before the sheet material 3 is loaded onto apparatus 1, or after the sheet material 3 is loaded onto apparatus 1. This may be referred to as "off-line" inspection, as the sheet material 3 is examined before feeder 2 transports the sheet material 3 along transport path 4.

[0181] 1, the supply apparatus 2 includes a storage mechanism 16 that stores a supply 17 of sheets of aerosol-generating material 3. In this example, the storage mechanism 16 is configured to store a bobbin 17 of sheets of aerosol-generating material 3. The bobbin 17 supplies a continuous web of sheets of aerosol-generating material 3 along the transport path 4. In an alternative embodiment (not shown), the supply apparatus 2 supplies individual sheets of aerosol-generating material along the transport path 4.

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

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

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

[0185] The collector 20 may include a funnel or cone (not shown) that is configured to collect the strips 19 as they exit the funnel or cone as rods.

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

[0187] The winding device 21 includes a garniture (not shown) configured to receive the collected rod of strip 19 and wrap the strip 19 in a wrapper. The wrapper is fed through the garniture as a continuous web on a garniture belt (not shown) that is configured to wrap the rod of strip 19 as the belt, wrapper and strip 19 pass through a narrowed cone or tongue of the garniture. The wrapper may then be secured in place using an adhesive that is applied or preapplied to the edges of the wrapper. It should be noted that in alternative embodiments, the winding device 21 may be of other construction including, for example, a winding drum that winds the wrapper around the rod of strip 19.

[0188] 1, the strip 19 is collected by a collecting device 20 and then the collected strip 19 is fed to a winding device 21. However, in another embodiment (not shown) a combined collecting and winding device collects the strip 19, forms it into a rod and wraps the strip 19 in a wrapper. For example, the strip 19 could be fed into a garniture which collects the strip 19, forms it into a rod and wraps the rod in a wrapper at the same time.

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

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

[0191] Alternatively or additionally, the controller 9 may be configured to associate the defect 6 with a batch of individual rods 23 produced by the rod forming apparatus 7. For example, if the defect 6 is detected by the sensor 5, the controller 9 may determine that a batch of individual rods 23 (e.g., a batch of 2, 3, 4, 5, 6, 7, 8, 10, 20, 50, or 100 rods) contains the defect 6. The entire batch containing the defect is then collected or discarded, or otherwise separated from the remaining batch of rods 23 that do not contain the defect. The controller 9 may further be configured to associate the defect 6 with a type of sheet material being fed along the transport path 4. For example, the controller 9 may be configured to associate the defect 6 with a sheet material having particular characteristics, such as a particular sheet material thickness / width / composition, or with a particular brand or manufacturer of sheet material. That is, the controller 9 may be configured to record that a particular type of sheet material is susceptible to the defect 6. For example, sheet material produced by a particular manufacturer may be more prone to defects and / or more and / or more severe defects.

[0192] In some embodiments, if the controller 9 detects that an area of ​​the sheet 3 does not meet one or more quality criteria (e.g., the sheet has a density, thickness or porosity that deviates from a target value or range), the controller 9 determines that the entire length or substantially the entire length of the sheet 3 (e.g., all of the sheet 3 on the bobbin) does not meet said one or more quality criteria. Accordingly, this may be communicated to an operator so that the entire bobbin of sheet 3 is removed. This may be done "off-line" (e.g., before the sheet 3 is loaded onto the feeder 2) or "on-line" (e.g., as the sheet 3 is fed along the transport path after being loaded onto the feeder 2). This helps to prevent the apparatus 1 from operating suboptimally with an otherwise defective sheet material 3 (e.g., sheet material with insufficient tension or sheet material that breaks / tears within the apparatus 1 causing the apparatus to jam).

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

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

[0195] Determining the location of the defect 6 is particularly advantageous when the rod forming apparatus 7 is configured to produce multiple lengths of individual rods 23, for example, rods that are 2, 3, 4, 5, 6, 7 or 8 times the length of a single rod, because only that portion of the individual rod 23 that contains the defect 6 will be removed. In some embodiments, the controller 9 is configured to determine the location of the defect 6 in the rod 8 based on the location of the defect 6 along the width and / or length of the sheet 3.

[0196] The parameters of the defects 6 determined by the controller 9 may include one or more of the length, width, depth, area and density of the defects. Once the defects 6 have been identified and measured, the controller 9 is configured to compare the parameters of the defects 6 to one or more pre-set values. This indicates the extent of the defects 6 and the controller 9 can determine whether or not a section of the rod 8 containing the defects 6 should be removed, for example by removing individual rods 23 having the defects 6 cut by a cutting device 22.

[0197] The controller 9 is configured to classify the defects 6 based on a comparison of the measured parameters with pre-set values. The classification may indicate the severity of the defect and therefore may indicate a defect that may degrade the quality of the consumable. For example, a hole is identified by the sensor 5 and the dimensions of the hole are calculated. The dimensions of the hole may be one or more of the length, width, radius or surface area of ​​the hole. For example, the severity of the defect 6 may be classified based on the size of the detected hole, the larger the hole, the more serious the defect 6. Additionally or alternatively, the severity of the defect 6 may be classified based on the number of anomalies within a given surface area, the depth of the defect 6, the density of the sheet 3 and / or the angle of the tear or tear extending into the sheet relative to the direction of the transport path 4.

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

[0199] For example, a single hole whose dimensions exceed a user-defined size can be classified as a defect, as well as a group of holes whose total area exceeds a user-defined limit within a user-defined boundary.

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

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

[0202] In some embodiments, the apparatus 1 includes a sorting device 24 for removing individual rods 23 determined by the controller 9 to contain one or more defects 6, or for removing a batch of individual rods 23 in which one or more of the individual rods 23 are determined to contain one or more defects 6. That is, if the sensor 5 detects an anomaly in the sheet 3 that is classified by the controller 9 as being a defect 6 as the sheet 3 moves along the transport path 4 toward the rod forming device 7, the controller 9 determines in which individual rod 23 the defect ends up based on the speed of the sheet passing the apparatus 1. This allows the defect to be removed from the production line without stopping the apparatus 1 and without manually removing the section of the sheet 3 containing the defect.

[0203] The quality of the sheet 3 of aerosol-generating material may also be assessed based on the number of defects 6 found on the sheet 3 and / or the classification of said defects. In some embodiments, the controller 9 is configured to assess the quality of a (e.g., portion) of a sheet 3 of aerosol-generating material by assessing both the amount or density of defects (e.g., surface density) and the classification of the defects. For example, a portion of the sheet 3 having many low severity defects may be assessed as being of low quality, and a portion of the sheet 3 having only one high severity defect may also be assessed as being of low quality. In some embodiments, each defect may be assigned a weighting based on the severity of the defect. The controller 9 then adds up all of the weightings of the defects detected on the sheet 3 or in a given area of ​​the sheet and determines the quality of the sheet accordingly.

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

[0205] In some embodiments, the controller 9 is configured to provide a quality assessment of the sheet 3 of aerosol-generating material (eg a portion thereof), the quality assessment being a function of both the severity of the defects and the number of defects.

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

[0207] In some embodiments, if the controller 9 determines that an entire area of ​​the sheet 3 has defects (e.g., a thickness, density or porosity outside of a target range or value), it is determined that it should be removed.

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

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

[0210] The defects 6 detected by the sensor 5 may include one or more of holes, slits, non-uniformity in the thickness of the sheet, areas of low density, voids, tears, and clumps. The sensor 5 may also determine the topology of the sheet 3 of aerosol-generating material and thus detect non-uniformity in the thickness of the sheet 3. Of course, the detected defects 6 may not be in a particular region of the sheet 3, but may be defects 6 in the entire sheet 3. For example, the sensor 5 may be configured to detect defects 6 in the entire sheet 3, such as in the density, porosity, thickness, or topology of the sheet 3. In some embodiments, regions of the sheet 3 (e.g., edge regions, such as the first 10 or 20 centimeters of the length of the sheet 3) are inspected online or offline and data obtained from the inspection is used to assess the quality of the entire sheet 3. For example, if an edge of the sheet 3 is inspected and found to be low density, the entire sheet 3 may be removed and discarded.

[0211] The presence of defects 6 in the sheet 3 of aerosol-generating material is undesirable as it reduces the consistency and / or quality of the final product. It is therefore advantageous to detect defects in the sheet 3 of aerosol-generating material so that the defective rods 23 can be removed. A defective rod is one that the controller has determined should be discarded based on its assessment of the number of defects and / or its classification of the defects in the rod, in some embodiments by assessing the quality of the sheet material from which the rod is formed as being of poor quality as described above. The sensor 5 is positioned such that defects 6 are detected before the sheet 3 of aerosol-generating material is formed into a rod 8. This allows for more accurate detection of defects than attempting to detect defects after the sheet 3 has been processed into a rod.

[0212] Furthermore, imperfections in the sheet 3 of aerosol-generating material may be detrimental to various components of the apparatus 1. Thus, the controller 9 may be configured to sound an alarm or shut down the apparatus 1 if a defect is detected in the sheet 3 that may be detrimental to the apparatus 1. For example, an alarm may be triggered and / or the apparatus 1 may be shut down if a structural defect is detected such that the defect may cause the apparatus 1 to jam, for example if the width of the defect is sufficient to cause separation of the strips 19 during cutting or shredding of the sheet 3.

[0213] Another embodiment provides an apparatus for detecting defects in a sheet, the apparatus including a controller and a sensor. In some embodiments, the apparatus for detecting defects may be separate from the consumable manufacturing apparatus 1. For example, the apparatus for detecting defects may be used to detect defects in at least a portion of the sheet 3 (e.g., an edge of the sheet 3 or the entire sheet 3) before the sheet 3 is processed by the consumable manufacturing apparatus 1. If the sheet 3 is determined to be of insufficient quality, an operator is notified by an indication (e.g., an alarm). Thus, the detected sheet 3 is not loaded into the consumable manufacturing apparatus.

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

[0215] It should be noted that other sensors may be used, such as sensors that detect any frequency of electromagnetic radiation, such as x-ray, ultraviolet, visible light, infrared or microwave, etc. In some embodiments the sensors are ultrasonic sensors or electric and / or magnetic sensors, and may include capacitive or inductive sensors.

[0216] The sensor 5 is positioned above an area 15 of the sheet of aerosol-generating material 3 that is to be scanned by the sensor 5. As the sheet of aerosol-generating material 3 is transported along the transport path 4, the signal generator 10 emits a signal 12 that is directed at an angle towards the sheet of aerosol-generating material 3. The signal 12 reflects from the sheet of aerosol-generating material 3 and is received by the signal receiver 11. If the signal receiver 11 does not receive the signal 12 emitted from the signal generator 10, it indicates that the sheet of aerosol-generating material 3 contains a hole. Optionally the signal may be a laser signal.

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

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

[0219] In some embodiments, the sensors 5 are arranged, for example, sequentially in the direction of the transport path 4 and are configured to detect areas of the sheet offset in the direction along the transport path. Multiple sensors 6 arranged in sequence allow scanning a large area of ​​the sheet of aerosol-generating material. Such an arrangement also provides some redundancy in case one of the sensors 5 fails to detect a defect, for example due to the speed of the sheet moving along the transport path 4. If the first sensor fails to detect, a second sensor located downstream of the first sensor along the transport path can detect the defect. This arrangement also allows the length of the defect 6 to be determined by counting the number of longitudinally arranged sensors 5 that simultaneously detect the defect 6. However, another option for determining the length of the defect 6 is to measure how long the defect 6 is detected by a particular sensor 5 (or by a sensor 5 in embodiments where the device 1 includes a single sensor 5).

[0220] Alternatively or additionally, in some embodiments, the sensors 5 may be offset in a direction perpendicular to the transport path 4. That is, the sensors 5 are configured to sense different areas across the width (arrow "W" in FIG. 5) of the sheet 3. This configuration is shown in FIG. 5, where each of the dashed lines R1-R9 represents an area sensed by a corresponding sensor 5. This helps to determine the size of the defect. For example, the number of sensors 5 that sense the defect 6 simultaneously or within a given time period can determine the width of the defect 6. However, it should be noted that in alternative embodiments, a single sensor 5 may be provided that scans only a portion of the width W of the sheet 3 or the entire width W of the sheet 3.

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

[0222] In another embodiment, as shown in FIGS.

[0223] Of course, any suitable model of camera 13 may be used, such as a Keyence™ CA-HL02MX camera.

[0224] The camera 13 is positioned above the sheet of aerosol-generating material 3 and is configured to image the sheet of aerosol-generating material 3 as it passes along the transport path 4. It will be appreciated that the camera 13 may be positioned below the sheet of aerosol-generating material 3 or cameras 13 may be provided on both sides of the sheet 3.

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

[0226] Camera 13 may include filters (not shown), such as polarizing filters, that improve the camera's ability to detect defects 6. In some embodiments, the filters of camera 13 are configured to filter out particular frequencies of electromagnetic radiation, e.g., above or below a predetermined value. The filters may be high-pass, low-pass, or band-pass filters.

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

[0228] The light emitter 14 is configured to illuminate an area 14A of the sheet 3. The light emitter 14 is configured to illuminate one or both sides of the sheet 3 in the area 14A that is aligned with the area 15 detected by the camera 13 in the direction of the transport path 4. That is, the light emitter 14 may illuminate the back of the sheet 3 relative to the area 15 detected by the camera 13 and / or illuminate the same side of the sheet 3 as the area 15 detected by the camera 13.

[0229] In some embodiments, the area 14 A of the sheet 3 illuminated by the light emitter 14 overlaps an area 15 of the sheet 3 detected by the camera 13 in the direction of the transport path 4 .

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

[0231] The light emitter 14 may include a source of electromagnetic radiation, for example a light source such as a bulb. The light emitter 14 may be configured to focus electromagnetic radiation towards the sheet 3.

[0232] The electromagnetic radiation source may be aimed at the sheeting such that greater than 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the electromagnetic radiation emitted by light emitter 14 or a particular frequency or range of frequencies of electromagnetic radiation strikes sheet 3, preferably on one or both sides of sheet 3 in area 15 detected by camera 13. For example, the electromagnetic radiation source may illuminate a side of sheet 3 behind area 15 detected by camera 13.

[0233] In some embodiments, the light emitters 14 are positioned up to 3 meters, up to 2 meters, up to 1 meter, up to 0.75 meters, up to 0.5 meters, up to 0.25 meters, or up to 0.15 meters or 0.1 meters from the sheet 3.

[0234] The light emitters 14 are positioned on the side of the sheet of aerosol-generating material 3 that is opposite the camera 13. This configuration has been found to be particularly effective in improving the camera's ability to detect defects. However, in some embodiments there may be light emitters 14 on both sides of the sheet of aerosol-generating material 3, for example above and below the sheet 3.

[0235] In the embodiment shown in FIG. 6, the camera 13 is positioned above the sheet of aerosol-generating material 3 and the light emitter 14 is positioned below the sheet of aerosol-generating material 3 opposite the camera 13.

[0236] The light emitter 14 may include a filter (not shown). In some embodiments, the filter is configured to filter out electromagnetic radiation of a particular frequency, e.g., above or below a predetermined value. The filter may be a high-pass, low-pass, or band-pass filter. At least a portion of the electromagnetic radiation that passes through the filter of the light emitter 14 passes through the filter of the camera 13. Illuminating the sheeting with filtered electromagnetic radiation, e.g., filtered light, allows the camera 13 to remove background light, improving detection of the illumination signal and improving detection of defects.

[0237] In some embodiments, the filter of the camera 13 and / or the filter of the illuminator 14 are polarizing filters. The use of polarizing filters in conjunction with the camera 13 and illuminator 14 reduces interference from ambient lighting, thus improving the accuracy of the sheet analysis.

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

[0239] In some embodiments, the controller 9 is configured to determine the size of the defects 6 in the sheet of aerosol-generating material 3 by performing a count of pixels that detect the presence or absence of defects 6. For example, holes or other defects in the sheet 3 may be a different color and / or lighter or darker than the sheet of material 3 itself. Additionally, areas of less density or thinner or more porous may result in lighter areas compared to the remainder of the sheet 3, for example because such areas tend to be less likely to block light emitted by the light emitters 14. Thus, pixels captured by the camera 13 in areas of holes or other defects will have non-standard characteristics compared to pixels captured in areas of the sheet 3 without such holes. The non-standard characteristics may include one or more of the brightness / darkness / color of the pixels.

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

[0241] The controller 9 can determine the size of the defect based on the number of pixels having said non-standard characteristics, e.g. the number of pixels that are darker than normal and thus indicating the presence or absence of a hole. In some embodiments, the controller 9 counts the number of adjacent pixels or pixels in a given area that have said non-standard characteristics, e.g. where the color differs from the expected color due to the presence of damaged sheet material or the lightness / darkness exceeds a threshold value.

[0242] The controller 9 may determine the length of the defect 6 by counting the number of pixels having said non-standard characteristics that are adjacent or close to each other along the length of the sheet 3 (in the direction of the transport path 4). Additionally or alternatively, the controller 9 may determine the width of the defect 6 by counting the number of pixels having said non-standard characteristics that are adjacent or close to each other along the width W of the sheet 3 (in a direction perpendicular to the transport path 4).

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

[0244] The controller 9 is configured to associate the image of the defect 6 in the sheet 3 of aerosol-generating material with one or more of a particular region of the rod 8, a particular individual rod 23, a batch of rods 23, and / or a particular source of the sheet material 3. A region of rod 8 having a defect 6, a particular individual rod 23 containing a defect 6, or a batch of individual rods 23 containing rods 23 having a defect 6 may be removed if the defect 6 meets certain pre-set removal criteria and is therefore classified as a defect 6 by the controller 9. For example, if the defect 6 has a sufficient length, width and / or surface area or if there are a sufficient number of defects 6.

[0245] Additionally, lighter / darker than normal colors detected by camera 13 indicate areas of non-uniformity in thickness of sheet 3. For example, lighter colors indicate that sheet 3 is thinner than normal, and darker colors indicate that sheet 3 is thicker than normal. Controller 9 may be configured to determine that there is a defect 6 if any of the pixels imaged by camera 13 are above or below a threshold brightness / darkness, or if more than a certain number of pixels exceed the threshold brightness / darkness. Alternatively, if all or substantially all areas of sheet 3 are lighter / darker than normal, this indicates that all or substantially all of sheet 3 has a suboptimal thickness, density and / or porosity.

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

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

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

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

[0250] 9, there is illustrated an embodiment of a method 200 for manufacturing a component for an aerosol delivery system. The method 200 of the present invention includes providing a sheet of aerosol-generating material along a transport path (step S1), detecting information indicative of defects in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path (step S2), forming the sheet of aerosol-generating material into a consumable (step S3), and determining whether or not the consumable is defective based on the detected information (step S4).

[0251] In another embodiment, detecting the defect indication (step S2) takes place before the sheet material 3 is fed along the transport path (eg before the sheet material 3 is loaded onto the feeder 2).

[0252] 10, there is illustrated another embodiment of a method 300 for manufacturing a component for an aerosol delivery system. The method 300 of the present invention includes feeding a sheet of aerosol-generating material along a transport path (step S1), detecting information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path (step S2), forming the sheet of aerosol-generating material into a consumable (step S3), and determining whether or not the consumable is defective based on the detected information (step S4). In another embodiment, detecting the information indicative of a defect (step S2) occurs before the sheet of material 3 is fed along the transport path (e.g., before the sheet of material 3 is loaded into the feeder 2).

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

[0254] The step (S2) of detecting information indicative of defects in the sheet may include illuminating the sheet of aerosol-generating material (step S2A). In some embodiments, the sheet is illuminated using electromagnetic radiation that is filtered to pass only a particular frequency or range of frequencies.

[0255] The step of detecting information indicative of defects in the sheet (S2) may include using a sensor to detect the presence or absence of defects (step S2B). In some embodiments, the sensor includes a signal generator and receiver, such as a laser generator and receiver, and / or includes a camera. In some embodiments, the sensor is filtered to pass only certain frequencies or ranges of frequencies, which may be the same as or overlap with the frequencies passed by the filters described above with respect to step S2A.

[0256] In some embodiments, the step of detecting (S2) information indicative of defects in the sheet may include using a plurality of sensors, which may be arranged sequentially in the direction of the transport path, or alternatively or additionally, the sensors may be offset along the width of the sheet.

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

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

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

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

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

[0262] The step of determining whether or not the consumable is defective (S4) further includes comparing parameters of the defect with one or more preset values ​​(step S4B) and classifying the defect based on the comparison of the parameters of the defect with the one or more preset values ​​(step S4C).

[0263] The step of determining whether the consumable is defective (S4) further includes associating the defect with the individual consumable (step S4D). Alternatively or additionally, step S4D includes associating the defect with the individual batch of consumables.

[0264] The method 300 of the present invention further includes separating (step S5) the individual consumables determined by the controller to contain one or more defects from the individual consumables not determined by the controller to contain one or more defects. Any individual consumables containing defects are removed from the device and discarded or recycled.

[0265] It will be appreciated that one or more of the steps of the methods of the invention described above may be omitted.Furthermore, the steps of the methods of the invention may be performed simultaneously or in a different order.

[0266] In this disclosure, "aerosol delivery system" refers to both combustion-based and non-combustion-based aerosol delivery systems.

[0267] For purposes of this disclosure, a "non-combustion based" aerosol delivery system is one that does not combust or burn the constituent aerosol-generating materials of the aerosol delivery system (or its components) to facilitate delivery of at least one substance to a user.

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

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

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

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

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

[0273] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include an aerosol generating material and are configured for use in non-combustion based aerosol delivery devices.

[0274] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that is energized to deliver power in the form of heat to an aerosol generating material or a thermally conductive material proximate to the heat generating power source.

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

[0276] In some embodiments, consumables for use in non-combustion based aerosol delivery systems may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0277] In some embodiments, the substance delivered may be an aerosol generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavorings, one or more aerosol forming materials, and / or one or more other functional materials.

[0278] In some embodiments, the substance delivered comprises an active agent.

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

[0280] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

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

[0282] As described herein, the active agent may include or be derived from a plant or its components, derivatives or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from a plant, such as extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically derived. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, cornstarch, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, oregano, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: mentha, moroccan mint, egyptian mint, peppermint, cologne mint, candy mint, curly mint, kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, english spearmint, and malva.

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

[0284] In some embodiments, the active agent may include or be derived from one or more of a plant or its components, derivatives or extracts, the plant being selected from eucalyptus, tallow tree, cocoa and hemp.

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

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

[0287] As used herein, the terms "flavorant" and "flavoring agent" are those permitted by local regulations and used to produce a taste, odor or other somatosensory stimulus desired by an adult consumer.They may be naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, raspberry ... Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang, Sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, burdock, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, scutellaria, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon. sucrose, damien, origanum, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.) and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners.They may be mimetics, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder or a gas.

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

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

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

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

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

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

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

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

[0296] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that the penetration of the varying magnetic field results in induction heating of the heating material. The heating material may be an electrically conductive material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

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

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

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

[0300] The various embodiments described herein are provided merely to aid in understanding and teaching of the claimed features. These embodiments are merely representative examples and are not exhaustive or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limiting the present disclosure to the claims as set forth herein or to the equivalents of the claims, and that other embodiments may be utilized or modified without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed elements, components, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A manufacturing apparatus for manufacturing a consumable for an aerosol delivery system, comprising: a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along the transport path; a consumable forming device configured to receive a sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable; a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor; The controller is configured to determine one or more parameters of the defect, the parameters of the defect including one or more of a length, a width, a depth, an angle of the extent of the defect relative to a direction of the transport path, an area of ​​the defect, a density of the sheet, a thickness of the sheet, or a porosity of the sheet.

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

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

4. 4. The manufacturing apparatus according to claim 1, wherein the controller is configured to compare a parameter of the defect with a preset value.

5. 5. The manufacturing apparatus of claim 4, wherein the controller is configured to classify the defect based on a comparison of a parameter of the defect to a preset value, the classification relating to a severity of the defect.

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

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

8. 8. The manufacturing apparatus of claim 7, wherein the defect is a deviation from a target range or value of at least one parameter of the sheet of aerosol-generating material that exists along substantially the entire length of the sheet of aerosol-generating material, the parameter being one or more of thickness, density or porosity of the sheet.

9. A manufacturing apparatus as claimed in any one of claims 6 to 8 dependent on claim 5, characterized in that the controller is configured to assess the quality of a region of the sheet of aerosol-generating material based on the amount or surface density of one or more defects in said region and / or a classification of one or more defects in said region.

10. 10. The manufacturing apparatus of claim 9, wherein the evaluation of quality produces quality requirement criteria, and the controller is configured to store the criteria in a memory, the criteria being associated with the region.

11. 11. The manufacturing device of claim 10, wherein the areas of the sheet correspond to individual consumable batches formed by individual consumable aerosol generating materials or devices.

12. 12. The manufacturing apparatus according to any one of claims 9 to 11, wherein the controller is configured to take specific actions depending on the assessment of the quality of the area.

13. 13. The manufacturing apparatus of claim 12, wherein the action includes sending a signal indicating that the quality of the area falls below a predefined value or that the area and / or the entire sheet material should be discarded and / or recycled.

14. 14. The manufacturing apparatus of claim 12 or 13, wherein the operation includes sending a signal indicating that the consumable or batch of consumables including the area should be sorted from other consumables or batches of consumables formed by the consumable forming apparatus if evaluation of the quality of the area determines that the quality falls below a predefined value or if evaluation determines that the consumable or batch of consumables including the area should be discarded and / or recycled.

15. 15. The manufacturing apparatus of claim 1, wherein the sensor comprises a signal generator and a signal receiver for detecting the defect, the signal being a laser signal.

16. 16. The manufacturing apparatus of claim 1, further comprising a plurality of sensors.

17. 17. The manufacturing apparatus of claim 16, wherein the sensors are configured to detect areas of the sheet that are offset in a direction perpendicular to the direction of the transport path and / or configured to detect areas of the sheet that are offset in a direction along the transport path.

18. 18. An apparatus as claimed in any one of claims 1 to 17, wherein the sensor is located above or below the sheet of aerosol-generating material.

19. 19. The manufacturing apparatus of claim 1, wherein the sensor comprises a camera.

20. A manufacturing apparatus as described in any one of claims 1 to 19, characterized in that the manufacturing apparatus further includes a light-emitting element configured to direct light onto the sheet of aerosol-generating material.

21. 21. The manufacturing apparatus of claim 20 when dependent on claim 19, wherein the light emitter is located on a surface of the sheet of aerosol-generating material that is distal to the camera.

22. 22. The manufacturing apparatus according to claim 20 or 21, wherein the light emitters are positioned on both sides of the sheet of aerosol-generating material.

23. 23. The manufacturing apparatus according to claim 20, wherein the light emitter includes a filter.

24. 20. The manufacturing apparatus of claim 19, wherein the camera includes a filter, the filter being a polarizing filter.

25. 25. The manufacturing apparatus of claim 24 when dependent on claim 23, wherein the filter of the illuminator is configured to pass electromagnetic radiation, at least a portion of which has the same frequency as the electromagnetic radiation passed by the filter of the camera.

26. 20. The manufacturing apparatus of claim 19, wherein the camera is a three-dimensional camera configured to sense a three-dimensional image of the sheet.

27. 27. The manufacturing apparatus of any one of claims 1 to 26, wherein the defects detected by the sensor include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

28. 28. The manufacturing apparatus of claim 1, wherein the supply device supplies a continuous sheet of the aerosol-generating material, the supply device includes a bobbin receiving mechanism for receiving a bobbin of the sheet of the aerosol-generating material, and the supply device includes a bobbin of the sheet of the aerosol-generating material.

29. 29. An apparatus as claimed in any preceding claim, wherein the sheet of aerosol-generating material comprises tobacco.

30. 30. The apparatus of any one of claims 1 to 29, wherein the consumable formation device includes a strip formation device configured to form the sheet of aerosol-generating material into a strip.

31. 31. The apparatus of claim 30, wherein the strip-forming device includes a cutting device configured to cut at least a portion of the sheet of aerosol-generating material into a strip of aerosol-generating material.

32. 32. The manufacturing apparatus of claim 30 or 31, wherein the consumable forming device includes a collector configured to collect the strip of aerosol-generating material.

33. 33. The apparatus of any one of claims 1 to 32, wherein the consumable forming device includes a wrapping device configured to wrap the aerosol-generating material in a wrapper.

34. 34. The manufacturing apparatus of any one of claims 1 to 33, wherein the consumable forming device includes a cutting device for cutting the consumable into individual consumables.

35. 35. The manufacturing apparatus of claim 34, wherein the individual consumables are single length or double length consumables.

36. 36. The manufacturing apparatus of claim 34 or 35, wherein the controller is configured to associate defects with individual consumables.

37. 37. The manufacturing device of any one of claims 34 to 36, wherein the controller is configured to associate defects with individual batches of consumables formed by the consumable forming device.

38. The manufacturing apparatus of any one of claims 34 to 37, characterized in that the manufacturing apparatus includes a sorting device configured to remove individual consumables determined by the controller to contain one or more defects.

39. 39. The manufacturing apparatus of any one of claims 1 to 38, wherein the consumable is a rod.

40. 1. An analytical apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, comprising: a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along the transport path; a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor; The controller is configured to determine one or more parameters of the defect, the parameters of the defect including one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

41. 1. A controller for an apparatus for analyzing a sheet of aerosol-generating material formed into a consumable for an aerosol delivery system, comprising: the controller is configured to connect to a sensor, the sensor being configured to detect information indicative of a defect in the sheet of aerosol-generating material, and the controller being configured to determine whether or not the sheet of aerosol-generating material is defective based on the information detected by the sensor; The controller is configured to determine one or more parameters of the defect, the parameters of the defect including one or more of a length, a width, a depth, an angle of the extent of the defect relative to a direction of the transport path, an area of ​​the defect, a density of the sheet, a thickness of the sheet, or a porosity of the sheet.

42. 42. The controller of claim 41, wherein the sensor is configured to detect information indicative of a defect in the sheet of aerosol-generating material as the sheet of aerosol-generating material passes along the transport path, or the sensor is configured to detect information indicative of a defect in the sheet of aerosol-generating material before the sheet of aerosol-generating material is fed along the transport path.

43. 1. A method for manufacturing a consumable for an aerosol delivery system, comprising: providing a sheet of aerosol-generating material along a conveying path; detecting information indicative of a defect in the sheet of aerosol-generating material as the sheet passes along a transport path; forming a sheet of aerosol-generating material into a consumable; determining whether or not the consumable is defective based on the detected information; The method further includes determining one or more parameters of the defect, the one or more parameters of the defect including one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

44. The method of claim 43, further comprising determining a location of the formed consumable defect based on the sensed information or determining an axial location of the consumable defect.

45. 45. The method of claim 43 or 44, further comprising comparing a parameter of the defect with one or more preset values ​​or classifying the defect based on a comparison of the parameter of the defect with one or more preset values.

46. 46. ​​The manufacturing method of any one of claims 43 to 45, wherein determining the presence or absence of a defect in the consumable based on the detected information comprises determining the presence or absence of a defect in at least one discrete area of ​​the sheet based on information detected by a sensor.

47. 46. ​​The manufacturing method of any one of claims 43 to 45, wherein determining whether or not there is a defect in the consumable based on the detected information comprises determining whether or not there is a defect present along substantially the entire length of the sheet based on the information detected by the sensor.

48. 48. The method of claim 47, wherein the defect is a deviation from a target range or value of at least one parameter of the sheet that exists along substantially the entire length of the sheet, the parameter being one or more of thickness, density or porosity of the sheet.

49. 49. The method of any one of claims 43 to 48, comprising using a sensor to detect information indicative of the defect, the sensor comprising a signal generator and a signal receiver for detecting the defect.

50. 50. The method of claim 49, wherein the sensor comprises a plurality of signal generators and signal receivers.

51. A manufacturing method as described in claim 49 or 50, characterized in that the sensor is configured to detect an area of ​​the sheet that is offset in a direction perpendicular to the direction of the transport path and / or configured to detect an area of ​​the sheet that is offset in a direction along the transport path.

52. 52. A method according to any one of claims 49 to 51, wherein the sensor is located above or below the sheet of aerosol-generating material.

53. 53. A method according to any one of claims 49 to 52, wherein the sensor comprises a camera, the camera being a three-dimensional camera configured to detect a three-dimensional image of the sheet.

54. 54. The method of claim 53, wherein the camera includes a filter, the filter being a polarizing filter.

55. 55. A method according to claim 53 or 54, comprising shining a light on the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

56. 56. The method of claim 55, further comprising shining light onto the sheet from a side of the sheet distal from the camera.

57. 57. A method according to claim 55 or 56, comprising exposing a sheet of aerosol-generating material to light on both sides.

58. 58. A method according to claim 54 or any one of claims 55 to 57 depending on claim 54, comprising directing light onto the sheet of aerosol-generating material through a filter configured to filter out electromagnetic radiation of the same frequency as the filter of the camera.

59. 59. The method of any one of claims 43 to 58, wherein the detected defects include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

60. 60. The method of claim 43, wherein feeding the sheet of aerosol-generating material along the transport path comprises feeding a continuous sheet of aerosol-generating material, the sheet being fed from a bobbin.

61. 61. A method as claimed in any one of claims 43 to 60, wherein the sheet of aerosol-generating material comprises tobacco.

62. 62. The method of any one of claims 43 to 61, wherein forming the sheet of aerosol-generating material into a consumable comprises forming the sheet of aerosol-generating material into a strip or comprises cutting at least a portion of the sheet of aerosol-generating material into the strip.

63. 63. The method of claim 62, wherein forming the sheet of aerosol-generating material into a consumable comprises collecting a strip of aerosol-generating material.

64. 64. The method of any one of claims 43 to 63, wherein forming the sheet of aerosol-generating material into a consumable product comprises encasing the aerosol-generating material in a wrapper.

65. 65. A method as claimed in any one of claims 43 to 64, wherein forming the sheet of aerosol-generating material into a consumable comprises cutting the consumable into individual consumables, the individual consumables being single or double length consumables.

66. 66. The method of claim 65, further comprising associating the defect with an individual consumable.

67. 67. The method of claim 66, including separating individual consumable items that are determined by the controller to contain one or more defects from individual consumable items that are not determined by the controller to contain one or more defects.

68. 68. The method of any one of claims 65 to 67, comprising associating defects with individual batches of consumables.

69. 69. The method of any one of claims 43 to 68, wherein the consumable is a rod.

70. 1. An analytical apparatus for analyzing a sheet of aerosol-generating material for use as a consumable for an aerosol delivery system, comprising: a sensor configured to detect information indicative of a defect in the sheet of aerosol-generating material; a controller configured to determine whether or not the sheet of aerosol-generating material is defective based on information sensed by the sensor; The controller is configured to determine one or more parameters of the defect, the parameters of the defect including one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

71. 71. The analyzer of claim 70, wherein the controller is configured to compare a parameter of the defect to a preset value.

72. 72. The analyzer of claim 71, wherein the controller is configured to classify the defect based on a comparison of a parameter of the defect to a preset value, the classification relating to a severity of the defect.

73. 73. The analytical device of any one of claims 70 to 72, wherein the controller is configured to determine the presence or absence of defects in at least one individual area of ​​the sheet of aerosol-generating material based on information detected by the sensor.

74. 73. The analytical device of any one of claims 70 to 72, wherein the controller is configured to determine the presence or absence of defects along substantially the entire length of the sheet of aerosol-generating material based on information detected by the sensor.

75. 75. The analytical device of claim 74, wherein the defect is a deviation from a target range or value of at least one parameter of the sheet of aerosol-generating material that is present along substantially the entire length of the sheet of aerosol-generating material, the parameter being one or more of thickness, density or porosity of the sheet.

76. An analytical device as described in any one of claims 73 to 75 depending on claim 72, characterized in that the controller is configured to assess the quality of a region of a sheet of aerosol-generating material based on the amount or surface density of one or more defects in said region and / or a classification of one or more defects in said region.

77. 77. The apparatus of claim 76, wherein the assessment of quality produces quality requirement criteria, and the controller is configured to store the criteria in memory, the criteria being associated with the region.

78. 78. The analytical device of claim 77, wherein said areas of the sheet correspond to individual consumable batches formed by individual consumable aerosol generating materials or devices.

79. 79. An analysis device according to any one of claims 76 to 78, wherein the controller is adapted to take specific actions depending on the assessment of the quality of the regions.

80. 80. The analytical apparatus of claim 79, wherein the action includes sending a signal indicating that the quality of the area falls below a predefined value or that the area and / or the entire sheet material should be discarded and / or recycled.

81. 81. The analytical device of any one of claims 70 to 80, wherein the sensor comprises a signal generator and a signal receiver for detecting the defect, the signal being a laser signal.

82. 82. An analytical device according to any one of claims 70 to 81, comprising a plurality of sensors.

83. 83. An analytical device according to any one of claims 70 to 82, wherein the sensor comprises a camera.

84. The analytical apparatus of claim 70, further comprising a light-emitting element configured to direct light onto the sheet of aerosol-generating material.

85. 85. An analysis device according to claim 84 when dependent on claim 83, wherein the light emitter is configured to be located on a surface of the sheet of aerosol-generating material that is distal to the camera.

86. 86. An analytical device according to claim 84 or 85, characterized in that the light emitters are arranged to be located on both sides of the sheet of aerosol-generating material.

87. 87. The analytical device of any one of claims 84 to 86, wherein the illuminator includes a filter.

88. 88. An analysis device according to any one of claims 83 to 87, wherein the camera includes a filter, the filter being a polarising filter.

89. 89. An analysis device as claimed in claim 88 depending on claim 87, characterized in that the filter of the illuminator is configured to pass electromagnetic radiation, at least a portion of which has the same frequency as the electromagnetic radiation passed by the filter of the camera.

90. 90. Analysis apparatus according to claim 83 or any one of claims 84 to 89 depending on claim 83, characterized in that the camera is a three-dimensional camera arranged to detect a three-dimensional image of the sheet.

91. 91. The analytical device of any one of claims 70 to 90, wherein the defects detected by the sensor include one or more of holes, slits, non-uniformity in the thickness of the sheet, low density areas, voids, tears, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value and / or a porosity of the sheet deviating from a desired range or value.

92. 92. An assay device according to any one of claims 70 to 91, wherein the sheet of aerosol-generating material comprises tobacco.

93. 1. A manufacturing apparatus for manufacturing a consumable for an aerosol delivery system, comprising: An analysis device for analyzing a sheet of an aerosol-generating material according to any one of claims 70 to 92; a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; a consumable formation device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

94. 1. A method for analyzing a sheet of aerosol-generating material for use in a consumable aerosol delivery system, comprising: detecting information indicative of a defect in the sheet of aerosol-generating material; determining whether or not the consumable is defective based on the detected information; The method further includes determining one or more parameters of the defect, the one or more parameters of the defect including one or more of the length, width, depth, angle of the extent of the defect relative to the direction of the transport path, area of ​​the defect, density of the sheet, thickness of the sheet or porosity of the sheet.

95. 95. The method of claim 94, further comprising: comparing a parameter of the defect to one or more preset values; or classifying the defect based on a comparison of the parameter of the defect to one or more preset values.

96. 96. The analysis method of claim 94 or 95, wherein determining the presence or absence of a defect in the consumable based on the detected information comprises determining the presence or absence of a defect in at least one discrete area of ​​the sheet based on information detected by the sensor.

97. 96. The method of claim 94 or 95, wherein determining whether or not a consumable is defective based on the detected information comprises determining whether or not a defect exists along substantially the entire length of the sheet based on information detected by the sensor.

98. 98. The method of claim 97, wherein the defect is a deviation from a target range or value of at least one parameter of the sheet of aerosol-generating material that is present along substantially the entire length of the sheet of aerosol-generating material, the parameter being one or more of thickness, density or porosity of the sheet.

99. 99. The method of any one of claims 94 to 98, further comprising using a sensor to detect information indicative of the defect, the sensor comprising a signal generator and a signal receiver for detecting the defect.

100. 100. The method of claim 99, wherein the sensor comprises a plurality of signal generators and signal receivers.

101. 101. A method of analysis according to claim 99 or 100, characterized in that the sensor comprises a camera, the camera being a three-dimensional camera configured to detect a three-dimensional image of the sheet.

102. 102. The method of claim 101, wherein the camera includes a filter, the filter being a polarizing filter.

103. 103. The method of claim 101 or 102, further comprising shining light onto the sheet of aerosol-generating material in an area of ​​the sheet detected by the camera.

104. 104. A method of analysis as claimed in claim 103, comprising shining light on the sheet from a side of the sheet distal from the camera.

105. 105. The method of claim 103 or 104, further comprising exposing a sheet of aerosol-generating material to light on both sides.

106. 102. A method of analysis according to claim 102 or any one of claims 103 to 105 depending on claim 102, comprising directing light onto the sheet of aerosol-generating material through a filter configured to filter out electromagnetic radiation of the same frequency as the camera filter.

107. 107. The method of claim 94, wherein the detected defects include one or more of holes, slits, non-uniformity in thickness of the sheet, low density areas, voids, cracks, lumps, a thickness of the sheet deviating from a desired range or value, a density of the sheet deviating from a desired range or value, and / or a porosity of the sheet deviating from a desired range or value.

108. 108. A method as claimed in any one of claims 94 to 107, wherein the sheet of aerosol-generating material comprises tobacco.

109. 1. A method for producing a consumable for an aerosol delivery system, the method comprising: Analysing a sheet of aerosol-generating material for use in an aerosol delivery system consumable by the method of any one of claims 94 to 108; The method further includes forming the sheet of aerosol-generating material into a consumable item.

110. 1. A system for manufacturing a consumable for an aerosol delivery system, comprising: an analysis device for analyzing a sheet of aerosol-generating material for use in a consumable aerosol delivery system according to any one of claims 70 to 92; a feeder for receiving the sheet of aerosol-generating material and configured to feed the sheet of aerosol-generating material along a transport path; a consumable forming device configured to receive the sheet of aerosol-generating material and form the sheet of aerosol-generating material into a consumable.

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