Mixed dyeing method and mixed dyeing system for cigarette filter sticks

Abstract

The invention discloses a mixed dyeing method and system for a cigarette filter stick, and the method comprises the following steps: a driving adjustment system adjusts the distance parameter of a separated nozzle assembly according to a driving parameter group, and the driving parameter group comprises the moving speed and / or the spray hole spacing of the separated nozzle assembly; the dyeing material is sprayed to cellulose acetate fibers of the cigarette filter sticks through the separated nozzle assembly according to a spraying parameter set for dyeing, and the spraying parameter set comprises spraying flow; the dyeing degree of the acetate fibers is collected and analyzed through the monitoring feedback system, so that the central control system can control the driving parameter set and / or the spraying parameter set according to the dyeing degree, and the dyeing degree comprises color depth and uniformity. The device realizes self-adjustment to adapt to cellulose acetate fibers with different specifications and has the functions of real-time monitoring and dynamic parameter adjustment and compensation.

Description

Technical Field

[0001] This patent belongs to the field of tobacco filter rod preparation technology, specifically relating to a mixed dyeing method and mixed dyeing system for tobacco filter rods. Background Technology

[0002] Fiber acetate, with its excellent adsorption properties, chemical stability, and biocompatibility, is widely used in the production of cigarette filter rods, playing a vital role, especially in the tobacco, environmental protection, and medical industries. As market demand for personalized and functional filter rods continues to grow, dyeing processes have become a key factor influencing the appearance quality and market competitiveness of filter rods.

[0003] Early methods of dyeing cellulose acetate filter rods involved dyeing the cellulose acetate slurry before filter rod production. This method had two main drawbacks: firstly, the equipment was difficult to clean, resulting in long changeover times; and secondly, the available colors were limited.

[0004] With increasing demands for efficiency in industrial production, spray coating technology has gradually replaced dip dyeing as the mainstream method. Traditional spray coating equipment mostly uses fixed nozzle groups, designed based on the production needs of filter rods of a single specification, with fixed nozzle spacing and spraying parameters. However, in actual production, the specifications of cellulose acetate filter rods are becoming increasingly diverse, and the fiber width and travel speed after opening are adjusted according to the production plan. Spray coating equipment with fixed parameters is difficult to adapt to these changes.

[0005] Specifically, the limitations of traditional technologies are mainly reflected in the following aspects:

[0006] Poor width adaptability: The fixed spacing of the nozzles cannot be flexibly adjusted according to the change of fiber width. When the fiber width increases, the edge area is prone to missed dyeing; when the width decreases, the area of ​​overlapping spraying by the nozzles will form dark patches, affecting the product qualification rate.

[0007] Parameter adjustment lag: The adjustment of parameters such as spray flow rate and distance relies on manual experience and lacks scientific and quantitative control standards. When the fiber travel speed fluctuates, parameter adjustments often cannot keep up with actual production needs, resulting in inconsistent dyeing depth and poor uniformity.

[0008] Lack of feedback compensation mechanism: The lack of real-time monitoring during the dyeing process makes it impossible to detect dyeing defects in time. By the time problems are discovered in subsequent quality inspection stages, a large number of unqualified products have already been produced, resulting in a lot of rework and seriously affecting production efficiency.

[0009] High dye loss rate: Due to unreasonable parameter matching, the amount of dye lost during the spraying process is large, which not only increases production costs, but also increases the pressure on environmental protection due to dye waste.

[0010] In recent years, with the development of intelligent manufacturing technology, the industry has placed higher demands on the intelligence and efficiency of filter rod dyeing processes. The market urgently needs a dyeing technology that can adapt to different specifications of cellulose acetate fibers and has real-time monitoring and dynamic compensation functions to solve problems such as uneven dyeing, low efficiency, and high costs in traditional processes, and to drive the filter rod manufacturing industry towards high quality and low energy consumption. Against this backdrop, developing new and efficient cellulose acetate filter rod dyeing technologies has become an inevitable trend in the industry. Summary of the Invention

[0011] The purpose of this patent is to provide a mixed dyeing method and system for tobacco filter rods, which can achieve self-adjustment to different specifications of acetate fiber and have real-time monitoring and dynamic parameter adjustment and compensation functions.

[0012] To solve the above-mentioned technical problems, this patent adopts the following technical solution:

[0013] A method for mixing and dyeing tobacco filter rods includes the following steps:

[0014] Step A: Adjust the distance parameters of the split nozzle assembly according to the drive parameter set, which includes the moving speed of the split nozzle assembly and / or the nozzle spacing.

[0015] Step B: The dyeing material is sprayed onto the cellulose acetate of the tobacco filter rod through the separate nozzle assembly according to the spraying parameter set, which includes the spraying flow rate.

[0016] Step C: The dyeing degree of acetate fiber is collected and analyzed through the monitoring feedback system, so that the central control system can control the drive parameter group and / or spraying parameter group according to the dyeing degree, including color depth and uniformity.

[0017] Furthermore, step C includes the following steps:

[0018] The monitoring and feedback system collects information on the degree of dyeing in real time and transmits it to the central control system. If the central control system finds a dyeing deviation after analysis, it adjusts the driving parameter group and / or the spraying parameter group.

[0019] In step B, the separate nozzle assembly sprays the dye onto the cellulose acetate in a fan-shaped spray pattern.

[0020] Furthermore, the spraying flow rate is 5-20 mL / min;

[0021] Adjusting the drive parameter group and / or spraying parameter group includes:

[0022] If the color of the cellulose acetate is detected to be too light, adjust the spray flow rate by 5-20%.

[0023] When the color of the cellulose acetate is detected to be too dark, adjust the spray flow rate to reduce it by 5-20%.

[0024] Furthermore, dyeing materials include one or more combinations of dyes, solvents, and auxiliaries;

[0025] By weight percentage, the amount of dye added is 1-30%, the amount of solvent added is 70-80%, and the amount of auxiliaries added is 5-10%.

[0026] This includes one or more combinations of natural and synthetic dyes;

[0027] Solvents include one or more of water, ethanol, and propylene glycol;

[0028] The additives include one or more of the following: dispersants, stabilizers, and defoamers; wherein the dispersants, stabilizers, and defoamers are all food-grade standard additives commonly used in the market.

[0029] This patent further provides a mixed dyeing system that applies any of the above-mentioned mixed dyeing methods for tobacco filter rods. The mixed dyeing system includes a dye supply system, a separate nozzle assembly, a drive adjustment system, a monitoring feedback system, and a central control system.

[0030] The dye supply system includes flow control valves for controlling the spray flow rate;

[0031] The split nozzle assembly is equipped with a flow-dividing channel, and at least four spray holes are connected to the end of the flow-dividing channel. An atomizing chamber is provided at the outlet of the spray holes. The dyeing material is dyed on the acetate fiber in a fan-shaped spray pattern under the action of the atomizing chamber.

[0032] The drive adjustment system is used to provide power to the split nozzle assembly to adjust the distance parameters;

[0033] The monitoring and feedback system is used to collect and analyze the dyeing degree of acetate fibers and provide the data to the central control system.

[0034] Furthermore, the dye supply system also includes a dye storage container and a dye supply pipeline, which connects the dye storage container and the separate nozzle assembly.

[0035] Furthermore, the monitoring feedback system includes a high-definition industrial camera for acquiring stained images and / or a spectrometer for detecting color parameters.

[0036] Furthermore, the nozzle diameter is 0.2-0.8 mm.

[0037] Furthermore, multiple separate nozzle assemblies are provided;

[0038] The mixed dyeing system also includes rollers, under which acetate fibers move from below the split nozzle assembly.

[0039] This patent provides a mixed dyeing method and system for tobacco filter rods, which has the following advantages compared to the prior art:

[0040] 1. Significantly improves product quality stability

[0041] This technical solution completely solves the problem of uneven dyeing in traditional dyeing processes. The modular layout of the separate nozzle assembly allows for flexible adjustment of the spacing according to the width of the acetate fiber. Combined with precise parameter control, this ensures that the dye evenly covers the fiber surface, avoiding problems such as missed dyeing at the edges or dark patches in overlapping areas. Simultaneously, the real-time feedback and dynamic compensation mechanism uses high-definition monitoring equipment to capture dyeing deviations and promptly corrects them through multi-dimensional adjustments such as flow rate and distance. This significantly improves the color uniformity of the filter rods and enhances color fastness, effectively ensuring the stability and consistency of product quality and meeting the stringent requirements of the high-end market for the appearance quality of filter rods.

[0042] 2. Significantly improve production efficiency

[0043] In terms of production efficiency, this solution demonstrates significant advantages. The intelligent parameter matching algorithm incorporates multiple working condition models, automatically recommending optimal parameters based on fiber specifications. This eliminates the need for repeated manual adjustments based on experience, a common practice in traditional processes, and significantly reduces changeover time. The real-time feedback compensation mechanism reduces rework due to dyeing defects, preventing a large number of defective products and making the production process smoother and more efficient. Furthermore, the independent drive design and automated control of the separate nozzle assembly reduce the frequency of manual intervention, further increasing output per unit time and providing strong support for enterprises to expand their production scale.

[0044] 3. Effectively reduce production costs

[0045] This technical solution demonstrates significant effectiveness in cost control. On one hand, precise parameter adjustment and feedback compensation mechanisms improve the utilization rate of dyes, reduce dye loss and waste during spraying, and lower dye procurement costs. On the other hand, increased production efficiency and reduced rework rates decrease the investment of manpower, materials, and time, indirectly reducing production costs. Simultaneously, stable equipment operation and reduced maintenance costs also save enterprises a considerable amount of money, enhancing their economic benefits and market competitiveness.

[0046] 4. Enhanced environmental performance

[0047] This technical solution aligns with the concept of environmentally friendly production. Increased dye utilization reduces dye waste, lowers the difficulty and cost of wastewater treatment caused by dye residue, and mitigates environmental pollution. Automated control and precise operation also reduce energy consumption during production, meeting the national requirements for low-energy and green production, helping companies establish a positive environmental image and achieve sustainable development.

[0048] 5. Promote technological upgrading in the industry

[0049] This technical solution integrates advanced technologies such as intelligent control and real-time monitoring, providing a brand-new technological paradigm for the filter rod dyeing industry. Its successful application will drive other companies in the industry to upgrade and transform traditional dyeing equipment, propelling the entire industry towards intelligent, efficient, and environmentally friendly development. At the same time, the innovative design concepts and technological ideas embodied in this solution also provide a reference for technological research and development in related fields, promoting the overall improvement of the industry's technological level. Attached Figure Description

[0050] The above content of this patent and the following detailed embodiments will be better understood when read in conjunction with the accompanying drawings. It should be noted that the drawings are merely examples of the claimed technical solution.

[0051] Figure 1 This is a schematic diagram of the mixed staining system in this patent.

[0052] The reference numerals in the attached figures are explained as follows:

[0053] Dye supply pipeline: 1

[0054] Dye imports: 11

[0055] Nozzle body: 2

[0056] Nozzle: 3

[0057] Atomizing chambers: 4

[0058] Rollers: 5

[0059] Fiber acetate: 6

[0060] Central control system: 7

[0061] Real-time monitoring equipment: 8 Detailed Implementation

[0062] The detailed features and advantages of this patent are described below in the specific embodiments. The content is sufficient to enable any person skilled in the art to understand the technical content of this patent and implement it accordingly. Based on the specification, claims and drawings disclosed in this specification, a person skilled in the art can easily understand the related objectives and advantages of this patent.

[0063] This specification also uses several compound terms to describe devices, components, equipment, etc. that include more than one function, or to assign additional functions to a corresponding device, component, equipment, etc. Those skilled in the art will understand that such compound terms can be implemented by a single or multiple devices, components, equipment, etc., as long as they are reasonable under the interpretation rules of this patent terminology.

[0064] It should be noted that in this specification, similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it does not need to be further defined and interpreted in subsequent figures. In this specification and claims, several terms will be used, and unless otherwise indicated, these terms will be defined as having the following meanings:

[0065] The terms “comprising” or “having” have the same meaning as “containing”, and also include other forms of the term, such as the gerund and singular forms in English, meaning including but not limited to, and not intended to exclude, for example, other elements, components, integers or steps.

[0066] All other terms used herein for special definition are intended to have the general meaning understood by one of ordinary skill in the art, and in particular, meaning that one of ordinary skill in the art, upon reading the claims, specification and drawings of this patent, can directly and without doubt determine how the technical solution of this patent can be implemented.

[0067] Even if there are incomplete descriptions, omissions, or ambiguities in the grammar, words, punctuation, graphics, symbols, etc. of the claims, specification, and drawings of this patent, a person skilled in the art can still arrive at the only correct understanding by reading the claims, specification, and drawings as a whole without extensive reasoning or experimentation, and effectively exclude various incorrect interpretations that are not aimed at achieving the purpose of this patent.

[0068] Those skilled in the art would first choose to read the claims, specification, and drawings of this patent to reasonably interpret the terms; secondly, they would choose to refer to the relevant definitions in other documents published by the applicant before the filing date to reasonably interpret the terms; thirdly, they would choose the references cited in this patent to reasonably interpret the terms; and finally, they would choose to combine the technical dictionaries, technical manuals, reference books, textbooks, national or industry technical standards, etc., commonly used by those skilled in the art to reasonably interpret the terms.

[0069] All references cited in this application are incorporated herein by way of quotation, to the extent that they do not contradict the disclosure herein. It will be apparent to those skilled in the art that products (apparatus, components, devices, compounds, compositions, materials, etc.) and methods (processes, steps, conditions, parameters, equipment, and test methods, equipment, etc.) not specifically described herein can be applied to the implementation of the inventions fully disclosed herein without the need for excessive experimentation. This patent is intended to cover all functional equivalents known in the art of the methods, apparatus, apparatus components, materials, processes, and techniques specifically described herein. All cited references include:

[0070] The following publications are included: Marks' Standard Handbook for Mechanical Engineers (11th edition and other editions prior to the filing date of this application), published by McGraw-Hill, Inc.; DeGarmo's Materials and Processes in Manufacturing (13th edition and other editions prior to the filing date of this application), published by Wiley; Oberg's Machine Handbook (32nd edition and other editions prior to the filing date of this application), published by IndustrialPress Inc.; Cheng Daxian's Mechanical Design Handbook (6th edition and other editions prior to the filing date of this application), published by Chemical Industry Press; and Wen Bangchun's Modern Mechanical Design Handbook (6th edition and other editions prior to the filing date of this application), published by Machinery Industry Press.

[0071] This patent provides a mixed dyeing method and system for tobacco filter rods, including the following steps:

[0072] S1. Preparation of dyeing materials

[0073] Based on the design color standards and color fastness requirements of the filter rod, different colors of dye are precisely formulated, and each dye is injected into an independent dye supply pipe 1 via a dedicated delivery pump. The pipe is made of corrosion-resistant 316 stainless steel to ensure the stability of the dye properties. Dye supply pipe 1, as part of the dye supply system, connects to the separate nozzle assembly and is also connected to a dye storage container for supplying material to the separate nozzle assembly.

[0074] The specific characteristics and proportions of each component in the dye are selected based on the following:

[0075] Dyes: The proportion ranges from 1% to 30%, depending on the final application of the filter rod. Dyes include natural and synthetic dyes; natural dyes, such as madder red and indigo, are derived from natural plants and have good biocompatibility and environmental friendliness, making them suitable for filter rod products with extremely high environmental requirements; synthetic dyes, such as acid red and disperse blue, have high color saturation and excellent lightfastness and washability, meeting the needs of long-term use. In actual formulation, light-colored dyes typically account for 1%-5%, while dark-colored dyes account for 10%-20%.

[0076] Solvent: 70%-80% of the total solvent, which must be well miscible with the selected dye. Solvents include water, ethanol, and propylene glycol. Water is the base solvent, suitable for water-soluble dyes, and is inexpensive and widely available. Ethanol has better solubility for hydrophobic dyes and also has some volatility, which can accelerate the drying speed after dyeing. Propylene glycol is used as an auxiliary solvent to improve the stability of the dye, especially at low temperatures, to prevent dye precipitation.

[0077] S2. Nozzle Installation and Adjustment

[0078] The split nozzle assembly adopts a modular design, with each nozzle (i.e., spray hole 3) mounted on a mounting bracket. The mounting bracket is equipped with a precision scale with a minimum scale of 1 mm. The lifting adjustment device driven by a servo motor serves as the drive adjustment system, which can accurately adjust the spacing between nozzles within a range of 10-50 cm, with an adjustment accuracy of ±0.5 mm, ensuring a perfect match with the width of the opened cellulose acetate.

[0079] The drive adjustment system includes a servo motor-driven lifting adjustment device and a servo motor-driven ball screw mechanism. The lifting adjustment device is used to adjust the spray height and nozzle spacing in the drive parameter set. The nozzle spacing refers to the positional distance between each nozzle, and the spray height refers to the distance between the nozzle and the cellulose acetate. This is used in conjunction with the electromagnetic flow control valve to control the spray flow rate. The ball screw mechanism is used to adjust the movement speed between each nozzle.

[0080] Spraying parameter adjustment:

[0081] Spraying flow rate: Adjusted by an electromagnetic flow control valve on the dye supply pipeline. The valve has a response time of less than 0.1 seconds and a flow control accuracy of ±0.1 mL / min. During commissioning, the theoretical flow rate is first calculated based on the fiber width and preset color depth, and then the final parameters are determined through test spraying.

[0082] Spraying speed: The movement speed between nozzles is controlled by a ball screw mechanism driven by a servo motor. The speed adjustment range is 0.5-3 meters / minute, with an adjustment step of 0.1 meters / minute. Through linkage control with the fiber travel speed, a constant amount of dye sprayed per unit area is ensured.

[0083] Spraying distance (i.e., spraying height): The distance between the nozzle and the cellulose acetate fiber is adjusted via a lifting adjustment device on the mounting bracket. The adjustment range is 30-200 mm, and the adjustment accuracy is ±1 mm. During the debugging process, the atomization effect can be observed in real time through a high-definition camera to help determine the optimal distance.

[0084] S3, Staining process

[0085] like Figure 1 As shown, when the central control system 7 is activated, the cellulose acetate 6 moves at a constant speed due to the rotation of the roller 5 driven by the variable frequency motor. The speed at which the cellulose acetate 6 moves under the action of the roller 5 is the material feeding speed. At the same time, the central control system 7 automatically starts the peristaltic pump and nozzle drive device of the dye supply pipeline 1, and each separate nozzle assembly starts the spraying operation synchronously according to the preset parameters.

[0086] The split nozzle assembly includes a nozzle body 2, a flow channel, a spray hole 3, an atomizing chamber 4, and a pressure pump.

[0087] The detailed dyeing process is as follows: After being precisely filtered (filtration accuracy of 5 microns), the dye enters the separate nozzle assembly. Specifically, the dye enters the nozzle body 2 through the dye inlet 11 at the top of the nozzle body 2. The flow distribution channel inside the nozzle body 2 adopts a fluid dynamics optimized design to evenly distribute the dye to 6-8 nozzles 3 with a diameter of 0.5 mm. The separate nozzle assembly includes a pressure pump. After the dye is sprayed out of the nozzles, it enters the atomization chamber 4 with a volume of 5 ml. Under the action of compressed air at 0.3-0.5 MPa, it is atomized into droplets with a diameter of 10-50 microns, and finally evenly covers the surface of the acetate fiber 6 in a fan-shaped spray pattern (spray angle of 60°-90°).

[0088] The influence of various parameters on staining results and their scientific control range:

[0089] Spray flow rate: Extensive experimental verification has shown that the optimal dyeing effect is achieved when the spray flow rate is in the range of 5-20 mL / min. For thin fibers with a thickness of 0.1-0.3 mm, the flow rate can be controlled at 5-10 mL / min; for thick fibers with a thickness of 0.3-0.5 mm, the flow rate needs to be adjusted to 10-20 mL / min. If the flow rate exceeds this range, it will at least affect the uniformity of color, and at worst, cause fiber deformation.

[0090] Spraying distance: 50-150 mm is the optimal distance determined through repeated testing. When the fiber travels at a faster speed (3-5 m / min), the distance can be appropriately reduced to 50-100 mm to reduce the loss of dye in the air; when the speed is slower (1-3 m / min), the distance can be increased to 100-150 mm to avoid excessive local dyeing.

[0091] S4, Feedback Mechanism Structure

[0092] The real-time monitoring equipment 8 includes a high-definition industrial camera and a spectrometer installed behind the dyeing unit. The high-definition industrial camera can capture dyed images of the acetate fiber surface with a resolution of 12 million pixels, and can clearly identify dyeing uneven areas larger than 0.1 mm, used to check the depth of the dyeing color; the spectrometer can accurately detect the color parameters of the filter rod, such as lightness, hue, and saturation, with a detection accuracy of ±3ΔE, used to determine the uniformity of dyeing.

[0093] Data transmission and analysis: Real-time monitoring device 8, acting as a monitoring feedback system, transmits the collected image and color data to the data analysis module of the central control system 7 in real time. This module uses deep learning algorithms to perform texture analysis and defect identification on the images, and compares and analyzes the color data to determine whether the dyeing meets the preset standards. When a dyeing deviation is detected, such as local colors being too dark or too light, or missed dyeing, the system will immediately issue a signal.

[0094] The compensation measures are as follows:

[0095] Flow compensation: When the spectrometer detects that the color in a certain area is too light and determines that the amount of dye sprayed is insufficient, the central control system 7 will control the flow control valve of the nozzle corresponding to that area to appropriately increase the spraying flow rate. The increase depends on the degree of deviation and is generally between 5% and 20% of the original flow rate. If the color is too dark, the spraying flow rate will be reduced, and the reduction will also be between 5% and 20%.

[0096] Distance compensation: If the high-definition industrial camera detects localized dripping, it may be due to the paint accumulating because the spraying distance is too close. The system will control the nozzle lifting adjustment device to increase the distance between the nozzle and the filter rod (i.e., the spraying height), with an adjustment increase of 5-10 mm. If localized areas are lighter in color and it is determined that the spraying distance is too far, the spraying distance will be reduced, with a reduction adjustment of 5-10 mm.

[0097] Speed ​​compensation: When uneven dyeing is detected due to fluctuations in fiber travel speed, the system adjusts the nozzle movement speed. If the increased fiber speed results in a lighter dyeing in a certain area, the nozzle movement speed is reduced accordingly, increasing the spraying time in that area; if the decreased fiber speed results in a darker dyeing, the nozzle movement speed is increased, reducing the spraying time.

[0098] Nozzle spacing compensation: During the production process, if there is a slight change in the fiber width and the high-definition industrial camera detects a risk of missing dye at the edge, the system will control the nozzle adjustment device to fine-tune the spacing between the nozzles to ensure that the nozzles can fully cover the fiber width, with the adjustment accuracy maintained at ±0.5 mm.

[0099] The core invention of this solution lies in the construction of a "dynamically adaptable dyeing control system". Through the modular layout of the separate nozzle assembly, multi-parameter coordinated adjustment and a sound feedback compensation mechanism, it achieves precise and efficient dyeing of acetate fibers of different specifications.

[0100] Traditional dyeing equipment uses fixed nozzle assemblies, and parameter adjustments rely on manual experience, lacking effective feedback and compensation mechanisms, making it difficult to cope with complex production conditions. This solution features three major innovative breakthroughs: First, the independent drive design of the separate nozzle assembly allows each nozzle to have its spacing, flow rate, and travel speed adjusted individually through the control system, essentially providing each fiber area with a "dedicated dyeing specialist." Second, the intelligent parameter matching algorithm incorporates parameter models for over 100 common production conditions, automatically recommending the optimal parameter combination based on fiber width, thickness, and travel speed, while also supporting manual fine-tuning. Third, the real-time feedback and dynamic compensation mechanism uses high-definition industrial cameras and spectrometers to monitor dyeing effects in real time, combined with deep learning algorithms to quickly identify deviations, and promptly corrects deviations through multi-dimensional compensation measures such as flow rate, distance, speed, and nozzle spacing, forming a complete closed-loop control system of "detection-analysis-feedback-compensation."

[0101] This patent aims to overcome the limitations of traditional dyeing techniques and construct an intelligent, adaptive dyeing system. Specific objectives include: first, achieving comprehensive dyeing coverage of acetate fibers of varying widths after opening, ensuring no missed dyeing or overlapping dyeing marks; second, adjusting dyeing parameters in real time to address changes in fiber travel speed, ensuring dyeing uniformity error is controlled within ±3%; third, introducing a feedback compensation mechanism to promptly correct dyeing effect deviations, thereby improving product qualification rates; and fourth, improving production efficiency while reducing dye waste, achieving a dual improvement in quality and efficiency, based on enhanced dyeing quality.

[0102] This dynamic adaptability and precise feedback compensation mechanism enable the dyeing equipment to be like a "Transformer," flexibly responding to various production needs and emergencies, fundamentally solving the problems of uneven dyeing and low efficiency in traditional technologies.

[0103] Example 1

[0104] Taking a batch of cellulose acetate filter rod orders as an example, the cellulose acetate used in this batch of filter rods has a width of 15 cm after opening, the travel speed is set at 3 meters / minute, and the color uniformity error after dyeing is required to be no more than ±3%, and the color fastness to meet or exceed the industry level 2 standard. The following is the specific implementation process and effect of this technical solution.

[0105] I. Dye Preparation Stage

[0106] Based on the dyeing requirements of the filter rods, prepare dyes of different colors and add each dye to its corresponding dye supply pipe. The dye composition includes 1%-20% dye, 70%-80% solvent, and 5%-10% auxiliaries. Among them, the cellulose acetate dye can be natural dye or synthetic dye, etc.; the solvent can be water, ethanol, propylene glycol, etc.; the auxiliaries include dispersants, stabilizers, defoamers, etc.

[0107] II. Nozzle Installation and Debugging Stage

[0108] Nozzle Installation: Four separate nozzle assemblies are selected and installed on the mounting bracket. Based on a fiber width of 15 cm, the spacing between the nozzles is adjusted to 5 cm using a servo motor-driven lifting adjustment device to ensure that the nozzles fully cover the fiber width.

[0109] Parameter adjustment:

[0110] Spraying flow rate: Based on color requirements and fiber specifications, the spraying flow rate of each nozzle is initially set to 8 mL / min through the flow control valve.

[0111] Spraying speed: Based on the fiber travel speed of 3 meters / minute, the nozzle movement speed is set to 2 meters / minute via the drive device to ensure an appropriate amount of dye sprayed per unit area.

[0112] Spraying distance: By adjusting the height, the distance between the nozzle and the cellulose acetate is set to 100 mm. At this time, the atomization effect displayed by the high-definition camera is good.

[0113] III. Staining and Feedback Compensation Stage

[0114] The dyeing equipment is started, and the acetate fiber moves at a constant speed of 3 meters per minute. At the same time, the peristaltic pump and nozzle drive device (i.e., drive adjustment system) of the dye supply pipeline are turned on, and the four separate nozzle assemblies begin spraying and dyeing according to the set parameters. After being filtered through a 5-micron precision filter, the dye enters the main body through the nozzle inlet, is distributed to six spray holes through the diversion channel, and is atomized into 20-30 micron droplets under the action of 0.4 MPa compressed air, and is evenly sprayed onto the fiber surface in a 75° fan-shaped spray angle.

[0115] In this embodiment, each separate nozzle assembly is configured with 6 nozzle holes based on multiple design considerations.

[0116] In terms of dyeing uniformity, six nozzles can distribute the dye more evenly. After the dye enters the nozzle body, it is distributed to the six nozzles through the distribution channel, allowing the dye to achieve preliminary uniform distribution before atomization. This avoids the concentration of dye caused by a single nozzle or too few nozzles, thus enabling more comprehensive coverage of the corresponding area of ​​acetate fiber during atomization spraying and reducing local dyeing differences.

[0117] From the perspective of atomization effect, the dye sprayed from multiple nozzles can be better mixed with compressed air in the atomization chamber. The layout of the 6 nozzles has been optimized by fluid dynamics, which can make the dye droplet size more uniform (20-30 micrometers) and the atomization range more in line with the fan-shaped spray angle (75°), ensuring that the dye sprayed on the filter rod is more evenly distributed and improving the dyeing quality.

[0118] Meanwhile, the design of the six spray holes is also compatible with the 15 cm wide cellulose acetate in this embodiment. Combined with the spacing of the four nozzles, it can form a complete and non-overlapping spray coverage, which not only ensures the dyeing effect but also improves the utilization rate of dye.

[0119] This design allows each separate nozzle assembly to achieve efficient dyeing while better cooperating with the parameter adjustment and feedback compensation mechanisms in the overall technical solution to meet production needs.

[0120] During the dyeing process, a high-definition industrial camera (12 megapixels) and a spectrometer installed behind the dyeing device operate in real time. The high-definition industrial camera captures 20 frames of images of the filter rod surface per second, while the spectrometer continuously monitors color parameters. After 10 minutes of operation, the spectrometer detected that the brightness of the filter rod edge area was slightly higher than that of the central area, and the color was lighter, with a deviation of 4%, exceeding the preset standard. The data analysis module of the central control system 7 quickly analyzed the data and determined that the amount of dye sprayed in the edge area was insufficient.

[0121] The system immediately activated its compensation mechanism: controlling the flow control valves of the two edge nozzles, increasing the spray flow rate from 8 mL / min to 9 mL / min (an increase of 12.5%); simultaneously, reducing the distance between these two nozzles and the fiber from 100 mm to 95 mm via the lifting adjustment device. Five minutes after adjustment, spectrometer readings showed that the color deviation in the edge area had decreased to 2%, meeting the requirements.

[0122] IV. Final Implementation Results

[0123] After two hours of continuous production, the dyeing of this batch of filter rods was completed, and the test results for various indicators are as follows:

[0124] Color uniformity: Tested with a professional colorimeter, the color uniformity error of each area on the filter rod surface is ±2.5%, which meets the order requirements.

[0125] Color fastness: After rubbing and washing tests, the color fastness meets the industry level II standard and complies with quality regulations.

[0126] Production efficiency: There is no rework due to dyeing defects in the entire production process, and the changeover time is only 4 minutes, which is 26 minutes shorter than the traditional process, and the output per unit time is significantly increased.

[0127] Dye utilization rate: By calculating the ratio of dye consumption to product output, the dye loss rate is controlled at 4.5%, which is more than 10% lower than that of traditional processes, effectively reducing production costs.

[0128] This embodiment fully verifies the feasibility and effectiveness of the technical solution in actual production, and can stably meet the dyeing requirements of cellulose acetate filter rods of different specifications.

[0129] The terminology and expressions used herein are for descriptive purposes only and this patent should not be limited to these terms and expressions. The use of these terms and expressions does not imply the exclusion of any illustrative and descriptive equivalent features (or parts thereof), and it should be recognized that various possible modifications should also be included within the scope of the claims. Other modifications, variations, and substitutions may also exist. Accordingly, the claims should be considered to cover all such equivalents.

[0130] Similarly, it should be noted that although this patent has been described with reference to the specific embodiments described above, those skilled in the art should recognize that the above embodiments are only used to illustrate this patent, and various equivalent changes or substitutions can be made without departing from the spirit of this patent. Therefore, any changes or modifications to the above embodiments within the essential spirit of this patent will fall within the scope of the claims of this patent.

Claims

1. A method for mixing and dyeing tobacco filter rods, characterized in that, Includes the following steps: Step A: Adjust the distance parameters of the split nozzle assembly according to the drive parameter set, which includes the moving speed and / or nozzle spacing of the split nozzle assembly; Step B: The dyeing material is sprayed onto the cellulose acetate of the tobacco filter rod through the separate nozzle assembly according to the spraying parameter set, which includes the spraying flow rate; Step C: The dyeing degree of the acetate fiber is collected and analyzed by the monitoring feedback system, so that the central control system can control the driving parameter group and / or the spraying parameter group according to the dyeing degree, wherein the dyeing degree includes color depth and uniformity.

2. The method for mixing and dyeing tobacco filter rods according to claim 1, characterized in that, Step C includes the following steps: The monitoring and feedback system collects information on the degree of dyeing in real time and transmits it to the central control system. If the central control system finds a dyeing deviation after analysis, it adjusts the driving parameter group and / or the spraying parameter group. In step B, the separate nozzle assembly sprays the dye onto the cellulose acetate in a fan-shaped spray pattern.

3. The method for mixing and dyeing tobacco filter rods according to claim 2, characterized in that, The spraying flow rate is 5-20 mL / min; The adjustment of the drive parameter group and / or the spraying parameter group includes: When the color of the cellulose acetate is detected to be too light, the spray flow rate is increased by 5-20%. When the color of the cellulose acetate is detected to be too dark, the spray flow rate is adjusted to be reduced by 5-20%.

4. The method for mixing and dyeing tobacco filter rods according to claim 1, characterized in that, The dyeing material includes one or more of dyes, solvents and auxiliaries; The dye is added at a weight percentage of 1-30%, the solvent at a weight percentage of 70-80%, and the auxiliaries at a weight percentage of 5-10%. The term includes one or more combinations of natural dyes and synthetic dyes; The solvent includes one or more of water, ethanol and propylene glycol; The additives include one or more of the following: dispersants, stabilizers, and defoamers.

5. A mixed dyeing system for using the mixed dyeing method for tobacco filter rods according to any one of claims 1-4, characterized in that, The hybrid dyeing system includes a dye supply system, a separate nozzle assembly, a drive and adjustment system, a monitoring and feedback system, and a central control system. The dye supply system includes a flow control valve for controlling the spraying flow rate; The split nozzle assembly is provided with a flow-dividing channel, and at least four spray holes are connected to the end of the flow-dividing channel. An atomizing chamber is provided at the outlet of the spray holes. The dyeing material is used to dye the acetate fiber in the fan-shaped spray pattern under the action of the atomizing chamber. The drive adjustment system is used to provide power to the split nozzle assembly to adjust the distance parameter; The monitoring and feedback system is used to collect and analyze the dyeing degree of the acetate fiber and provide it to the central control system.

6. The mixed staining system according to claim 5, characterized in that, The dye supply system also includes a dye storage container and a dye supply pipeline, the dye supply pipeline being used to connect the dye storage container and the separate nozzle assembly.

7. The mixed staining system according to claim 5, characterized in that, The monitoring feedback system includes a high-definition industrial camera for acquiring stained images and / or a spectrometer for detecting color parameters.

8. The mixed staining system according to claim 5, characterized in that, The diameter of the nozzle is 0.2-0.8 mm.

9. The mixed staining system according to claim 5, characterized in that, Multiple separate nozzle assemblies are provided; The mixed dyeing system also includes rollers, under which the acetate fibers move from below the separate nozzle assembly.

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