A cigarette high-efficiency filter chip and a continuous production method thereof

Abstract

The application provides a cigarette high-efficiency filter chip and a continuous production method thereof. The cigarette high-efficiency filter chip comprises a lower filter chip and an upper filter chip. The lower filter chip comprises a lower filter chip body, an air inlet and a micro channel. The lower filter chip body and the upper filter chip are both circular sheet structures with the same center, and the upper filter chip covers part of the micro channel. The cigarette high-efficiency filter chip is a batch processing product, has good and stable adsorption performance, combines femtosecond laser precision machining and roll-to-roll mold stamping process, converts a laboratory-level microfluidic chip into a filter chip roll that can be produced at a high speed in an industrial manner, and provides a new path with high filtering performance, excellent consistency and large-scale production feasibility for reducing tar and harm of cigarettes.

Description

Technical Field

[0001] This invention relates to the field of tobacco technology, specifically to a high-efficiency cigarette filter chip and its continuous production method. Background Technology

[0002] With increasing global health awareness, the development of efficient and stable tar-reducing and harm-reducing filter technology has become an urgent need in the industry. Existing technologies mainly focus on adding adsorption materials or optimizing physical structures, but they generally suffer from bottlenecks in filtration efficiency, manufacturing precision, and compatibility with industrial production.

[0003] The closest existing technologies and their drawbacks are as follows: 1) Passive adsorption type filter: Plant particles (such as rice husks, corn cobs) or activated carbon are added to the fiber substrate to form a composite filter rod; however, this method relies on passive physical adsorption, which has limited efficiency, poor particle dispersion uniformity in high-speed production, and extremely unstable filtration consistency.

[0004] 2) Discrete particle online injection type filter: The particulate medium is injected into the center of the fiber bundle using a continuous device; however, this method is essentially still a simple mixture of "fiber bundle + discrete particles", which cannot achieve active and precise filtration, and its efficiency has a fundamental bottleneck.

[0005] 3) Irregularly shaped injection / stamped filter tip: This method uses thermoplastic polymers such as PET to prepare a chip-type filter component with a "buffer cavity" and a "deposition cavity" through integrated molding. Although this method can significantly improve the interception efficiency through active structure, it relies on injection / stamping process, cannot achieve continuous roll-to-roll high-speed production, is difficult to integrate seamlessly with existing high-speed cigarette machines, and has high mass production costs.

[0006] Existing technologies either suffer from efficiency bottlenecks in their filtration mechanisms or lack sufficient manufacturing precision and consistency. In particular, there is an irreconcilable contradiction between high-throughput continuous production and high-performance precision structural design. Therefore, there is a need for a filter tip that can be continuously produced and has good and stable filtration performance, as well as a method for its production. Summary of the Invention

[0007] This invention aims to address the efficiency bottleneck of cigarette filtration mechanisms and the lack of manufacturing precision and consistency, particularly the irreconcilable contradiction between high-throughput continuous production and high-performance precision structural design. It provides a high-efficiency cigarette filter chip and its continuous production method, integrating femtosecond laser precision machining with roll-to-roll die imprinting technology. This transforms laboratory-grade microfluidic chips into industrially producible high-speed filter chip rolls, offering a novel path for reducing tar and harm in cigarettes that combines high filtration performance, excellent consistency, and large-scale production feasibility.

[0008] This invention provides a high-efficiency cigarette filter chip, comprising a lower filter chip and an upper filter chip; The lower-layer filter chip includes a lower-layer filter chip body, and components that are connected to the lower-layer filter chip body and are evenly distributed circumferentially along the center of the lower-layer filter chip body. n An air inlet is connected to the surface of the lower filter chip body, with one end communicating with the air inlet and the other end extending along the radius of the lower filter chip body to the outer edge of the lower filter chip body. n A micro-channel; Both the lower filter chip body and the upper filter chip are circular sheet structures with their centers on the same axis. The upper filter chip covers part of the microchannels. The microchannel includes a first microchannel covered by the upper filter chip and a second microchannel not covered by the upper filter chip; The air inlet, the lower surface of the upper filter chip, and the front end of the first microchannel form a preliminary collection channel. The first microchannel and the lower surface of the upper filter chip covering the first microchannel form a centrifugal separation channel. The n second microchannels and the upper surface of the lower filter chip body located between the second microchannels form an air outlet. The centrifugal separation channel is perpendicular to the preliminary collection channel, and its cross-sectional area is less than or equal to the cross-sectional area of ​​the preliminary collection channel. The high-efficiency filter chip is located between the tobacco and the filter rod or between two filter rods, and is wrapped by cigarette paper or filter paper. The air inlet faces the tobacco and serves as the inlet for the smoke flow.

[0009] The present invention discloses a high-efficiency cigarette filter chip, in which smoke enters the preliminary collection channel from the air inlet for diversion, preliminary acceleration and preliminary collection. In the centrifugal separation channel, the airflow direction is changed, and the separation of substances is achieved by means of centrifugal force. The aerosol is condensed and dripped through the condensation deposition effect, and then enters the oral cavity through the air outlet along the filter rod. The substances include tar.

[0010] In a preferred embodiment of the high-efficiency cigarette filter chip of the present invention, the diameter of the lower filter chip body is equal to the inner diameter of the cigarette paper and the inner diameter of the filter tip paper, and the width of the microchannel is less than or equal to the width of the air inlet and the depth is less than the thickness of the lower filter chip body. The diameter of the upper filter chip is smaller than the diameter of the lower filter chip body, and the lower filter chip and the upper filter chip are bonded together by compression.

[0011] In a preferred embodiment of the high-efficiency cigarette filter chip described in this invention, the thickness of the lower filter chip body is 0.10~0.30 mm. n The range is 6 to 18. The air inlet is a circular through-hole; The depth of the microchannel is 1 / 3 to 1 / 2 of the thickness of the lower filter chip body, and the width of the microchannel is 1 / 2 to 2 of the depth of the microchannel. The diameter of the upper filter chip is 4 / 5 to 19 / 20 of the diameter of the lower filter chip body.

[0012] The present invention discloses a high-efficiency cigarette filter chip, in which both the lower and upper filter chips are made of plastic, and the high-efficiency filter chip is produced by continuous roll-to-roll manufacturing. At least two lower filter chip bodies are processed on the lower filter chip substrate, and at least two upper filter chips are processed on the upper filter chip substrate. Both the lower filter chip substrate and the upper filter chip substrate are in roll form. The lower filter chip body and the upper filter chip are respectively engraved with outlines by mechanical imprinting. The air inlet and microchannels are processed by laser etching with a processing error of ≤ ±10 μm. After dispensing adhesive on the lower filter chip substrate area outside the lower filter chip body, the upper filter chip substrate is pressed onto the lower filter chip substrate by a pressure roller, thereby pressing and bonding the upper filter chip onto the lower filter chip to obtain a high-efficiency filter chip.

[0013] This invention provides a continuous production method for high-efficiency cigarette filter chips, comprising the following steps: S1. Assembly of high-efficiency filter chip continuous production line. The high-efficiency filter chip continuous production line is provided with traction power by the winding device at the end, which drives the unwinding and lamination of the lower filter chip substrate and the upper filter chip substrate. S2. The lower filter chip substrate is sleeved on the outside of the lower filter chip roller, and the upper filter chip substrate is sleeved on the outside of the upper filter chip roller. Both the lower filter chip substrate and the upper filter chip substrate are roll-shaped substrates. S3. The high-efficiency filter chip continuous production line starts to operate. The lower filter chip roller and the upper filter chip roller start to unwind. The first laser engraving machine etches the lower alignment mark on the lower filter chip substrate and processes the air inlet and micro-channel. Then, the lower filter chip stamping upper mold and the lower filter chip stamping lower mold mechanically press the edge contour of the lower filter chip. Meanwhile, the second laser engraving machine etches the upper alignment mark on the upper chip substrate, and then the upper filter chip stamping upper mold and the upper filter chip stamping lower mold mechanically press the edge contour of the upper filter chip. S4. The roll-to-roll dispensing machine dispenses adhesive onto the lower layer filter chip substrate. Simultaneously, the lower layer vision alignment device captures the lower layer alignment mark in real time, and the upper layer vision alignment device captures the upper layer alignment mark in real time. Based on the positional deviation between the lower and upper layer alignment marks, the path is finely adjusted. The lower and upper layer filter chip substrates enter the first and second composite pressure rollers simultaneously to be composited to obtain a composite chip array. The winding device then winds the chip up.

[0014] The continuous production method for high-efficiency cigarette filter chips according to the present invention, in a preferred embodiment, in step S1, the continuous production line for high-efficiency filter chips includes an upper filter chip roller and a lower filter chip roller arranged vertically, a first laser engraving machine, a lower vision alignment device, and a lower filter chip upper stamping die arranged sequentially in the unwinding direction of the lower filter chip roller, a lower filter chip lower stamping die arranged below the lower filter chip upper stamping die, a second laser engraving machine, an upper vision alignment device, and an upper filter chip upper stamping die arranged sequentially in the unwinding direction of the upper filter chip roller, a lower filter chip lower stamping die arranged below the upper filter chip upper stamping die, a first composite pressure roller and a second composite pressure roller arranged vertically behind the lower filter chip lower stamping die, a winding device located at the rear end of the first composite pressure roller, and a correction execution mechanism arranged in front of the first composite pressure roller and the second composite pressure roller; The alignment actuator moves the lower and upper filter chip substrates laterally or adjusts their positions forward and backward after mechanical imprinting to align them. The alignment actuator is either a lateral movement device or a rotatable guide roller.

[0015] In a preferred embodiment of the continuous production method of a high-efficiency cigarette filter chip according to the present invention, during laser engraving and mechanical imprinting in step S3, at least two rows and at least two columns of lower filter chip arrays are uniformly arranged on the lower filter chip substrate, and at least two rows and at least two columns of upper filter chip arrays are uniformly arranged on the upper filter chip substrate. The lower layer alignment mark is located between two adjacent rows of lower layer filter chip arrays and is located outside the lower layer filter chip array. All lower layer alignment marks are arranged in a row and are all the same distance from the edge of the lower layer filter chip substrate. The upper alignment marks are located between two adjacent rows of upper filter chip arrays and outside the upper filter chip array. All upper alignment marks are arranged in a row and are equidistant from the edge of the upper filter chip substrate.

[0016] In the continuous production method of a high-efficiency cigarette filter chip according to the present invention, as a preferred embodiment, in step S4, both the lower alignment mark and the upper alignment mark are circular. The positional deviations of the lower and upper alignment marks include: the deviation between the center distance of two adjacent lower alignment marks and the center distance of two adjacent upper alignment marks; the deviation between the center distance of the lower alignment mark and the adjacent lower filter chip and the center distance of the upper alignment mark and the adjacent upper filter chip; the deviation between the center distance of two adjacent rows of lower filter chip arrays and the center distance of two adjacent rows of upper filter chip arrays; the deviation between the distance from the center of the lower alignment mark to the edge of the substrate of the adjacent lower filter chip and the distance from the center of the upper alignment mark to the edge of the substrate of the adjacent upper filter chip; the deviation between the radius of the lower filter chip and the radius of the upper filter chip; and the deviation between the center distance of two adjacent lower filter chips in the same row of lower filter chip arrays and the center distance of two adjacent upper filter chips in the same row of upper filter chip arrays.

[0017] In the continuous production method of high-efficiency cigarette filter chips described in this invention, as a preferred embodiment, in steps S3 and S4, the speeds of the unwinding, laser engraving, stamping, and compounding rollers are all synchronized by a servo system, and the production speed of the continuous production line for high-efficiency filter chips is 1.0 ~ 5.0 meters / minute. In step S3, the first laser engraving machine and the second laser engraving machine perform pre-contour engraving on the area to be subsequently stamped. In step S4, the roll-to-roll dispensing machine performs non-contact dispensing at the center of the space formed by the four adjacent lower-layer filter chip bodies.

[0018] This invention provides a high-efficiency cigarette filter chip based on the principle of microfluidic dynamics.

[0019] This invention aims to solve the following three technical problems: 1) Solve the problems of low filtration efficiency and poor consistency: Overcome the limitations of traditional passive adsorption mode, and provide an active structured filter chip based on microfluidic dynamics to achieve efficient and consistent tar reduction and harm reduction.

[0020] 2) Solve the problem of continuous production of precision microstructures: Overcome the shortcomings of slow speed and high cost of single laser processing and difficulty in processing micron-level fine structures by single mold stamping, and provide a composite manufacturing method that combines high performance and high efficiency.

[0021] 3) Solve the problem of transforming laboratory-grade microfluidic devices into industrial applications: Transform high-performance microfluidic filtration structures into continuous rolls that can be industrially produced at high speeds, meeting the rigid requirement of seamless integration with existing high-speed cigarette equipment.

[0022] This invention aims to systematically resolve the core contradiction in existing cigarette filtration technology: the irreconcilable conflict between high-throughput continuous production and high-performance precision microstructure design.

[0023] The present invention has the following advantages: (1) This invention solves the problems of existing technologies that rely on physical adsorption, have limited filtration efficiency, and poor consistency. Existing solutions that add expanded plant particles (such as rice husks and corn cobs) to fiber substrates are low in cost, but their filtration mechanism is passive, relying on the physical adsorption of the particulate material. Moreover, the uniformity and stability of particle dispersion during high-speed production are difficult to guarantee, resulting in limited filtration effect and poor consistency. In contrast, the cigarette high-efficiency filter chip of this invention is a mass-produced product, which not only has good adsorption performance but is also stable.

[0024] (2) This invention solves the problem that continuous production cannot achieve active, structured precision filtration. Existing continuous production methods that use rotating multi-chamber wheels and other devices to inject particulate media into fiber bundles online can adapt to high-speed production and facilitate product diversification, but their core is still a simple mixing mode of "fiber bundle + discrete particles", which cannot achieve active, structured precision filtration based on microfluidic dynamics principles, and the efficiency has a fundamental bottleneck. This invention uses a composite layer of lower and upper filter chips. When flue gas enters the narrow microchannel between the lower and upper filter chips from the inlet, the flow velocity increases sharply. Due to inertia, the tar droplets and solid particles in the airflow cannot follow the airflow line sharply, thus deviating from the mainstream and impacting and adhering to the channel wall, thus being initially captured. Subsequently, the airflow changes direction under the guidance of a specific channel structure, and the separation of tar and other substances is achieved by centrifugal force. At the same time, the aerosol is condensed and dripped through the condensation deposition effect. Finally, the filtered gas enters the mouth through the filter rod wrapped with filter paper. This invention greatly improves filtration efficiency through a graded and selective physical capture mechanism.

[0025] (3) This invention solves the problem that high-performance structural filter rods cannot be manufactured continuously and at low cost. Existing solutions for preparing high-performance filter rod components with irregular structures such as "buffer chamber" and "deposition chamber" by injection molding can significantly improve the retention efficiency of harmful components by guiding the collision of smoke, but they rely on discrete injection molding processes, resulting in slow production cycles and high costs. They cannot meet the rigid requirements of the cigarette industry for continuous, high-speed production of cigarettes and seamless integration with existing high-speed cigarette machines.

[0026] (4) This invention provides a cigarette high-efficiency filter chip and its continuous production method that can transform laboratory-grade high-performance microfluidic filter structures into continuous roll forms that can be industrially produced at high speed in a high-precision, high-consistency and low-cost manner, thereby meeting the triple requirements of high-efficiency filtration, precision structure and large-scale continuous production at one time. Attached Figure Description

[0027] Figure 1 A schematic diagram showing the structure and operation of a high-efficiency cigarette filter chip located between tobacco and a filter rod; Figure 2 A schematic diagram showing the structure and operation of a high-efficiency cigarette filter chip located between two filter rods; Figure 3a A 3D view of a high-efficiency cigarette filter chip; Figure 3b A front view of a high-efficiency cigarette filter chip; Figure 3c A top view of a high-efficiency cigarette filter chip; Figure 3d A bottom view of a high-efficiency cigarette filter chip; Figure 4 This is a schematic diagram of the structure of a high-efficiency cigarette filter chip. Figure 5a This is a side view of a cigarette butt after it has been smoked. Figure 5b A top-down view of a cigarette butt after it has been smoked. Figure 5c This is a diagram showing the internal state of a cigarette butt after it has been smoked. Figure 5d A side view of a cigarette butt after the cigarette has been smoked, with a high-efficiency filter chip located between two filter rods. Figure 5e A top view of a cigarette butt after the cigarette has been smoked, with a high-efficiency filter chip located between two filter rods. Figure 5f This is a schematic diagram showing the internal state of a cigarette butt after it has been smoked, and the state of the high-efficiency filter chip, when the high-efficiency filter chip is located between two filter rods. Figure 6a A diagram showing the state of a regular cigarette after the tobacco and filter cotton have been assembled and smoked. Figure 6b This is a diagram showing the internal state of a conventional cigarette after the tobacco and filter cotton have been assembled. Figure 6c This is a schematic diagram showing the cigarette after it has been smoked, with a high-efficiency filter chip located between the tobacco and the filter rod. Figure 6d This is a schematic diagram of the internal state of a cigarette after it has been smoked, where a high-efficiency filter chip is located between the tobacco and the filter rod. Figure 7 A flowchart illustrating a continuous production method for a high-efficiency cigarette filter chip; Figure 8 A schematic diagram of a continuous production method for a high-efficiency cigarette filter chip; Figure 9 This is a diagram showing the processing state of the lower filter chip substrate in a continuous production method for a high-efficiency cigarette filter chip. Figure 10 This is a diagram showing the processing state of the upper filter chip substrate in a continuous production method for a high-efficiency cigarette filter chip. Figure 11 This is a schematic diagram of the dispensing process for a continuous production method of a high-efficiency cigarette filter chip.

[0028] Figure label: 1. Lower filter chip; 11. Lower filter chip body; 12. Air inlet; 13. Microchannel; 131. First microchannel; 132. Second microchannel; 2. Upper filter chip; 3. Cigarette; 31. Tobacco; 32. Filter rod; 33. Cigarette paper; 34. Filter tip paper; 35. Smoke; 41. Lower filter chip substrate; 42. First laser engraving machine; 43. Lower alignment mark; 44. Lower vision alignment device; 45. Upper die for stamping the lower filter chip; 46. Lower die for stamping the lower filter chip; 47. Roll material dispensing machine; 48. Dispensing array; 51. Upper filter chip substrate; 52. Second laser engraving machine; 53. Upper alignment mark; 54. Upper vision alignment device; 55. Upper die for stamping the upper filter chip; 56. Upper filter chip stamping die; 61. First composite pressure roller; 62. Second composite pressure roller; 63. Composite chip array; 64. Winding device; A. Preliminary collection channel; B. Centrifugal separation channel; C. Air outlet. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Example 1

[0030] A high-efficiency cigarette filter chip and its continuous production method are disclosed. The high-efficiency filter chip has a precise two-layer bottom structure, composed of a lower filter chip 1 and an upper filter chip 2 (e.g., Figure 1 , Figure 2As shown in the diagram, an irreversible three-dimensional microfluidic channel is formed. Its design abandons the traditional passive adsorption mode, achieving efficient filtration through active fluid manipulation. Specifically, during the combustion of tobacco 31 wrapped in cigarette paper 33 in cigarette 3, smoke 35 is generated. When the smoke 35 enters the narrow microchannel 13 between the lower filter chip 1 and the upper filter chip 2 from the air inlet 12, the flow velocity increases sharply. Larger tar droplets and solid particles in the airflow, due to inertia, cannot follow the airflow line sharply and thus deviate from the mainstream, impacting and adhering to the channel wall, thus being initially captured. Subsequently, the airflow direction is changed under the guidance of the specific channel structure of the microchannel 13, and tar and other substances are separated by centrifugal force. At the same time, the aerosol condenses and drips through the condensation deposition effect. Finally, the filtered gas enters the oral cavity through the filter rod 32 wrapped in filter paper 34. This graded and selective physical capture mechanism has far superior efficiency and consistency compared to traditional filter materials.

[0031] like Figures 3a-3d and Figure 4 As shown, the composite filter chip of this invention is a precise two-layer stacked structure, composed of a lower filter chip 1 and an upper filter chip 2 stacked in three-dimensional space. Its core structural features and assembly relationship are as follows: the lower filter chip 1 serves as the air intake and primary filtration layer, and the diameter of the lower filter chip body 11 is [missing information]. D 1. The inner diameter is equal to that of the filter paper 34 (taking a regular cigarette as an example). D 1 = 7.60 ± 0.10 mm), the thickness of the lower filter chip body 11 is T 1 ( T 1 = 0.10~0.30 mm), and its center has evenly distributed [missing information] along the center of the chip. n 12 circular air inlets (6-18 in diameter) R 1 = 0.15~0.20 mm; the distance between the center of the circular air inlet 12 and the center of the lower filter chip body 11. L 1 = 0.60~0.80 mm), and etched within the plane of the lower filter chip body 11. n 13 microchannels 13 (6-18 channels) radially distributed (width of microchannel 13) W 1 = 0.10~0.20 mm, depth H 1 = 0.10~0.20 mm), used for diverting and initially accelerating flue gas, the microchannel 13 includes a first microchannel 131 covered by the upper filter chip 2 and a second microchannel 132 not covered by the upper filter chip 2; the diameter of the upper filter chip 2 is D 2 (Taking regular cigarettes as an example, D 2 = 7.20 ± 0.10 mm), thickness is T 2 ( T2 = 0.10~0.30 mm), the flue gas flows through a complete "inlet-filter channel-outlet" path. The inlet 12, the lower surface of the upper filter chip 2, and the front end of the first microchannel 131 form the initial collection channel A. The first microchannel 131 and the lower surface of the upper filter chip 2 covering the first microchannel 131 form the centrifugal separation channel B. n second microchannels 132 and the upper surface of the lower filter chip body 11 located between the second microchannels 132 form the outlet C. The two layers of chips are pressed together by pressure rollers to finally form a chip with a predetermined thickness ( T 1+ T 2) Disk-shaped composite chip unit. This assembly is in the axial direction ( Figure 3a , 3b It presents a clear functional hierarchy on the plane ( Figure 3c , 3d The upper part, through the symmetrical arrangement of the microchannels 13 and the air inlet 12, forms an irreversible, continuous three-dimensional microfluidic channel that guides the flue gas through acceleration, swirling, confluence deposition, and deep filtration. All its key dimensions, including the width and depth of the microchannels 13, are consistent with these dimensions. W 1, H 1) 12-hole air inlet ( L 1) and aperture ( R 1) All parameters are controlled within micron-level tolerances to ensure consistency of hydrodynamic effects and repeatability of filtration efficiency. When the high-efficiency filter chip is positioned between the two filter rods 32, the effect before and after smoking a blank regular cigarette is tested (e.g., ...). Figure 5a , Figure 5b and Figure 5c (As shown) and the filtration effect after smoking a regular cigarette with a high-efficiency filter chip ( Figure 5d , Figure 5e and Figure 5f (As shown) for comparison. The flue gas test conditions were as follows: under the standard conditions specified in GB / T 22838.5—2024, a negative pressure was applied to the output end while maintaining a gas volumetric flow rate of 17.5 mL / s for a duration of 120.0±10 s, with environmental conditions controlled at 22±2°C and relative humidity of 60±5%. Comparison Figure 5a and Figure 5d It can be observed that after smoking a regular cigarette with a high-efficiency filter chip (C3), there is significant amount of e-liquid trapped at the filter chip location. (Comparison) Figure 5b and Figure 5e , Figure 5c and Figure 5f It can be observed that after a regular cigarette burns out, the filter rod 32 turns noticeably yellow; while after a regular cigarette 3 with a high-efficiency filter chip burns out, the filter rod 32 is significantly cleaner, demonstrating the effective retention of tar by the high-efficiency filter chip. This further proves that during smoking, tar, nicotine, and other substances in the smoke are effectively retained after passing through the high-efficiency filter chip.

[0032] When the high-efficiency filter chip is located between the tobacco shreds 31 and the filter rod 32, the filtration effect of a regular cigarette with the high-efficiency filter chip before and after smoking is as follows: Figures 6a-6d As shown, after a regular cigarette 3 with a high-efficiency filter chip is finished smoking, there is obvious e-liquid trapped at the filter chip position and the filter rod 32 is clean, indicating that the high-efficiency filter chip has a significant effect in trapping e-liquid.

[0033] This invention employs a continuous production process combining femtosecond laser etching and roll-to-roll die stamping (e.g., Figures 7-11 As shown), two parallel roll-to-roll paths process two layers of substrate (lower filter chip substrate 41 and upper filter chip substrate 51, both in roll shape, with a width of...). w 3, Figure 9 and Figure 10 The core process involves the following: the entire production line is propelled forward by the winding device 64 at the end. The roller speeds at each station (unwinding, laser processing, stamping, and lamination) are synchronized via a servo system to ensure the substrate remains taut and slip-free during transport. Typical continuous production speeds can be controlled within the range of 1.0 to 5.0 meters per minute. This speed range represents a proven balance: it ensures sufficient dwell time for the femtosecond laser to achieve micron-level precision machining while fully leveraging the capacity advantages of roll-to-roll stamping to meet the pace of industrial production.

[0034] Laser processing and die stamping are not independent operations, but rather follow an irreversible sequence of "laser calibration and micromachining first, followed by macroscopic die forming," and are tightly integrated spatially. For example... Figure 9 , Figure 10 As shown, for the lower filter chip 1, the laser does not only process the alignment marks. The core tasks are: (1) the first laser engraving machine 42 etches high-precision lower alignment marks 43 on the lower filter chip substrate 41; (2) precisely process the air inlet 12 and the precise contours of the complex radial microchannels 13; (3) as needed, pre-contour lines are drawn on the area to be formed by subsequent stamping to guide the material to flow precisely during stamping. For the upper filter chip, the core tasks are: (1) the second laser engraving machine 52 etches high-precision upper alignment marks 53 on the upper chip substrate 51; (2) as needed, pre-contour lines are drawn on the area to be formed by subsequent stamping to guide the material to flow precisely during stamping. Laser processing is performed using a laser etching machine: (1) precisely control the structure, including the size and aperture of the air inlet 12 ( R 1) The channel width of microchannel 13 ( W 1) and depth ( H 1); (2) Precisely control the relative position, including aligning the lower alignment mark 43 with the upper alignment mark 53: l 1 – l 2, - , - d1 – d2, - , - ,like Figure 9 , Figure 10 As shown, l 1 represents the center distance between the two lower-level alignment marks 43. l 2 represents the center distance between the two upper alignment marks 53. l 1' represents the center distance between the lower layer alignment mark 43 and the adjacent lower layer filter chip 1. l 2' represents the center distance between the upper alignment mark 53 and the adjacent upper filter chip 2. l 1'' represents the center-to-center distance between two adjacent rows of lower-layer filter chips 1. l 2'' represents the center-to-center distance between two adjacent upper-layer filter chips 2. d 1 represents the distance from the center of the lower alignment mark 43 to the edge of the adjacent lower filter chip substrate 41. d 2 represents the distance from the center of the upper alignment mark 53 to the edge of the adjacent upper filter chip substrate 51. d 1' represents the radius of the lower filter chip 1. d 2' represents the radius of the upper filter chip 2. The center-to-center distance between two adjacent lower-layer filter chips 1 in the same row. The center-to-center distance between two adjacent upper-layer filter chips 2 in the same row is used to achieve micron-level feature control.

[0035] Multiple sets of vision alignment devices: lower vision alignment device 44 and upper vision alignment device 54 capture the markings in real time and perform micron-level correction: during the laser processing stage, each chip layer has a unique lower alignment mark 43 and upper alignment mark 53 etched at a preset position in each repeating unit (chip) for real-time correction. The lower filter chip substrate 41 and the upper filter chip substrate 51 enter the die stamping unit, such as... Figure 8 As shown, the lower filter chip stamping upper die 45 and the lower filter chip stamping upper die 46 cooperate, and the upper filter chip stamping upper die 55 and the upper filter chip stamping upper die 56 cooperate. During high-speed continuous movement, the lower filter chip substrate 41 and the upper filter chip substrate 51 are mechanically stamped to form the main three-dimensional outline of the chip array (the circular outline of the chip edge) (lower filter chip body 11 and upper filter chip 2) in one step. This step is extremely efficient and lays the foundation for high production volume.

[0036] Before the lower layer filter chip substrate 41 and the upper layer filter chip substrate 51 enter the first composite pressure roller 61 and the second composite pressure roller 62, the lower layer vision alignment device 44 and the upper layer vision alignment device 54 (at least one group corresponding to one layer) will synchronously capture the alignment marks on their respective substrates. The image processing system calculates the positional deviation of the current interlayer marks in real time; the system drives the downstream correction actuator (such as a guide roller that can move or rotate slightly laterally) to fine-tune the path of the corresponding substrate in real time, ensuring that at the composite point, the microfluidic channels (air inlet 12, microchannel 13, oil storage cavity) of all layers achieve micron-level alignment accuracy (usually ≤ ±10μm).

[0037] The first composite pressure roller 61 and the second composite pressure roller 62 are the core units for aligning and hot-pressing the lower filter chip 1 and the upper filter chip 2. The first composite pressure roller 61 and the second composite pressure roller 62 adopt an upper and lower roller structure, with the main body made of carbon fiber composite material and a surface roughness Ra≤0.8 μm to ensure alignment stability during high-speed continuous production. Their key operating parameters are: roller pressure controlled at 0.3~1.0 MPa; operating temperature set within the window of the hot melt adhesive glass transition temperature Tg+10℃, to meet the hot melt adhesive curing requirements while avoiding film thermal deformation; and production line speed synchronized with the upstream imprinting and laser stations, maintained at 5~20 m / min. Furthermore, the circumferential runout of the first composite pressure roller 61 and the second composite pressure roller 62 should be ≤0.03 mm (at a rotation speed of 360 r / min), and the gap between the rollers should be equal to the designed total thickness of the lower filter chip 1 and the upper filter chip 2 ±10 μm. Real-time calibration is performed through an online visual alignment system and closed-loop pressure feedback to ensure that the composite accuracy is always within the micron-level tolerance range.

[0038] The completed roll-to-roll dispensing machine 47 performs precise micro-dispensing on the lower filter chip substrate 41 (e.g., ... Figure 11 As shown, the adhesive is precisely applied to the center of the space enclosed by four adjacent lower filter chip bodies 11; a high-precision dispensing machine 47 is used for non-contact jet dispensing to obtain a dispensing array 48. The diameter and dosage of each adhesive dot are strictly controlled to ensure that the adhesive diffusion range does not intrude into the functional area after lamination. Finally, precise lamination is completed at the first composite pressure roller 61 and the second composite pressure roller 62 to obtain a composite chip array 63, which is then wound up by a winding device 64 into a finished product after online inspection.

[0039] The core advantage of this invention lies in the design of a high-efficiency cigarette filter chip that is simple in structure, low in cost, and easy to manufacture continuously. Simultaneously, the aforementioned synergistic process perfectly resolves the fundamental contradiction between "efficiency" and "precision" in the industrialization of high-performance microstructures. Femtosecond laser technology achieves extreme precision control and final shaping of microscopic features. Die stamping undertakes efficient macroscopic forming, laying the foundation for high production volume. The seamless online integration of these two technologies, coupled with full-process visual alignment closed-loop control, enables for the first time the transformation of laboratory-level microfluidic chip design into industrial cigarette rolling products that can be directly applied to high-speed cigarette rolling machines in a highly consistent and low-cost manner, providing a completely new technological path for reducing tar and harm in cigarettes.

[0040] The composite filter chip design of this invention achieves efficient filtration of substances such as tar and nicotine in cigarette smoke, while also featuring simple structure, low cost, and ease of mass production.

[0041] The microfluidic chip material of the present invention can be selected from polymer materials such as PET and PI, which are easy to be precisely laser etched and stamped.

[0042] This invention utilizes a synergistic approach to composite processes: protecting the specific, irreversible process sequence of "first performing femtosecond laser precision feature processing and shaping, then performing roll-to-roll die imprinting to form the main body." This sequence is fundamental to leveraging the advantages (efficiency and precision) of both processes.

[0043] This invention employs a collaborative task allocation of "microscopic laser processing calibration + macroscopic imprinting": femtosecond lasers are explicitly responsible for alignment marking and micro-hole processing, precise control of channel depth, and critical dimension sizing, while roll-to-roll molds are used to imprint the three-dimensional contour of the filter valve unit body. This division of labor is the core breakthrough in overcoming the bottleneck of a single process.

[0044] This invention utilizes an online, buffer-free continuous production integration mode: a technical solution that directly connects the femtosecond laser processing unit and the roll-to-roll die imprinting unit online on a single production line (without intermediate roll-up or unrolling buffers). This is a key equipment layout for achieving truly high-speed continuous production and reducing production costs.

[0045] This invention utilizes a process window for die imprinting: During the composite process, the roll-to-roll die imprinting step is performed under a pressure of 0.3~1.0 MPa. This window is crucial for achieving stable body formation without damaging the film processing.

[0046] This invention provides an overall architecture for a multilayer composite roll material: the invention comprises a roll material structure formed by combining a lower filter chip 2 with an integrated microvalve array and an upper filter chip 1. This structure is a basic product form for realizing microfluidic functions and facilitating industrial processing and application.

[0047] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-efficiency cigarette filter chip, characterized in that: It includes a lower filter chip (1) and an upper filter chip (2); The lower filter chip (1) includes a lower filter chip body (11), and is connected to the lower filter chip body (11) and is evenly distributed circumferentially along the center of the lower filter chip body (11). n An air inlet (12) and a part connected to the surface of the lower filter chip body (11), one end of which communicates with the air inlet (12), and the other end extends along the radial direction of the lower filter chip body (11) towards the outer edge of the lower filter chip body (11). n One microchannel (13); The lower filter chip body (11) and the upper filter chip (2) are both circular sheet structures with their centers on the same axis. The upper filter chip (2) covers part of the microchannel (13). The microchannel (13) includes a first microchannel (131) covered by the upper filter chip (2) and a second microchannel (132) not covered by the upper filter chip (2). The air inlet (12), the lower surface of the upper filter chip (2), and the front end of the first microchannel (131) form a preliminary collection channel (A). The first microchannel (131) and the lower surface of the upper filter chip (2) covering the first microchannel (131) form a centrifugal separation channel (B). The n second microchannels (132) and the upper surface of the lower filter chip body (11) located between the second microchannels (132) form an air outlet (C). The centrifugal separation channel (B) is perpendicular to the preliminary collection channel (A), and its cross-sectional area is less than or equal to the cross-sectional area of ​​the preliminary collection channel (A). The high-efficiency filter chip is located between the tobacco (31) and the filter rod (32) or between two filter rods (32), and is wrapped by cigarette paper (33) or filter paper (34). The air inlet (12) faces the tobacco and is the inlet for the flow of smoke.

2. The cigarette high-efficiency filter chip according to claim 1, characterized in that: The flue gas enters the preliminary collection channel (A) from the air inlet (12) for diversion, preliminary acceleration and preliminary collection. In the centrifugal separation channel (B), the airflow direction is changed, and the material is separated by centrifugal force. The aerosol is condensed and dripped through the condensation deposition effect, and then enters the oral cavity through the air outlet along the filter rod (32). The material includes tar.

3. The cigarette high-efficiency filter chip according to claim 1, characterized in that: The diameter of the lower filter chip body (11) is equal to the inner diameter of the cigarette paper (33) and the inner diameter of the filter tip paper (34). The width of the microchannel (13) is less than or equal to the width of the air inlet (12) and the depth is less than the thickness of the lower filter chip body (11). The diameter of the upper filter chip (2) is smaller than the diameter of the lower filter chip body (11), and the lower filter chip (1) and the upper filter chip (2) are bonded together by pressure bonding.

4. The high-efficiency cigarette filter chip according to claim 1, characterized in that: The thickness of the lower filter chip body (11) is 0.10~0.30 mm. n The range is 6 to 18. The air inlet (12) is a circular through hole; The depth of the microchannel (13) is 1 / 3 to 1 / 2 of the thickness of the lower filter chip body (11), and the width of the microchannel (13) is 1 / 2 to 2 of the depth of the microchannel (13). The diameter of the upper filter chip (2) is 4 / 5 to 19 / 20 of the diameter of the lower filter chip body (11).

5. The cigarette high-efficiency filter chip according to claim 1, characterized in that: The lower filter chip (1) and the upper filter chip (2) are both made of plastic, and the high-efficiency filter chip is produced by continuous roll-to-roll production. At least two lower filter chip bodies (11) are processed on the lower filter chip substrate (41), and at least two upper filter chips (2) are processed on the upper filter chip substrate (51). Both the lower filter chip substrate (41) and the upper filter chip substrate (51) are rolled. The lower filter chip body (11) and the upper filter chip (2) are respectively engraved with outlines by mechanical imprinting. The air inlet (12) and the microchannel (13) are processed by laser etching with a processing error of ≤ ±10 μm. After applying adhesive to the area of ​​the lower filter chip substrate (41) outside the lower filter chip body (11), the upper filter chip substrate (51) is pressed onto the lower filter chip substrate (41) by a pressure roller, thereby pressing the upper filter chip (2) onto the lower filter chip (1) to obtain the high-efficiency filter chip.

6. A continuous production method for a high-efficiency cigarette filter chip according to any one of claims 1 to 5, characterized in that: Includes the following steps: S1. Assembly of a high-efficiency filter chip continuous production line, wherein the high-efficiency filter chip continuous production line is provided with traction power by a winding device (64) located at the end, which drives the unwinding and lamination of the lower filter chip substrate (41) and the upper filter chip substrate (51); S2. The lower filter chip substrate (41) is sleeved on the outside of the lower filter chip roller, and the upper filter chip substrate (51) is sleeved on the outside of the upper filter chip roller. Both the lower filter chip substrate (41) and the upper filter chip substrate (51) are roll-shaped substrates. S3. The high-efficiency filter chip continuous production line starts to operate. The lower filter chip roller and the upper filter chip roller start to unwind. The first laser engraving machine (42) etches the lower alignment mark (43) on the lower filter chip substrate (41) and processes the air inlet (12) and microchannel (13). Then the lower filter chip stamping upper mold (45) and the lower filter chip stamping lower mold (46) mechanically press the edge contour of the lower filter chip (1). Meanwhile, the second laser engraving machine (52) etches the upper alignment mark (53) on the upper chip substrate (51), and then the upper filter chip stamping upper mold (55) and the upper filter chip stamping lower mold (56) mechanically press the edge contour of the upper filter chip (2); S4. The roll-to-roll dispensing machine (47) dispenses adhesive onto the lower layer filter chip substrate (41). Simultaneously, the lower layer vision alignment device (44) captures the lower layer alignment mark (43) in real time, and the upper layer vision alignment device (54) captures the upper layer alignment mark (53) in real time. The path is finely adjusted according to the positional deviation between the lower layer alignment mark (43) and the upper layer alignment mark (53). The lower layer filter chip substrate (41) and the upper layer filter chip substrate (51) enter the first composite pressure roller (61) and the second composite pressure roller (62) simultaneously to form a composite chip array (63). The winding device (64) winds up the composite chip array.

7. The continuous production method of a high-efficiency cigarette filter chip according to claim 6, characterized in that: In step S1, the high-efficiency filter chip continuous production line includes an upper filter chip roller and a lower filter chip roller arranged vertically, a first laser engraving machine (42), a lower vision alignment device (44), and a lower filter chip stamping upper die (45) arranged sequentially in the unwinding direction of the lower filter chip roller, a lower filter chip stamping lower die (46) arranged below the lower filter chip stamping upper die (45), and a second laser engraving machine (52) arranged sequentially in the unwinding direction of the upper filter chip roller. The upper visual alignment device (54), the upper filter chip stamping upper die (55), the upper filter chip stamping lower die (56) located below the upper filter chip stamping upper die (55), the first composite pressure roller (61) and the second composite pressure roller (62) located behind the upper filter chip stamping lower die (56), the winding device (64) located at the rear end of the first composite pressure roller (61), and the correction execution mechanism located in front of the first composite pressure roller (61) and the second composite pressure roller (62); The correction mechanism moves the lower filter chip substrate (41) and the upper filter chip substrate (51) laterally or adjusts their positions forward and backward after mechanical imprinting, so that the lower filter chip (1) and the upper filter chip (2) are aligned. The correction mechanism is a lateral movement device or a rotatable guide roller.

8. A continuous production method for a high-efficiency cigarette filter chip according to claim 6, characterized in that: In step S3, during laser engraving and mechanical imprinting, at least two rows and at least two columns of lower filter chip arrays are evenly arranged on the lower filter chip substrate (41), and at least two rows and at least two columns of upper filter chip arrays are evenly arranged on the upper filter chip substrate (51). The lower alignment mark (43) is located between two adjacent rows of lower filter chip arrays and outside the lower filter chip array. All the lower alignment marks (43) are arranged in a row and are at the same distance from the edge of the lower filter chip substrate (41). The upper alignment mark (53) is located between two adjacent rows of upper filter chip arrays and outside the upper filter chip array. All the upper alignment marks (53) are arranged in a row and are at the same distance from the edge of the upper filter chip substrate (51).

9. A continuous production method for a high-efficiency cigarette filter chip according to claim 7, characterized in that: In step S4, both the lower alignment mark (43) and the upper alignment mark (53) are circular; The positional deviations of the lower alignment mark (43) and the upper alignment mark (53) include: the deviation between the center distance of two adjacent lower alignment marks (43) and the center distance of two adjacent upper alignment marks (53); the deviation between the center distance of the lower alignment mark (43) and the adjacent lower filter chip (1) and the center distance of the upper alignment mark (53) and the adjacent upper filter chip (2); and the deviation between the center distance of two adjacent rows of lower filter chip arrays and the center distance of two adjacent rows of upper filter chip arrays. Deviation, the deviation between the distance from the center of the lower alignment mark (43) to the edge of the adjacent lower filter chip substrate (41) and the distance from the center of the upper alignment mark (53) to the edge of the adjacent upper filter chip substrate (51), the deviation between the radius of the lower filter chip (1) and the radius of the upper filter chip (2), and the deviation between the center distance between two adjacent lower filter chips (1) in the same row of the lower filter chip array and the center distance between two adjacent upper filter chips (2) in the same row of the upper filter chip array.

10. A continuous production method for a high-efficiency cigarette filter chip according to claim 6, characterized in that: In steps S3 and S4, the speeds of the unwinding, laser engraving, stamping, and compounding rollers are synchronized by a servo system, and the production speed of the high-efficiency filter chip continuous production line is 1.0 ~ 5.0 meters / minute. In step S3, the first laser engraving machine (42) and the second laser engraving machine (52) perform pre-contour engraving on the area to be stamped later; In step S4, the roll material dispensing machine (47) performs non-contact dispensing at the center of the space formed by the four adjacent lower filter chip bodies (11).

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