Adjustable Casting Blade for Homogeneous Tobacco Web
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Standard casting methods for homogenized tobacco material result in unintended variations and inhomogeneities due to inconsistencies in slurry properties, leading to defects in the cast web, which can cause issues in aerosol delivery and production efficiency in 'heat-not-burn' aerosol-generating articles.
Innovation Solution
A casting apparatus with adjustable actuators to control the distance between the casting blade and the movable support, ensuring uniform thickness and viscosity of the cast web, using a slurry comprising tobacco powder, cellulose pulp, binder, and aerosol-former, with sensors for real-time monitoring and feedback control to maintain optimal casting conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard casting methods are used to produce homogenized tobacco material webs, then the production process is simple and fast, but the cast web exhibits inhomogeneity and defects due to variations in slurry properties
Solution Approach 1:
The casting blade is made adjustable in its position relative to the support, allowing dynamic modification of the gap dimension. This enables adaptation to varying slurry properties (consistency, viscosity, fibre size, particle size, moisture) to maintain uniform web thickness and homogeneity despite slurry variations.
Solution Approach 2:
The gap dimension between the casting blade and support is modified as a process parameter to compensate for slurry property variations. By changing this parameter, the casting process can maintain consistent web quality even when slurry characteristics vary, directly addressing the inhomogeneity problem.
2Manufacturing precision
If the slurry viscosity and consistency vary, then the casting process can be completed quickly, but the cast web thickness becomes non-uniform leading to defects
Solution Approach 1:
The casting blade position is made dynamically adjustable to compensate for viscosity and consistency variations in real-time during casting, ensuring uniform web thickness without requiring slower casting speeds.
Solution Approach 2:
The gap dimension parameter is modified to account for slurry viscosity and consistency variations, allowing the casting process to maintain precision while operating at optimal speeds.
3Manufacturing precision
If the casting blade distance from support is fixed, then the apparatus is simple to operate, but variations in slurry properties cause unintended variations in web application
Solution Approach 1:
The casting blade is equipped with adjustable positioning mechanisms that allow modification of the gap dimension. This provides operators with control capability to compensate for slurry property variations, improving web application consistency while maintaining reasonable operational simplicity.
Solution Approach 2:
The gap dimension can be adjusted as a controllable parameter to compensate for slurry variations, giving operators the ability to maintain consistent web application despite changes in slurry properties.
4Strength
If inhomogeneous cast web is produced, then production continues without interruption, but the web suffers from tearing and rupture during handling and processing
Solution Approach 1:
By making the casting blade position adjustable, the process can produce more homogeneous webs with improved internal structure and bonding, thereby increasing tensile strength and reducing susceptibility to tearing and rupture during handling.
Solution Approach 2:
Modifying the gap dimension parameter improves web homogeneity, which directly enhances tensile strength and reduces defects that would cause tearing and rupture during subsequent handling and processing operations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention is relative to a casting apparatus for the production of a cast web of homogenized tobacco material, said casting apparatus comprising ⋅ a casting box adapted to contain a slurry of said homogenized tobacco material; ⋅ a movable support; ⋅ a casting blade adapted to cast said slurry contained in said casting box onto said movable support in order to form the cast web; ⋅ wherein said casting apparatus further comprises a first, a second and a third actuator coupled to said casting blade in a first, a second and third position, respectively, said first, second and third actuator being suitable to change a distance between said casting blade and said movable support in said first, second and third position, respectively.