Automated Cigarette Manufacturing Apparatus for Small Batch Production

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Solution Overview

Problem

Existing methods for manufacturing cigarettes are inefficient in producing small quantities of consistent quality, requiring significant skill, time, and equipment, and often result in cigarettes with varying smoking characteristics.

Innovation Solution

An automated cigarette manufacturing apparatus that forms a finite length cigarette rod, which is then cut into individual cigarettes, allowing for the production of small lots of cigarettes with consistent quality and customizable tobacco blends, filters, and wrapping papers, enabling efficient manufacturing of different smoking characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional automated cigarette-making machines are used, then large quantities of cigarettes can be produced efficiently, but they are unsuitable for manufacturing small quantities with consistent quality

Engineering Contradiction:

Improveproduction efficiencyVSAvoidflexibility for small batch production

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent divides the cigarette manufacturing process into separate functional modules: a tobacco filler delivery system, a wrapper delivery system, a rod forming mechanism, and a cutting mechanism. This segmentation allows each module to be independently controlled and optimized for small batch production while maintaining overall production efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs dynamic control systems that allow the manufacturing parameters (such as tobacco filler amount, wrapper length, and rod formation speed) to be adjusted in real-time based on the desired batch size and cigarette specifications, enabling consistent quality across varying production quantities.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If hand-rolling methods are used, then consumers can produce a variety of cigarettes with different characteristics, but the process requires significant skill, time, and specialized equipment

Engineering Contradiction:

Improvecustomization capabilityVSAvoidequipment and skill requirements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent designs an automated system that performs all manufacturing operations without requiring operator skill for tobacco handling, rod formation, or cutting. The machine autonomously controls tobacco filler delivery, wrapper application, and cutting operations, eliminating the need for specialized hand-rolling skills while maintaining customization capability through programmable parameters.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical hand-rolling operations with automated mechanical systems including a controlled tobacco filler delivery mechanism, an automated wrapper forming system, and a precision cutting mechanism, thereby reducing both skill requirements and equipment complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If conventional machines produce cigarettes, then consistent quality can be achieved, but cigarettes from different packs have varying smoking characteristics

Engineering Contradiction:

Improvequality consistencyVSAvoidsmoking characteristic uniformity

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal manufacturing platform that can produce cigarettes with consistent quality across different tobacco blends, wrapper types, and filter configurations. The system's multi-functional capability allows it to maintain precise control over rod formation and cutting parameters regardless of the specific cigarette variant being produced, ensuring uniform smoking characteristics across all packs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If automated cigarette-making machines are used, then production efficiency is high, but the ability to produce small lots with customizable characteristics is limited

Engineering Contradiction:

Improvemanufacturing speedVSAvoidcustomization for small batches

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent utilizes parameter change capability to allow rapid adjustment of manufacturing settings including tobacco filler quantity, wrapper dimensions, rod formation speed, and cutting length. These parameter adjustments enable the system to efficiently produce small batches of customized cigarettes without sacrificing production speed, as the automated system can quickly reconfigure parameters through programmable control.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7677251B2Apparatus and methods for manufacturing cigarettes

Publication Date: 2010.03.16 R J REYNOLDS TOBACCO COMPANY

AI summary

An apparatus and method for manufacturing small quantities of cigarettes provides for such manufacture in a substantially simultaneous fashion while maintaining consistent quality between the cigarettes. The apparatus and method provide for delivering at least one charge of tobacco filler from a supply of tobacco filler onto a predetermined length of wrapping paper in a garniture. The wrapping paper can be formed about the charge of tobacco filler by a forming mechanism in the garniture to form a cigarette rod having a finite length. The formed cigarette rod can then be transferred to a cutting device where, in a separate step, the cigarette rod can be cut into a plurality of individual cigarettes. The cigarettes may have filter elements attached, and may be packaged for a consumer. The filter element and tipping paper can provide for air dilution of the cigarettes.