Composite Filter Manufacturing with Integrated Heterogeneous Particles

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Solution Overview

Problem

The manufacturing process for composite filters with heterogeneous materials is complex, leading to variations in physical properties and increased time and cost, due to the need for multiple processes and wrappers.

Innovation Solution

A filter manufacturing method involving a first filter segment with heterogeneous material particles, a second filter segment, and a wrapper that aligns them longitudinally, with the particles injected at preset intervals, simplifying the process and reducing physical property variations and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If composite filters are manufactured by bonding separate filters (one with filtering material, one with heterogeneous material), then the filter includes heterogeneous material, but the manufacturing process becomes complicated and variations in physical properties increase

Engineering Contradiction:

Improveinclusion of heterogeneous materialVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the filtering material and heterogeneous material into a single integrated filter element rather than bonding separate filters. The heterogeneous material particles are distributed within the filter material matrix, creating one unified structure that performs both filtration and heterogeneous material delivery functions simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filter is divided into multiple segments along its longitudinal axis, where each segment contains heterogeneous material particles at different positions. This segmentation allows for controlled distribution of heterogeneous material while maintaining manufacturing simplicity through a single continuous filter structure.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If composite filters are manufactured by bonding separate filters, then the filter includes heterogeneous material, but manufacturing time and cost increase

Engineering Contradiction:

Improveinclusion of heterogeneous materialVSAvoidmanufacturing time and cost

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges the manufacturing of filtering material and heterogeneous material into a single process step. Heterogeneous material particles are injected into the filter tow during the filter manufacturing process itself, eliminating the need for separate filter manufacturing and bonding operations, thereby reducing manufacturing time and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Heterogeneous material particles are injected into the filter tow at predetermined positions before the filter is completed. This preliminary action allows for precise placement of heterogeneous material during the main manufacturing process, avoiding later assembly steps and reducing overall manufacturing time.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If multiple wrappers are used to wrap separate filter segments, then each segment is protected, but manufacturing cost and energy consumption increase

Engineering Contradiction:

Improvefilter segment protectionVSAvoidenergy consumed to form perforations

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent uses a single wrapper to enclose the entire filter element instead of multiple wrappers for separate segments. This unified wrapping approach reduces the number of perforations needed (since only one wrapper requires perforations for aerosol passage) and lowers both material cost and energy consumption associated with forming multiple sets of perforations.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240196964A1Filter, an aerosol-generating article comprising the same, and a method of manufacturing the filter

Publication Date: 2024.06.20 KT&G CO LTD

AI summary

A filter included in an aerosol-generating article, according to embodiments, includes a first filter segment including a first filter element in which at least one heterogeneous material particle is contained, a second filter segment including a second filter element, and a wrapper wrapping the first filter segment and the second filter segment, wherein the first filter segment and the second filter segment are aligned in a longitudinal direction of the filter, and the first filter segment and the second filter segment are not physically separated.