Corrugated Cigarette Filter Sheet with Perforations
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Solution Overview
Problem
Existing cigarette filters do not provide consistent airflow or effective prevention of filler loss during hand rolling, as they lack a corrugated design with perforations, leading to inconsistent results and filler leakage.
Innovation Solution
A corrugated filter sheet with perforations that can be easily rolled into a cylinder, serving as both a tip and a plug to maintain airflow and prevent filler loss, integrated with pre-gummed rolling paper for seamless hand rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-sized cotton or fiber filter is used, then the filter can prevent filler loss during packing, but it is not readily adaptable to hand rolling cigarettes and does not provide consistent airflow
Solution Approach 1:
The filter is designed as a flat sheet with perforations that can be easily segmented or divided into sections, making it adaptable to hand rolling while maintaining its filtering function. The perforations allow the sheet to be easily formed into a roll shape without requiring pre-sized molded filters.
Solution Approach 2:
The filter transitions from a pre-sized molded shape to a flat sheet configuration with specific dimensional parameters (length, width, thickness) that allow it to be easily manipulated during hand rolling while still providing effective filtering and consistent airflow when formed.
2Ease of operation
If a rectangular piece of paper is rolled into a cylinder to form a tip, then it can serve as a disposable tip, but it lacks the corrugated design needed for consistent airflow and effective filler containment
Solution Approach 1:
The flat sheet filter is formed into a cylindrical shape during hand rolling, creating a curved three-dimensional structure that provides consistent airflow channels while maintaining the disposable tip function. The curvature of the rolled cylinder ensures uniform smoke distribution.
Solution Approach 2:
The filter sheet incorporates specific local features such as perforations and varying thickness in different areas to optimize both airflow consistency and filler containment, while maintaining overall simplicity for disposable use.
3Reliability
If the zigzag or accordion method is used to contain tobacco, then it can prevent filler loss during packing, but it requires folding back and forth which complicates the structure and does not completely stop filler from falling out
Solution Approach 1:
The filter design extracts the essential function of filler containment from the complex zigzag folding structure and achieves it through a simpler flat sheet configuration with perforations that guide the rolling process and maintain filler containment without requiring back-and-forth folding.
Solution Approach 2:
Instead of using complex folding structures to contain filler, the invention inverts the approach by using a flat sheet that is rolled into a cylinder, where the rolling action itself provides the containment function while the perforations guide the process and maintain structure.
4Reliability
If a corrugated filter sheet with perforations is used, then consistent airflow and filler loss prevention are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The filter utilizes a corrugated structure with inherent porosity and perforations that create consistent airflow channels. The porous nature of the corrugated design allows for uniform smoke distribution while the structure itself provides the framework for easy manufacturing through standard sheet forming processes.
Data Source
AI summary
A backing with corrugations on a first surface. The corrugations are parallel and each has an airspace along an entire longitudinal length. A second surface of the backing includes perforations or scores oriented perpendicularly or parallel to the corrugations. The corrugations or scores are fold lines or frangible tear lines. The airspaces may also include a filter material. The second surface of the backing may be adhered to a corner of a rolling paper on the surface but opposite edge as a gum strip. The corrugations are parallel to the gum strip.