Crimped Sheet Material Dispensing Apparatus
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Solution Overview
Problem
Existing apparatus for supplying crimped sheet material to filter making devices lacks flexibility in producing various types and properties of filters, limiting productivity and cost efficiency.
Innovation Solution
An apparatus that includes a winding unit, crimping unit, dispensing unit for adding particulate add-on materials, and a control unit, allowing for flexible processing of different sheet materials and add-on materials to be integrated into the crimping structure before forming filters, with features like adjustable crimping rollers and a cutting unit for varying sheet material width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the outlet of the crimping unit is arranged to directly feed the crimped paper to the filter making device, then the apparatus structure is simple, but the flexibility for producing different types of filters is limited
Solution Approach 1:
The apparatus is divided into separate functional units: a crimping unit for creating crimped structures, a dispensing unit for adding particulate materials, and a rod forming device. This segmentation allows each unit to be independently controlled and configured for different filter types, enhancing flexibility without requiring complete redesign of the entire system.
Solution Approach 2:
The control unit dynamically adjusts the operation of various units based on sensor signals and production requirements. The system can adapt its operation in real-time to produce different types of filters by controlling the crimping parameters, dispensing rates, and rod forming conditions, providing flexibility without permanent structural changes.
2Reliability
If add-on material is added before crimping, then the processing sequence is simple, but the add-on material is not retained in the crimped structures
Solution Approach 1:
The crimping operation is performed first to create the crimped structures in the sheet material. Then, the dispensing unit adds particulate add-on materials to these pre-formed crimped structures. This preliminary crimping action creates retention sites that effectively hold the add-on materials, ensuring they remain in place during subsequent rod forming and cutting operations.
Solution Approach 2:
The crimped structures act as an intermediary element between the sheet material and the add-on materials. The crimping process creates physical structures (folds, creases, or three-dimensional forms) that serve as receptacles or anchoring points for the particulate materials, mediating the retention mechanism without requiring direct bonding between the sheet material and add-on materials.
3Adaptability or versatility
If the apparatus is designed for high productivity, then output increases, but the ability to meet variety of consumer needs decreases
Solution Approach 1:
The apparatus is designed with multi-functional capabilities through its modular structure. The same crimping unit, dispensing unit, and rod forming device can produce different types of filters by adjusting operational parameters rather than requiring separate dedicated equipment for each filter type. This universality allows the system to meet diverse consumer needs while maintaining high productivity through continuous operation.
Solution Approach 2:
The control unit enables rapid adjustment of operational parameters such as crimping depth, frequency, particulate material type and quantity, and rod forming conditions. By changing these parameters rather than reconfiguring the entire apparatus, the system can quickly adapt to produce different filter varieties while maintaining high output levels, resolving the contradiction between versatility and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances flexibility and productivity by allowing the production of a wide variety of filter types and properties, reducing costs by utilizing crimped sheet material effectively and maintaining particulate add-on material retention within the crimped structure.
Implementation Method 1
a crimping unit for crimping the sheet material
Implementation Method 2
a dispensing unit for adding a particulate add-on material to the sheet material
Implementation Method 3
the add-on material or at least a substantial amount thereof is retained in or on the crimped structures
Data Source
Figure 1
Figure 2~3
AI summary
An apparatus for supplying a continuous web of crimped sheet material to a rod forming device comprises: - a winding unit (3) for unwinding the sheet material from a bobbin (21) on which the sheet material is provided, - a crimping unit (7) for crimping the sheet material, - a dispensing unit (8) for adding a particulate or liquid add-on material to the sheet material, and - a control unit (9) for controlling the various units of the apparatus in response to sensor signals received from the respective units. The dispensing unit (8) is arranged downstream of the crimping unit (7) when viewed in the direction of transport of the sheet material, and upstream of the rod forming device to which the crimped sheet material is supplied.