Filter Cigarette Perforation with Dual Laser Patterns
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Solution Overview
Problem
Existing methods for producing filter cigarettes lack variability in perforation, which restricts the customization and quality control of filter cigarettes during the manufacturing process.
Innovation Solution
A method involving a filter attachment machine with two perforation devices and a series of conveyor drums that allows for the transverse axial conveying of tobacco rod-filter plug-tobacco rod groups, enabling the creation of two parallel rows of single-length filter cigarettes with independently controlled perforation patterns, followed by testing and further perforation to ensure consistent quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single perforation device is used in existing filter cigarette production methods, then the manufacturing process is simple, but the perforation variability and customization capability are limited
Solution Approach 1:
The single perforation operation is segmented into two distinct perforation devices: a first perforation device that creates a first perforation pattern on the tobacco rod-filter plug-tobacco rod group, and a second perforation device that creates a second perforation pattern on the individual filter cigarettes. This segmentation enables different perforation patterns to be applied at different stages of production, increasing perforation variability and customization capability while maintaining manageable device complexity through modular design
Solution Approach 2:
The first perforation device performs preliminary perforation on the assembled tobacco rod-filter plug-tobacco rod group before the final cutting and individual cigarette formation. This preliminary action allows the filter plug and tobacco rods to be pre-perforated in a coordinated pattern, which is then refined by the second perforation device on individual cigarettes, enabling progressive customization throughout the manufacturing process
2Productivity
If double-length tobacco rod-filter plug-tobacco rod groups are cut into single-length filter cigarettes, then the production efficiency is high, but the coordination of perforation patterns across multiple cigarettes becomes complex
Solution Approach 1:
The first perforation device performs preliminary perforation on the assembled tobacco rod-filter plug-tobacco rod group before the final cutting and individual cigarette formation. This preliminary action allows the filter plug and tobacco rods to be pre-perforated in a coordinated pattern, which is then refined by the second perforation device on individual cigarettes, enabling progressive customization throughout the manufacturing process
Solution Approach 2:
A testing device is positioned between the first and second perforation devices to measure properties such as draw resistance and ventilation of the preliminarily perforated groups. This feedback information is used to adjust and optimize the second perforation device's operation, ensuring that the final perforation patterns on individual cigarettes achieve the desired coordination and performance characteristics while maintaining high production efficiency
3Reliability
If perforation is performed only at the final stage, then the process is simple, but the quality control and testing opportunities are limited
Solution Approach 1:
The first perforation device performs preliminary perforation on the assembled tobacco rod-filter plug-tobacco rod group before the final cutting and individual cigarette formation. This preliminary action allows the filter plug and tobacco rods to be pre-perforated in a coordinated pattern, which is then refined by the second perforation device on individual cigarettes, enabling progressive customization throughout the manufacturing process
Solution Approach 2:
A testing device is positioned between the first and second perforation devices to measure properties such as draw resistance and ventilation of the preliminarily perforated groups. This feedback information is used to adjust and optimize the second perforation device's operation, ensuring that the final perforation patterns on individual cigarettes achieve the desired coordination and performance characteristics while maintaining high production efficiency
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
This approach allows for variable and precise perforation of filter cigarettes, enhancing customization and quality control by creating filter cigarettes with two distinct perforation patterns and ensuring consistent ventilation and draw resistance, thereby improving the manufacturing process.
Implementation Method 1
EP-A-0 659 354 there is shown a machine for perforating filter rods, the perforation being carried out with the aid of a laser
Data Source
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AI summary
The method involves conveying a tobacco rod-filter plug-tobacco rod-groups (30) to conveyor units of a filter attaching machine (F) in cross-axial manner. The conveyed tobacco rod-filter plug-tobacco rod-groups are individually provided with two, longitudinal axially spaced perforation patters (M1) by a perforation unit (152). The tobacco rod-filter plug-tobacco rod-groups are sectioned before and afterwards in plainly long filter cigarettes (30.1,30.2), so that two parallel rows of cross-axially arranged plainly long filter cigarettes are formed. An independent claim is included for a machine for tobacco processing industry, particularly filter attaching machine.