Filter Rod Manufacturing Thread Impregnation Consistency
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Solution Overview
Problem
The existing filter rod manufacturing machines experience variation in the impregnated amount of additive liquid due to direct contact between the additive-impregnated thread and thread guides/nozzles, leading to inconsistent additive content in filter rods.
Innovation Solution
The thread member is fed into the filter tow downstream of the merging position, and the additive liquid is discharged internally within the filter tow, eliminating the need for thread guides/nozzles, thus preventing liquid compression and ensuring consistent impregnation. The thread feed-out nozzle and liquid supply nozzle are positioned to discharge the liquid inside the wrapping section, minimizing contact and ensuring uniform impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the additive-impregnated thread slidingly contacts the thread guide and thread nozzle to be fed into the filter tow, then the thread can be accurately guided and fed, but the additive liquid is squeezed from the thread causing variation in impregnated amount
Solution Approach 1:
The patent removes the thread guide and thread nozzle components from the system. Instead of guiding the additive-impregnated thread through mechanical guides that squeeze the liquid, the thread is fed directly into the filter tow using a feed-out unit that eliminates intermediate contact points, thereby preventing additive liquid loss while maintaining feeding accuracy
Solution Approach 2:
The filter tow itself serves as an intermediary medium. The additive-impregnated thread is fed directly into the filter tow material, which acts as a protective matrix that receives the thread without requiring separate guiding components that would compress and squeeze the additive liquid from the thread
2Measurement precision
If thread guides and thread nozzle are used to feed the additive-impregnated thread, then the thread can be accurately positioned, but the additive liquid adheres to these mechanical components causing loss and variation
Solution Approach 1:
The patent extracts and eliminates the thread guide and thread nozzle components that cause additive liquid adhesion and loss. The feed-out unit directly feeds the impregnated thread into the filter tow without intermediate mechanical guides, preventing substance loss to components
Solution Approach 2:
The patent applies local quality by creating a localized feeding zone where the additive-impregnated thread is directly introduced into the filter tow material. This localized approach ensures the additive liquid remains confined to the thread-filter tow interface rather than being exposed to and lost on extended mechanical guiding components
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 configuration effectively reduces variation in the impregnated additive liquid amount per filter rod, enhancing the quality and consistency of filter rods by preventing liquid loss and adherence to mechanical components.
Implementation Method 1
a liquid supply nozzle (86) extending along the thread feed-out nozzle (76) to supply a propylene glycol-based liquid to be impregnated into the thread member (S)
Implementation Method 2
supply an additive liquid to be impregnated into the thread member (S)
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A manufacturing machine carrying out a filter rod manufacturing method of the present invention includes: a thread feed-out end (80) located more downstream than a merging position (MP) where a filter tow (T) and a paper web (PW) are merged together in a process of forming a tow rod (TR) from the filter tow (T) and the paper web (PW); a thread feed-out nozzle (76) for feeding a thread member (S) from the thread feed-out end (80) into the filter tow (T) inside the tong (54); and a liquid discharge outlet (88) located more downstream than the thread feed-out end (80), and further includes a liquid supply nozzle (86) for discharging a flavor liquid (L) from the liquid discharge outlet (88) toward the thread member (S) in a manner as to impregnate the flavor liquid (L) into the thread member (S).