Filter Element Sensor Analysis for Defect Detection

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Solution Overview

Problem

Existing systems for manufacturing filter rods in smoking articles are limited in detecting defective objects, such as missing, misoriented, or ruptured elements, which can lead to defective products reaching consumers, and require contrasting shades or colors for inspection, failing to address the variety of objects and defects effectively.

Innovation Solution

A system and method for analyzing filter elements using sensor means to determine object insertion status, including presence, absence, proper, or defective insertion, employing sensor elements and an analysis unit to generate indicia corresponding to the object insertion status, capable of detecting various objects without relying on specific attributes like contrasting shades or colors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensor means are used to detect objects in filter elements, then detection capability is improved, but the system requires contrasting shades or colors which limits the variety of detectable objects

Engineering Contradiction:

Improvedetection capabilityVSAvoidvariety of detectable objects

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent changes the detection parameter from optical properties (color, shade) to physical properties (density, mass) by using sensor means that measure these alternative parameters. This allows detection of objects regardless of their visual characteristics, thereby detecting a broader variety of objects including those with similar colors to the filter material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the optical inspection system with a sensor-based detection system that uses physical measurement principles (density, mass sensing) instead of optical detection. This substitution enables detection of objects based on their physical properties rather than visual contrast, expanding the range of detectable objects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If inspection systems detect defective objects, then product quality is improved, but defective products may still reach consumers due to limited detection of various defect types

Engineering Contradiction:

Improveproduct qualityVSAvoiddetection of various defect types

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent employs sensor means with multi-functional detection capabilities that can identify multiple types of defects (missing objects, misoriented objects, ruptured objects) using a single detection system. This universal detection approach improves reliability by comprehensively detecting various defect types that would otherwise require multiple specialized inspection systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent detects defects by measuring physical parameters (density variations, mass changes) rather than relying on visual inspection. This parameter change enables detection of subtle defects such as ruptured objects or misoriented objects that may not be visually apparent, thereby improving product quality and reducing defective products reaching consumers.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple types of objects are inserted into filter elements, then product versatility is improved, but detection of defective objects becomes more difficult

Engineering Contradiction:

Improvevariety of objectsVSAvoiddetection of defective objects

Core Design Contradiction:

Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent detects objects and defects by measuring physical parameters (density, mass) that are independent of the object's visual or material composition. This approach maintains detection effectiveness across a variety of object types (capsules, pellets, strands, beads) because the detection method relies on physical properties common to all objects rather than object-specific characteristics.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces visual inspection methods with sensor-based physical measurement systems that can detect objects regardless of their material composition or visual appearance. This substitution enables consistent detection across diverse object types, maintaining detection difficulty at acceptable levels even as product versatility increases.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2249670B1System for analyzing a filter element associated with a smoking article, and associated method

Publication Date: 2019.05.15 R J REYNOLDS TOBACCO COMPANY

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AI summary

A system and associated method for analyzing a filter element of at least one of a filter rod and a smoking article is provided. At least one sensor element is adapted to interact with the filter element so as to determine an object insertion status with respect thereto and to generate an output signal in response. The object insertion status includes at least one of an object presence within the filter element, an object absence from the filter element, a proper insertion of an object into the filter element, a defective insertion of an object into the filter element, a proper object within the filter element, and a defective object within the filter element. An analysis unit is in communication with the at least one sensor element and responsive to the output signal therefrom to generate an indicia corresponding to the object insertion status.