Multi-segment Filter Assembly with Spreading Drum Gap Formation
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Solution Overview
Problem
Existing methods for producing multi-segment filters in the tobacco processing industry fail to maintain a consistent and precise size of the gaps or chambers between filter segments, leading to suboptimal filter properties due to varying gap volumes.
Innovation Solution
A method involving the formation of a stream of transversely axially conveyed filter segments, where one segment is moved longitudinally to create a defined gap, followed by transfer to a longitudinally axially conveyed filter train, with the use of a modular multi-segment filter assembly device and a spreading drum to maintain precise positioning and filling of the gap with filter material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If filter segments are assembled and then conveyed to a strand-forming device through multiple transfer steps, then the filter segments can be assembled into groups, but the distance between filter segments varies minimally causing gaps to not be completely filled with activated charcoal granules
Solution Approach 1:
The invention creates the gap between filter segments at the assembly device before transfer to the strand-forming device, rather than relying on subsequent positioning during conveyance. This preliminary gap creation ensures consistent spacing is established when the filter segments are still under precise control of the assembly mechanism, eliminating variability introduced by multiple transfer operations.
Solution Approach 2:
The gap creation function is extracted from the strand-forming process and integrated into the assembly device itself. By incorporating a gap-forming mechanism directly at the assembly station, the invention separates the gap creation step from the conveyance and filling operations, ensuring that gap dimensions are determined independently and precisely during assembly rather than being affected by subsequent handling.
2Ease of operation
If filter segments are conveyed through multiple transfer operations, then groups of filter segments can be formed and transferred to strand-forming device, but filter segments jump or change position resulting in imprecise gap formation
Solution Approach 1:
The invention performs preliminary positioning and gap creation at the assembly device before any transfer operations occur. By establishing the precise relative positions of filter segments and creating the gap during the assembly process itself, the system ensures that subsequent conveyance and transfer operations do not alter the predetermined spacing, as the gap structure is already locked in during assembly.
3Ease of manufacture
If gaps between filter segments are not precisely controlled, then the production process is simpler, but the filter properties do not correspond to optimal conditions due to incomplete filling with activated charcoal granules
Solution Approach 1:
The invention establishes precise gap dimensions during the assembly process itself, creating a predetermined spacing structure before the filling operation. This preliminary gap definition ensures that when activated charcoal granules are subsequently introduced, they are guaranteed to completely fill the gap space, as the gap boundaries are already precisely established and cannot shift during the filling process.
Solution Approach 2:
The invention replaces reliance on mechanical conveyance precision with a predetermined gap structure created during assembly. Instead of depending on the mechanical accuracy of multiple transfer devices to maintain consistent spacing, the system uses the assembly device to create fixed gap dimensions that are independent of subsequent mechanical handling, thereby ensuring consistent filter performance.
Data Source
AI summary
The invention relates to a method for manufacturing multi-segment filters for the tobacco processing industry. The invention further relates to a multi-segment filter manufacturing device (1) with a multi-segment filter assembly device (10) configured to assemble groups of filter segments (15, 16) during transverse axial conveying, wherein a transfer device (14) is provided which transfers the assembled groups of filter segments to a strand forming device (11), the strand forming device conveying the groups of filter segments longitudinally axially.The method according to the invention provides that a stream of transversely axially conveyed groups of filter segments is first formed, which are arranged longitudinally axially aligned with one another, wherein a gap (17) is then formed in the group of filter segments by longitudinally axial displacement of at least one filter segment, and wherein the group of filter segments provided with the gap is subsequently transferred into a longitudinally axially conveyed filter strand (18). The device according to the invention is characterized in that the transfer device comprises a spreading drum (31) by means of which a gap is formed or can be formed in the formed group of filter segments.