Filter Tow Bale Packaging with Cushioning Sleeve
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Solution Overview
Problem
Current packaging methods for filter tow material result in high failure rates and quality defects during the production of filter rods, due to excessive compressive forces and strapping, leading to uneven prestressing and tensile strength fluctuations, and the risk of bale bursting after release from the baling press.
Innovation Solution
A method involving the production of a compressed filter tow bale wrapped with an airtight packaging sleeve, where the sleeve closely adjoins the bale to minimize air volume and absorb the elastic restoring force, reducing the risk of bursting and allowing for predictable expansion, thereby maintaining bale integrity and stackability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If filter tow material is highly compacted in the baling press, then bale density and transport efficiency are improved, but the risk of bale bursting increases due to excessive elastic restoring force
Solution Approach 1:
The patent applies beforehand cushioning by providing a cushioning element between the packaging sleeve and the filter tow material before the compression process. This cushioning element absorbs part of the elastic restoring force that arises during decompression, preventing the bale from bursting while still allowing high compaction densities to be achieved.
Solution Approach 2:
The cushioning element acts as an intermediary between the packaging sleeve and the filter tow material. It mediates the interaction during compression and decompression, distributing the elastic restoring force and preventing direct contact that would cause bursting, thus enabling reliable high-density baling.
2Stability of the object's composition
If additional strapping or packaging materials are used to secure the bale, then bale stability during transport is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the need for additional strapping or complex packaging materials by using a cushioning element that inherently stabilizes the bale during transport. The cushioning element alone provides sufficient stability, eliminating the requirement for separate strapping systems or additional packaging layers.
Solution Approach 2:
The cushioning element serves multiple functions: it prevents bale bursting during decompression, maintains bale stability during transport, and eliminates the need for additional strapping. This multi-functionality reduces overall packaging complexity while achieving both protection and stability.
3Volume of moving object
If compressive force during baling is increased to reduce bale volume, then transport efficiency is improved, but quality defects occur due to excessive prestressing
Solution Approach 1:
By placing the cushioning element beforehand, the system allows higher compressive forces to be applied during baling without damaging the filter tow material structure. The cushioning element protects the material during compression and absorbs the elastic restoring force during decompression, preventing quality defects while achieving reduced bale volume.
4Reliability
If packaging sleeve is positioned farther from the bale to allow expansion, then bale integrity is maintained, but air volume increases leading to unstable stacking
Solution Approach 1:
The cushioning element enables the packaging sleeve to remain in close contact with the bale (minimal air volume) while still preventing bursting. The cushioning absorbs the elastic restoring force, allowing the sleeve to be positioned tightly without creating the instability that would result from large air gaps, thus enabling stable stacking.
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
The method significantly reduces the failure rate of filter tow bales to less than 1%, ensures consistent quality, and allows for safe stacking and transport without additional strapping or packaging materials, maintaining the conventional press throughput.
Implementation Method 1
the packaging sleeve is applied to the compressed filter tow material in such a way that the packaging sleeve absorbs the elastic restoring force
Data Source
AI summary
The present invention relates to a method for producing a packed bale of highly compacted filter tow material. A compressed filter tow bale is first provided in cuboid shape in a baler. Then the compressed filter tow bale is packaged, having an air-tight packaging sleeve fully enclosing the compressed filter tow bale. According to the invention, the packaging sleeve is applied to the compressed filter tow bales such that at least 80%, preferably at least 90% and more preferably at least 95%, of the packaging sleeve is directly adjacent to the highly compacted filter tow material and touches, or is at least spaced less than 15 mm from, the highly compacted filter tow material.