Garniture Device Pneumatic Compaction for Multi-Segment Filter Rods
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Solution Overview
Problem
Existing methods for manufacturing multi-segment filter rods with loose materials, such as activated charcoal, often result in incomplete filling, leading to smoke bypass and deformation issues, and may cause contamination or occupy excessive space in manufacturing machines.
Innovation Solution
A machine with a garniture device that uses a feeding unit to arrange rod-like elements on a moving belt, where a filling unit supplies loose material into compartments between the elements, and a cleaning unit removes excess material, with a diameter adjustment mechanism to concentrate the loose material and prevent contamination, ensuring maximum filling without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pin is used to push the inner part of the segment into the charcoal segment to eliminate empty spaces, then the filling degree is improved, but the segments are deformed
Solution Approach 1:
The patent replaces the mechanical pin-based compaction system with a pneumatic system. A pneumatic compaction element (air cannon) delivers a controlled air jet into the charcoal segment to compact the loose material without mechanical contact, thereby achieving high filling degree without deforming the rod-like elements
Solution Approach 2:
The invention uses pneumatic pressure to compact the charcoal granulate. The air cannon generates a high-velocity air jet that penetrates the loose material and compacts it through pneumatic force, eliminating the need for mechanical pins and avoiding segment deformation while achieving near 100% filling
2Manufacturing precision
If granulate is introduced on two stations with pressing after each introduction, then the filling degree is improved, but the product is contaminated with granulate and dust and the machine occupies lots of space
Solution Approach 1:
The patent introduces all the loose charcoal material in advance into a single compartment formed by the rod-like elements before compaction occurs. This preliminary positioning of material eliminates the need for multiple introduction stations and subsequent pressing operations, reducing contamination risk and machine footprint
Solution Approach 2:
The invention extracts the filling operation from a multi-station process and consolidates it into a single compartment filling step. By taking out the material introduction step and performing it once before compaction, the system eliminates repeated handling that causes dust and granulate contamination
3Manufacturing precision
If multiple pressing stations are used to increase filling degree, then the filling completeness is improved, but the machine size increases and compactness is reduced
Solution Approach 1:
The patent merges the material introduction and compaction operations into a single integrated process step. All loose material is introduced into one compartment and then compacted in one operation using the air cannon, eliminating the need for multiple pressing stations and reducing machine size
Solution Approach 2:
The system performs preliminary material introduction into a confined compartment formed by the rod-like elements before compaction. This preliminary positioning allows subsequent single-stage pneumatic compaction to achieve high filling completeness without requiring multiple pressing stations
Data Source
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Figure 3
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AI summary
A garniture device for a machine used in tobacco industry for manufacturing a continuous rod (CR) comprising a loose material wrapped with a wrapper, wherein the garniture device comprises: a lower garniture part (7); a garniture duct (9) formed in the lower garniture part (7); a garniture belt movable in the garniture duct (9) for transporting the wrapper along the garniture duct (9); an upper garniture part (11) comprising wrappers (11a) for forming the wrapper (101) around the loose material; wherein the garniture duct (9) comprises: an inlet part for transforming the garniture belt from a flat configuration into a U-shaped configuration; a U-shaped part for guiding the garniture belt in the U-shaped configuration; an outlet part for transforming the garniture belt from the U-shaped configuration into the flat configuration; characterized in that: the U-shaped part of the garniture duct (9) comprises, at the side of the inlet part, a first section (9a) having a first diameter (D1) and, at the side of the outlet part, a second section (9b) having a second diameter (D2) being smaller than the first diameter (D1), wherein the first section (9a) is connected to the second section (D2) by a transition section (9c) having a surface of a variable diameter.