Continuous Granular Filter Rod Forming via Negative Pressure Adsorption
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Solution Overview
Problem
Existing cigarette making and filter rod forming machines are unable to produce fully granular cigarette/filter rods through continuous forming of reconstituted tobacco granules or filter rod granule additives, leading to increased production and use costs.
Innovation Solution
A device comprising a mesh conveyor belt with sequentially mounted feeding, pre-forming, curing, and cooling/drying apparatuses, utilizing negative pressure, water-containing hot air, and adjustable microwave heating to continuously form fully granular cigarette/filter rods by adsorbing, heating, and drying granular materials, resulting in a solid porous material with firm adhesion and appropriate moisture content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional cigarette making machines or forming machines are used, then shredded tobacco cigarettes can be produced, but fully granular cigarettes/filter rods cannot be produced
Solution Approach 1:
The manufacturing process is divided into distinct functional modules: feeding apparatus for material input, pre-forming apparatus for initial granule arrangement, curing apparatus for heating and bonding, and cooling/drying assembly for final processing. Each module performs a specific operation on the granular material, enabling continuous production of fully granular cigarettes that traditional monolithic machines cannot achieve.
2Adaptability or versatility
If granule additives are uniformly added to cellulose acetate tows to prepare granular composite filter rod, then granular filter rod can be prepared, but production and use costs greatly increase
Solution Approach 1:
The invention extracts and eliminates the need for expensive granule additives and cellulose acetate tows by using only reconstituted tobacco granules as the base material. The granules are directly formed into filter rods through the continuous forming process without requiring additional costly binding materials, thereby reducing production costs while maintaining granular structure benefits.
3Adaptability or versatility
If granule additives are intensively and loosely packed to prepare ternary composite filter rod, then ternary composite filter rod can be prepared, but production and use costs greatly increase
Solution Approach 1:
The invention removes the requirement for ternary composite structures and associated granule additives by forming filter rods from reconstituted tobacco granules alone. The continuous forming process creates a coherent granular structure without needing intensive or loose packing of multiple material components, thereby eliminating the cost penalty of complex composite formulations.
4Productivity
If reconstituted tobacco granules or filter rod granule additives are continuously formed, then fully granular cigarette/filter rod can be produced, but existing machines are unable to implement this process
Solution Approach 1:
The continuous forming process is implemented by segmenting the manufacturing system into four sequential apparatuses: feeding, pre-forming, curing, and cooling/drying. This modular segmentation allows each component to be optimized for its specific function while working together in a continuous flow, making the complex continuous production process manageable and implementable with existing technological capabilities.
5Ease of operation
If the cross-sectional area of pre-forming cavity discharge port is larger than forming cavity, then material can enter forming cavity smoothly, but material may not be tightly stacked and adhered
Solution Approach 1:
The cavity design implements local quality variations: the pre-forming cavity has a larger cross-sectional area at its discharge port to ensure smooth material flow, while the forming cavity has a precisely controlled cross-sectional area matched to the final rod dimensions. This local variation in dimensions ensures both smooth transitions and proper compaction/adhesion in the forming zone, with the cavity shapes tailored to specific positional requirements along the material path.
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
Enables the first continuous production of fully granular cigarette/filter rods, reducing costs and enhancing product functionality, providing a new form that can offer better consumer experiences.
Implementation Method 1
A side wall of the pre-forming cavity is provided with a plurality of first through holes for providing negative pressure to adsorb a granular material
Implementation Method 2
A side wall of the forming cavity of the curing apparatus is provided with a plurality of second through holes for providing water-containing hot air and/or saturated water vapor to heat and humidify the material
Implementation Method 3
A side wall of the cooling/drying cavity of the cooling/drying assembly is provided with a plurality of third through holes for providing negative pressure to further discharge excess moisture under the negative pressure
Implementation Method 4
The mesh conveyor belt includes an upper conveyor belt and a lower conveyor belt connected into a whole, and the upper conveyor belt passes a feeding port of the feeding apparatus and passes through the pre-forming cavity of the pre-forming apparatus, the forming cavity of the curing apparatus, and the cooling/drying cavity of the cooling/drying assembly
Data Source
AI summary
A device and method for preparing a fully granular cigarette/filter rod, and a prepared fully granular cigarette/filter rod are disclosed. In certain embodiments, negative pressure is used to adhere granular material onto a mesh-type conveyor belt. The granular material is preliminarily formed into fully granular cigarette/filter rod material by means of a pre-forming apparatus; the fully granular cigarette/filter rod material, traveling with the mesh-type conveyor belt, enters into a forming cavity, and undergoes heating and humidifying treatment, and a continuous solid porous substance is formed; the continuous solid porous substance is moved into the cooling/drying cavity, drying and cooling treatment are performed under the action of negative pressure, and a fully granular cigarette/filter rod with strong adhesion, porosity, permeability, and appropriate moisture is obtained.