Microwave Resonator Filter Rod Plasticizer Measurement
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Solution Overview
Problem
Existing methods for measuring the mass of plasticizer and moisture in cigarette filter rods are limited by the need for space in filter rod machines and result in periodic production rejects due to triacetin switching off, and they lack precision in determining the plasticizer content without additional sensors.
Innovation Solution
A separate filter rod measuring station equipped with a microwave measuring device that measures mass, draw resistance, and resonance parameters to determine the plasticizer content, allowing for precise measurement of the plasticizer and moisture content using a microwave resonator and transport means to evaluate local concentrations and create a concentration profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If microwave sensors are installed in the filter rod machine to measure plasticizer content online, then measurement capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent extracts the measurement function from the production machine by using a separate microwave sensor system that measures filter rods after they leave the production line. This eliminates the need to install complex sensors within the filter rod machine while maintaining measurement capability.
Solution Approach 2:
The patent introduces an intermediary measurement system using microwave resonators that can measure plasticizer content without direct contact with the production process. The sensor acts as an intermediary that captures measurement data from filter rods after they exit the production machine, avoiding integration complexity.
2Measurement precision
If triacetin is periodically switched off to measure filter rod mass without plasticizer, then measurement accuracy is improved, but production reliability deteriorates due to periodic rejects
Solution Approach 1:
The patent changes the measurement approach by using microwave resonance parameters (frequency shift and line broadening) that can distinguish between different components (filter material, plasticizer, moisture) based on their unique electromagnetic properties. This allows simultaneous measurement of all components without needing to switch off the plasticizer.
Solution Approach 2:
The patent replaces the mechanical approach of physically separating plasticizer from filter rod for measurement with an electromagnetic field-based microwave measurement system. This substitution allows non-contact measurement of all components simultaneously, eliminating the need for periodic triacetin switching off and maintaining production continuity.
3Device complexity
If only one sensor is used to measure mass flow and plasticizer mass, then device complexity is reduced, but measurement precision deteriorates due to inability to separate components accurately
Solution Approach 1:
The patent utilizes multiple microwave resonance parameters (frequency shift A and line broadening B) that provide independent information about different components. By analyzing both parameters together with mass and draw resistance data, the system achieves accurate component separation using a single sensor type.
Solution Approach 2:
The patent makes the single microwave sensor multi-functional by having it measure multiple parameters simultaneously (mass, moisture, plasticizer content) through different resonance characteristics. This universal sensor approach eliminates the need for multiple specialized sensors while maintaining measurement precision.
4Measurement precision
If filter rods are measured after plasticizer application in a separate measuring station, then measurement accuracy is improved, but productivity deteriorates due to additional measurement step
Solution Approach 1:
The patent implements continuous measurement of filter rods as they pass through the measuring station without interrupting the production flow. The microwave measurement system operates continuously as filter rods pass by, eliminating the need for periodic stopping or complex sampling procedures.
Solution Approach 2:
The patent uses rapid microwave measurement techniques that quickly determine plasticizer content in the time it takes for filter rods to pass through the measuring station. This rushing through approach minimizes the additional time required for measurement while maintaining accuracy.
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 precise and reliable measurement of plasticizer and moisture content in cigarette filter rods, improving production efficiency by reducing rejects and providing accurate control over the manufacturing process.
Implementation Method 1
a microwave measuring device is used, which determines two parameters determining the mass and the moisture before and after the addition of triacetin
Implementation Method 2
In a liquid, ternary mixture of two polar substances (e.g. water and acetone) and a third non-polar component (e.g. cellulose acetate) to record the concentration of the individual components separately
Data Source
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Figure 4
AI summary
The station has a measuring equipment for measuring mass and pulling resistance of a filter rod, and a micro-wave measuring device for measuring the mass of a softening agent and/or moisture content and/or dry mass of a filter material in the filter rod. The measuring device has a microwave resonator and a measuring unit for determining changes in resonance of the filter rod, where the measuring unit determines a shifting of a resonance frequency and a spreading of a resonance curve.