Nozzle Trough Addition of Shredded Web Segments in Tobacco Rod Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the tobacco processing industry, the random distribution and accumulation of tobacco foil pieces within the processing machine lead to quality issues such as visual defects, mechanical entanglement, and operational inefficiencies, particularly during the production of rod-shaped tobacco products.
Innovation Solution
A machine with a distribution unit and strand forming unit that includes a nozzle trough, suction conveyor, and a defined addition point for flat web sections, ensuring precise placement within the material strand, preventing accumulation and contact with wrapping material, and utilizing a shredding device to comminute flat webs into controlled sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tobacco foil pieces are mixed with fibrous tobacco material and processed together, then the tobacco foil can be distributed statistically within the material, but tobacco particles accumulate in certain areas and adhere to walls forming nests
Solution Approach 1:
The patent applies preliminary action by cutting the tobacco foil into strips before mixing it with the fibrous tobacco material. This pre-processing step ensures that the foil is divided into manageable pieces that can be uniformly distributed throughout the material stream, preventing later accumulation and nesting issues during processing.
Solution Approach 2:
The patent segments the tobacco foil into strips before incorporation into the tobacco material. This segmentation allows the foil to be more evenly distributed within the material stream and prevents the formation of large accumulations or nests, thereby improving processing reliability and quality consistency.
2Productivity
If tobacco foil pieces are processed together with fibrous tobacco material, then they can be statistically distributed in the final product, but tobacco particles enter the processing chain for extended periods causing brand change complications
Solution Approach 1:
The patent applies preliminary action by pre-cutting the tobacco foil into strips before mixing. This ensures uniform distribution from the start of processing, preventing particles from lingering in the system and complicating subsequent brand changes, thus reducing time loss during transitions.
Solution Approach 2:
By segmenting the tobacco foil into strips before processing, the patent enables more uniform distribution throughout the material stream. This prevents particles from accumulating and remaining in the processing chain during extended periods, facilitating quicker and cleaner brand changes.
3Ease of manufacture
If tobacco foil pieces are mixed with fibrous tobacco material, then they can be processed together, but particles become entangled in the seam of encasing material causing visual defects
Solution Approach 1:
The patent applies preliminary action by cutting the tobacco foil into strips before mixing with the fibrous material. This pre-segmentation ensures that the foil pieces are of appropriate size and shape to be uniformly distributed and embedded within the tobacco material, preventing them from becoming entangled in the encasing material seam and causing visual defects.
Solution Approach 2:
The patent segments the tobacco foil into strips before processing, which allows for more uniform distribution and better integration with the fibrous tobacco material. This segmentation prevents the foil pieces from becoming large enough to entangle in the encasing material, thereby maintaining manufacturing precision and product quality.
4Productivity
If tobacco foil pieces are statistically distributed in the material stream, then they can be processed continuously, but they accumulate in dust return systems hindering their function
Solution Approach 1:
The patent applies preliminary action by pre-cutting the tobacco foil into strips before mixing with the fibrous material. This ensures uniform distribution and prevents accumulation in the dust return system, maintaining its function while enabling continuous processing.
Solution Approach 2:
By segmenting the tobacco foil into strips before processing, the patent prevents the formation of large accumulations that would hinder the dust return system. The segmented foil distributes more evenly throughout the material stream, maintaining both continuous processing capability and dust return system functionality.
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
Prevents visual defects and operational inefficiencies by maintaining flat web sections in a defined position, reducing accumulation, and enhancing the quality and production efficiency of rod-shaped tobacco products.
Implementation Method 1
convey tobacco material or aerosol-forming material that can be fed to the distribution unit fluidically along a guide surface
Implementation Method 2
a shredding device (226) that is designed and equipped to comminute the flat web (218) into a plurality of flat web parts
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Machine 100 for the tobacco processing industry, comprising a distribution unit 102 and a downstream strand forming unit 104. The distribution unit 102 has a nozzle trough 13 and a suction strand conveyor 17 and is configured to convey tobacco material or aerosol-forming material 50 fluidically along a guide surface 15 of the nozzle trough 13 to the suction strand conveyor 17. The suction strand conveyor 17 provides a material stream and transfers it to the strand forming unit 104, which forms a material strand from the material stream and encases it with a wrapping material strip 21. The machine 100 further comprises: a supply device 216, a comminution device 226, and a feed device 234. The supply device 216 is configured to provide a flat web 218 and feed it to the comminution device 226.The comminution device 226 is configured to comminute the flat web 218 into a plurality of flat web segments 206, and the feed device 234 is configured to convey a stream of flat web segments 206 to an addition point 200. The addition point 200 is integrated into the nozzle trough 13, so that the stream of flat web segments can be added to the tobacco material or aerosol-forming material 50, which is guided fluidically along the guide surface 15 of the nozzle trough 13.