Plasma Perforation of Tipping Paper Using Inert Gas
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for perforating tipping paper, such as mechanical, laser, and electroperforation, face challenges in achieving precise small hole sizes and positions without causing visible burn marks or mechanical wear, particularly in producing holes smaller than 0.05 mm.
Innovation Solution
A method using low-temperature plasma generation by ionizing a gas mixture with a high inert gas concentration, introduced in a ring around a punctiform energy source, to create a localized plasma that causes sublimation rather than oxidation, resulting in small, accurately positioned holes without visible burn marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electro-perforation is used to produce very small holes (0.01 mm diameter), then hole size precision is improved, but visible burn marks are created on the hole edges
Solution Approach 1:
The patent applies inert atmosphere by introducing a pressurized inert gas or gas mixture with high inert gas concentration in a ring shape around the energy source. This inert gas environment prevents oxidation of the paper edges during plasma perforation, thereby eliminating visible burn marks while maintaining precise hole sizes of 0.01 mm diameter.
Solution Approach 2:
The patent uses local quality by creating a localized plasma discharge in a highly confined area directly at the paper surface using a needle-shaped electrode. The plasma is generated only in the immediate vicinity of the electrode tip where the paper contact occurs, allowing precise control of hole formation without affecting surrounding areas, thus achieving both small hole sizes and clean edges.
2Ease of manufacture
If mechanical perforation is used, then ease of manufacture is improved, but mechanical wear of needles occurs causing hole size fluctuations
Solution Approach 1:
The patent replaces the mechanical needle-based perforation system with a plasma-based system using a needle-shaped electrode that generates plasma discharge. This substitution eliminates mechanical wear of the electrode while maintaining the ability to create precise holes, as the plasma discharge does not physically contact or wear the electrode tip in the same way mechanical needles do.
3Manufacturing precision
If laser perforation is used to achieve small hole sizes (0.05 mm or smaller), then manufacturing precision is improved, but holes smaller than 0.05 mm cannot be produced
Solution Approach 1:
The patent changes the physical parameters of the energy source and process conditions by using plasma discharge instead of laser radiation. The plasma process allows for smaller minimum hole diameters (0.01 mm) compared to laser perforation (0.05 mm), while maintaining precision through controlled plasma discharge parameters and inert gas environment.
4Manufacturing precision
If plasma discharge is used in a closed working area with defined atmosphere, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential function of atmosphere control from a complex closed working area system by using a simple pressurized gas delivery system that introduces inert gas directly at the perforation site. This localized approach maintains manufacturing precision while significantly reducing device complexity compared to maintaining a fully enclosed atmospheric control chamber.
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 production of very small hole diameters with precise control and positional accuracy, avoiding the drawbacks of existing methods by minimizing oxidation and preventing visible burn marks, thus enhancing the quality and appearance of perforated tipping paper.
Implementation Method 1
a pressurized inert gas or a gas mixture with a high inert gas concentration is introduced in a ring shape around the energy source in the direction of the tipping paper, whereby the ionizable gas mixture is locally confined to a very small surface area of the tipping paper
Implementation Method 2
a low-temperature plasma is generated on the surface of the tipping paper by briefly ionizing an ionizable gas mixture by an energy source that is as point-like as possible
Implementation Method 3
the ionizable gas mixture is locally confined to a very small surface area of the tipping paper in front of the energy source... resulting in small, accurately positioned holes without visible burn marks
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method and device for the plasma perforation of tipping paper (4), wherein a low temperature plasma (3) is generated on the surface of the tipping paper (4) by briefly ionizing a gas mixture using an energy source that is as close in form to a point as possible, wherein the ionizable gas mixture is locally restricted to a very small surface region of the tipping paper (4).