Pressure-Formed Tobacco Sheet Mixing for Uniform Thickness Control
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Solution Overview
Problem
Existing methods for producing reconstituted tobacco sheets do not consider the production of pressure-molded tobacco sheets, and there is a need for a method that can produce uniform thickness regardless of the moisture content in the raw material.
Innovation Solution
A method involving mixing powdered tobacco raw materials with a liquid raw material in a mixer, followed by extrusion through an extruder to form a pressure-molded sheet, with adjustments in moisture levels using additional liquid raw materials to prevent adhesion and ensure easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple powdered raw materials are mixed together with liquid raw material simultaneously, then the mixing process is simpler, but the powdered raw materials cannot be thoroughly mixed
Solution Approach 1:
The mixing process is divided into two distinct stages: first mixing only powdered raw materials, then adding liquid raw material separately. This segmentation ensures thorough mixing of powdered materials before liquid binding, resolving the contradiction between process simplicity and mixing uniformity.
Solution Approach 2:
The powdered raw materials are pre-mixed together before the liquid raw material is added. This preliminary action ensures that all powdered components are uniformly distributed prior to binding, achieving thorough mixing while maintaining a relatively simple overall process.
2Quantity of substance
If the amount of liquid raw material is increased to prevent adhesion, then the reconstituted tobacco sheet gains sufficient moisture, but the sheet becomes difficult to handle due to excessive adhesion
Solution Approach 1:
The viscosity of the liquid raw material is modified by adding specific additives (such as polyethylene glycol or glycerol) to change its flow properties. This allows the liquid to provide sufficient moisture while reducing excessive adhesion, enabling easier handling of the reconstituted tobacco sheet.
Solution Approach 2:
Additives such as polyethylene glycol or glycerol are introduced as intermediary substances that modify the interaction between liquid raw material and powdered tobacco. These intermediaries reduce surface tension and adhesion while maintaining moisture content, resolving the handling difficulty.
3Ease of manufacture
If conventional rolling or casting methods are used, then the production process is well-established, but uniform thickness cannot be achieved regardless of moisture content variations
Solution Approach 1:
The extrusion molding method is designed to be universally applicable regardless of the moisture content of the raw material mixture. By using an extruder with a die, the system can produce reconstituted tobacco sheets with uniform thickness whether the material is relatively dry or has higher moisture content, making the process adaptable to different material conditions.
Solution Approach 2:
The molding method transitions from conventional rolling or casting to extrusion molding, changing the fundamental processing parameter from surface-based forming to volumetric extrusion through a die. This parameter change enables consistent thickness control independent of moisture content variations in the raw material.
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
The method allows for the production of uniform reconstituted pressure-molded tobacco sheets with enhanced strength and aerosol generation, while maintaining ease of handling and reducing adhesion issues.
Implementation Method 1
the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced
Implementation Method 2
the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol
Implementation Method 3
a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet
Data Source
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AI summary
Provided is a method for producing a reconstituted pressure-formed tobacco sheet. The production method has: a first step for introducing a first liquid raw material into a mixer; a second step for putting, into the mixer, a powdery raw material including at least tobacco and mixing the same with the first liquid raw material, after the first step; and a forming step for forming the raw material mixed in the second step into a pressure-formed sheet.