Method and apparatus for manufacturing recycled resin granules

Abstract

This invention provides a method for manufacturing recycled pellets, which can utilize thicker loss films, wider loss films, and loss films made of materials with high hardness and difficulty in bending, which were previously unsuitable, and can also produce recycled pellets that are close to the original pellets. In the recycled pellet manufacturing method, one or more loss films (R) continuously supplied in one direction are stretched and twisted, and the twisted portions are pressed to press the contact portions of the loss films (R) together to form strands (R). The strands (R) are then cut to produce recycled pellets (P). In the stage before the stage of stretching and twisting the loss films (R), the loss films (R) are preheated to their softening temperature.

Description

Technical Field

[0001] The present invention relates to an improvement of the method and apparatus for manufacturing recycled resin particles, for example, using cut-off chips (edges) from both ends of a bilayer film manufactured by blow molding or loss films (e.g., poor thickness, bilayer films that break during manufacturing) generated in other manufacturing processes as raw materials. Background Technology

[0002] The processing of the large quantities of lost film (long strips with a certain width at the edges, product losses) generated during the manufacturing process of resin films, etc., and their utilization as recycled resin granules (hereinafter referred to as "recycled granules") has been widely carried out. To manufacture these recycled granules, the lost film is heated and melted, and a strip of resin with a slender, circular cross-section is extruded. When this strip of resin is cut, uniform cylindrical granules with a shape similar to the original rice-grain-shaped granules can be produced. However, it has been pointed out that the resin quality deteriorates due to the heating used for remelting. Therefore, a technology is needed to manufacture such recycled granules without heating.

[0003] As an example of a regenerated pellet manufacturing apparatus capable of producing regenerated pellets without heating, Patent Document 1 is known. The regenerated pellet manufacturing apparatus described in Patent Document 1 consists of a loss film supply section, an extension section, a rotary compression section, and a cutting section.

[0004] The loss membrane supply section is the part that feeds one or more loss membranes made of synthetic resin into the extension section by overlapping them and applying a certain tension.

[0005] The extension section is a portion that stretches one or more loss films supplied in a non-heated state, narrows the stretched thin-walled extension film to a thinner form to form a thin-walled extended converging loss film, and feeds the thin-walled extended converging loss film to a rotary compression section disposed on the downstream side.

[0006] The rotary compression section includes a pair of compression rollers with concave and convex surfaces formed on their outer peripheral surfaces and a traction roller connected to the pair of compression rollers, and rotates relative to the extension section. The rotary compression section forms a crimped strand with concave indentations by point compression of the thin-walled extended convergent loss film pulled from the extension section through this relative rotation, while simultaneously imparting torsion to the film. Because the strand is forcefully compressed to form deep concave indentations, it is fed out as a flat strand. The traction roller is the part that clamps the flat crimped strand with the concave indentations and rotates it in the feeding direction to feed the crimped strand towards the cutting section.

[0007] The cutting section includes a circular saw-shaped cutter and a guide roller positioned immediately preceding the cutting position of the stranded wire based on the cutter. The guide roller, while rotating, clamps the stranded wire drawn from the traction roller of the rotating compression section from above and below, and feeds it to the cutting position. Then, the cutter cuts the stranded wire into shorter, flat, recycled pellets with concave indentations on both the surface and the inside.

[0008] Prior art literature

[0009] Patent documents

[0010] Patent Document 1: Japanese Patent Application Publication No. 2012-81605 Summary of the Invention

[0011] The problem that the invention aims to solve

[0012] In the conventional apparatus shown in Patent Document 1, although concave indentations can be used to form recycled granules that do not break apart, the cross-sectional area of ​​the twisted wire cannot be increased due to the limitation of the depth of the concave indentations (i.e., the indentation needs to be formed near the core of the stranded wire). Therefore, it is impossible to produce recycled granules with a larger cross-sectional area, and productivity is limited.

[0013] Furthermore, in the production of loss membranes, there are not only loss membranes within the applicable scope of conventional devices (i.e., thin and flexible loss membranes that are easily indented or twisted and are not very wide), but also a large number of loss membranes outside the applicable scope, including thicker loss membranes, wider loss membranes, and loss membranes made of materials with high hardness that are difficult to bend. Such thicker loss membranes and loss membranes made of materials with high hardness and difficulty in bending cannot form indentations, and even when compressed, they are difficult to press together. In addition, they tend to break during stretching, and they cannot be twisted at high density, making it difficult to form a strip. Even if it is set into a strip, it can only become a loose, gap-filled rope, unable to be recycled into high-quality granules. Therefore, from the perspective of resource reuse, it is desirable to further expand the applicable scope of loss membranes in the manufacture of such recycled granules.

[0014] Furthermore, in this conventional apparatus, since recycled granules can be produced continuously, high-speed processing of the worn membrane is possible, resulting in high productivity. However, as mentioned above, strong compression is required to create indentations. This strong compression flattens the cross-section of the stranded wire. If this flattened stranded wire is cut, the shape of the resulting recycled granules will also become flat. Since they differ from the rice-grain-shaped original granules, there is a drawback: poor material mixing accuracy with the original granules.

[0015] This invention addresses the problems of the prior art. Its first objective is to produce recycled particles with a larger diameter without being limited by the depth of the concave indentation. Its second objective is to produce recycled particles with a cross-sectional shape that is close to a circle to some extent, thus producing recycled particles that are close to the original particles. Its third objective is to provide a method and apparatus for manufacturing recycled particles that can not only use conventional loss films, but also use loss films that are not previously applicable, such as thicker loss films, wider loss films, or loss films made of materials with high hardness and difficulty in bending, as specified strands. The specified strands can be cut to produce recycled particles that are no less than the original particles.

[0016] Methods for solving problems

[0017] The invention described in technical solution 1 is a recycled pellet manufacturing apparatus A1 (A2, A3), which comprises:

[0018] The loss film supply unit 1 gathers one or more loss films R made of thermoplastic resin into a predetermined width W2 and supplies them to the intermediate conveying unit 5.

[0019] The intermediate conveying section 5, while clamping the supplied loss film R, simultaneously conveys the loss film R, becoming the starting point K of the twisting of the loss film R; and

[0020] The rotary compression unit 10 receives the loss film R from the intermediate conveying unit 5, rotates relative to the intermediate conveying unit 5 to twist the loss film R, and pulls it faster than the delivery speed of the intermediate conveying unit 5 to extend the loss film R and deliver the stranded wire R.

[0021] The recycled pellet manufacturing apparatus A1 (A2, A3) will extract the pellets from the rotary compression section at a predetermined length. 10 The delivered stranded wire R is cut to produce recycled granules P.

[0022] Its features are,

[0023] The recycled pellet manufacturing apparatus A1 (A2, A3) has a first heating unit 60 provided between the loss film supply unit 1 and the intermediate conveying unit 5. The first heating unit 60 preheats the loss film R at the softening temperature of the loss film R.

[0024] The first heating unit 60 consists of a heating unit body 61, an opening and closing cover 62, and a hot air supply unit 75.

[0025] The heating unit body 61 reciprocates between a heating position and a retraction position deviating from the heating position along a moving line L around the convergent loss film R to be heated. During this reciprocation, the opening 61a, which serves as the inlet and outlet of the loss film R to be heated, is formed across the entire surface of the surface on the moving direction side.

[0026] When heated, the opening 62 closes the opening 61a, creating a heating space Z inside for the loss film R.

[0027] The hot air supply unit 75 delivers hot air into the heating space Z.

[0028] Since the preheating temperature is the softening temperature of the loss film R, the material of the loss film R will not deteriorate. If, in the next process, the loss film R, softened by the preheating, is stretched while being twisted, and the twisted portion is further pressurized, the loss film R will fuse together at least in the closely adhering portion of its surface. Therefore, even if the loss film R is cut and granulated, it will fuse together at least in its surface portion, and the recycled particles P will not disperse. Furthermore, through this preheating, the pressure can be applied less forcefully (or without the deep indentation Y) than in the past, allowing the recycled particles P to have a cross-section that is approximately circular or nearly circular elliptical, similar to the original rice-grain-sized particles, and also enabling the production of recycled particles P with a larger diameter. In other words, the cross-section of the recycled particles P in this invention will not be flat as in conventional examples.

[0029] By further pre-stretching the loss film R during the preheating process, thicker and harder loss films R that are difficult to twist can be thinned. In the subsequent stretching and twisting process (twisting process), the loss film R can be easily stretched and twisted, making the aforementioned loss films R, which were not previously processed, available for processing. Furthermore, the usual raw material loss film R is not pre-stretched.

[0030] According to the recycled pellet manufacturing apparatus A1 (A2, A3) described in technical solution 1, the invention described in technical solution 2 is characterized in that...

[0031] A second heating section 80 is also provided between the intermediate conveying section 5 and the rotary compression section 10. The second heating section 80 heats the pre-pressurized extended strand R, which is twisted and extended by the intermediate conveying section 5 and the rotary compression section 10, at the softening temperature of the pre-pressurized extended strand R.

[0032] The second heating unit 80 consists of a heating unit body 81, an opening and closing cover 82, and a hot air supply unit 95.

[0033] The heating unit body 81 of the second heating unit 80 reciprocates between a heating position and a withdrawal position deviating from the heating position on the moving line L surrounding the secondary heating extension strand R. During this reciprocation, the opening 81a, which serves as the inlet and outlet of the secondary heating extension strand R, is formed across the entire surface of the surface on the moving direction side.

[0034] The opening and closing cover 82 of the second heating section 80 closes the opening 81a during heating, forming a heating space Z inside for the extended stranded wire R that is subjected to secondary heating.

[0035] The hot air supply unit 95 of the second heating unit 80 sends hot air into the heating space Z.

[0036] As a result, the twisting of the loss membrane R becomes denser, enabling the production of regenerated particles P with higher density and closer resemblance to the original particles.

[0037] Invention Effects

[0038] As can be seen from the above, the present invention is capable of producing recycled particles ranging from small to large diameter, and can also produce recycled particles with a cross-sectional shape that is somewhat close to a circle. Furthermore, not only conventional loss films, but also loss films that were previously unsuitable, such as thicker loss films, wider loss films, and loss films made of materials with high hardness and difficulty in bending, can be made into specified strands, and these specified strands can be cut to produce recycled particles that are no less superior than the original particles.

[0039] Furthermore, by designing the position of the cutter's rotation axis as described above, reliable cutting of the crimped stranded wire can be achieved. Attached Figure Description

[0040] Figure 1 This is a top view of the basic form of the present invention.

[0041] Figure 2 (a) is Figure 1 (a) is a top sectional view of the intermediate conveying section, rotary compression section and cutting section, and (b) is a cross-sectional view of the XX section.

[0042] Figure 3 yes Figure 2 (a) is a longitudinal sectional view, and (b) is a side view of the shell in the figure.

[0043] Figure 4 It is shown Figure 1 A diagram of the main parts of the rotary compression section.

[0044] Figure 5 This is a longitudinal sectional view of the contraction portion of the first heating section and the loss film supply section of the present invention.

[0045] Figure 6 yes Figure 5 Top sectional view.

[0046] Figure 7 (a) is a diagram of the first and second heating parts retracting to the retracted position, (b) is a diagram of the first and second heating parts returning to the heating position, and (c) is a diagram of the first and second heating parts entering the heating state.

[0047] Figure 8 This is an enlarged cross-sectional view of the cut portion of the present invention.

[0048] Figure 9 It is shown Figure 8 A diagram showing the cut state of the stranded wire.

[0049] Figure 10 (a) is a perspective view of the recycled particles formed by the apparatus of the present invention, (b) is a side view of the recycled particles, (c) is a front view of the recycled particles, and (d) is another front view of the recycled particles.

[0050] Figure 11 (a) is a top view of the first embodiment of the present invention, and (b) is a variation thereof.

[0051] Figure 12 (a) is a top view of the second embodiment of the present invention, and (b) is a variation thereof. Detailed Implementation

[0052] The apparatus of the present invention will now be described with reference to the illustrated embodiments. Figures 1-9 As shown, the basic form of the present invention consists of a loss film supply section 1 with a shrinkage section 2, a first heating section 60, an intermediate conveying section 5, a rotary compression section 10, a cutting section 50, and a base 7 on which they are mounted, as follows. Figure 11 As shown, in the first embodiment, a pre-extension conveying section 3 is further provided between the shrinkage section 2 of the loss film supply section 1 and the first heating section 60, such as... Figure 12 As shown, in the second embodiment, a second heating unit 80 is further provided between the intermediate conveying unit 5 and the rotary compression unit 10. The descriptions will proceed sequentially from the basic form. In the first and second embodiments, the descriptions will focus on the parts that differ from the basic form; for the parts that are the same, the descriptions of the basic form will be used as references.

[0053] In the above embodiments, the loss film R changes shape in each process. In the basic form, the section from the shrinkage section 2 to the loss film supply section 1 is designated as the raw material loss film R, the section from the shrinkage section 2 to the intermediate conveying section 5 is designated as the preheated or preheated convergent loss film R, the section from the intermediate conveying section 5 to the compression roller section 22 of the rotary compression section 10 is designated as the extension strand R, and the section from the compression roller section to the cutting section 50 is designated as the crimped strand R, all of which are indicated by the reference numeral R.

[0054] Similarly, in the first embodiment, the section from the shrinking section 2 to the intermediate conveying section 5 is also provided as a preheated extended convergent loss film R, and in the second embodiment, the section from the intermediate conveying section 5 to the compression roller section 22 is also provided as a secondary heated or secondary heated extended strand R.

[0055] Furthermore, the motors used in this invention can also be motors with gearboxes, but for ease of speed control, variable frequency motors, servo motors, or stepper motors are primarily used. Additionally, as belt-type motors, synchronous belts can be used to accurately transmit rotation.

[0056] As described in the background section, the loss film R is a large quantity of loss film (long strips with a certain width at the edges, product loss) generated during the manufacturing process of resin film (thermoplastic resin) in blow molding or T-molding. Its width, wall thickness, and type vary widely, including hard or thick loss films that are difficult to bend, and wide loss films, etc. The width of the loss film R for all raw materials is denoted as W1.

[0057] (Basic form)

[0058] The loss film supply unit 1 overlaps one or more loss films R vertically, or narrows and folds them to a width W2 that allows them to pass through the next first heating unit 60, and supplies them to the first heating unit 60. The narrowing of the loss film R can be done by any method, but in this embodiment, a shrinkage section 2 is used. The loss film R can be supplied either by rewinding a roll (not shown) or online from a film forming machine.

[0059] The shrinking section 2 narrows and folds one or more wide loss membranes R used as conveyed raw materials, and sets them as a narrower convergent loss membrane R with a width of W2.

[0060] In this embodiment, the contraction section 2 is a component similar to a mold, with a wider inlet and a narrower funnel-shaped hole or slit formed at the outlet, where the contraction hole 2a is formed. The opening width of the inlet is wider than the width W1 of the loss membrane R, which is the conveyed raw material, and the outlet is formed with a width W2 that is narrower than the heating space Z of the loss membrane R of the first heating section 60.

[0061] As described above, the contraction section 2 causes one or more overlapping loss films R to pass through the contraction hole 2a, thereby causing the loss film R to contract or fold and form the aforementioned width W2.

[0062] The loss film R supplied to the shrinkage section 2 is matched with the size and volumetric density of the recycled particles P. The number of sheets supplied, the width W1, the wall thickness, the hardness, etc. can be appropriately selected according to the application of the recycled particles P.

[0063] As another structure of the loss membrane supply unit 1, although not shown, the structure described in Patent Document 1 can be used for example (a tension adjustment roller is provided between the inlet fixed roller and the outlet fixed roller, and a certain tension is applied to one or more loss membranes that are mounted between the two fixed rollers and continuously transported).

[0064] In this embodiment, the first heating unit 60 is composed of a heating unit body 61, an opening and closing cover 62, a body driving unit 66, a cover opening and closing mechanism 70, and a hot air supply unit 75. Figure 7 ).

[0065] The heating element body 61 is a long strip member with a U-shaped cross-section, and an opening 61a is provided along its entire length on one side (the side with the movable side). On the upper surface of the heating element body 61, an opening and closing cover 62 is provided to open and close the opening 61a via a hinge 62a, and when closed, it forms a cylindrical heating space Z with the heating element body 61.

[0066] The main drive unit 66 is provided from the back side (exit side) of the heating unit main body 61 to the bottom, and consists of a sliding mechanism 67 (a slider 67b equipped with a ball bearing on the guide shaft 67a) that enables the heating unit main body 61 to move to the heating position and the exit position, and a main drive cylinder 68 provided on the back side of the heating unit main body 61.

[0067] As described above, the cover opening and closing mechanism 70 is opened and closed by a hinge mechanism and by a cover opening and closing cylinder 71.

[0068] The hot air supply unit 75 consists of a hot air supply pipe 76 installed on the upper surface, the lower surface (not shown), or both of the heating unit body 61, and a heater 77 disposed inside the hot air supply pipe 76. Here, it is only provided on the upper surface side of the heating unit body 61.

[0069] A hot air supply pipe 76 is connected to a blower (not shown) to supply air into the heating unit body 61. Furthermore, a temperature sensor (not shown) installed in the heating unit body 61 is used for temperature management, and hot air heated to a softening temperature (e.g., 100°C to 500°C) is used to heat the loss film R passing through the heating space Z. As a result, the loss film R exhibits rubber elasticity. The heating temperature is pre-input into a temperature control device (not shown) that matches the type of loss film R, and an optimal temperature is appropriately selected.

[0070] The intermediate conveying section 5 consists of a pair of upper and lower intermediate rollers 5a and 5b and an intermediate drive motor 6 connected to the intermediate roller 5b on the drive side. The surfaces of the intermediate rollers 5a and 5b are provided with knurling (embossing) to prevent slippage of the convergent loss film R during its extension in the next process after shrinkage. The portion where the loss film R is clamped by the pair of upper and lower intermediate rollers 5a and 5b is the "twisting starting point K".

[0071] The rotary compression unit 10 is composed of a rotary unit 11, a compression unit 21 installed in the rotary unit 11, and first and second drive units 15 and 35 that enable the rotary unit 11 and the compression unit 21 to rotate independently, and is disposed on the base 7.

[0072] The rotating part 11 is composed of a housing 12 and a first driven pulley 19. The housing 12 is rotatably mounted on the base 7 via bearings 8 and 9.

[0073] The housing 12 of the rotating part 11 is divided into a front section 12a and a rear section 12b. The front section 12a is cylindrical and is equipped with the aforementioned first driven pulley 19 and one of the bearings 8.

[0074] The rear section 12b is a hollow rectangular box shape, with the front section 12a integrally protruding from its front end, and the other bearing 9 is assembled in the support part of the outlet section.

[0075] The compression section 21 is composed of upper and lower compression rollers 22a and 22b constituting the compression roller section 22, upper and lower traction rollers 25a and 25b, a hollow main gear member 40 equipped with a second driven pulley 39, and a gear system consisting of multiple gears meshing with the main gear member 40 and rotating the drive-side compression roller 22b and the drive-side traction roller 25b. Furthermore, any one of the compression rollers 22a and 22b and the traction rollers 25a and 25b can be used as the drive side.

[0076] The main gear component 40 is composed of a main gear 40a and a hollow shaft portion 40b. The hollow shaft portion 40b is rotatably housed in the front section 12a of the housing 12. A second driven pulley 39 is fitted on this part that protrudes to the outside of the front section 12a.

[0077] A main gear 40a is provided at the end of the housing 12 inside the hollow shaft portion 40b, and the main gear 40a is configured to face the cutout window of the housing 12.

[0078] On the outside of the housing 12, the driven gear 41 is configured such that a portion of it enters the housing 12 through the aforementioned cut-out window and meshes with the main gear 40a through the aforementioned cut-out window.

[0079] A main worm gear 42 is mounted on the rotating shaft of the driven gear 41, and a driven worm gear 43 meshes with the main worm gear 42. The driven worm gear 43 is mounted on one end of the rotating shaft 23 of the compression roller 22b on the drive side.

[0080] And, as Figure 2 , Figure 3 As shown in (a) and (b), a first transmission gear 44 is mounted at the other end of the rotation shaft 23 of the compression roller 22b on the drive side, and the rotation is transmitted to the third transmission gear 46 mounted on the traction roller 25b on the drive side via the intermediate second transmission gear 45. The traction roller 25b on the drive side is configured to rotate about 10% faster than the compression roller 22b on the drive side via the gear train from the first transmission gear 44 to the third transmission gear 46.

[0081] The aforementioned first drive unit 15 is composed of a first drive motor 16 and a first drive pulley 17 mounted on the rotating shaft of the first drive motor 16. The first drive pulley 17 is connected to the first driven pulley 19 via a first synchronous belt 18.

[0082] Similarly, the second drive unit 35 is composed of a second drive motor 36 and a second drive pulley 37 mounted on the rotating shaft of the second drive motor 36. The second drive pulley 37 is connected to the second driven pulley 39 via a second synchronous belt 38.

[0083] The compression rollers 22a and 22b of the compression section 21 are cylindrical components (or components formed by stacking multiple circular plates with multiple serrated protrusions on their outer periphery into a cylindrical shape). Their outer surface is a flat circular curved surface (not shown), or multiple protrusions 24 are formed all over their entire surface, with the front end being hemispherical (bumpy) or oblong when viewed from above and trapezoidal when viewed from the front (see reference). Figure 2 (Enlarged view enclosed in a circular frame). Rotating shafts 23 are respectively provided at the center of the compression roller 22a on the pressurizing side and the compression roller 22b on the driving side, and their two ends are rotatably supported on the housing 12.

[0084] Furthermore, the upper compression roller 22a is configured to press against the lower drive-side compression roller 22b via a spring (not shown). Thus, the upper compression roller 22a rotates passively due to the rotation of the lower drive-side compression roller 22b. The pressure applied by the compression roller 22a on the pressure side is adjusted by a compression force adjustment mechanism (not shown). Alternatively, if adjusting the compression force is not required, the compression force adjustment mechanism may be omitted.

[0085] The upper and lower traction rollers 25a and 25b of the compression section 21 are arranged on the downstream side of the compression roller section 22. Similar to the compression rollers 22a and 22b, their respective rotation shafts 26 are rotatably supported on the housing 12. Rotational force is transmitted from the compression roller 22b on the drive side through the gear train from the first transmission gear 44 to the third transmission gear 46.

[0086] Similar to the compression rollers 22a and 22b, the aforementioned traction rollers 25a and 25b are also provided with a pressing pressure adjustment mechanism (not shown). This mechanism adjusts the pressing pressure so that the upper pressing side traction roller 25a is pressed against the lower pressing side traction roller 25b by a spring (not shown). If adjusting the pressing pressure is not required, the pressing pressure adjustment mechanism may not be provided.

[0087] In the aforementioned relationship between the compression roller 22b on the drive side and the intermediate roller 5b on the drive side, the compression roller 22b is set to rotate faster relative to the intermediate roller 5b. As a result, the convergent loss film R, which is prepared to be heated and exhibits rubber elasticity, is stretched while being twisted between the compression rollers 22a, 22b and the intermediate rollers 5a, 5b.

[0088] Furthermore, in the relationship between the rotating section 11 and the compression section 21, the main gear member 40 of the compression section 21 rotates independently of the rotation of the housing 12 of the rotating section 11. Also, if the rotation of the main gear member 40 is faster than the rotation of the housing 12, the compression rollers 22a, 22b and the traction rollers 25a, 25b will also rotate clockwise, feeding the crimped strand R towards the cutting section 50. If the rotational speeds are the same, the compression rollers 22a, 22b and the traction rollers 25a, 25b will remain stationary. Therefore, by adjusting the rotational speeds of the rotating section 11 and the compression section 21, the feeding speed of the crimped strand R can be adjusted.

[0089] The cutting section 50 cuts the crimped strand R, which has been compressed and has formed concave indentations Y (embossing) as needed in the compression section 21 and is then drawn out by the traction rollers 25a and 25b. The crimped strand R with the applied concave indentations Y is cut at intervals containing at least one concave indentation Y, preferably at intervals wider than the intervals of the concave indentations Y formed on its surface, thereby achieving regenerated granulation. Figure 8As shown, the cutting section 50 is generally composed of a housing 54, a cutter 51, a receiving blade 57, and a motor (not shown) with a gearbox.

[0090] The outer casing 54 is a box-shaped component with an inlet 55 for crimped stranded wire R formed on the front surface of its upper end, and a regenerated particle receiving box (not shown) is detachably disposed at its lower end.

[0091] A cutter 51 is rotatably mounted on the upper part of the housing 54, and a motor (not shown) with a gearbox is connected to the rotating shaft O of the cutter 51. The rotational speed of the cutter 51 can be appropriately set according to the feed speed of the crimped strand R and the size of the regenerated particles P.

[0092] Depend on Figure 8 It can be seen that the center of the rotation axis O of the cutter 51 is set to be higher than the extension line of the moving line L of the crimped wire R by a height H. A receiving blade 57 is provided on the back (cutter side) of the inlet 55. The shearing surface 57s of the receiving blade 57 is slightly curved into a concave shape on the inner side, and is formed in the direction of the tangent T that is tangent to the rotation trajectory D of the end of the cutting edge 52 of the cutter 51 at its cutting position C. Therefore, the angle between the upper surface of the receiving blade 57 (the sliding surface of the crimped wire R) and the shearing surface 57s is an obtuse angle. In addition, as Figure 4 As shown, the cutting blade 52 is inclined relative to the receiving blade 57, which can cut the crimped stranded wire R.

[0093] Next, the process of manufacturing recycled particles P using the recycled particle manufacturing apparatus A1 will be described. At the setting time of the loss film R, the heating unit body 61 of the first heating unit 60 is in an open state at a retracted position that deviates from the moving line L of the narrower convergent loss film R to be heated. Figure 7 (a)).

[0094] First, one or more wide loss membranes R, which will become raw materials, are set in the loss membrane supply section 1 as specified. If there are multiple wide loss membranes R, they are aligned and overlapped vertically, and their ends are gently twisted to gather them into one.

[0095] Next, the loss film R is passed through the shrinkage hole 2a of the shrinkage section 2. By passing the raw material loss film R with a width of W1 through the shrinkage hole 2a, it is shrunk and becomes a convergent loss film R with a width of W2.

[0096] As described above, the narrow-width convergence loss membrane R is extracted and bypasses the area located in... Figure 1 The heating body 61 of the first heating section 60, which is shown in the retracted position with double dashed lines, is pulled into the intermediate conveying section 5. Since the intermediate rollers 5a and 5b of the intermediate conveying section 5 have irregularities formed on their outer peripheral surfaces, the convergence loss film R can be pulled out from the shrinkage section 2 by their engagement and rotation.

[0097] Then, the loss film R, which passes between the intermediate rollers 5a and 5b of the intermediate conveying section 5, passes through the inlet 55 between a pair of compression rollers 22a and 22b and between traction rollers 25a and 25b, so that the end of the loss film R faces the cutter 51.

[0098] Furthermore, at this moment, since it is the pre-processing stage, in the loss film R in the state where the twisting has not been extended, when the loss film R is passed between a pair of compression rollers 22a and 22b, the pressing pressure of the compression roller 22a on the pressure side relative to the compression roller 22b on the drive side is released in advance, so that the compression roller 22a on the pressure side is free.

[0099] Then, the main body drive cylinder 68 of the first heating section 60 is activated to move the main body 61 of the heating section forward from the retracted position to the heating position surrounding the loss film R. Next, the cover opening and closing cylinder 71 is activated to close the opening and closing cover 62, so that the loss film R can pass through the heating space Z.

[0100] If the loss membrane R is set as described above, the power is turned on to start the regenerated particle manufacturing device A1 and begin manufacturing the regenerated particles P.

[0101] In the intermediate conveying section 5, rollers 5a and 5b are operated to apply a certain tension to the loss membrane R while passing the loss membrane R through the contraction section 2 of the loss membrane supply section 1.

[0102] As described above, since the outlet of the shrinkage orifice 2a is narrower than the inlet, the wide-width loss membrane R is here shrinked or folded and is drawn out from the outlet as a narrower converging loss membrane R.

[0103] In the first heating section 60, the heater 77 is energized, and air supplied through the hot air supply pipe 76 is heated to a predetermined temperature (softening temperature) and blown into the heating section body 61 to heat the loss film R passing through the heating space Z at this temperature. The loss film R exhibits rubber elasticity. The hot air flows in a rotating manner in the heating space Z, heating not only the surface of the loss film R but also, to some extent, its interior, at least uniformly heating the surface portion of the film. Then, while heating the surface of the loss film R, it is ejected from the front and rear openings of the heating section body 61 along the surface of the loss film R.

[0104] In the basic form, since the converging loss membrane R is only subjected to tension when it is pulled out from the shrinkage section 2, it hardly stretches even though it is heated. In other words, the converging loss membrane R is heated to a softening temperature that exhibits the rubber elasticity described above, but since the tension at the shrinkage hole 2a is not large, the converging loss membrane R does not stretch significantly due to extension even when heated.

[0105] The preheated convergent loss film R, fed from intermediate rollers 5a and 5b to compression rollers 22a and 22b, extends between the intermediate rollers 5a and 5b and the compression rollers 22a and 22b. Simultaneously, the convergent loss film R is twisted into an extended strand R, and then compressed by the compression rollers 22a and 22b into a crimped strand R. Then, through the pressure applied by the intermediate rollers 5a and 5b (this pressure is strong), the surfaces of the preheated convergent loss films R in contact are bonded together.

[0106] Furthermore, the preheated convergent loss film R is fed out from the intermediate rollers 5a and 5b, stretched into a thinner and finer form through this extension, and simultaneously twisted, with the contact surfaces of the twisted portions adhering to each other to form a cylindrical extended strand R. The compression rollers 22a and 22b here do not require the strong compression that flattens the cross-section as in the past, but rather a weaker compression that imparts a degree of twisting to the preheated and extended convergent loss film R. Next, the function of the rotary compression unit 10 will be explained.

[0107] When the first and second drive motors 16 and 36 are operating, the first and second driven pulleys 19 and 39 rotate around the moving line L of the pre-heated convergent loss film R fed from the intermediate rollers 5a and 5b via the first and second synchronous belts 18 and 38. Since the first driven pulley 19 is mounted on the front section 12a of the housing 12, the compression rollers 22a and 22b and the traction rollers 25a and 25b assembled inside also rotate together. The loss film in this part is held and twisted by the compression rollers 22a and 22b and conveyed. Therefore, the compression rollers 22a and 22b, which rotate together with the housing 12 from the clamping point K of the intermediate rollers 5a and 5b, are twisted to form an extended strand R.

[0108] Furthermore, this process involves twisting and extending the pre-heated convergent loss film R (stretching and twisting process). However, the aforementioned compression force is sufficient if it is such that the extended strand R, which is easily stretched and twisted by heating, does not slip relative to the compression rollers 22a and 22b due to tension during extension, and is thus twisted to the extent required. In other words, it is not the conventional compression force that induces twisting in the unheated state and flattens the convergent loss film into a flat shape to form a deeper concave indentation.

[0109] As the second driven pulley 39 rotates around the extended strand R, the main gear assembly 40 rotates. The main gear 40a of the main gear assembly 40 rotates the driven gear 41 on the side, and via the driving worm gear 42 and the driven worm gear 43, causes the compression roller 22b on the drive side to rotate in the feed direction of the extended strand R. Since the compression roller 22a on the pressure side presses against the compression roller 22b on the drive side with a predetermined pressure, the compression roller 22a on the pressure side and the compression roller 22b on the drive side rotate together in the feed direction of the extended strand R. Since the extended strand R being twisted is held by the compression rollers 22a and 22b with a predetermined pressure, when a protrusion 24 is formed in this part, a concave indentation Y is continuously formed on both the upper and lower surfaces. As described above, since the extended strand R is prepared to be heated to a softening temperature, the films are more firmly pressed together at the bottom of the concave indentation Y. (Furthermore, if the films on the surface portions produced by the above-mentioned pressing are sufficiently bonded to each other, the indentation Y can be omitted.)

[0110] Furthermore, as described above, a first transmission gear 44 is mounted at the other end of the compression roller 22b on the drive side, and a third transmission gear 46 mounted on the traction roller 25b on the drive side is rotated via a second transmission gear 45. Since the traction roller 25a on the pressure side clamps the extended strand R while pressing it against the traction roller 25b on the drive side with a certain pressing force, the traction roller 25a on the pressure side also rotates in the feed direction. This causes the pressed extended strand R to become a pressed strand R.

[0111] When protrusions 24 are formed on the compression rollers 22a and 22b, the protrusions 24 may enter the crimped wire R, making it difficult to pull out the crimped wire R. However, since the traction rollers 25a and 25b rotate slightly faster in the feed direction than the compression rollers 22a and 22b, tension is applied to the crimped wire R that is caught between the compression rollers 22a and 22b and whose protrusions 24 enter the concave indentation Y, making it difficult to pull out. This allows the crimped wire R to be smoothly pulled out from between the compression rollers 22a and 22b. The pulled-out crimped wire R is fed towards the cutting section 50 by the traction rollers 25a and 25b. As described above, the feed speed of the traction rollers 25a and 25b is faster than the feed speed of the compression rollers 22a and 22b, and the crimped wire R pulled out from the compression rollers 22a and 22b is pulled out in a tensioned state.

[0112] The crimped strand R, under tension, is fed from the traction rollers 25a and 25b and passes through the inlet 55 without moving up, down, left, or right, and is fed into the cutting section 50 after passing the cutting position C. Then, by rotating the cutter 51, the crimped strand R is cut at the cutting position C, producing recycled pellets P.

[0113] Figure 10The diagram shows the recycled particles P. (b) shows the case where the compression rollers 22a and 22b are weaker and the cross-section is approximately circular. (c) shows the case where the compression is slightly stronger and the cross-section is deformed into a flattened shape. The case where the cross-section is approximately circular is close to the original particles and is therefore preferred. Although all have concave indentations Y, the concave indentations Y can also be set as described above when heated. However, as described above, it is not necessary to have concave indentations Y, and it is also possible to have no concave indentations Y.

[0114] In the cutting of the crimped stranded wire R, the cutting angle generated by the shearing force F of the cutting blade 52 is the tilting angle θ relative to the vertical line S standing at the cutting position C towards the rotating compression part 10. Figure 8 The straight line is the tangent T to the trajectory D of the cutting position C relative to the end of the cutting blade 52. If the shearing force F is decomposed, it can be decomposed into a force F1 in the direction perpendicular to the S (the force used to cut the crimped strand R) and a force F2 perpendicular to the vertical S and in the direction of feeding the crimped strand R.

[0115] This force F2 becomes the pulling force of the crimped wire R during cutting. Since the cutting blades 52 reach the cutting position C one after another in a short period, a continuous pulling force F2 is applied to the crimped wire R during cutting. As a result, combined with the aforementioned feeding state, the inserted end of the crimped wire R during cutting does not shift within the inlet 55, allowing for smooth cutting without the need for conventional guide rollers. Therefore, the twisting release during cutting, which was previously a problem, can be eliminated.

[0116] In the above operation, when the loss membrane R is cut off at any location, the movement of the loss membrane R is stopped, the cover opening / closing cylinder 71 is activated to open the cover 62, and then the main body drive cylinder 68 is activated to retract the heating unit main body 61 from the movement line L of the loss membrane R. In order to retract the heating unit 61, it is not necessary to stop the air supply of the first heating unit 60 and the power supply of the heater 77 (reducing the heating time after recovery).

[0117] Then, the cut portion of the loss film R is removed, and the loss film R is reset and the first heating section 60 is restored as described above, and the process is restarted.

[0118] (First implementation method:) Figure 11 )

[0119] In the apparatus A2 of the first embodiment, a pre-extension conveying section 3 is also provided between the loss film supply section 1 and the first heating section 60.

[0120] Here, a pre-extension conveying section 3 and an intermediate conveying section 5 are prepared for the transport of the loss membrane R. Therefore, there are two possibilities: either a drive motor 4 and a drive motor 6 are provided on both the pre-extension conveying section 3 and the intermediate conveying section 5, or a drive motor is provided only on the pre-extension conveying section 3.

[0121] According to Figure (a), the case in which drive motors 4 and 6 are provided on both the pre-extension conveying section 3 and the intermediate conveying section 5 will be described.

[0122] In this case, the structure of the pre-extension conveying section 3 is the same as that of the intermediate conveying section 5 in its basic form, consisting of a pair of upper and lower pre-extension rollers 3a and 3b and a pre-extension drive motor 4 connected to the pre-extension roller 3b on the drive side.

[0123] The feed speed of the pre-extension conveying section 3 is slower than the traction speed of the intermediate conveying section 5. Within the first heating section 60, under a softened temperature atmosphere, tension is applied to the convergence loss film R between the pre-extension conveying section 3 and the intermediate conveying section 5, preparing it for extension. This allows for the production of materials that are not suitable for conventional devices, making them thin enough to be twisted, or allowing for a wider width. Furthermore, even harder materials can be softened.

[0124] In addition, to prevent slippage during the pre-extension process, the surfaces of the pre-extension rollers 3a and 3b are also provided with embossing (knurling, knurling). The other parts are the same as the basic shape.

[0125] In contrast, in the case shown in Figure (b), the intermediate conveying section 5 only has intermediate rollers 5a and 5b, and no intermediate drive motor 6 is provided. Therefore, the intermediate rollers 5a and 5b clamp the loss film R and rotate passively by being pulled in by the rotary compression section 10, becoming the starting point K of the twisting. Therefore, the delivery speed of the pre-extension conveying section 3 is slower than the pulling speed of the rotary compression section 10.

[0126] Furthermore, within the first heating section 60, under a softened temperature atmosphere, tension is applied to the convergence loss membrane R between the pre-extension conveying section 3 and the intermediate conveying section 5 to prepare it for extension.

[0127] (Second implementation method:) Figure 12 )

[0128] In the second embodiment, as described above, a second heating section 80 is also provided between the intermediate conveying section 5 and the rotary compression section 10.

[0129] The second heating unit 80 differs in size, but its structure and operation are the same as the first heating unit 60. It consists of a heating unit body 81, an opening and closing cover 82, a main body drive unit 86, a cover opening and closing mechanism 90, and a hot air supply unit 95, and includes a hinge 82a and a sliding mechanism 87 (guide shaft 87a, slider 87b, main body drive cylinders 88 and 91). Figure 7 To simplify the drawing, the first heating element 60 and the second heating element 80 are used together. Figure 5 , Figure 6 , Figure 7 ).

[0130] That is, in the second heating section 80, the heater 97 is energized while it is operating, and the air supplied through the hot air supply pipe 96 is heated to a predetermined temperature (softening temperature) and blown into the heating section body 81 to heat the secondary-heated stranded wire R passing through the heating space Z at this temperature. The hot air flows in a rotating manner in the heating space Z, heating the secondary-heated stranded wire R from the surface to the interior to a certain extent, at least uniformly heating the film on its surface portion, and then being ejected from the openings at the front and rear of the heating section body 81.

[0131] Since the second heating section 80 reheats the stranded wire R before it is pressed out from the intermediate conveying section 5 at a softening temperature, the viscosity is further improved. The density generated by the adhesion and twisting of the contacting loss films R is increased, and it is possible to produce regenerated particles with a density close to that of the original particles.

[0132] Furthermore, in this case, there are two possibilities: either the drive motors 4 and 6 are provided on both the pre-extension conveying section 3 and the intermediate conveying section 5, or the drive motor is provided only on the pre-extension conveying section 3. In both cases, the extension can be performed as described in the first embodiment, and further extension and twisting can be achieved during the secondary heating performed by the second heating section 80.

[0133] Explanation of reference numerals in the attached figures

[0134] A1, A2, A3: Regenerated granule manufacturing apparatus of the present invention; C: Cutting position; D: Trajectory of the cutting blade; F: Shearing force; F1: Force in the vertical direction; F2: Force in the pulling direction; H: Height of the cutter; Ko: Starting point of pre-extension; K: Starting point of twisting; L: Moving line; O: Rotation axis of the cutter; P: Regenerated (resin) granules; R: Raw material loss film; Pre-heated or pre-heated convergent loss film; Extended strand; Crimped strand; Pre-heated pre-extended convergent loss film; Secondary heating or secondary heating extended strand; S: Vertical line; T: Tangent; W1: Width of the raw material loss film; W2: Width of the convergent loss film; Y: Concave indentation; Z: Heating space; θ: Cutting angle.

[0135] 1: Loss film supply section; 2: Shrink section; 2a: Shrink hole; 3: Pre-extension conveying section; 3a, 3b: Pre-extension rollers; 4: Pre-extension drive motor; 5: Intermediate conveying section; 5a, 5b: Intermediate rollers; 6: Intermediate drive motor; 7: Base; 8, 9: Bearing; 10: Rotary compression section; 11: Rotating section; 12: Housing; 12a: Front section; 12b: Rear section; 15: First drive section; 16: First drive motor; 17: First drive pulley; 18: First synchronous belt; 9: First driven pulley; 21: Compression section; 22: Compression roller section; 22a: Compression roller on the pressure side; 22b: Compression roller on the drive side; 23: Rotating shaft; 24: Protrusion; 25a: Traction roller on the pressure side; 25b: Traction roller on the drive side; 26: Rotating shaft; 35: Second drive section; 36: Second drive motor; 37: Second drive pulley; 38: Second synchronous belt; 39: Second driven pulley; 40: Main gear component; 40a: Main gear; 40b: Hollow shaft section; 41: Driven... 42: Main worm gear; 43: Driven worm gear; 44: First transmission gear; 45: Second transmission gear; 46: Third transmission gear; 50: Cutting part; 51: Cutter; 52: Cutting blade; 54: Housing; 55: Inlet; 57: Receiving blade; 57s: Shearing surface; 60: First heating part; 61: Heating part body; 61a: Opening; 62: Opening and closing cover; 62a: Hinge; 66: Main body drive part; 67: Sliding mechanism; 67a: Guide shaft; 67b: Slider; 68 70: Main drive cylinder; 71: Cover opening and closing mechanism; 75: Cover opening and closing cylinder; 76: Hot air supply unit; 77: Hot air supply pipe; 88: Heater; 89: Second heating unit; 80: Heating unit main body; 81a: Opening; 82: Cover opening and closing mechanism; 82a: Hinge; 86: Main drive unit; 87: Sliding mechanism; 87a: Guide shaft; 87b: Slider; 88: Main drive cylinder; 90: Cover opening and closing mechanism; 91: Cover opening and closing cylinder; 95: Hot air supply unit; 96: Hot air supply pipe; 97: Heater.

Claims

1. A recycled pellet manufacturing apparatus, the recycled pellet manufacturing apparatus comprising: The loss film supply unit gathers one or more loss films made of thermoplastic resin to a predetermined width and supplies them to the intermediate conveying unit; The intermediate conveying section, while clamping the supplied loss membrane, simultaneously delivers the loss membrane, marking the starting point of the loss membrane's torsion; and A rotary compression section receives the loss membrane from the intermediate conveyor section, rotates relative to the intermediate conveyor section to twist the loss membrane, and pulls it faster than the delivery speed of the intermediate conveyor section to extend the loss membrane and deliver the stranded wire. The recycled pellet manufacturing apparatus manufactures recycled pellets by cutting the stranded wire fed from the rotary compression section to a predetermined length. Its features are, The recycled pellet manufacturing apparatus has a first heating unit provided between the loss membrane supply unit and the intermediate conveying unit. The first heating unit preheats the loss membrane at its softening temperature. The first heating unit consists of a heating unit body, an opening and closing cover, and a hot air supply unit. The main body of the heating section reciprocates between a heating position and a retraction position deviating from the heating position along a moving line around the convergent loss film to be heated. During this reciprocation, the opening, which serves as the inlet and outlet of the loss film to be heated, is formed across the entire surface of the surface on the moving direction side. The opening and closing cover closes the opening during heating, creating a heating space inside for the loss film. The hot air supply unit delivers hot air into the heating space.

2. The regenerated pellet manufacturing apparatus according to claim 1, characterized in that, A second heating section is also provided between the intermediate conveying section and the rotary compression section. The second heating section heats the pre-pressurized extended strand, which is twisted and extended by the intermediate conveying section and the rotary compression section, at the softening temperature of the pre-pressurized extended strand. The second heating unit consists of a heating unit body, an opening and closing cover, and a hot air supply unit. The main body of the second heating section reciprocates between a heating position and a retraction position that deviates from the heating position of the moving wire of the extended stranded wire undergoing secondary heating. During this reciprocation, the opening that serves as the inlet and outlet of the extended stranded wire undergoing secondary heating is formed across the entire surface of the surface on the moving direction side. The opening and closing cover of the second heating section closes the opening during heating, creating a heating space inside for the extended stranded wire undergoing secondary heating. The hot air supply unit of the second heating unit sends hot air into the heating space.

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