Mesh structure and method of forming the same

Abstract

A method of forming a web of thermoplastic material, the method comprising the steps of: providing an apparatus comprising a comminutor and a bonding station; causing thermoplastic material to pass through the comminutor to form a ribbon of comminuted material; and then conveying the comminuted thermoplastic material through the bonding station to form a more integrated web configuration from the comminuted thermoplastic material. Such web material can be used for a variety of applications, such as cushioning, etc.

Description

Technical Field

[0001] Various embodiments of the present invention relate to mesh structures and methods for forming such mesh structures, particularly mesh structures made of thermoplastic materials. Background Technology

[0002] Plastic material recycling technologies that employ mechanical crushing of plastic materials are generally known.

[0003] For example, US6623676 describes a continuous method for reusing waste polyurethane, which involves moving fragments of thermosetting polyurethane foam while heating and subjecting the fragments to heat and pressure to form a web. The resulting material is said to be useful in many industrial applications, including fillers, gaskets, and insulation materials.

[0004] US7514026 describes, in another example, a method for recycling used floor coverings, wherein the floor coverings are pulverized to form a fiber dispersion. The pulverized fiber dispersion is fed into a chute feeder, which converts the pulverized fiber dispersion into wadding, which is heated, compressed, and cooled to form a durable backing particularly suitable for floor applications.

[0005] Thermoplastic flexible films, such as laminates, polyethylene, polypropylene, PET, polyester, polyamide (etc.), can often become waste unusable for their intended purpose. This can be due to improper storage conditions, where the thermoplastic material may be exposed to the natural environment, which degrades its properties, rendering it unusable for its intended use. Other reasons may include incorrect or outdated printing on these materials, rendering the film unusable for its intended purpose. Further reasons for this unusable waste may include waste generated during processes such as printing, cutting, or packaging (etc.). Such materials can be in the form of sheet rolls, thermoplastic material packages (etc.).

[0006] From both a commercial and environmental perspective, it is advantageous to find alternative uses for these degraded, low-cost (or potentially free) thermoplastic materials that still retain useful properties. Summary of the Invention

[0007] The following implementation methods and aspects thereof are described and illustrated in conjunction with systems, tools, and methods intended to be exemplary and illustrative rather than limiting.

[0008] In one embodiment, a method for forming a mesh structure from a thermoplastic material is provided, the method comprising the steps of: providing an apparatus including a pulverizer and a bonding station; causing the thermoplastic material to pass through the pulverizer to form strips of pulverized material; and then conveying the pulverized thermoplastic material through the bonding station to form a more integrated mesh configuration from the pulverized thermoplastic material.

[0009] In addition to the exemplary aspects and embodiments described above, other aspects and embodiments will become apparent by referring to the accompanying drawings and by studying the following detailed description. Attached Figure Description

[0010] Exemplary embodiments are illustrated in the accompanying drawings. The embodiments and drawings disclosed herein are intended to be illustrative rather than restrictive. However, both the organization and operation of the invention, as well as its objects, features, and advantages, can be best understood by referring to the following detailed description, in conjunction with the accompanying drawings:

[0011] Figure 1A An apparatus for forming a mesh from a roll of thermoplastic material according to an embodiment of the present invention is shown schematically.

[0012] Figure 1B It schematically shows that it can be Figure 1A Possible combination stations used in the equipment;

[0013] Figure 2 A schematic view of an embodiment of a device for receiving incoming materials, such as the pulverizer shown in Figure 1;

[0014] Figure 3 schematically shown Figure 2 An enlarged cross-section of a portion of the shredder shown;

[0015] Figure 4 The illustration shows a material made by a pulverizer, such as... Figure 3 The strips of thermoplastic material pulverized by the pulverizer shown are shown; and

[0016] Figure 5 A cross-section of a mesh according to an embodiment of the present invention is shown schematically.

[0017] It will be understood that, for the sake of brevity and clarity, the elements shown in the accompanying drawings are not necessarily drawn to scale. For example, for clarity, the dimensions of some elements may be enlarged relative to others. Furthermore, reference numerals may be repeated in the drawings where deemed appropriate to indicate similar elements. Detailed Implementation

[0018] First, focus on Figure 1, which schematically illustrates an apparatus 10 for forming a mesh 12 according to an embodiment of the present invention. In this example, the apparatus 10 is arranged to convey a thermoplastic material 14 (possibly a thermoplastic laminate) downstream, optionally from coil 16 toward the pulverizer 18 of the apparatus. Examples of thermoplastic materials that can be used in various embodiments of this disclosure may include thermoplastic flexible films, such as laminates, polyethylene, polypropylene, PET, polyester, polyamide (etc.).

[0019] As can be seen, for example, in Figure 1, the thermoplastic material 14 can be in the form of a sheet of material, which can be wound onto a reel. In other embodiments, a package (not shown) containing the thermoplastic material can be used to supply material such as the thermoplastic material 14. The thermoplastic material in such a package can be recycled plastic received from a material recycling facility (etc.).

[0020] The equipment also includes an optional conveyor 20 for conveying the thermoplastic material in its pulverized form 22 downstream toward a bonding station 24 after passing through the pulverizer 18, where the pulverized material 22 can be converted into a mesh 12 suitable for various applications.

[0021] exist Figure 1A In the example shown, the bonding station is optionally in the form of a heating station, where the pulverized thermoplastic material 22 can be formed into a mesh 12. Figure 1B In the example shown, the bonding station is optionally in the form of a packaging station, such as a continuous packaging machine or a packer, where the pulverized thermoplastic material 22 can be formed into a mesh 12.

[0022] According to various aspects of the invention, the pulverizer 18 can be of various types, such as a twin-roller single-shaft pulverizer, a twin-roller rotor double-single-shaft pulverizer, etc. In the examples described in detail below, the selection of the pulverizer 18 as a twin-shaft shearing pulverizer will be discussed.

[0023] focus on Figure 2 It provides a view of the thermoplastic material 14 as it is conveyed downstream to enter the pulverizer 18. In embodiments of the invention, the pulverizer 18 may be a preferred form of a biaxial shear pulverizer, as seen here, which includes an upper shaft member 181 and a lower shaft member 182.

[0024] focus on Figure 3The illustration provides an enlarged view of section III of the crusher 18, where shaft members 181 and 182 engage. In the example shown, each shaft member includes a respective array 171 and 172 of spaced-apart teeth 17; and the tooth tip region 1 of each array is arranged within a spacing 2 between the teeth 17 of the opposing array of another shaft member, where the shaft members 181 and 182 engage.

[0025] Material 14 passing through the region where the central axial members 181 and 182 engage may be subjected to a considerable shear force F applied by the engaging teeth, thereby forming substantially continuous strips of pulverized material that are substantially separated from each other.

[0026] In an aspect of the invention, a shear force F is applied to the material during the formation of each strip to deform the thermoplastic material within each strip, thereby creating a configuration similar to a coiled spring at each strip.

[0027] focus on Figure 4 The illustration shows a series of enlarged cross sections, starting with the thermoplastic material in its pulverized form 22 after passing through the pulverizer 18, and then an enlarged view of the cross section showing a single strip 221, and then a further enlarged view showing a close-up view of the strip 221, which shows a spring-like coiled structure 2210 formed within each strip due to passing through the pulverizer 18.

[0028] Therefore, the thermoplastic material in its pulverized form 22 exhibits spring-like elasticity due to its formation of intertwined strips, and thus the pulverized form 22 can be regarded as having a spring structure similar to foam, wherein air pockets are formed between the intertwined strips.

[0029] Return to Follow Figure 1A The thermoplastic material, in its pulverized form 22, is then conveyed within the apparatus 10 via a bonding station 24 to form a mesh 12. In an aspect of the invention, the bonding station 24 can be used to at least slightly stabilize the thermoplastic material in its pulverized form, so that it presents a more useful structure that can have a variety of applications.

[0030] The combined station 24, in an optional form as a heating station, is implemented as a pair of hot wheels through which the pulverized material passes. However, in other embodiments (not shown), the heating station may be in the form of any device suitable for melting at least a portion of thermoplastic material (e.g., by applying heat, ultrasonic vibration, etc.).

[0031] focus on Figure 5The illustration shows an embodiment of the mesh 12, wherein the upper and lower portions 121 of the mesh 12 are slightly melted due to exposure to a heating station. By causing the thermoplastic material to slightly melt and then harden, at least some of the thermoplastic material within the mesh 12 is reshaped, thereby transforming the mesh 12 into a slightly more integral configuration, thus making it suitable for various applications accordingly.

[0032] As mentioned earlier, the combination station 24 can take various forms, such as Figure 1A The heating station seen in the video Figure 1B The packaging station seen in the image, or any other suitable solution that helps to form a more integrated and usable mesh structure.

[0033] In a non-constrained example, the mesh 12 can be used as an insulating and / or lining material and / or cushioning and / or packaging material for various object types.

[0034] In the specification and claims of this application, each verb in the verb form, including, comprising, and having, and its cognates, is used to indicate one or more objects of the verb, which are not necessarily a complete list of components, parts, elements, or portions of one or more subjects of the verb.

[0035] Furthermore, although this application or technology has been illustrated and described in detail in the accompanying drawings and foregoing description, such illustrations and descriptions should be considered illustrative or exemplary rather than restrictive; therefore, this technology is not limited to the disclosed embodiments. Those skilled in the art and those skilled in the art practicing the claimed technology will understand and implement variations of the disclosed embodiments by studying the drawings, the technology, and the appended claims.

[0036] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude multiple. A single processor or other unit can perform the functions of several items stated in the claims. The fact that certain measures are stated only in mutually different dependent claims does not mean that a combination of these measures cannot be used advantageously.

[0037] In this context, terms, features, values, or ranges, when used in conjunction with terms such as "about," "approximately," "substantially," "generally," or "at least," are also understood to include precise terms, features, values, or ranges. In other words, "about 3" should also include "3," or "substantially vertical" should also include "vertical." No reference numerals in the claims should be considered as limiting the scope.

[0038] Although this embodiment has been described to some extent, it should be understood that various changes and modifications can be made without departing from the scope of the invention as claimed.

Claims

1. A method for forming a mesh structure from a thermoplastic flexible film, the method comprising the following steps: Equipment is provided that includes a dual-shaft shear-type shredder and a combined unit in the form of a heating station. The thermoplastic flexible film is passed through the pulverizer to form strips of pulverized material, and then... The pulverized thermoplastic material is conveyed through the bonding station to form a more integrated mesh configuration of the mesh structure. In this process, most of the strips of the pulverized thermoplastic material are substantially continuous, wherein the thermoplastic material is exposed to shear forces applied by the engaging teeth as it passes through the pulverizer, thereby forming the pulverized thermoplastic material, wherein the shear forces applied to the material as each strip is formed within the pulverized material deform the thermoplastic material within each strip, thereby producing a configuration similar to a coiled spring at each strip; Furthermore, the pulverized thermoplastic material strips include a configuration similar to a coiled spring. Furthermore, the strips of pulverized thermoplastic material are wound within the mesh structure.

2. The method according to claim 1, wherein, The heating station is adapted to melt one or more outer portions of the pulverized thermoplastic material to form a more integrated mesh configuration of the mesh structure.

3. The method according to claim 1, wherein, The pulverizer includes a pair of shaft members, and the thermoplastic material passes through the pulverizer between the pair of shaft members.

4. The method according to claim 3, wherein, Each shaft member includes an array of spaced-apart teeth, and the tooth tip region of each array is arranged within the spacing between the teeth of the opposing array formed on another shaft member, the shaft members engaging at the tooth tip region.

5. The method according to claim 1, wherein, The mesh structure is used as an insulating material and / or lining material and / or cushioning material and / or packaging material.

6. A cushioning material formed of a mesh structure, said mesh structure comprising strips of thermoplastic material, wherein, The strip has a configuration similar to a coiled spring. The thermoplastic material strips are formed by passing sheets of thermoplastic material through a shredder, wherein the shredder is a biaxial shear-type shredder comprising a pair of shaft members, and the thermoplastic material passes through the shredder between the pair of shaft members. The passage of the thermoplastic material through the shredder exposes it to shear forces applied by engaging teeth, thereby forming the shredded thermoplastic material. The shear forces applied to the material deform the thermoplastic material within each strip, thereby creating a spring-like configuration at each strip. The strips of thermoplastic material are bonded in a bonding station that serves as a heating station.

7. The cushioning material according to claim 6, wherein, Most of the strips of pulverized thermoplastic material are substantially continuous.

8. The cushioning material according to claim 7, wherein, The strips of pulverized thermoplastic material are wound around the mesh structure.

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