System and method for space-efficient distribution of shredded material in storage bins

Abstract

Low air-flow rate blower (23) applied to a shredded material storage bin (28) obtaining even, space-efficient, distribution of shredded material within storage bins' volumes.

Description

[0001] SYSTEM AND METHOD FOR SPACE-EFFICIENT DISTRIBUTION

[0002] OF SHREDDED MATERIAL IN STORAGE BINS

[0003] FIELD OF THE INVENTION

[0004] The present invention generally relates to the storage of shredded material, and more particularly to a system and method for the improved space efficiency of shredded material in storage bins.

[0005] BACKGROUND OF THE INVENTION

[0006] Recycling processes are configured to receive an input of disposed material and products thereof and to convert it to intermediary materials that may be used in downstream manufacture or ecologically safe disposal processes. Efficient and effective recycling processes are a key component in the development of sustainable infrastructure, considered generally as a global priority for industry and policy, and thus the barriers to entry presented by components of such processes represent significant challenges for the widespread adoption of recycling practice. Despite the multitude of available recyclable material types, shredding is process whose requirement is virtually unanimous to prepare materials for down stream processes. The economic efficiency of the shredding process is limited by a range of factors, including by the storage and transport costs of the shredded material.

[0007] Certain materials exiting a shredder, and thus entering a storage bin, will fall into and distribute within a storage bin in a Gaussian-like manner, producing a large void space in the storage bin. The total volume thus constituted by the storage bin is severely under-utilized by the stored recyclable material, and the resulting storage and subsequent transport costs are far higher than they would be for a storage bin with lower void space. Recyclable materials that demonstrate this behaviour include but are not limited to: paper; glass; aluminium; and various types of plastic.

[0008] This efficiency barrier is well recognised in the field, and a number of inventions have been disclosed in the prior art that provide partial solutions, each bearing their own limitations.

[0009] The system and method disclosed in US20090057455 describe a paper shredding system in which a vibration device is installed, wherein the vibration of the storage bin allows for more uniform settling of the shredded material therein. This system is highly effective for small scale paper shredding applications, where the low mass of the storage bin and its contents enable vibration with low energy requirements. The vibration method taught in US20090057455 is not applicable to larger shredding systems and systems configured to shred heavier material, as the energy required to effectively vibrate the storage bin and material contained therein would be unsuitably high, and the risk to other structural components posed by vibration of that strength would render the entire system too dangerous for use. For this reason and others, the system and method taught in US20090057455 is not applicable for use by waste recycling / reprocessing plants.

[0010] The system and method taught in US20110192922 describe a shredding system installed with an additional rotatable device with flexible fingers positioned beneath the shredder outlet, capable of disrupting the movement of shredded material from the shredding knives into the storage bin. Whilst the invention disclosed as US20110192922 is intended to solve the problem of shredded material becoming lodged or jammed on the underside of drive shafts installed with certain types of shredding knives, the introduction of disruption or turbulence to the flow of the shredded material into the storage bin has the indirect effect of decreasing void space within the storage bin, thus improving the storage and transport efficiency. The system and method taught in US20110192922 presents several key drawbacks that constrain the efficiency, cost, durability, and safety of shredding systems. Firstly, the system requires the installation of an additional mechanical part, which requires extra gearing components with associated mechanical failure risk, and the rotation of the rotatable device requires more energy, decreasing the efficiency of the overall system. Secondly, the rotatable device is required to be in contact with the shredding knives, presenting a range of mechanical risks to the: rotatable device; and the shredding knives; and the drive shaft and gearing mechanism to which they are attached. Thirdly, the system is designed to solve the problem caused by pieces of shredded paper jamming two shaft paper shredders, and the mechanism by which it operates would not be applicable to other kinds of shredding knives nor to other kinds of shredded material. For these reasons and others, the system and method taught in US20110192922 is not applicable for use by waste recycling / reprocessing plants.

[0011] These disclosures, and others known to a person skilled in the art, do not describe an efficient, durable, and adaptable system or method by which shredded material can be evenly distributed within storage bins, nor do they describe components which could be combined in order to do so. A need therefore exists for a system and method with which waste recycling / reprocessing plants might reduce void space in storage bins and thus improve storage efficiency.

[0012] SUMMARY OF THE INVENTION

[0013] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, devices and methods which are meant to be exemplary and illustrative and not limiting in scope. In various embodiments, one or more of the above- described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements.

[0014] According to one aspect of the invention, a system for the space-efficient distribution of shredded material produced by shredding machinery in storage bins comprises: a shredding device, at least one storage bin configured to aggregate shredded material flakes; a blowing device configured to produce low air-flow rate in the at least one storage bin; pipes, connectors and valves configured to distribute the blown air; a power source; a control device; whereby shredded material exiting the shredding device and entering the at least one storage bin is exposed to the air flow produced by the blowing device thereby equally distributing the shredded material in the storage bin volume.

[0015] According to another aspect of the invention, the blowing device is capable of producing an air flow rate of between 50 and 400 liters per second and an air speed between 10 and 100 kilometers per hour.

[0016] According to another aspect of the invention, once subject to the blowing device the shredded material is distributed within the at least one storage bin in a non-Gaussian-like distribution.

[0017] According to another aspect of the invention, the control device is configured to connect the power source to the blowing device during operation of the shredding device, and wherein the control device is configured to disconnect the power source from the blowing device when the shredding device is not operating.

[0018] According to another aspect of the invention, a method for the space-efficient distribution of shredded material produced by shredding machinery in storage bins comprises the steps: (a) inserting shredded material into a storage bin, equipped with a low rate air blowing apparatus; (b) connecting a power source to a blowing device using a control device; (c) exposing shredded material to low velocity air flow using a blowing device; (d) ejecting the shredded material into at least one storage bin in a non-Gaussian-like distribution; (e) disconnecting a power source from a blowing device using a control device.

[0019] BRIEF DESCRIPTION OF THE FIGURES

[0020] Some embodiments of the invention are described herein with reference to the accompanying figures. The description, together with the figures, makes apparent to a person having ordinary skill in the art how some embodiments may be practiced. The figures are for the purpose of illustrative description and no attempt is made to show structural details of an embodiment in more detail than is necessary for a fundamental understanding of the invention.

[0021] In the Figures:

[0022] FIG. la and FIG. lb constitute cross sections of storage bins without and with the present invention, respectively, according to some embodiments of the invention.

[0023] FIG. 2 constitutes a systematic overview of the complete shredding system, according to some embodiments of the invention.

[0024] FIG. 3 constitutes a 3 -dimensional diagram of the complete shredding system, according to some embodiments of the invention.

[0025] FIG. 4A - 4D constitutes cross sections of the blowing device, according to some embodiments of the invention

[0026] FIG. 5 constitutes a cross section of the blowing device, according to an embodiment of the invention. FIG. 6 constitutes a cross section of the blowing device, according to an embodiment of the invention.

[0027] FIG. 7A - 7F constitutes diagrams of the end section of the compound of pipes, valves, and connectors, according to some embodiments of the invention.

[0028] DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0029] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components, modules, units and / or circuits have not been described in detail so as not to obscure the invention. Some features or elements described with respect to one embodiment may be combined with features or elements described with respect to other embodiments. For the sake of clarity, discussion of same or similar features or elements may not be repeated.

[0030] Unless explicitly stated, the method embodiments described herein are not constrained to a particular order or sequence. Additionally, some of the described method embodiments or elements thereof can occur or be performed simultaneously, at the same point in time, or concurrently.

[0031] The present invention discloses a system and method of reducing void space in the storage bin of a shredding system.

[0032] Reference is made to FIG. la and FIG. lb, which constitute cross sections of storage bins without and with the present invention, respectively, according to some embodiments of the invention. In FIG. la a top opening 10 to a storage bin 11 having sides 12 is positioned underneath a shredding system not installed with the present invention, the shredded material 13 falls and distributes according to a Gaussian-like distribution, wherein the intersection 17a of: sides of the bin 12; the material 13; and the void space 14, is significantly lower than the peak of the material 17b, such that a significant portion of the volume of the storage bin 11 is void space 14, a large proportion of the available space that produces significant storage and transport inefficiency compared to a lower void space proportion. This case is contrasted with FIG. lb, with a top opening 10 to a storage bin 11 having sides 12 is positioned underneath a shredding system installed with a blowing device according to an embodiment of the invention. When affected by the employment of the blowing device of the present invention, shredded material 15 falls in a non-Gaussian-like distribution in the volume of the storage bin 11, wherein the intersection 18a of: sides of the bin 12, the material 15, and the void space 16, is only minimally lower than the peak of the material 18b, such that a very small portion of the volume of the storage bin 11 is void space 16. The reduction in size of the void spaces

[0033] 14 and 16, and the corresponding increase in the size of volumes occupied by shredded material 13 and 15, represents a major increase in the storage efficiency of shredded particles compared to the case illustrated by FIG. la.

[0034] Reference is made to FIG. 2, which constitutes a systematic overview of the complete shredding system, according to some embodiments of the invention. A power source 20 is in communication with a switch or valve 21 controlled by a control unit 22 which transfers electrical power from the power source 20 to a blowing device 23. According to some embodiments, the switch or valve 21 and the control unit 22 form part of a control system. The blowing device 23 produces a flow of air that travels through a compound of pipes, valves, and connectors 24 to a flake distribution zone 25 positioned underneath a shredding device 26 having an input 27 and a storage bin 28 having an internal storage volume 29. According to some embodiments, material is inserted into the input 27 of the shredding device 26 wherein it is shredded by the shredding device 26 to form shredded flakes that exit the shredding device 26 and enter the flake distribution zone 25. A control unit 22 is configured to sense the operation of the shredding device 26 and to connect the power source 20 to the blowing device 23 via the switch or valve 21, initiating the production of an airflow in the blowing device 23 that is transmitted through the compound of pipes, valves, and connectors 24 to the flake distribution zone 25. Airflow exiting the compound of pipes, valves, and connectors 24 into the flake distribution zone 25 interacts with the shredded flakes exiting the shredding device 26 as they fall into the internal volume 29 of the storage bin 28. Due to the interaction of the airflow with the shredded flakes in the flake distribution zone 25, the flakes accumulate in the internal volume 29 of the storage bin 28 in a non- Gaussian-like distribution, therefore producing a lower void space proportion of the volume and thus a higher storage efficiency.

[0035] Reference is made to FIG. 3, which constitutes a 3 -dimensional diagram of the complete shredding system, according to some embodiments of the invention. A power source 20 is in communication with a switch or valve 21 controlled by a control unit 22 which transfers electrical power from the power source 20 to a blowing device 23. According to some embodiments, the switch or valve 21 and the control unit 22 form part of a control system. The blowing device 23 produces a flow of air that travels through a compound of pipes, valves, and connectors 24 to a flake distribution zone 25 positioned underneath a shredding device 26 having an input 27 and a storage bin 28 having an internal storage volume 29. According to some embodiments, material is inserted into the input 27 of the shredding device 26 wherein it is shredded by the shredding device 26 to form shredded flakes that exit the shredding device 26 and enter the flake distribution zone 25. A control unit 22 is configured to sense the operation of the shredding device 26 and to connect the power source 20 to the blowing device 23 via the switch or valve 21, initiating the production of an airflow in the blowing device 23 that is transmitted through the compound of pipes, valves, and connectors 24 to the flake distribution zone 25. Airflow exiting the compound of pipes, valves, and connectors 24 into the flake distribution zone 25 interacts with the shredded flakes exiting the shredding device 26 as they fall into the internal volume 29 of the storage bin 28. Due to the interaction of the airflow with the shredded flakes in the flake distribution zone 25, the flakes accumulate in the internal volume 29 of the storage bin 28 in a non-Gaussian-like distribution, therefore producing a lower void space proportion of the volume and thus a higher storage efficiency. For the sake of clarity, the fitting between the compound of pipes, valves, and connectors 24 and the blowing device 23 is illustrated in FIG. 3 in an exploded fashion. For the sake of clarity, the storage bin 28 in FIG. 3 is illustrated with a partial cross section so as to reveal the internal volume 29 therein.

[0036] Reference is made to FIG. 4, which constitutes a cross section of the blowing device, according to two embodiments of the invention. According to some embodiments, the blowing device is a rotary lobe two-lobe positive displacement blower, as illustrated in FIG. 4a and FIG. 4b in different stages of the operation cycle. Air enters through inlet 40 where it is manipulated by the rotation of rotors 41 and 42, whose lobes tesselate to one another, and which rotate counter-clockwise and clockwise, respectively. Air is forced by the rotation of rotors to the outlet 43 through the central volume 44, as illustrated by the movement of air particles 47 through the volume 44 toward the outlet 43 from the cross-section FIG. 4a to the cross-section FIG. 4b. According to some embodiments, the blowing device is a rotary lobe three-lobe positive displacement blower, as illustrated in FIG. 4c and FIG. 4d in different stages of the operation cycle. Air enters through inlet 40 where it is manipulated by the rotation of rotors 45 and 46, whose lobes tesselate to one another, and which rotate counterclockwise and clockwise, respectively. Air is forced by the rotation of rotors to the outlet 43 through the central volume 44, as illustrated by the movement of air particles 48 and 49 through the volume 44 toward the outlet 43 from the cross-section FIG. 4c to the cross- section FIG. 4d. According to some embodiments, the lobes of the rotary lobe positive displacement blowers are extended as tessellating helices in the axis perpendicular to the viewing angle of the cross sections 4a-d to form a helical screw blower. Configuring an embodiment of the invention wherein the blowing device is a: two lobe positive displacement blower; a three-lobe positive displacement blower; or a helical screw blower, may be appropriate for shredding devices or combinations thereof of medium to large sizes, and / or for shredded materials requiring relatively high flow rates or flow velocities in order to fall into a storage bin in a Gaussian-like distribution.

[0037] Reference is made to FIG. 5, which constitutes a cross section of the blowing device, according to an embodiment of the invention. According to some embodiments, the blowing device is a centrifugal pump or impeller, having: an inlet 50; casing 51; internal volume 52; eye 53; a plurality of blades 54; and outlet 55. Air is drawn into the inlet 50 and forced by the rotation of the plurality of blades 54 around the axis of the eye 53 within the internal volume 52 of the casing 51 to the outlet 55. Configuring an embodiment of the invention wherein the blowing device is an impeller is appropriate for a broad range of shredding devices with broad range of sizes and for shredded materials including plastic, aluminium cans, and other similar material.

[0038] Reference is made to FIG. 6, which constitutes a cross section of the blowing device, according to an embodiment of the invention. According to some embodiments, the blowing device is an axial centrifugal pump, having: an inlet 60; internal volume 61; a plurality of blades 62; casing 63; an outlet 64; and a rotor 65. Air is drawn into the inlet 60 and forced by the rotation of the plurality of blades 62 around the axis of the rotor 65 within the internal volume 61 of the casing 63 to the outlet 64. Configuring an embodiment of the invention wherein the blowing device is an impeller is appropriate for a broad range of shredding devices with broad range of sizes and for shredded materials including plastic, aluminium cans, and other similar material.

[0039] Reference is made to FIG. 7, which constitutes diagrams of the end section of the compound of pipes, valves, and connectors, according to some embodiments of the invention. FIG 7a demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a circular cross section 70 of the pipe in communication with the blowing device extends to a small width horizontal slot shaped nozzle 71, according to an embodiment of the invention. FIG 7b demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a circular cross section 70 of the pipe in communication with the blowing device extends to a large width horizontal slot shaped nozzle 72, according to an embodiment of the invention. FIG 7c demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a circular cross section 70 of the pipe in communication with the blowing device extends to a horizontal wavy shaped nozzle 73, according to an embodiment of the invention. FIG 7d demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a circular cross section 70 of the pipe in communication with the blowing device extends to a horizontal rectangle shaped nozzle 74, according to an embodiment of the invention. FIG 7e demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a circular cross section 70 of the pipe in communication with the blowing device extends to a circular shaped nozzle 75, according to an embodiment of the invention. FIG 7f demonstrates a design of the end section of the compound of pipes, valves, and connectors, wherein a rectangular cross section 76 of the pipe in communication with the blowing device extends to a horizontal rectangular nozzle 77, according to an embodiment of the invention. According to some embodiments, the surface area of the cross section of the nozzle is larger than the surface area of the cross section of the pipe in communication with blowing device, producing a lower flow rate than that produced by the blowing device within the pipe. According to some embodiments, the surface area of the cross section of the nozzle is smaller than the surface area of the cross section of the pipe in communication with blowing device, producing a higher flow rate than that produced by the blowing device within the pipe. This range of end section geometries embodied in embodiments of the invention produce a range of air flows suitable for the interaction with various kinds of shredded flakes so as to produce non-Gaussian-like distributions of said flakes within storage bins below.

[0040] Although the present invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.

Claims

1. A system for the space-efficient distribution of shredded material produced by shredding machinery in storage bins, comprising: i. a shredding device, ii. at least one storage bin configured to aggregate shredded material flakes; iii. a blowing device configured to produce low air-flow rate in the at least one storage bin; iv. pipes, connectors and valves configured to distribute the blown air; v. a power source; vi. a control device; whereby shredded material exiting the shredding device and entering the at least one storage bin is exposed to the air flow produced by the blowing device thereby equally distributing the shredded material in the storage bin volume.

2. The system of claim 1, where the blowing device is capable of producing an air flow rate of between 50 and 400 liters per second and an air speed between 10 and 100 kilometers per hour.

3. The system of claim 1, wherein once subject to the blowing device the shredded material is distributed within the at least one storage bin in a non-Gaussian-like distribution.

4. The system of claim 1, wherein the control device is configured to connect the power source to the blowing device during operation of the shredding device, and wherein the control device is configured to disconnect the power source from the blowing device when the shredding device is not operating.A method for the space-efficient distribution of shredded material produced by shredding machinery in storage bins, comprising the steps: a. inserting shredded material into a storage bin, equipped with a low rate air blowing apparatus; b. connecting a power source to a blowing device using a control device; c. exposing shredded material to low velocity air flow using a blowing device; d. ejecting the shredded material into at least one storage bin in a non-Gaussian- like distribution; e. disconnecting a power source from a blowing device using a control device.

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