Semi-automated mobile reactor for multi-purpose household and personal care products

Abstract

The present invention introduces the first semi-automated mobile reactor designed for making household and personal care products. It consists of two stands: one for holding a mixing container and the other for supporting a motor, hoppers, and a paddle mixer. The motor is placed in front of the hoppers and connected to the paddle mixer through a shaft suspended in the mixing container, which the paddle mixer has three blades, one of which is perforated for improved dispersibility of chemical ingredients. The control panel, attached to the second stand, includes components like a circuit breaker, on / off button, timer switch, solenoid valve, indicator switch, and emergency stop button. Chemical ingredients are fed and dispensed into the hoppers through the solenoid valve, regulated by the timer.

Description

[0001] SEMI-AUTOMATED MOBILE REACTOR FOR MULTI-PURPOSE HOUSEHOLD AND PERSONAL CARE PRODUCTS

[0002] Specification

[0003] FIELD OF THE INVENTION

[0004] This invention relates to a mobile reactor for multi-purpose household and personal care products. More particularly, it relates to a reactor equipped with a semiautomated operation system capable of accommodating a maximum capacity of 100 liters per batch for the production of liquid dishwashing detergent and other personal care products.

[0005] BACKGROUND OF THE INVENTION

[0006] Most of Micro, Small and Medium Scale Entrepreneurs (MSME's) involved in the manufacture of liquid dishwashing and detergent are using the tedious process of manual mixing of production. Varied reasons why most MSME's opted the manual production instead of a semi-automated process of mixing are due to availability of local design, access to suppliers or local fabricators and high cost of imported equipment. Based on Industrial Technology Development Institute (ITDI) experience and feedbacks, most clientele and technology adaptors of liquid dishwashing and detergent soaps are seeking for local suppliers of equipment that will offer a better, efficient and preferably equipped with semi-automated type of operation for producing such product.

[0007] Since ITDI is the forefront in research and technology of the government, the Process Development Section of Chemicals and Energy Division (PDS-CED) embarked on a project and developed locally designed and fabricated relatively low- cost reactor / mixer for the production of liquid dishwashing and detergent using a semi-automated system of operation. Through semi-automation process, the developed technology provides several advantages such as increase in productivity, improved equipment utilization, consistent product quality, better material efficiency usage, reduced health risk of production workers and offers an ergonomically designed processing reactor that is convenience to the whole production system.

[0008] The present semi-automated mobile reactor will basically cater existing producers of liquid dishwashing and detergent who wanted to shift from manual production to semi-automated system of production. It will also be an option for new entrepreneurs who would like to venture into business at a level of a commercial scale of at least 100L capacity per batch. The present semi-automated mobile reactor will also provide business opportunities for local fabrication industry services in the Philippines.

[0009] The project will likewise be beneficial and useful for GAD related projects in relation to women empowerment on entrepreneurial skills development as well as serve as an alternative livelihood project. The present semi-automated mobile reactor is useful for actual demonstration, presentations, and in-house trainings for liquid dishwashing and detergent soap processing.

[0010] SUMMARY AND OBJECT OF THE INVENTION

[0011] The primary object of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products which comprises a first frame stand configured to support a mixing container and a second frame stand configured to hold a motor, hoppers and a paddle mixer at its top portion thereof, said motor positioned in front of the hoppers and coupled to the paddle mixer through a shaft downwardly suspended at the center of the mixing container, said paddle mixer comprises three blades, with the center blade is perforated; and a control panel mounted on a side of the second frame stand comprises a circuit component of a circuit breaker, on and off button, analog timer switch, electric solenoid valve, light indicator switch and emergency stop button, wherein feeding and dispensing mechanism of chemical ingredients at the hoppers is controlled by the electric solenoid valve and is regulated by the analog timer.

[0012] Another objective of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products to address the need for locally available designs that can be readily adopted by local fabricators and household product manufacturers, at an affordable price and with ease of maintenance and fabrication.

[0013] Still, the objective of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products having a semi-automated system of operation with a maximum capacity of 100 liters per batch of production.

[0014] Still, the objective of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products equipped with a hopper and an electric solenoid valve of which the head is attached to a stopper made of high temperature engineered plastic placed inside the stopper guide which serve as the major components of the feeding and dispensing mechanism, configured to hold the chemical ingredients, and it features an ergonomically designed detachable mixing assembly installed with three impeller mixers, with the middle portion perforated.

[0015] Still, the objective of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products equipped with an analog timer device serving as a controller to manage all the components of the feeding and dispensing process of chemical ingredients inside the hopper.

[0016] Still, the object of the present invention is to provide a semi-automated mobile reactor for multi-purpose household and personal care products that is equipped with wheels making it mobile and transportable from one place to another suitable as a shared service unit, among producers within members of a cooperative or an association.

[0017] These and other objects will become apparent upon reading the following detailed description taken in conjunction with the accompanying drawing.

[0018] BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0019] Figure 1 is a perspective view of a semi-automated mobile reactor for multipurpose household and personal care products as embodied in the present invention;

[0020] Figure 2 is a front view of a control panel as embodied in the present invention;

[0021] Figure 3 is a perspective view of a disunited first frame stand and second frame stand as embodied in the present invention;

[0022] Figure 4 is a perspective view of a paddle mixer;

[0023] Figure 5 shows a perspective view of an upper portion of a shaft having knurled for adding grip;

[0024] Figure 6 shows perspective view of an electric powered push and pull cylindrical solenoid valve attached with high temperature engineered plastic;

[0025] Figure 7 shows hoppers with cover; and

[0026] Figure 8 shows a perspective view of a connector bolted in a motor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The present invention will now be described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process or method have not been described in detail in order to not unnecessarily obscure the present invention.

[0028] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.

[0029] With reference to the several views of the drawings, it shows a perspective view of a semi-automated mobile reactor for multi-purpose household and personal care products generally known as reference 10. The reactor 10 comprises a first frame stand 16 and a second frame stand 17. Both frames 16 and 17 are equipped with caster wheels 15 and handle 18a placed at the back for ease of transport within the production area and provision in case the reactor 10 requires service maintenance. The two rear caster wheels of both frames 16 and 17 are equipped with breaking mechanism to ensure immobility and complete stop of the first frame 16 when removing the mixing paddle and replace the mixing container 14 and the second frame 17 when transferring the loaded mixing container 14 in product holding area. The height of the first frame stand 16 is enough to load the mixing container 14. The first frame stand 16 is also called as a drum trolly truck 18. The drum trolley truck 18 elevation can accommodate even 5 gallons container. The base of the trolley truck 18 was installed with angle bars to secure and support the load of the mixing container 14 during operation even at full capacity. The trolley truck 18 is equipped with a metal chain belt 32 to safeguard and hold the mixing container 14 in place during mixing operation and transport of mixed product within the production and bottling / packing area.

[0030] In the present invention, the mixing container 14 is configured to accommodate 100 liters by volume of chemical ingredients, but not limited thereto, providing optimal capacity for the intended chemical reactions. The mixing container 14 discharge valve height is situated at the lower portion and can accommodate big container such as gallon or carboy of 4 to 20L capacity in repacking of products for institutional market.

[0031] In the present invention, the semi-automated mobile reactor 10 includes a control panel 13 mounted at the right portion of the second frame stand 17, but not limited in such location. The control panel 13 housed the circuit components of circuit breaker, On and Off buttons 21 to 24, analog timer switches T1 to T5, electric solenoid valve 60, light indicator switch 26, magnetic contactor (not shown) and emergency stop button 25.

[0032] The hoppers 12 for chemical ingredients comprises a cover 12a to prevent contamination and tapered bottom 12aa concentrated towards the center of the mixing container 14. The mixing container 14 is a High-Density Polyethylene (HDPE) drum, but not limited thereto, any type of mixing container may also be applied.

[0033] The geared motor 11 was strategically placed in front of the hoppers 12 to attune the design of a paddle mixer 40 at the center of the mixing container 14 as depicted in Figs. 3 and 4.

[0034] Another embodiment of the present invention includes other mechanical parts such as hoppers 12, hopper cover 12a, hinges, hopper guide and panel box, electricals and controls including circuit breaker, "On" and "Off button, emergency stop button, analog timer switch, electric solenoid valve, light indicator switch, magnetic contactor; and other peripherals necessary for the completion on semiautomated mobile reactor 10. Figure 7 shows feeding / dispensing mechanism of hoppers 12 of different volumes installed with covers 12 and hinges 12b made of SS material, while Figure 6 shows the electric cylindrical solenoid valve 60 capable of push and pull motion. The solenoid head 61 is attached to a stopper 62 made of high temperature engineered plastic placed inside the stopper guide 63.

[0035] The three blades 41 of paddle mixer 40 of different orientations were connected in a stainless-steel shafting 30. The center blade 42 is perforated to facilitate better dispersion of solids and to enhance mixing and reaction process of chemical ingredients. These blades 41 provide agitation and promotes radial and tangential flow. Other embodiment of the paddle blades 41 may also applied to enhance better rotation and mixing especially for viscous products. The upper portion of shafting 30 is knurled 50 for adding grip and to provide assistance in the assembly and disassembly of mixing paddle 40 (see Figs. 4 and 5). The diagonal angle of the paddle blades 41 is raised to 45 °C to be able to create better axial and longitudinal agitation movement even at full capacity of the mixing container 14. The orientation of the bottom paddle blade 42 and center paddle blade 43 create an upward movement of the liquid while the topmost paddle blade 44 pushed the liquid down creating a better and more efficient vertical circulatory flow.

[0036] Figure 8 shows the shafting of the paddle mixer 40 vertically suspended to an ergonomically designed connector or collar 80, providing a quick release and easy attachment of the paddle mixer 40 after end of every production cycle. Its "U" shaped grooved design 82 hold and secures the lock pin 81 in place and ensure sturdiness of the paddle mixer 40 during operation. This connector is bolted in the geared motor shaft for added stability. The geared motor 11 drives the paddle mixer 40 in clockwise manner.

[0037] The dispensing of chemicals inside the hopper 12 is controlled by an analog timer T1 to T5 through an electric powered cylindrical solenoid valve 60. The five analog timers T1 to T5 correspond to five electric solenoids found at the bottom of the hopper 12. The topmost timer T1 controls the leftmost hopper while the bottom timer T5 relates to the rightmost hopper following a clockwise orientation of dispensing. Light indicators 26 are provided to inform the operator whether the machine is operational or in hibernate mode. Emergency stop button 25 is also installed for safety and added protection of operators. Setting can be done in seconds or minutes for a maximum time of 1 .5 hour (see Fig. 2).

[0038] Several advantages were observed when using the present 100L semiautomated mobile reactor 10. Table A shows detailed comparative analysis of semiautomated mobile reactor 10 from the existing reactor.

[0039] Table A

[0040] The foregoing preferred embodiments of this invention are illustrated as an example ofthis invention ratherthan limitation of this invention. It is intended to cover various modifications and changes included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar products.

Claims

What is claimed is:

1. A semi-mobile automated reactor for multi-purpose household and personal care products, comprising: a first frame stand configured to support a mixing container and a second frame stand configured to hold a motor, hoppers and a paddle mixer at its top portion thereof, said motor positioned in front of the hoppers and coupled to the paddle mixer through a shaft downwardly suspended at the center of the mixing container, said paddle mixer comprises three blades, with the center blade is perforated; and a control panel mounted on a side of the second frame stand comprises a circuit component of a circuit breaker, on and off buttons, an analog timer switch, an electric solenoid valve, a light indicator switch and an emergency stop button, wherein feeding and dispensing mechanism of chemical ingredients at the hoppers is controlled by the electric solenoid valve and is regulated by the analog timer.

2. The semi-mobile automated reactor according to claim 1 , wherein both the first frame stand and second frame stand are equipped with caster wheels and handle at the back, respectively, for ease of transport within the production area and provision in case the reactor requires service maintenance.

3. The semi-mobile automated reactor according to claim 2, wherein the two rear caster wheels of both frames are equipped with breaking mechanism to ensure immobility and complete stop of the first frame when removing the paddle mixer and replace the mixing container and the second frame when transferring the loaded mixing container in product holding area.

4. The semi-mobile automated reactor according to claim 1 , wherein the mixing container is capable of accommodating a maximum capacity of 180 liters per batch for the production of liquid dishwashing detergent and other personal care products.

5. The semi-mobile automated reactor according to claim 1 , wherein the hopper is made of stainless steel and is equipped with the electronic solenoid valve, the head of which is attached to a stopper made of high-temperature engineered plastic placed inside a stopper guide.

6. The semi-mobile automated reactor according to claim 4, wherein the mixing container is High-Density Polyethylene drum.

7. The semi-mobile automated reactor according to claim 4, wherein the mixing container comprises a discharge valve situated at the lower portion thereof.

8. The semi-mobile automated reactor according to claim 7, wherein the mixing container discharge valve height situated at the lower portion can accommodate big container of 4 to 20L capacity.

9. The semi-mobile automated reactor according to claim 1 , wherein each of said three blades is oriented differently, with the center perforated to facilitate improved dispersion of solids and to enhance mixing and reaction of chemical ingredients within the mixing container.

10. The semi-mobile automated reactor according to claim 9, wherein the bottom blade is oriented upwardly to push the liquid upward, while the top blade is oriented downwardly to top push liquid downward.11 . The semi-mobile automated reactor according to claim 1 , wherein said shaft upper portion was knurled to add gripping and to provide assistance in the assembly and disassembly of the paddle mixer.

12. The semi-mobile automated reactor according to claim 11 , wherein said shaft is vertically coupled to the motor through an ergonomically designed connector or collar, thereby providing a quick release and easy attachment of the shaft after end of every production cycle.

13. The semi-mobile automated reactor according to claim 12, wherein the connector comprises a U-shaped groove like that is configured to hold and secures a lock pin in place and ensure sturdiness of the paddle mixer during operation.

14. The semi-mobile automated reactor according to claim 10, wherein the angle of the paddle mixer is 45 °C.

15. The semi-mobile automated reactor according to claim 1 , wherein the hopper includes a cover and tapered bottom concentrated towards the center of the mixing container.

16. The semi-mobile automated reactor according to claim 1 , wherein the first frame stand includes a metal chain belt for securing the mixing container during the production process.

17. The semi-mobile automated reactor according to claim 1 , wherein the mixing container is configured to accommodate precisely 100 liters by volume of chemical ingredients, providing optimal capacity for the intended chemical reactions.

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