Compacting Roller with Protruding Elements for Hollow Bodies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing compacting units for hollow bodies like beverage containers often result in permanent deformation and destruction of control marks, and the walls of compacted containers tend to separate during storage or transport, leading to inefficiencies and potential damage.
Innovation Solution
A compacting unit with a drivable roller featuring protruding elements that interact with a counter plate and scraper, allowing for controlled perforation and interlocking of container walls, along with a spring-loaded counter plate to manage non-compactable objects and a modular design for easy maintenance and replacement of worn parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two rollers with hook-shaped cutting edges are used for compaction, then the hollow body is drawn in and woven effectively, but the wall sections are pulled apart again during emergence, increasing storage volume
Solution Approach 1:
Instead of using two active rollers that both rotate and drive the material apart, the invention uses one driven roller with cutting edges and one stationary counter plate. The counter plate provides a fixed surface against which the roller's cutting edges work, preventing the wall sections from being pulled apart during emergence while maintaining effective compaction.
Solution Approach 2:
The roller is segmented into multiple cutting edges arranged around its circumference, allowing continuous processing of hollow bodies. The cutting edges are distributed along the roller surface to ensure uniform compaction and interlocking of wall sections without separation.
2Reliability
If control marks are destroyed on beverage containers, then deposit refund prevention is achieved, but the compaction process becomes more complex
Solution Approach 1:
The roller with cutting edges serves multiple functions simultaneously: it compacts the hollow body, interlocks the wall sections, and destroys control marks through the mechanical action of the cutting edges. This multi-functionality achieves deposit refund control without requiring additional specialized components.
3Manufacturing precision
If a fixed gap is maintained between roller and counter plate, then compaction precision is improved, but wear and maintenance requirements increase
Solution Approach 1:
The counter plate is made movable rather than fixed, allowing it to adjust its position dynamically. This dynamic adjustment compensates for wear of the cutting edges and maintains the optimal gap for compaction precision over time, reducing maintenance frequency while preserving manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables cost-effective, efficient compaction that prevents wall separation, devalues containers for deposit purposes, and reduces wear and maintenance needs, while maintaining operational safety and reducing odor formation through cooling.
Implementation Method 1
The elements interact with a counter plate as a non-driven counter bearing in such a way that a hollow body, such as a plastic bottle or a beverage can, is drawn in and crushed by the rotation of the roller
Implementation Method 2
a spring-loaded counter plate to manage non-compactable objects
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
In order to simplify the assembly and to achieve an improved compaction, the unit for compacting hollow bodies, for instance for non-returnable bottles, comprises a roller which can be driven, (1) featuring a plurality of protruding elements and a non-driven counter bearing (9', 9', 9'') with at least one recess, and is constructed in such a manner that the protruding elements, upon rotation of the roller, temporarily and at least partly engage with the recess and a deflector (6) which is downstream from the counter bearing in a rotational direction of the operated roller. Said deflector features at least one recess in which the protruding elements of the roller (1) temporarily engage during operation, at least partially.