Continuous Recyclable Shingle Processing System
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Solution Overview
Problem
The existing batch process systems for recycling asphalt shingles are energy-intensive, time-consuming, and prone to material degradation, leading to high costs and inefficiencies in producing recyclable materials that meet performance standards.
Innovation Solution
A continuous system comprising a milling device to process recyclable materials into particulate, a transfer device for storage, a continuous processor to mix the particulate with admixtures, and a filler mixer to form shingle cores, controlled by a panel to optimize energy use and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a batch process system is used to recycle asphalt shingles, then the material can be processed and meet performance standards, but the energy consumption is high and processing time is long
Solution Approach 1:
The patent implements a continuous processing system where recycled asphalt shingles are continuously fed, ground, mixed with virgin asphalt, and formed into new shingles without batch interruptions. This continuous operation eliminates the heating and cooling cycles required in batch processes, significantly reducing energy consumption while maintaining product quality standards.
Solution Approach 2:
The system performs preliminary grinding of recycled shingles into fine particles before mixing, ensuring proper surface area for asphalt adhesion. This preliminary preparation allows the recycling process to integrate smoothly with the existing continuous shingle manufacturing line, avoiding the need for separate batch processing steps.
2Reliability
If a batch process system is used to recycle asphalt shingles, then the material can be processed, but the processing time is excessive leading to material degradation
Solution Approach 1:
The continuous processing system maintains constant motion through all processing stages—feeding, grinding, mixing, and forming—without the start-stop cycles inherent in batch processing. This eliminates extended exposure to heat and mechanical stress, preventing degradation of polymers and chemical additives while meeting performance standards.
Solution Approach 2:
The system rapidly processes recycled materials through the grinding and mixing stages in a continuous flow, minimizing the time materials spend in high-temperature zones. This rushed-through approach prevents thermal degradation while ensuring thorough mixing and proper bonding.
3Adaptability or versatility
If a batch process system is used, then recycling can be achieved, but the system complexity and cost increase due to additional tanks and heat exchangers
Solution Approach 1:
The patent merges the recycling process with the existing continuous shingle manufacturing line by integrating the ground recycled particles directly into the asphalt mixing and forming sections. This consolidation eliminates the need for separate batch tanks, heat exchangers, and handling systems, reducing overall complexity while maintaining full recycling capability.
Solution Approach 2:
The continuous processing system is designed to handle both virgin asphalt and recycled asphalt shingles through the same equipment train. The system can adjust parameters to process different material compositions, making the equipment multi-functional and eliminating the need for dedicated recycling infrastructure.
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 continuous system significantly reduces processing time, minimizes energy consumption, and prevents material degradation, enabling the efficient production of recyclable shingles while maintaining desired physical characteristics.
Implementation Method 1
A continuous processor receives the particulate and heats and mixes the particulate with asphalt and other components to form a homogenous mixture
Implementation Method 2
A mill receives the recyclable material and grinds the material into fine particles
Data Source
AI summary
A continuous system for making shingles from recyclable material is provided comprising a milling device to receive recyclable material and process the recyclable material into particulate and a transfer device to receive and transfer the particulate from the milling device. An apparatus receives the particulate from the transfer device and weighs the particulate. A continuous processor receives the particulate and reacts and/or mixes the particulate with at least one admixture to form a homogenous mixture. A filler mixer receives the homogenous mixture and incorporates the homogenous mixture with shingle material to form core product and a control panel controls input of the homogenous mixture into the filler mixer.