Counter-Rotating Plastic Processing Screw Design

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Solution Overview

Problem

Existing apparatuses for recycling plastics face issues with inconsistent quality and throughput due to variations in material properties, leading to mechanical and thermal stress, wear, and inefficiencies in processing sensitive or strip-shaped materials, which result in reduced performance and increased energy consumption.

Innovation Solution

The apparatus reverses the direction of rotation of the mixing and comminution implements relative to the conveyor, reducing feed pressure and preventing overfilling, allowing for improved intake and processing of materials with high quality and high throughput, while using smaller container diameters without compromising residence time or quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the screw rotation rate is raised to increase quantitative output, then productivity increases, but mechanical and thermal stress on material increases causing molecular chain damage

Engineering Contradiction:
Improvequantitative output of screwVSAvoidmechanical and thermal stress
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional approach by rotating the mixing and comminution implements in the opposite direction to the conveyor movement. This creates a counter-rotating effect that reduces feed pressure and prevents overfilling of the screw, allowing the screw to operate at lower rotation rates while maintaining productivity. The reverse rotation of mixing implements reduces mechanical and thermal stress on the plastic material, preventing molecular chain damage.

Inventive Principle:
Principle #13The other way round (Inversion)

2Manufacturing precision

If the flight depth of the metering zone of the screw is increased to improve material homogeneity, then manufacturing precision improves, but the screw rotation rate must be reduced lowering productivity

Engineering Contradiction:
Improvequality of plastified materialVSAvoidquantitative output of screw
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies reverse rotation of the mixing and comminution implements to reduce feed pressure and prevent overfilling of the screw. This allows the screw to operate with appropriate flight depth for material homogeneity while maintaining higher rotation rates and productivity. The counter-rotating mixing implements ensure uniform material distribution without requiring excessive flight depth.

Inventive Principle:
Principle #13The other way round (Inversion)

3Manufacturing precision

If the container residence time is increased to improve material homogeneity, then manufacturing precision improves, but productivity decreases

Engineering Contradiction:
Improvethermal and mechanical homogeneityVSAvoidthroughput of apparatus
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent uses counter-rotating mixing and comminution implements to enhance material homogeneity through improved mixing action. This allows for shorter residence times in the container while still achieving the required thermal and mechanical homogeneity, thereby increasing overall productivity. The reverse rotation creates more effective mixing patterns that reduce the time needed for homogeneous material preparation.

Inventive Principle:
Principle #13The other way round (Inversion)

4Manufacturing precision

If the diameter of the container is increased to improve material homogeneity, then manufacturing precision improves, but device complexity and space requirements increase

Engineering Contradiction:
Improvemechanical and thermal homogeneityVSAvoidcontainer size
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs counter-rotating mixing and comminution implements to achieve effective material homogenization without requiring large container diameters. The reverse rotation creates improved mixing patterns and heat distribution, allowing for compact container designs that maintain manufacturing precision while reducing device complexity and space requirements.

Inventive Principle:
Principle #13The other way round (Inversion)

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

This design enhances intake performance, increases throughput, and maintains high-quality output with reduced energy consumption and extended maintenance intervals, allowing for efficient processing of diverse plastic materials.

Implementation Method 1

is comminuted through rotation of the comminution and mixing implements and is fluidized, and is simultaneously heated by the energy introduced

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 2

is conveyed and, during this process, plastified or melted

Methodology Applied
Scientific EffectCompression: Compression

Implementation Method 3

the screw to subject the processed material to higher mechanical and thermal stress

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 4

is simultaneously heated by the energy introduced

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 5

heated by the energy introduced

Methodology Applied
Scientific EffectThermal energy: Thermal Energy Storage

Data Source

PatentUS9221198B2Apparatus for pre-treatment and subsequent conveying, plastification or agglomeration of plastic material
Publication Date: 2015.12.29 EREMA ENGINEERING RECYCLING MASCHINEN & ANLAGEN GMBH
  • US9221198B2 patent drawing
  • US9221198B2 patent drawing
  • US9221198B2 patent drawing

AI summary

Disclosed is an apparatus for processing plastics, having a mixing implement rotatable around an axis of rotation, wherein, in a side wall, an aperture is formed, through which the plastics material is removed, a conveyor being provided, with a screw rotating in a housing wherein the imaginary continuation of the longitudinal axis of the conveyor in a direction opposite to the direction of conveying passes the axis of rotation, and on the outflow side, an offset distance between the longitudinal axis and the radial that is parallel to the longitudinal axis, and the diameter D of the container has the following relationship to the diameter d of the screw:D=10·K·d23,whereD is the internal diameter in mm of the containerd is the diameter in mm of the screw andK is a constant which is in the range from 60 to 180.