Detectable Composite Material for Wear-Resistant Food Processing
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Solution Overview
Problem
Current composite materials detectable by metal detectors are not adequately used in food and pharmaceutical production lines due to lack of resistance to wear and fragmentation, and existing solutions are limited in applicability and effectiveness.
Innovation Solution
A composite material comprising a first plastic material and magnetizable, magnetized, or metal particles with a density gradient distribution within the plastic material, primarily using stainless steel particles, which can be manufactured through rotational molding or injection molding, ensuring detectability by metal detectors and enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plastic elements are used in production and packing lines, then they provide flexibility and ease of operation, but they are subject to wear and breakage causing fragments to contaminate products
Solution Approach 1:
The patent applies composite materials by incorporating magnetisable particles (such as iron, nickel, or cobalt) into the plastic matrix. This creates a composite plastic element that maintains the flexibility and operational advantages of plastic while adding detectability through the embedded magnetic particles. The composite structure allows the material to be detected by metal detectors even when fragmented, solving the reliability issue without sacrificing operational ease.
2Difficulty of detecting and measuring
If metal particulate is added to plastic material to enable detection, then detectability by metal detectors is improved, but the resistance to wear and fragmentation deteriorates
Solution Approach 1:
The patent applies parameter changes by carefully controlling the size, concentration, and distribution of magnetisable particles within the plastic matrix. By optimizing these parameters, the material achieves sufficient detectability by metal detectors while maintaining adequate mechanical strength and wear resistance. The particle size is kept small enough to not compromise structural integrity but large enough to provide detectable signal.
3Difficulty of detecting and measuring
If existing composite materials with metal particles are used, then detectability is achieved, but they are not suitable for food and pharmaceutical industries due to wear and fragmentation issues
Solution Approach 1:
The patent enables the use of detectable plastic elements in food and pharmaceutical applications by making fragments detectable through embedded magnetisable particles. This allows for monitoring and replacement of worn components before they cause contamination, effectively creating a system where components can be safely used until detection indicates they need replacement, reducing contamination risk.
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 composite material provides improved resistance to wear and fragmentation, ensuring detectability of fragments by metal detectors, thus preventing contamination in food and pharmaceutical production lines, with enhanced durability and suitability for various applications such as conveyors and seals.
Implementation Method 1
a first plastic material and a magnetisable, magnetised or metal material... The fragments of the composite material are detectable by a metal detector
Implementation Method 2
at least a first layer in the first plastic material in which the particles of magnetisable, magnetised or metal are sunk... has a gradient of density of the magnetisable, magnetised or metal particles
Implementation Method 3
The composite material articles of the first embodiment are produced with the following method which comprises the use of an apparatus for rotational moulding
Data Source
AI summary
The invention relates to embodiments of a new composite material comprising at least a first plastic material and particles of magnetisable, magnetised or metal material. The invention further concerns an article made of the composite material and a method for obtaining an article from the composite material.