Frictional Heater for Plastic Processing

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Solution Overview

Problem

Existing plastic processing systems are inefficient, unable to handle all types of plastics, particularly film plastic and contaminated plastics, and are energy-intensive, with low tolerance for foreign bodies and unsuitable for processing blends, leading to energy wastage and equipment damage.

Innovation Solution

A system utilizing a cylindrical frictional heater with radially arranged molten plastic conduits and a drive mechanism for frictional heating, allowing localized heating and intimate mixing of plastics, including contaminants, with adjustable rotational speed and pusher pressure for efficient processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional heating methods are used to process plastic, then the plastic can be melted and processed, but the energy consumption is high due to heating the entire body of plastic

Engineering Contradiction:

Improveenergy consumptionVSAvoidenergy wastage

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The frictional heater applies localized heating at the point of contact between the rotating heater and plastic material, rather than heating the entire body of plastic. This localized approach significantly reduces energy consumption by concentrating thermal energy only where needed for processing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system replaces conventional thermal heating systems with a mechanical friction-based heating system. The rotating frictional heater generates heat through friction with the plastic material, substituting mechanical energy for thermal energy input and improving overall energy efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If shredder or scissor type plastic processing machines are used, then plastic can be processed, but the machines are easily damaged by foreign bodies within the plastic

Engineering Contradiction:

Improveprocessing capabilityVSAvoidequipment durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention replaces blade-based mechanical cutting systems with a frictional heating and compression system. This substitution eliminates the vulnerability to foreign bodies that plagues blade systems, as the frictional heater and compression mechanism are more tolerant of contaminants and foreign objects in the plastic material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If conventional plastic processing machines with low tolerance requirements are used, then the machines can operate with simple designs, but they are ill-suited for all types of plastics or foreign bodies

Engineering Contradiction:

Improvemachine design simplicityVSAvoidplastic type compatibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The frictional heating system provides a universal processing approach that can handle diverse plastic types and contaminated materials. The combination of frictional heating and compression creates a versatile system that adapts to different material compositions without requiring complex adjustments or specialized components for each plastic type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If conventional heating systems are used for plastic recycling, then plastic can be melted and reprocessed, but the process is energy intensive requiring heating of the entire body of plastic

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidheating energy requirement

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The frictional heater concentrates heating energy at the specific location where plastic material contacts the rotating heater surface. This localized heating approach processes plastic efficiently while minimizing the energy required compared to conventional systems that must heat the entire material body.

Inventive Principle:

Principle #3Local quality

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 system achieves energy-efficient processing, tolerates contaminants and foreign bodies, and can handle diverse plastic types, including blends, reducing energy consumption and equipment wear, while producing uniform and coherent products.

Implementation Method 1

a system and a method for frictional heating of plastic

Methodology Applied

Scientific EffectFrictional heating: Friction

Implementation Method 2

the frictional heater is adapted to rotate sufficient speed to cause intimate mixing

Methodology Applied

Scientific EffectIntimate mixing: Diffusion

Implementation Method 3

the frictional heater is arranged to allow molten plastic to flow from within the frictional heater and out of an outlet under gravity

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentEP3003668B1A system and a method for processing plastic

Publication Date: 2019.08.28 POLYWASTE INTPROP PTY LTD

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Figure 2

AI summary

There is provided with a system [100] for processing plastic wherein, in use, the system is adapted for the frictional heating of the plastic.