Hygiene Article Recycling Unit With Air-Jet Pulp and SAP Separation
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Solution Overview
Problem
Current hygiene article recycling systems face challenges in achieving high purity separation of pulp and superabsorbent polymer (SAP) from plastic materials, leading to reduced recyclate value, congestion during processing, and high operational costs due to complex sealing and heavy bearings.
Innovation Solution
A hygiene article recycling unit comprising an infeed buffer, stream equalization, pre-destruction device, shredding and separation system, and pulp/SAP separation system, utilizing rotating drums with apertured shells, vibration separators, and air jet systems to achieve purities of over 99% for pulp and SAP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gravity-based transfer between stages is used, then equipment structure is simplified, but material congestion occurs during transfer
Solution Approach 1:
The patent employs pneumatic conveyance systems to transport separated materials between processing stages, replacing gravity-based transfer. This eliminates material congestion by using controlled air streams to move materials smoothly and continuously through the recycling unit, maintaining high productivity while keeping the equipment structure relatively simple.
2Ease of manufacture
If cantilevered mounting of rotating drum is used, then installation is simplified, but heavy and costly bearings are required
Solution Approach 1:
The patent employs counterbalancing mechanisms for the rotating drum assembly, using counterweights to offset the drum's weight. This allows the use of lighter, less expensive bearings while maintaining stable operation, as the counterweights compensate for the gravitational force on the drum, reducing the load on the bearing supports.
3Adaptability or versatility
If moving parts interfaces between stage modules are used, then modular assembly is enabled, but complex sealing is required
Solution Approach 1:
The patent employs flexible sealing elements such as bellows or expandable membranes at the interfaces between modular stages. These flexible components can accommodate relative movement and misalignment between modules while maintaining effective seals, enabling modular assembly without requiring complex rigid sealing arrangements.
4Manufacturing precision
If separation purity of 99% is achieved, then recyclate value is maintained, but additional purification steps are needed
Solution Approach 1:
The patent replaces complex mechanical purification systems with field-based separation methods, such as electrostatic or magnetic fields, to achieve the required 99% purity. This reduces mechanical complexity while maintaining high separation efficiency, as field-based methods can achieve fine separation without multiple mechanical stages.
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 effectively separates pulp and SAP with purities greater than 99%, enabling direct reuse in hygiene article manufacturing, reduces congestion, and lowers operational costs by using lightweight components and efficient air management.
Implementation Method 1
air jet systems to achieve purities of over 99% for pulp and SAP
Implementation Method 2
vibration separators
Data Source
AI summary
The present invention relates to an equipment in the field of hygiene article manufacturing, in particular to a hygiene article recycling unit for disintegrating and separating hygiene articles allowing to separate raw materials at a purity allowing to directly use it in the manufacturing process of the hygiene articles. The recycling unit comprised several devices as sub-units. The present invention further relates to a process for operating such an equipment.