Plastic Compactor Using Mechanical Press Rollers for Granulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current plastic granulation methods using slit die extruders are energy-intensive, costly, and result in significant material loss due to filtration and cooling processes, leading to suboptimal mechanical properties and increased production costs, with high energy consumption and inefficient use of materials.
Innovation Solution
A compactor system that uses mechanical energy to granulate plastic materials at controlled temperatures between 100°C and 120°C, eliminating the need for heating and cooling, and incorporating a perforated spinneret with rollers to produce uniform granules with improved mechanical resistance and surface welding, allowing for continuous extrusion without gaseous formations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional slit die extruders are used to melt and granulate plastic materials, then granules can be produced, but energy consumption is excessively high due to heating and cooling processes
Solution Approach 1:
The patent replaces the thermal field (heating elements) with a mechanical field (press rollers). Instead of using heating elements to melt plastic material, the invention uses press rollers to apply mechanical pressure, transforming the material through compression and friction at ambient or controlled temperatures, thereby eliminating the need for energy-intensive heating and cooling processes
Solution Approach 2:
The invention changes the fundamental processing parameter from temperature-based melting to pressure-based compaction. By controlling pressure, temperature, and speed parameters of the press rollers, the system achieves granulation without the extreme temperature cycles (heating to melting point then cooling) required by traditional extrusion methods
2Temperature
If high temperatures are used to melt plastic material in traditional extruders, then material can be processed, but thermal energy consumption increases significantly
Solution Approach 1:
The patent replaces the thermal field (heating elements) with a mechanical field (press rollers). Instead of using heating elements to melt plastic material, the invention uses press rollers to apply mechanical pressure, transforming the material through compression and friction at ambient or controlled temperatures, thereby eliminating the need for energy-intensive heating and cooling processes
Solution Approach 2:
The system utilizes the friction and compression heat generated during the pressing process itself to achieve the necessary temperature for material transformation, rather than requiring external heating. The mechanical energy input is partially converted to thermal energy through friction, providing self-heating that eliminates the need for separate heating systems
3Loss of substance
If traditional granulation processes are used, then plastic material can be transformed into granules, but material loss occurs due to filtration and cooling requirements
Solution Approach 1:
The invention extracts and eliminates the filtration step from the traditional granulation process. By using press rollers with controlled pore sizes, the system directly compacts material into granule form without requiring separate filtration equipment, thereby reducing material loss and simplifying the overall process
Solution Approach 2:
The pressing operation continuously produces granules in a single uninterrupted process, eliminating the separate cooling and drying steps required by traditional methods. The granules are formed and discharged continuously, maintaining productive action throughout the process cycle
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 compactor system significantly reduces energy consumption and production costs, increases yield by 3 to 5 times, and enhances the mechanical properties of granules, including impact resistance and elasticity, while eliminating volatile substances and gaseous contaminations, resulting in more efficient and cost-effective plastic granule production.
Implementation Method 1
the friction generated by the rotation of the press rollers on the material to be granulated, in addition to the compression heat, brings the temperature of the material to be granulated to a temperature between 100°C and 120°C
Implementation Method 2
the compression heat, brings the temperature of the material to be granulated to a temperature between 100°C and 120°C
Implementation Method 3
a perforated spinneret (110) which rotates, and press rollers (105), the friction generated by the rotation of the press rollers on the material to be granulated
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Compactor (100) for the "granulation" of plastic materials, the compactor (100) comprising a first zone or unit (101) for loading and distribution capable of being loaded with plastic material and distributing the plastic material loaded to other zones and/or units of the compactor (100); a second zone or unit (104) comprising a perforated spinneret (110) and at least one compacting roller (105) installed external to the spinneret (110), where the material is "granulated" by "sinterization" deriving from its forced passage through the perforations of the spinneret (110) under the action of the at least one roller (105); a third zone or unit for the forced feeding of the material, being provided at the at least one roller (105) comprising at least one rotating feeder auger (111) housed at least partially in a tubular housing (113).