Plastic Recycling Melt Homogenization and Filtration
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Solution Overview
Problem
Existing plastic recycling methods often result in end products with compromised mechanical and optical properties due to residual impurities and gas bubbles, which are not effectively removed by conventional filtration and degassing processes.
Innovation Solution
A method and device that sequences processing steps to include homogenization after filtration and before degassing, utilizing intensive shear stress and elevated temperatures to break down and distribute impurities, and introducing cell-forming media to enhance degassing, ensuring a gas-free and agglomerate-free final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional filtration and degassing processes are used in sequence, then gas bubbles are removed from the melt, but impurities and agglomerates remain that compromise mechanical and optical properties
Solution Approach 1:
The patent applies preliminary action by performing homogenization before degassing. The homogenization step breaks down agglomerates and distributes impurities uniformly throughout the melt before the degassing process removes gas bubbles. This sequence ensures that when gas bubbles form during degassing, they are not nucleated around large agglomerates, improving both gas removal efficiency and final product quality.
2Object-affected harmful factors
If filtration is performed before homogenization, then solid foreign matter is removed, but agglomerates and impurities remain distributed unevenly in the melt
Solution Approach 1:
The patent performs homogenization as a preliminary action after filtration and before degassing. This homogenization step actively breaks down remaining agglomerates and ensures uniform distribution of any residual impurities throughout the melt, creating a stable and homogeneous composition before the final degassing step.
3Productivity
If the processing sequence is optimized for gas removal, then degassing efficiency increases, but impurity distribution and product quality deteriorate
Solution Approach 1:
The patent applies preliminary homogenization before degassing to break down agglomerates and uniformly distribute impurities. This preliminary action enhances degassing efficiency by eliminating nucleation sites for gas bubbles, while simultaneously improving end product quality through uniform impurity distribution achieved during homogenization.
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 approach significantly improves the quality of recycled plastics by effectively removing impurities and gas bubbles, enhancing mechanical and optical properties, and increasing productivity through a continuous, efficient processing chain.
Implementation Method 1
utilizing intensive shear stress and elevated temperatures to break down and distribute impurities
Implementation Method 2
homogenization after filtration and before degassing, utilizing intensive shear stress and elevated temperatures to break down and distribute impurities
Implementation Method 3
melting of the processed material, at least to the extent that filtration is possible
Implementation Method 4
can first be processed in a cutter/compactor at elevated temperature and, if necessary, under a vacuum
Implementation Method 5
the rest is distributed and crushed in the homogenization section and temperature-sensitive contaminants are caused to decompose by the shear stress that occurs. This gas is eliminated in the subsequent melt degassing
Data Source
Figure 1~2
Figure 3a~5
AI summary
The invention relates to a method and an arrangement for recycling plastics comprising the following processing steps: a) preparation of the raw material, wherein the material is, if necessary, crushed and brought into a fluid-like form and, while maintaining its granularity and flowability, heated and continuously mixed, and optionally degassed, softened, dried, its viscosity increased and/or crystallized, b) melting of the processed material, at least to the extent that filtration is possible, c) filtration of the melt to remove impurities, d) homogenization of the filtered melt, e) degassing of the homogenized melt, and f) discharge and/or subsequent processing of the melt, e.g. by granulation, blown film processing, wherein these processing steps follow one another in the specified order (Fig. 2).