Rotary Impact Separator for Plastic and Paper Debris Removal

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Solution Overview

Problem

Current methods for recycling paper and plastic are inefficient due to contamination with debris, leading to equipment damage, increased costs, and reduced recyclability, as existing technologies lack effective mechanical solutions for separating non-ferrous contaminants from paper and plastic streams.

Innovation Solution

The use of a rotary impact separator (RIS) to separate contaminants from paper and plastic by applying mechanical force, reducing particle size, and selectively separating larger particles from smaller ones, allowing for the recovery of clean cellulose-rich and plastic-rich streams with reduced debris content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hand-picking is used to remove contaminants from paper streams, then debris removal is achieved, but labor costs and processing time increase significantly

Engineering Contradiction:

Improvedebris removal effectivenessVSAvoidprocessing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces manual hand-picking with an automated mechanical system consisting of a rotary drum with abrasive surfaces and high-velocity airflow. The mechanical abrasion and air classification automatically separate contaminants from paper fibers, eliminating manual labor while maintaining effective debris removal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical parameters of the separation process by using controlled abrasion intensity and air velocity to differentiate between paper fibers and contaminants. By adjusting these parameters, the system achieves automatic separation without manual intervention, resolving the contradiction between effectiveness and time consumption.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If washing is used to remove dirt from plastic, then contaminant removal is achieved, but water consumption increases significantly

Engineering Contradiction:

Improvedirt removal effectivenessVSAvoidwater consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent replaces water washing with a mechanical abrasion system using a rotary drum with abrasive surfaces. This mechanical approach removes dirt and contaminants from plastic through friction and impact forces, eliminating the need for large volumes of water while achieving effective cleaning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potentially harmful effect of mechanical abrasion (which could damage plastic) into a beneficial cleaning mechanism by carefully controlling the abrasion intensity. The controlled mechanical action effectively removes contaminants without significantly damaging the plastic, providing a water-free cleaning solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If mechanical force is applied to separate contaminants, then separation efficiency improves, but particle size reduction of principal component occurs

Engineering Contradiction:

Improveseparation efficiencyVSAvoidmaterial loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies different treatment zones within the separation system: a gentle abrasion zone for contaminant removal and a classification zone for particle separation. By localizing the mechanical force application, the system achieves effective separation while minimizing unnecessary size reduction of the principal component.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses dynamic control of the rotary drum speed and airflow velocity to optimize separation. The system dynamically adjusts these parameters to apply sufficient force for contaminant removal while maintaining particle integrity, resolving the contradiction between separation efficiency and material preservation.

Inventive Principle:

Principle #15Dynamics

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 RIS effectively removes contaminants, protecting downstream equipment, reducing material loss, and enabling the recycling of clean plastic and paper products with minimal water usage, thereby enhancing the recyclability and economic viability of the process.

Implementation Method 1

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 2

A rotary impact separator has been previously described for the recycling of carpet and carpet-like materials in U.S. 2017/0305038, by separating the face fiber from the backing fiber, and both of the fiber components from the calcium carbonate-rich adhesive

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS11707745B2Processes and structures for plastic separation and products of such processes

Publication Date: 2023.07.25 BROADVIEW GROUP INTERNATIONAL LLC

AI summary

Methods and apparatus are provided for the separation of a feedstock stream comprising a principle component and at least one secondary component such that at least one component has greater friability that the others using a rotary impact separator. The methods allow the recovery of two or more streams, one rich in the more friable component, and one lean in the more friable component.