Rubber De-Vulcanisation Mixing for Impurity-Free Tire Recycling
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Solution Overview
Problem
Existing rubber recycling processes are hindered by the presence of metallic and textile components in end-of-life tires, which inhibit the de-vulcanization of rubber, leading to impure materials and limited recyclability, and require high energy consumption and large footprints due to multiple mill stations.
Innovation Solution
A system and method involving a cleaning device for sanitization and a mixing device with rotors and chemical additives to de-vulcanize rubber, using mechanical stress and controlled chemical agents to break cross-links, combined with a peeling mechanism to separate rubber from textile components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rubber components are shredded with metallic and textile components, then rubber particles are obtained, but the presence of impurities inhibits de-vulcanisation
Solution Approach 1:
The invention separates the de-vulcanisation process into distinct stages: first removing metallic and textile impurities through screening and separation devices, then processing the purified rubber particles through the rotor-stator mixing system. This segmentation ensures impurities do not interfere with the de-vulcanisation chemistry.
Solution Approach 2:
The invention extracts and removes impurities (metallic components and textile cords) from the rubber shreds before de-vulcanisation. Separation devices and screening mechanisms extract these harmful components, allowing the subsequent chemical treatment to work effectively on pure rubber particles only.
2Ease of manufacture
If multiple mill stations are used to soften and homogenise rubber, then rubber is reworked, but energy consumption and footprint increase
Solution Approach 1:
The invention combines the softening, homogenisation, and de-vulcanisation functions into a single integrated rotor-stator mixing device. The interlocking rotors with varying diameters create progressive mechanical action that simultaneously achieves all three functions in one unit, eliminating the need for separate mill stations.
Solution Approach 2:
The rotor-stator mixing device performs multiple functions: it mechanically softens the rubber through shear action, homogenises the material through intensive mixing, and facilitates de-vulcanisation through controlled mechanical stress and heat generation. This multi-functional device replaces multiple specialized machines.
3Ease of manufacture
If multiple mill stations are used for rubber reworking, then non-vulcanised rubber is processed, but device complexity increases
Solution Approach 1:
The invention merges multiple processing functions (softening, homogenisation, de-vulcanisation) into a single rotor-stator mixing device with interlocking rotors of varying diameters. This integration dramatically reduces the number of separate machines needed while maintaining comprehensive processing capability.
4Reliability
If chemical additives are added to aid breaking cross-links, then de-vulcanisation is enhanced, but material purity is affected
Solution Approach 1:
The invention carefully controls the type and concentration of chemical additives used in de-vulcanisation. By selecting specific chemicals and optimizing their dosage, the process efficiently breaks cross-links while minimizing residual contamination. The subsequent washing and drying stages further remove chemical residues to maintain rubber purity.
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
Enables high-quality reusable rubber production with reduced energy consumption and footprint, allowing complete separation of rubber from impurities and efficient recycling without stopping tire production lines.
Implementation Method 1
The cleaning device is configured to clean and/or sanitize the rubber by applying heat and/or pressure to the rubber
Implementation Method 2
The at least one rotor of the mixing device has at least one blade (flight) which is configured to apply mechanical stress to the cleaned and/or sanitized rubber to de-vulcanise the cleaned and/or sanitized rubber
Implementation Method 3
the mixing device is further configured to add at least one chemical additive to the cleaned and/or sanitized rubber which aids breaking the cross-links of the cleaned and/or sanitized rubber
Data Source
Figure 1a~1b
Figure 2~2a
Figure 3
AI summary
The invention provides an apparatus for de-vulcanisation of rubber from a rubber component, preferably a rubber tire. The apparatus comprises a cleaning device configured to clean and/or sanitize the rubber and a mixing device having at least one rotor configured to de-vulcanise the cleaned and/or sanitized rubber.