Series Filtration Filter for Recycled Plastic Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current plastic recycling filtration methods require high costs, generate waste, and deteriorate the physical characteristics of plastic material due to the need for double filtration processes, which are expensive and inefficient, especially when trying to achieve high purity levels.
Innovation Solution
A filter system with two filtration devices in series, driven by a single shaft, where scrapers remove clogged material and maintain pressure control, allowing for continuous operation and efficient removal of impurities without cooling the plastic material, reducing the need for multiple machines and minimizing material deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If double filtration is employed to achieve high purity levels, then filtration quality is improved, but production time and costs increase
Solution Approach 1:
The filter element is divided into multiple filtration zones with different pore sizes arranged in series. The first zone removes coarse impurities while the second zone removes fine impurities, enabling double filtration functionality within a single continuous filtration chamber without requiring multiple separate filtration steps or machines.
Solution Approach 2:
The patent implements a nested filtration structure where the second filtration zone is positioned downstream of the first filtration zone within the same filter element housing. This nested arrangement allows the molten plastic to pass sequentially through both filtration zones in a single continuous operation, achieving high purity without extending production time.
2Manufacturing precision
If two separate machines are used for cascade filtering, then filtration quality is improved, but device complexity and costs increase
Solution Approach 1:
The patent merges the functions of two separate filtration machines into a single integrated filtration device. The filter element contains both filtration zones in one housing, and the molten plastic flows through both zones sequentially through a single extruder, eliminating the need for multiple machines while maintaining high filtration quality.
Solution Approach 2:
The single filter element performs multiple filtration functions simultaneously - removing both coarse and fine impurities - making it a universal filtration solution that replaces the need for specialized separate filtration machines. The same filter element handles all filtration tasks that would otherwise require multiple dedicated devices.
3Manufacturing precision
If cooling and re-heating steps are added between filtration stages, then material purity is improved, but energy consumption and material deterioration increase
Solution Approach 1:
The patent maintains continuous heating of the molten plastic throughout the entire filtration process. The plastic remains in a molten state as it passes through both filtration zones, eliminating the need for cooling and re-heating cycles. This continuous thermal state preserves material properties while achieving high purity filtration.
Solution Approach 2:
The patent controls the temperature parameter to remain above the melting point of the plastic material throughout the filtration process. By maintaining this temperature parameter change, the plastic stays in a molten state suitable for continuous filtration without undergoing phase changes that would consume energy or deteriorate material properties.
4Productivity
If filters are replaced simultaneously on multiple machines, then production downtime is reduced, but maintenance complexity and costs increase
Solution Approach 1:
The patent combines multiple filtration elements into a single integrated filter unit that can be replaced as one component. This merging eliminates the complexity of coordinating replacements across multiple separate machines, as only one filter element needs to be removed and replaced at a time, simplifying maintenance operations while minimizing production downtime.
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 solution provides efficient, cost-effective filtration with reduced waste and maintenance requirements, maintaining the physical characteristics of the plastic material while achieving high purity in a single pass, thus reducing production downtime and financial costs.
Implementation Method 1
a first perforated sheet with a first average diameter of the holes, for the passage of the molten material, and a second perforated sheet with a second average diameter of the holes, for the passage of the molten material, with the first average diameter being larger than the second average diameter
Data Source
AI summary
What is presented is a filter for plastic material, in particular a device that filters recycled plastic material, to clean it of extraneous bodies and foreign elements by means of several filtration units within a single body.