Toothed Disc Cleaner Gap Geometry for Uniform Plastic Flake Pre-Cleaning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing toothed disc cleaners are inadequate for reliable and complete pre-cleaning of pre-comminuted plastic waste, particularly due to fluctuating feed consistencies leading to uneven distribution and incomplete removal of impurities.
Innovation Solution
A toothed disc cleaner design with a radially narrowing working gap in the first section and a constant width in the second section, combined with oblique cleaning teeth, ensures uniform distribution and effective pre-cleaning of plastic flakes, achieving less than 200 ppm residual contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional washing technologies with cold or hot process water are used, then cleaning process is simple, but complete removal of hot-melt adhesives, printing inks, and metallizations is not achieved
Solution Approach 1:
The cleaning process is segmented into two distinct stages: pre-cleaning using a toothed disc cleaner to remove loosely adhering impurities, and main cleaning using traditional washing technologies. This segmentation allows each stage to be optimized for its specific function, achieving both operational simplicity and high cleaning quality.
Solution Approach 2:
The toothed disc cleaner performs preliminary cleaning action before the main washing process. By removing loosely adhering impurities such as adhesive labels, plastic films, and metal foils in advance, the subsequent main cleaning process achieves superior results with reduced complexity.
2Adaptability or versatility
If fluctuating feed consistencies are fed into the working gap, then processing flexibility is maintained, but uneven distribution of plastic waste occurs leading to incomplete cleaning
Solution Approach 1:
The working gap is designed with dynamic geometric features including a conical first section that narrows radially outward and a cylindrical second section with constant width. This dynamic geometry automatically adapts to fluctuating feed consistencies, maintaining uniform distribution and complete cleaning regardless of feed variations.
Solution Approach 2:
The cleaning tools feature locally differentiated properties: the first section has a conical geometry for material distribution and homogenization, while the second section has a cylindrical geometry for consistent cleaning action. The cleaning teeth are arranged with specific spacing and orientation to handle varying feed conditions while maintaining uniform cleaning quality.
3Productivity
If cleaning teeth are positioned close together for effective cleaning, then cleaning efficiency increases, but plastic waste may be damaged or clogging may occur
Solution Approach 1:
The cleaning teeth are strategically positioned with different spacing characteristics in different sections: the first conical section has wider spacing for material distribution and reduced clogging, while the second cylindrical section has optimized spacing for efficient cleaning. This local differentiation maintains both cleaning efficiency and operational stability.
Solution Approach 2:
The conical geometry of the first section creates a dynamic narrowing effect that controls material flow and prevents clogging, while the cylindrical second section provides stable, consistent cleaning. This dynamic design maintains operational stability while achieving high cleaning efficiency.
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 design achieves uniform distribution and effective pre-cleaning of plastic flakes, ensuring high-purity pre-cleaning results, facilitating subsequent main cleaning and reducing process liquid use, while maintaining optimal energy consumption.
Implementation Method 1
Impurities are largely abraded from the flakes by the cooperating discs of the disc refiner
Implementation Method 2
the cleaning teeth of the working surfaces are positioned opposite each other and mesh together in a mutually spaced manner
Data Source
AI summary
A toothed disc cleaner includes a first cleaning tool and a second cleaning tool that face each other and a rotary drive configured to rotationally drive at least one of the first and second cleaning tools. The first and second cleaning tools each include a working surface including a plurality of cleaning teeth, and an annular working gap delimited between the working surfaces and structured for pre-cleaning the plastic waste. An inlet opens centrally into the working gap and a feed apparatus is structured to feed the plastic waste through the inlet. An outlet is structured to discharge the pre-cleaned plastic waste in the working gap. A width of the working gap narrows outward from the inlet in a first section and is kept constant in a second section arranged radially outside of the first section. The cleaning teeth of the working surfaces mesh together in a mutually spaced manner.