Vacuum Detoxification Using Low-Volume Gaseous Rinsing Medium

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Solution Overview

Problem

Current recycling methods for plastics face challenges in effectively removing contaminants and impurities from thermoplastic materials, especially when trying to maintain a sufficient vacuum while using a rinsing medium, as large quantities of the medium reduce the vacuum, and increasing vacuum pressure is costly and inefficient.

Innovation Solution

The method involves using a small quantity of a rinsing medium, such as air or water, at a controlled temperature and vacuum pressure below 50 mbar, with the medium being introduced at a velocity of at least 1 m/min to enhance contaminant detachment and removal, while maintaining a vacuum in the receiving tank, and using multiple tanks with different conditions for optimal detoxification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If large quantities of rinsing medium are introduced into the evacuated container, then the detachment and transport of contaminants is improved, but the vacuum is greatly impaired or reduced

Engineering Contradiction:

Improvedetachment efficiencyVSAvoidvacuum pressure

Core Design Contradiction:

Manufacturing precisionVSStress or pressure

Solution Approach 1:

The patent changes the physical state of the rinsing medium from liquid to gas through evaporation, allowing it to effectively detach contaminants while maintaining vacuum. The gaseous medium can penetrate and detach contaminants without the volume constraints of liquids, resolving the contradiction between detachment efficiency and vacuum maintenance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition of water from liquid to vapor form. By introducing a small amount of liquid rinsing medium that evaporates into gas, the system achieves effective contaminant detachment through the gaseous phase while consuming minimal volume, thus preserving the vacuum condition.

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If vacuum pressure is increased to achieve greater migration and detachment of contaminants, then the detachment efficiency is improved, but the overhead and operating costs increase

Engineering Contradiction:

Improvedetachment efficiencyVSAvoidvacuum pump power

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The patent replaces the mechanical approach of using high vacuum pressure with a thermal approach. Instead of increasing vacuum pump power to enhance contaminant migration, the system uses heated gaseous rinsing medium to facilitate contaminant detachment and migration, substituting mechanical energy with thermal energy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If large quantities of rinsing medium are used to transport away contaminants, then the elimination efficiency is improved, but the vacuum maintenance becomes impossible

Engineering Contradiction:

Improveelimination efficiencyVSAvoidvacuum pressure

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The patent changes the rinsing medium to gaseous form, which has much lower density and volume requirements compared to liquid form. This allows sufficient quantities of medium to be introduced for effective contaminant transport while the low volume of gas maintains the vacuum pressure.

Inventive Principle:

Principle #35Parameter changes

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 boosts cleaning efficiency by 5-65% compared to treatments without a rinsing medium, reduces process time, and ensures compliance with standards like ILSI and FDA certification, while being more economical and efficient in maintaining the necessary vacuum.

Implementation Method 1

Thanks to the invention's choice of an appropriately high temperature, the providing of an appropriate vacuum and the introducing of a rinsing medium, a good efficiency of the detoxification can be achieved.

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

The detachment is facilitated by a rinsing medium and is dependent on the ambient pressure, or facilitated by applying a vacuum. An effective detachment can only be achieved with a vacuum under 100 mbar.

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 3

Hence, a large quantity of rinsing medium by itself is not helpful. If a corresponding vacuum is to be maintained, it would no longer be possible to introduce sufficient rinsing medium without reducing the vacuum

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS9914156B2Method for preparing and detoxifying using liquid rinsing medium

Publication Date: 2018.03.13 EREMA ENGINEERING RECYCLING MASCHINEN & ANLAGEN GMBH

AI summary

The present invention concerns a method for processing and detoxification of a material, especially a thermoplastic material, and for removal of contaminants or impurities from this material, wherein the material is heated under vacuum in at least one receiving tank, mixed and possibly comminuted, and wherein a rinsing medium is introduced into the receiving tank beneath the material level, conducted through at least a partial region of the material, and the rinsing medium enriched or saturated with contaminants is brought out from the receiving tank once more. According to the invention, the quantity of rinsing medium introduced into the receiving tank is less than 0.1 liter per hour per kilogram of material or material throughput per hour, while at the same time the vacuum in the receiving tank is kept constantly below 100 mbar.