Vertical Plastic Processing Device with Segmented Chambers
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Solution Overview
Problem
Existing plastic processing devices face challenges in achieving sufficient homogenization and drying of plastic materials, leading to inhomogeneities and increased energy consumption, with bulky designs and inefficient material handling.
Innovation Solution
A device with intermediate bases dividing the container into chambers, allowing for separate zones for material processing and exchange between adjacent steps, ensuring even temperature distribution and reduced energy usage by maintaining a consistent inlet temperature, thus preventing thermal damage and improving material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple containers are arranged in series to improve material homogeneity, then the homogeneity of processed material is improved, but the device becomes bulky and requires large space
Solution Approach 1:
The receiving container is divided into multiple chambers (first chamber, second chamber, third chamber) separated by intermediate floors, allowing sequential processing stages within a single compact vessel. This segmentation enables material to progress through different treatment zones (crushing, heating, drying) without requiring multiple separate containers, thus maintaining homogeneity while reducing overall device footprint
Solution Approach 2:
The patent transitions from a horizontal arrangement of multiple containers to a vertical stacking configuration with chambers arranged one above the other. Material flows downward through the chambers under gravity, utilizing the vertical dimension to achieve sequential processing in a compact space, thereby resolving the contradiction between homogeneity and space requirement
2Ease of operation
If a permanently open annular gap is used for material exchange between stages, then material flow is simplified, but friction increases and residence time spectrum broadens
Solution Approach 1:
The intermediate floors are equipped with adjustable openings that can be dynamically controlled to regulate material flow between chambers. This dynamic control allows optimization of residence time in each chamber while maintaining ease of operation, contrasting with the fixed permanently open gap that cannot be adjusted for different processing requirements
Solution Approach 2:
The intermediate floors act as intermediary structures between chambers, providing controlled transition zones for material exchange. These floors with adjustable openings serve as mediators that can regulate the flow rate and timing of material transfer, thereby controlling residence time more precisely than a permanently open gap
3Stability of the object's composition
If high initial temperature is applied to ensure sufficient plasticization, then plasticization is improved, but thermal damage and energy consumption increase
Solution Approach 1:
The first chamber performs preliminary processing including crushing, heating, and drying of plastic material before it enters subsequent chambers. This preliminary action prepares the material in advance, reducing the temperature and energy requirements for final plasticization, thereby decreasing overall energy consumption while maintaining plasticization quality
Solution Approach 2:
The patent employs progressive temperature changes across different chambers rather than applying high temperature uniformly. The first chamber operates at lower temperatures for preliminary treatment, while subsequent chambers gradually increase temperature for plasticization. This parameter change approach reduces thermal damage and energy consumption compared to high initial temperature application
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 solution ensures homogeneous material processing with reduced energy consumption and extended tool life, achieving consistent plasticization temperatures and improved material purity by minimizing thermal stress and volatile component carry-over.
Implementation Method 1
the mixing and comminuting tools (7a, 7b, 7c) have a mixing, heating or possible comminuting effect on the plastic material
Implementation Method 2
the mixing and comminuting tools (7a, 7b, 7c) have a mixing, heating or possible comminuting effect on the plastic material
Implementation Method 3
Volatile components can be suctioned off or flushed with inert gas or reactive gases in every chamber (6a, 6b, 6c)
Implementation Method 4
The mixing and comminuting tool (7a, 7b, 7c) is controlled or designed in such a way that it has a mixing, heating or possible comminuting effect on the plastic material
Data Source
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AI summary
The device has a housing container (1) divided into cylindrical upper chambers (6a, 6b) and a lower chamber (6c). A mixing and/or shredding tool (7a) is rotated around a vertical axis (8) and arranged in each chamber. A material is brought into permanent pieced and/or particulate shaped and non-fused state by the tool, and a unit (5') e.g. feed screws, exchanges and/or tests the non-fused material between the chambers. The chamber (6a) and/or relatively lying upper chamber (6b) comprise a diameter that is larger than the diameter of the chamber (6c) subjacent in a material flow direction. An independent claim is also included for a method for treating a thermoplastic plastic material e.g. polyester and polyethylene.