WO2022091134A1 - A system for manufacturing wood from mix plastic waste - Google Patents
A system for manufacturing wood from mix plastic waste Download PDFInfo
- Publication number
- WO2022091134A1 WO2022091134A1 PCT/IN2021/051032 IN2021051032W WO2022091134A1 WO 2022091134 A1 WO2022091134 A1 WO 2022091134A1 IN 2021051032 W IN2021051032 W IN 2021051032W WO 2022091134 A1 WO2022091134 A1 WO 2022091134A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- assembly
- motor
- mix
- barrel
- plastic waste
- Prior art date
Links
- 239000013502 plastic waste Substances 0.000 title claims abstract description 58
- 239000002023 wood Substances 0.000 title claims abstract description 42
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 41
- 229920003023 plastic Polymers 0.000 claims abstract description 43
- 239000004033 plastic Substances 0.000 claims abstract description 41
- 239000000428 dust Substances 0.000 claims abstract description 27
- 238000013329 compounding Methods 0.000 claims abstract description 15
- 238000000227 grinding Methods 0.000 claims abstract description 15
- 239000000155 melt Substances 0.000 claims abstract description 12
- 239000002440 industrial waste Substances 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 66
- 239000000203 mixture Substances 0.000 claims description 55
- 239000002699 waste material Substances 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 150000001875 compounds Chemical class 0.000 claims description 7
- 239000000654 additive Substances 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 4
- 239000010720 hydraulic oil Substances 0.000 claims description 4
- 239000012265 solid product Substances 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- 239000012467 final product Substances 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 3
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 25
- 239000000047 product Substances 0.000 description 15
- 229920000642 polymer Polymers 0.000 description 13
- 238000004064 recycling Methods 0.000 description 10
- 238000012546 transfer Methods 0.000 description 9
- 238000002156 mixing Methods 0.000 description 6
- 239000002131 composite material Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 239000002983 wood substitute Substances 0.000 description 5
- 239000011155 wood-plastic composite Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 4
- 229920001587 Wood-plastic composite Polymers 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 238000004806 packaging method and process Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 230000004075 alteration Effects 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 244000198134 Agave sisalana Species 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000004594 Masterbatch (MB) Substances 0.000 description 1
- 229920000426 Microplastic Polymers 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 241000237502 Ostreidae Species 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- 235000013361 beverage Nutrition 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 235000013351 cheese Nutrition 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 239000010903 husk Substances 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000010169 landfilling Methods 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000011205 natural fiber plastic composite Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 235000020636 oyster Nutrition 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000012958 reprocessing Methods 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000003911 water pollution Methods 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 235000013618 yogurt Nutrition 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/04—Disintegrating plastics, e.g. by milling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/08—Moulding or pressing
- B27N3/28—Moulding or pressing characterised by using extrusion presses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
- B29B2017/0213—Specific separating techniques
- B29B2017/0217—Mechanical separating techniques; devices therefor
- B29B2017/0231—Centrifugating, cyclones
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/04—Disintegrating plastics, e.g. by milling
- B29B2017/0424—Specific disintegrating techniques; devices therefor
- B29B2017/0484—Grinding tools, roller mills or disc mills
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/62—Plastics recycling; Rubber recycling
Definitions
- the present invention generally relates to the conversion of mix plastic waste to a wood substitute, which can be utilized in the industry.
- the invention provides the system for manufacturing wood from mix plastic waste.
- Plastic packaging e.g. plastic bags, plastic packaging of ham, cheese, yoghurt, other foods and consumer products, and plastic utensils
- other plastic waste bottle crates, garden furniture, buckets, plastic sledges, car bumpers, petrol cans, pipes, spools, computer shells, TV shells, plastic parts of fridges, etc.
- this type of waste is primarily landfilled, burned or used as filler.
- plastic -waste recycling solutions where the waste is first sorted, then cleaned, and plastics of the same type are recycled into a uniform mass, granules or new products.
- the process of recycling is type-based, which means that, for example, LDPE (plastic packaging and bags), HDPE (plastic bags and thick-walled plastic products) or PET (plastic bottles of beverages) waste is washed, ground, dried and granulated.
- LDPE plastic packaging and bags
- HDPE plastic bags and thick-walled plastic products
- PET plastic bottles of beverages
- MLP Multi-Layered Polymers
- the patent document US20050051646A1 relates to a system and process for recycling plastic waste into a usable item. It provides a processing system which recycles all plastic waste and utilizes troublesome waste product in a productive manner. Accordingly, the present invention provides for a recycling system, including a first granulator for reducing plastic waste to a first particle size, and a second granulator for reducing plastic waste to a second particle size. The system also provides a frictional melting structure which melts said first particles and said second particles via use of a rotating plate. The present invention also provides for a process for recycling plastic waste, including the step of first granulating the plastic waste. Thereafter, the plastic waste is melted via a friction or rotating plate. The plastic is molded into a suitable form.
- the recycling system of the present invention can be used to manufacture numerous different products, for instance, but not limited to, vineyard posts, oyster posts, pipe supports, slats, spat trays, manhole covers, and railroad ties.
- the said invention fails to provide suitable solution for recycling polymers of different types.
- the invention does not provide the system for manufacturing wood-like substitute from the mix plastic waste.
- Another patent document WO2008066751A1 relates to systems for fabricating wood or natural fiber-plastic composite extrusions that employ recycled carpet waste as a component of the composite.
- the systems and methods can be used to process and combine recycled carpet waste with a fiber-polymer composite mixture to form a woodplastic composite with equivalent properties at reduced cost.
- the composite also includes unseparated processed carpet waste, which can be blended or dispersed within the fiber-polymer compound, resulting in a WPC of equivalent physical properties.
- the recycled carpet waste can include wool, nylon, polyester, polypropylene, jute, sisal, like materials, and combinations thereof.
- the composite may include additives such as colorants, lubricants, flame retardants, mold inhibitors, compatiblizers, coupling agents, other materials, and combinations thereof.
- the primary object of the present invention is to provide the system for manufacturing wood from mix plastic waste.
- Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which re-utilizes the mix plastic waste to prepare the wood product.
- Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which reduces the water pollution and air pollution (from landfilling) by reducing the need for conventional waste disposal and thus reduces greenhouse emissions.
- Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which recycles all the types of mix plastic waste including Multi-Layered Polymer (MLP) into a single product.
- MLP Multi-Layered Polymer
- Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the wood substitute that has the potential to replace wood as a material.
- Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the weather-proof and water-proof wood substitute.
- Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which reduces the dependency on forests for wood.
- Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces termiteresistant wood.
- Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which results in end products that are environment friendly and recyclable themselves.
- Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the woodplastic composite that can be nailed, screwed, glued, pinned and additional alterations can be made using standard joinery tools.
- Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, that obviates the problem of prior art.
- the present invention provides the system for manufacturing wood from mix plastic waste.
- the system for manufacturing wood from plastic waste comprises: a dust removing assembly (1), a melt compacting assembly (2), a compounding assembly (3), a grinding assembly (4) and a mix planking assembly (5).
- Said dust removing assembly (1) removes the excessive dust from the mix plastic waste material.
- Said melt compacting assembly (2) catches the material with deep and long pitch grooves and then squeezes the material to remove water from the material. The material further enters a compacting zone to densify the material together and ejects from the barrel die hole to cut into small densified lumps at high speed. The resultant densified material is fed into the compounding assembly (3).
- the material is mixed with other chemical additives and binders to achieve the compound in the compounding assembly (3); the compounded material is fed through the grinding assembly (4), which reduces the size.
- the grinded high density material is fed into the two-stage plastic planking assembly (5).
- the plastic planking assembly comprises an extruder for mixing the hot material, the cooling system attached to the mold with high compression force to create a solid product.
- the present invention provides the system for manufacturing wood from mix plastic wastes. By turning mix plastic wastes into a wood-like substitute used for making furniture, directly helps to reduce deforestation.
- the present invention provides the system for manufacturing wood that utilizes any kind of plastic in mix form by their types and industrial wastes in manufacturing said composites; thereby providing an alternative solution to get rid of plastic waste which is environment friendly.
- the system for manufacturing wood from mix plastic wastes comprises of: a dust removing assembly (1), a melt compacting assembly (2), a compounding assembly (3), a grinding assembly (4), a planking assembly (5);
- the dust removing assembly (1) receives the bulk of plastic or industrial waste material and removes the excessive dust from the mix plastic waste material.
- the waste material is fed into the dust removing assembly (1), which spins at high speed and thrashes the waste by centrifugal force. It throws the waste out on other side, while all the dust and sand falls down into the collection tray of the assembly (1).
- the plastic obtained after removing dust from the dust removing assembly (1) is fed into the melt compacting assembly (2);
- Said dust removing assembly (1) comprises of:
- Said mam stand (1.1) is the structure/ body of machine made of Mild Steel (MS) angle frame.
- the main frame of whole press is made up of thick Mild Steel (MS) plates;
- Said anti-vibration jumpers (1.2) are attached at the base of main stand
- Said side panel (1.3), is the external openable panel for easy maintenance and cleaning of the dust collection tray;
- Said motor (1.4), is used to power the rotor (1.5);
- Said motor plate (1.4.1), is the adjustable base plate of motor (1.4) on which it is fitted;
- Said motor guard (1.4.2), is the safety guard around the pulleys and belt (1.6);
- Said rotor (1.5) is the high speed component having a conical tri-wing bladeless design, thrashes the waste by centrifugal force and throws it out on the other side; Said rotor pulley
- V-belt (1.5.1), the pulley attached to the rotor, which receives the power through V-belt (1.6); Said V-belt (1.6), the component which transfers power from motor pulley (1.4.3) to rotor pulley (1.5.1); Said inlet hopper (1.7), is the feeding zone for the material; Said outlet hopper (1.8), is the zone throwing the thrashed/ clean material; Said screen (1.9), is the semi-cylindrical component below the rotor (1.5), which allows the dust to pass and collect in the tray; Said pedestel (1.10), supports the rotation of the rotor (1.5);
- the melt compacting assembly (2) catches the material with deep and long pitch grooves and then squeezes the material to remove water from the material.
- the material further enters a compacting zone to densify the material together and ejects from the barrel die hole to cut into small densified lumps at high speed.
- the resultant densified material is fed into the compounding assembly (3);
- Said melt compounding assembly (2) comprises of:
- Said main stand (2.1) is the structure/ body of machine made of Mild Steel (MS) angle frame.
- the main frame of whole press is made up of thick Mild Steel (MS) plates;
- Said antivibration jumpers (2.2) are attached at the base of main stand (2.1) and act as a cushion between machine and floor preventing any vibration transfer;
- Said mold/die (2.3) is circular shaped mold with holes in it, through which the semi-melted material comes out after processing;
- Said inlet hopper (2.4), is the feeding zone of the material;
- Said outlet hopper (2.5), is the zone throwing the thrashed / clean material;
- Said motor (2.6) is used to power the screw (2.10);
- Said motor pulley (2.6.1) is attached to the motor (2.6), which transmits the power through V-belt
- V-belt (2.7) is the component, which transfers the power from motor pulley (2.6.1) to gear pulley (2.8.1); Said helical gearbox
- Said screw (2.10) with deep and long pitch grooves for catching the material, is the main component which pushes, compacts, churns and semi-melts the material;
- Said water tank (2.11) is attached below the barrel (2.12), to remove the moisture from the plastic wastes;
- the middle barrel (2.12.2), is the middle portion of the barrel (2.12), where the plastic is compacted and churned;
- the gearside barrel (2.12.3), is the part between inlet hopper (2.4) and gearbox (2.8);
- the compounding assembly (3) wherein, the material is mixed with other chemical additives and binders to achieve the compound; the compounded material is fed through the grinding assembly (4);
- Said compounding assembly (3) comprises of:
- Said main stand (3.1) is the structure/ body of machine made of Mild Steel (MS) angle frame.
- the main frame of whole press is made up of thick Mild Steel (MS) plates;
- Said anti-vibration jumpers (3.2) are attached at the base of main stand (3.1) and act as a cushion between machine and floor preventing any vibration transfer;
- Said motor (3.3), is used to power the screw (3.5);
- Said motor guard (3.3.1), is the safety guard around the motor (3.3);
- Said motor pulley (3.3.2) is the pulley attached to the motor (3.3), which transmits the power through V-belt (3.6);
- Said rotor pulley (3.4), is the pulley attached to the rotor, which receives the power through V-belt (3.6);
- Said screw (3.5) is used for opening and closing the release for the material;
- Said screw guard is the safety guard around the motor (3.3)
- Said motor pulley (3.3.2) is the pulley attached to
- Said drum (3.8) is the main body/ vessel, in which the material is processed;
- the grinding assembly (4) grinds the compounded material and reduces the size of the material.
- the grinded high density material is fed into the two -stage plastic planking assembly (5);
- Said grinding assembly (4) comprises of:
- Said main stand (4.1) is the structure/ body of machine made of Mild Steel (MS) angle frame.
- the main frame of whole press is made up of thick Mild Steel (MS) plates;
- Said anti-vibration jumpers (4.2) are attached at the base of main stand (4.1) and act as a cushion between machine and floor preventing any vibration transfer;
- Said motor (4.3), is used to power the rotor (4.4);
- Said motor plate (4.3.1), is the base plate on which the motor is fitted and is adjustable for varying the tension in the belt (4.8);
- Said rotor (4.4) is the high speed rotating part inside the body; Said rotor pulley (4.4.1) is attached to the rotor, which receives the power through V-belt (4.8); Said rotor blade (4.4.2), attached to the rotor (4.4) and fix blades (4.5); Said fix blades (4.5), adjustable blades on the body for wear and tear compensation; Said inlet hopper (4.6), is the feeding zone for the material; Said outlet hopper (4.7), the portion through which the grinded material falls out; Said V- belt (4.8), the component which transfers the power from motor pulley
- the plastic planking assembly (5) comprises an extruder for mixing the hot material, the cooling system attached to the mold with high compression force to create a solid product;
- Said planking assembly (5) comprises of:
- Said main stand (5.1) is the structure/ body of machine made of Mild Steel (MS) angle frame.
- the main frame of whole press is made up of thick Mild Steel (MS) plates;
- Said anti-vibration jumpers (5.2) are attached at the base of main stand (5.1) and act as a cushion between machine and floor preventing any vibration transfer;
- Said motor (5.3), is used to power the screw (5.13);
- Said motor plate (5.3.1), is the base plate on which the motor is fitted and is adjustable for varying the tension in the belt (5.7);
- Said motor pulley (5.3.3), is the pulley attached to the motor (4.3), which transmits the power through V-belt (5.7);
- the present invention provides the system for manufacturing wood from mix plastic wastes, which is economical, energy efficient, reduces/ reuses the waste and carbon footprint and helps in environmental protection.
- the system for manufacturing wood from mix plastic wastes provides the process steps as follows:
- the plastic obtained after removing the dust is fed into the melt compacting assembly (2). It catches the material with deep and long pitch grooves and then squeezes the material to remove the moisture. After removing the moisture, it enters the compacting zone to densify the material together. There are heater zones, which semi-melts the densified material and by ejecting the barrel die hole, the material is cut into small densified lumps.
- the semi-melted small densified lumps are then fed into the compounding assembly (3), where it is mixed with other additives, pigment, masterbatch, fillers/ Calcium powder, wood powder/ rice husk powder, chemicals and binders to prepare the compound.
- the compounded material is the fed into the grinding assembly (4) to reduce the size.
- the present invention provides the system for manufacturing wood from mix plastic waste.
- This invention provides the system for manufacturing wood from mix plastic waste, which recycles all types of mix plastic waste into a single product.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
Abstract
The present invention provides a system for manufacturing wood from mix plastic waste. The system for manufacturing wood from mix plastic waste comprises: a dust removing assembly (1), a melt compacting assembly (2), a compounding assembly (3), a grinding assembly (4) and a mix planking assembly (5). The system utilizes any kind of plastic in mix form by their types and industrial wastes in manufacturing wood, thereby providing an alternative solution to get rid of plastic waste which is environment friendly.
Description
“A system for manufacturing wood from mix plastic waste”
FIELD OF INVENTION:
The present invention generally relates to the conversion of mix plastic waste to a wood substitute, which can be utilized in the industry. In particular, the invention provides the system for manufacturing wood from mix plastic waste.
BACKGROUND OF INVENTION:
Plastic packaging (e.g. plastic bags, plastic packaging of ham, cheese, yoghurt, other foods and consumer products, and plastic utensils) and other plastic waste (bottle crates, garden furniture, buckets, plastic sledges, car bumpers, petrol cans, pipes, spools, computer shells, TV shells, plastic parts of fridges, etc.) are most problematic and the fastest- growing type of waste. According to common solutions, this type of waste is primarily landfilled, burned or used as filler. These solutions pollute the environment, are expensive and waste material that could be used as a raw material for new products.
Apart from that, everyone knows about plastic -waste recycling solutions where the waste is first sorted, then cleaned, and plastics of the same type are recycled into a uniform mass, granules or new products. The process of recycling is type-based, which means that, for example, LDPE (plastic packaging and bags), HDPE (plastic bags and thick-walled plastic products) or PET (plastic bottles of beverages) waste is washed, ground, dried and granulated. The plastics industry can use plastic
granules made of one polymer as raw material for making new products. As sorting plastic waste by type is very expensive and time-consuming, mixed plastic waste that is not easy to sort and is usually not recycled; it is either incinerated or landfilled.
There is no suitable solution for recycling polymers of different types or Multi-Layered Polymers (MLP). Compared to other materials, such as glass or metals, plastic polymers need to be processed longer to be recycled. The biggest problem is that polymers of different types do not mix because their molecular weight differs and they have long polymer chains. Heating polymers is not enough to break down their molecules. So, to be recycled, polymers need to be identical to achieve effective mixing. If different types of plastic are melted together, they do not mix, like oil and water - they form layers.
The mixing and melting of different types of plastic results in a very unstable mass that is difficult to handle in a common plastics manufacturing process in order to achieve a stable process and product. To mix different types of plastic waste in reprocessing, other materials are added to the mixture.
Therefore, there is a need of a system for manufacturing wood from mix plastic waste to avoid shortcomings of conventional techniques.
PRIOR ART:
The patent document US20050051646A1 relates to a system and process for recycling plastic waste into a usable item. It provides a
processing system which recycles all plastic waste and utilizes troublesome waste product in a productive manner. Accordingly, the present invention provides for a recycling system, including a first granulator for reducing plastic waste to a first particle size, and a second granulator for reducing plastic waste to a second particle size. The system also provides a frictional melting structure which melts said first particles and said second particles via use of a rotating plate. The present invention also provides for a process for recycling plastic waste, including the step of first granulating the plastic waste. Thereafter, the plastic waste is melted via a friction or rotating plate. The plastic is molded into a suitable form. The recycling system of the present invention can be used to manufacture numerous different products, for instance, but not limited to, vineyard posts, oyster posts, pipe supports, slats, spat trays, manhole covers, and railroad ties.
However, the said invention fails to provide suitable solution for recycling polymers of different types. The invention does not provide the system for manufacturing wood-like substitute from the mix plastic waste.
Another patent document WO2008066751A1 relates to systems for fabricating wood or natural fiber-plastic composite extrusions that employ recycled carpet waste as a component of the composite. The systems and methods can be used to process and combine recycled carpet waste with a fiber-polymer composite mixture to form a woodplastic composite with equivalent properties at reduced cost. The composite also includes unseparated processed carpet waste, which can be blended or dispersed within the fiber-polymer compound, resulting in a WPC of equivalent physical properties. Depending on the
composition of the carpet used, the recycled carpet waste can include wool, nylon, polyester, polypropylene, jute, sisal, like materials, and combinations thereof. The composite may include additives such as colorants, lubricants, flame retardants, mold inhibitors, compatiblizers, coupling agents, other materials, and combinations thereof.
However, the weakness of such products is that the additives make these less weatherproof, and they are difficult to be nailed, milled or processed in any other way.
DISADVANTAGES OF PRIOR ART:
The existing prior art suffers from all or any of the following disadvantages :
• In the said prior arts, the plastic waste needs to be cleaned and different types of plastic wastes need to processed separately.
• Many of them fail to provide the suitable solution for recycling polymers of different types.
• Most of them fail to provide the fast and continuous process for manufacturing wood-substitute from plastic wastes.
• Conventional applications follow the plastic waste recycling solutions, where the waste is first sorted and plastics of the same type are recycled into a uniform mass, granules or new products. The mix plastic waste is not easy to sort and it is time-consuming.
• Many of them fail to provide weather-proof and water-proof end product.
• None of the prior art provides the system for manufacturing wood from mix plastic waste and thereby requires substantial amount
of energy in the process and hence is time consuming as well as is not energy efficient.
Thus, there is an unmet urge to provide the invention that obviates the disadvantages of prior art and provides a solution to the problems yet unaddressed.
OBJECTS OF INVENTION:
The primary object of the present invention is to provide the system for manufacturing wood from mix plastic waste.
Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which re-utilizes the mix plastic waste to prepare the wood product.
Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which reduces the water pollution and air pollution (from landfilling) by reducing the need for conventional waste disposal and thus reduces greenhouse emissions.
Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which recycles all the types of mix plastic waste including Multi-Layered Polymer (MLP) into a single product.
Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the wood substitute that has the potential to replace wood as a material.
Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the weather-proof and water-proof wood substitute.
Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which reduces the dependency on forests for wood.
Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces termiteresistant wood.
Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which results in end products that are environment friendly and recyclable themselves.
Another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, which produces the woodplastic composite that can be nailed, screwed, glued, pinned and additional alterations can be made using standard joinery tools.
Yet another object of the present invention is to provide the system for manufacturing wood from mix plastic waste, that obviates the problem of prior art.
SUMMARY OF THE INVENTION:
The present invention provides the system for manufacturing wood from mix plastic waste. The system for manufacturing wood from plastic waste, comprises: a dust removing assembly (1), a melt compacting
assembly (2), a compounding assembly (3), a grinding assembly (4) and a mix planking assembly (5). Said dust removing assembly (1), removes the excessive dust from the mix plastic waste material. Said melt compacting assembly (2), catches the material with deep and long pitch grooves and then squeezes the material to remove water from the material. The material further enters a compacting zone to densify the material together and ejects from the barrel die hole to cut into small densified lumps at high speed. The resultant densified material is fed into the compounding assembly (3). The material is mixed with other chemical additives and binders to achieve the compound in the compounding assembly (3); the compounded material is fed through the grinding assembly (4), which reduces the size. The grinded high density material is fed into the two-stage plastic planking assembly (5). The plastic planking assembly comprises an extruder for mixing the hot material, the cooling system attached to the mold with high compression force to create a solid product.
DETAILED DESCRIPTION OF INVENTION:
The present invention provides the system for manufacturing wood from mix plastic wastes. By turning mix plastic wastes into a wood-like substitute used for making furniture, directly helps to reduce deforestation. In particular, the present invention provides the system for manufacturing wood that utilizes any kind of plastic in mix form by their types and industrial wastes in manufacturing said composites; thereby providing an alternative solution to get rid of plastic waste which is environment friendly.
Referring to Fig. 6, the system for manufacturing wood from mix plastic wastes comprises of: a dust removing assembly (1), a melt compacting assembly (2), a compounding assembly (3), a grinding assembly (4), a planking assembly (5);
Wherein,
Meaning of reference numerals used in the present system from manufacturing wood from mix plastic waste:
: Dust removing assembly.1: Main stand .2: Anti -vibration jumpers .3: Side panel .4: Motor .4.1: Motor plate .4.2: Motor guard .4.3: Motor pulley .5: Rotor .5.1: Rotor pulley .6: V-belt .7 Inlet hopper .8: Outlet hopper .9: Screen .10: Pedestel : Melt compounding assembly.1: Main stand .2: Anti-vibration jumpers .3: Mold/ die .4: Inlet hopper .5: Outlet hopper .6: Motor .6.1: Motor pulley .7: V-belt .8: Helical gearbox .8.1: Gear pulley .9: Heater .10: Screw
.11: Water tank .12: Barrel .12.1: Heater barrel .12.2: Middle barrel .12.3: Gearside barrel.12.4: Inlet hopper barrel : Compounding assembly.1: Main stand .2: Anti-vibration jumpers.3: Motor .3.1: Motor guard .3.2: Motor pulley .4: Rotor pulley .5: Screw .5.1: Screw guard .6: V-belt .7: Cutting blades .7.1: Rotor blade .8: Drum .8.1: Drum support .8.2: Drum top cover .8.3: Drum flap .8.4: MS round plate : Grinding assembly .1: Main Stand .2: Anti-vibration jumpers.3: Motor .3.1: Motor plate
.3.2: Motor pulley .4: Rotor .4.1: Rotor pulley .4.2: Rotor blade .5: Fix blades .6: Inlet hopper .7: Outlet hopper .8: V-belt : Planking assembly .1: Main stand .2: Anti-vibration jumpers.3: Motor .3.1: Motor plate .3.2: Motor pulley .4: Helical gearbox .4.1: Gear pulley .5: Barrel .5.1: Barrel cover guard .6: Hydraulic cylinder.6.1: Hydraulic oil tank .7: V-belt .8: Lower die .8.1: Lower die support plate.9: Upper die .9.1: Upper die support plate.10: Inlet hopper .11: Outlet hopper .12: Heater
5.13: Screw
Referring to Fig.1, the dust removing assembly (1), receives the bulk of plastic or industrial waste material and removes the excessive dust from the mix plastic waste material. The waste material is fed into the dust removing assembly (1), which spins at high speed and thrashes the waste by centrifugal force. It throws the waste out on other side, while all the dust and sand falls down into the collection tray of the assembly (1). The plastic obtained after removing dust from the dust removing assembly (1) is fed into the melt compacting assembly (2);
Said dust removing assembly (1) comprises of:
Main stand (1.1),
Anti -vibration jumpers (1.2),
Side panel (1.3),
Motor (1.4),
Motor plate (1.4.1),
Motor guard (1.4.2),
Motor pulley (1.4.3),
Rotor (1.5),
Rotor pulley (1.5.1),
V-belt (1.6),
Inlet hopper (1.7),
Outlet hopper (1.8),
Screen (1.9),
Pedestel (1.10);
Referring to Fig. IB and 1C, Said mam stand (1.1) is the structure/ body of machine made of Mild Steel (MS) angle frame. The main frame of whole press is made up of thick Mild Steel (MS) plates; Said anti-vibration jumpers (1.2) are attached at the base of main stand
(1.1) and act as a cushion between machine and floor preventing any vibration transfer; Said side panel (1.3), is the external openable panel for easy maintenance and cleaning of the dust collection tray; Said motor (1.4), is used to power the rotor (1.5); Said motor plate (1.4.1), is the adjustable base plate of motor (1.4) on which it is fitted; Said motor guard (1.4.2), is the safety guard around the pulleys and belt (1.6); Said motor pulley (1.4.3), the pulley attached to the motor (1.4), which transmits the power through V-belt (1.6);
Referring to Fig. 1A, Said rotor (1.5), is the high speed component having a conical tri-wing bladeless design, thrashes the waste by centrifugal force and throws it out on the other side; Said rotor pulley
(1.5.1), the pulley attached to the rotor, which receives the power through V-belt (1.6); Said V-belt (1.6), the component which transfers power from motor pulley (1.4.3) to rotor pulley (1.5.1); Said inlet hopper (1.7), is the feeding zone for the material; Said outlet hopper (1.8), is the zone throwing the thrashed/ clean material; Said screen (1.9), is the semi-cylindrical component below the rotor (1.5), which allows the dust to pass and collect in the tray; Said pedestel (1.10), supports the rotation of the rotor (1.5);
Referring to Fig.2, the melt compacting assembly (2), catches the material with deep and long pitch grooves and then squeezes the material to remove water from the material. The material further enters a compacting zone to densify the material together and ejects from the
barrel die hole to cut into small densified lumps at high speed. The resultant densified material is fed into the compounding assembly (3);
Said melt compounding assembly (2) comprises of:
Main stand (2.1),
Anti -vibration jumpers (2.2),
Mold/ die (2.3),
Inlet hopper (2.4),
Outlet hopper (2.5),
Motor (2.6),
Motor pulley (2.6.1),
V-belt (2.7),
Helical gearbox (2.8),
Gear pulley (2.8.1),
Heater (2.9),
Screw (2.10),
Water tank (2.11),
Barrel (2.12),
Heater barrel (2.12.1),
Middle barrel (2.12.2),
Gearside barrel (2.12.3),
Inlet hopper barrel (2.12.4);
Wherein,
Referring to Fig. 2 and 2B, Said main stand (2.1) is the structure/ body of machine made of Mild Steel (MS) angle frame. The main frame of whole press is made up of thick Mild Steel (MS) plates; Said antivibration jumpers (2.2) are attached at the base of main stand (2.1) and
act as a cushion between machine and floor preventing any vibration transfer; Said mold/die (2.3) is circular shaped mold with holes in it, through which the semi-melted material comes out after processing; Said inlet hopper (2.4), is the feeding zone of the material; Said outlet hopper (2.5), is the zone throwing the thrashed / clean material; Said motor (2.6), is used to power the screw (2.10); Said motor pulley (2.6.1), is attached to the motor (2.6), which transmits the power through V-belt
(2.7); Said V-belt (2.7), is the component, which transfers the power from motor pulley (2.6.1) to gear pulley (2.8.1); Said helical gearbox
(2.8), a gearbox, which reduces the rotational speed received via V-belt (2.7) from motor (2.6); Said gear pulley (2.8.1), the pulley attached to the gear, which receives power through the V-belt (2.7); Said heater
(2.9), attached at the end of the barrel (2.12), which heats the plastic into semi-melted form;
Referring to Fig. 2A, Said screw (2.10), with deep and long pitch grooves for catching the material, is the main component which pushes, compacts, churns and semi-melts the material; Said water tank (2.11), is attached below the barrel (2.12), to remove the moisture from the plastic wastes;
Referring to Fig. 2C, Said barrel (2.12), wherein, the heater barrel (2.12.1), is the rear part of the barrel (2.12), where the external heater
(2.9) is attached; the middle barrel (2.12.2), is the middle portion of the barrel (2.12), where the plastic is compacted and churned; the gearside barrel (2.12.3), is the part between inlet hopper (2.4) and gearbox (2.8); the inlet hopper barrel (2.12.4), attached with inlet hopper (2.4).
Referring to Fig. 3, the compounding assembly (3), wherein, the material is mixed with other chemical additives and binders to achieve
the compound; the compounded material is fed through the grinding assembly (4);
Said compounding assembly (3) comprises of:
Main stand (3.1),
Anti -vibration jumpers (3.2),
Motor (3.3),
Motor guard (3.3.1),
Motor pulley (3.3.2),
Rotor pulley (3.4),
Screw (3.5),
Screw guard (3.5.1),
V-belt (3.6),
Cutting blades (3.7),
Rotor blade (3.7.1),
Drum (3.8),
Drum support (3.8.1),
Drum top cover (3.8.2),
Drum flap (3.8.3)
MS round plate (3.8.4);
Wherein,
Said main stand (3.1) is the structure/ body of machine made of Mild Steel (MS) angle frame. The main frame of whole press is made up of thick Mild Steel (MS) plates; Said anti-vibration jumpers (3.2) are attached at the base of main stand (3.1) and act as a cushion between machine and floor preventing any vibration transfer; Said motor (3.3), is used to power the screw (3.5); Said motor guard (3.3.1), is the safety guard around the motor (3.3); Said motor pulley (3.3.2), is the pulley
attached to the motor (3.3), which transmits the power through V-belt (3.6); Said rotor pulley (3.4), is the pulley attached to the rotor, which receives the power through V-belt (3.6); Said screw (3.5), is used for opening and closing the release for the material; Said screw guard
(3.5.1), which guards the screw, responsible to release the material; Said V-belt (3.6), the component which transfers the power from motor pulley
(3.3.2) and rotor pulley (3.4); Said cutting blades (3.7), are the stationary blades attached on the inner part of the drum (3.8); Said rotor blade
(3.7.1), the main plate below the cutting blades (3.7) flat in the rotor; Said drum (3.8), is the main body/ vessel, in which the material is processed; Said drum support (3.8.1), made of Mild Steel (MS) channel, is the part between main body and the drum (3.8); Said drum top cover
(3.8.2), the top cover of the drum, which supports the drum flap (3.8.3) and the MS round plate (3.8.4); Said Ms round plate (3.8.4), is the cylindrical part attached to the inner part of the drum flap (3.8.3), which prevents when the hatch is opened during addition of the material.
Referring to fig. 4, the grinding assembly (4), grinds the compounded material and reduces the size of the material. The grinded high density material is fed into the two -stage plastic planking assembly (5);
Said grinding assembly (4) comprises of:
Main stand (4.1),
Anti -vibration jumpers (4.2),
Motor (4.3),
Motor plate (4.3.1),
Motor pulley (4.3.2), Rotor (4.4), Rotor pulley (4.4.1);
Rotor blade (4.4.2),
Fix blades (4.5),
Inlet hopper (4.6),
Outlet hopper (4.7), V-belt (4.8);
Wherein,
Referring to Fig. 4B and 4C, Said main stand (4.1) is the structure/ body of machine made of Mild Steel (MS) angle frame. The main frame of whole press is made up of thick Mild Steel (MS) plates; Said anti-vibration jumpers (4.2) are attached at the base of main stand (4.1) and act as a cushion between machine and floor preventing any vibration transfer; Said motor (4.3), is used to power the rotor (4.4); Said motor plate (4.3.1), is the base plate on which the motor is fitted and is adjustable for varying the tension in the belt (4.8); Said motor pulley
(4.3.2), is the pulley attached to the motor (4.3), which transmits the power through V-belt (4.8);
Referring to Fig. 4A, Said rotor (4.4), is the high speed rotating part inside the body; Said rotor pulley (4.4.1) is attached to the rotor, which receives the power through V-belt (4.8); Said rotor blade (4.4.2), attached to the rotor (4.4) and fix blades (4.5); Said fix blades (4.5), adjustable blades on the body for wear and tear compensation; Said inlet hopper (4.6), is the feeding zone for the material; Said outlet hopper (4.7), the portion through which the grinded material falls out; Said V- belt (4.8), the component which transfers the power from motor pulley
(4.3.2) to rotor pulley (4.4.1).
Referring to Fig.5, the plastic planking assembly (5), comprises an extruder for mixing the hot material, the cooling system attached to the mold with high compression force to create a solid product;
Said planking assembly (5) comprises of:
Main stand (5.1),
Anti -vibration jumpers (5.2),
Motor (5.3),
Motor plate (5.3.1),
Motor pulley (5.3.2),
Helical gearbox (5.4),
Gear pulley (5.4.1),
Barrel (5.5),
Barrel cover guard (5.5.1),
Hydraulic cylinder (5.6),
Hydraulic oil tank (5.6.1),
V-belt (5.7);
Lower die (5.8);
Lower die support plate (5.8.1);
Upper die (5.9);
Upper die support plate (5.9.1),
Inlet hopper (5.10),
Outlet hopper (5.11),
Heater (5.12),
Screw (5.13);
Wherein,
Said main stand (5.1) is the structure/ body of machine made of Mild Steel (MS) angle frame. The main frame of whole press is made up of thick Mild Steel (MS) plates; Said anti-vibration jumpers (5.2) are attached at the base of main stand (5.1) and act as a cushion between machine and floor preventing any vibration transfer; Said motor (5.3), is used to power the screw (5.13); Said motor plate (5.3.1), is the base plate on which the motor is fitted and is adjustable for varying the tension in the belt (5.7); Said motor pulley (5.3.3), is the pulley attached to the motor (4.3), which transmits the power through V-belt (5.7); Said helical gearbox (5.4), a gearbox, which reduces the rotational speed received via V-belt (5.7) from motor (5.3); Said gear pulley (5.4.1), the pulley attached to the gear, which receives power through the V-belt (5.7); Said barrel (5.5), long chamber inside which the plastic is processed; Said barrel cover guard (5.5.1), is used to prevent accidents, as the barrels (5.5) and heaters (5.12) are very hot; Said hydraulic cylinder (5.6), converts the high pressure oil into high force; Said hydraulic storage tank (5.6. 1), is the storage unit for hydraulic oil, which provides high pressure oil to cylinder (5.6); Said lower die (5.8), is the lower half of the die of the finished product having cross flow type water cooling; Said lower die support plate (5.8.1), placed horizontally, the mold/ die rests upon this plate; Said upper die (5.9), is the upper half of the die having straight flow type water cooling; Said upper die support plate (5.9.1), placed vertically, wherein, the upper die is attached on the lower end of this plate; Said inlet hopper (5.10), is the feeding zone for the material; Said outlet hopper (5.11), from this point, the melted material ejects out of the barrel (5.5); Said heater (5.12), provides external heating to melt and mix the material;
Referring to Fig. 5A, the screw (5.13), divided in zones, for mixing high viscosity material; the screw (5.13) and barrel (5.5) are driven by motor (5.3) via the helical gearbox (5.4).
The present invention provides the system for manufacturing wood from mix plastic wastes, which is economical, energy efficient, reduces/ reuses the waste and carbon footprint and helps in environmental protection.
WORKING OF THE INVENTION:
The system for manufacturing wood from mix plastic wastes; provides the process steps as follows:
1 . Removing dust using dust removing assembly
2. Removing moisture and melting the densified material using the melt compacting assembly
3. Preparing compound
4. Grinding the mixture
5. Molding the mixture in the final product using plastic planking assembly
Step 1: Removing dust using dust removing assembly
First, the mix plastic waste material is fed into said assembly (1) having conical tri wing bladeless design which spins at high speed and thrashes the waste by centrifugal force and throws it out on the other side and the dust falls down into the collection tray below.
Step 2: Removing moisture and melting the densified material using melt compacting assembly
Second, the plastic obtained after removing the dust is fed into the melt compacting assembly (2). It catches the material with deep and long pitch grooves and then squeezes the material to remove the moisture. After removing the moisture, it enters the compacting zone to densify the material together. There are heater zones, which semi-melts the densified material and by ejecting the barrel die hole, the material is cut into small densified lumps.
Step 3: Preparing compound
The semi-melted small densified lumps are then fed into the compounding assembly (3), where it is mixed with other additives, pigment, masterbatch, fillers/ Calcium powder, wood powder/ rice husk powder, chemicals and binders to prepare the compound.
Step 4: Grinding the mixture
The compounded material is the fed into the grinding assembly (4) to reduce the size.
Step 5: Molding the mixture in the final product using plastic planking assembly
The grinded material is fed into the plastic planking assembly (5). The assembly comprises of screw having different zones for mixing the high viscosity material. As the material exits the extruder, it is fed hot in
directly into the molding-press. The cooling system attached to the mold with high compression force creates a solid product. The operating temperature of extruder is in the range of 170-180 degrees Celsius. Once the product is cooled, it is automatically ejected, as the mold opens with the hydraulic press.
ADVANTAGES OF THE INVENTION:
The advantages of the present invention are:
• The present invention provides the system for manufacturing wood from mix plastic waste.
• Said invention provides the system for manufacturing wood from mix plastic waste, which reduces the dependency on forests for wood.
• This invention provides the system for manufacturing wood from mix plastic waste, which produces weather-proof, water-proof and termite-proof wood substitute.
• It provides environment friendly solution.
• The system produces the wood-plastic composite that can be nailed, screwed, glued, pinned and additional alterations can be made using standard joinery tools.
• This invention provides the system for manufacturing wood from mix plastic waste, which recycles all types of mix plastic waste into a single product.
Claims
1. A system for manufacturing wood from mix plastic waste, comprises:
A dust removing assembly (1),
A melt compacting assembly (2),
A compounding assembly (3),
A grinding assembly (4),
A planking assembly (5);
Wherein,
Said dust removing assembly (1) is connected to the melt compacting assembly (2) and is configured to receive the bulk of plastic or industrial waste material for removing the excessive dust from the mix plastic waste material;
Said melt compacting assembly (2) is connected to the compounding assembly (3) and is configured to catch and squeeze the material for removing moisture and cutting them into small densified lumps at high speed;
Said compounding assembly (3), is connected to the grinding assembly (4) and is configured to mix the material with other chemical additives and binders;
Said grinding assembly (4) is connected to the planking assembly (5) and is configured to grind the compounded material;
Said planking assembly (5) is configured to mix the hot material and prepare the solid product.
2. The system for manufacturing wood from mix plastic waste, wherein, the dust removing assembly (1) as claimed in claim 1, comprises:
Main stand (1.1),
Anti-vibration jumpers (1.2),
Side panel (1.3),
Motor (1.4),
Motor plate (1.4.1),
Motor guard (1.4.2),
Motor pulley (1.4.3),
Rotor pulley (1.5.1),
V-belt (1.6),
Inlet hopper (1.7),
Outlet hopper (1.8),
Screen (1.9),
Pedestel (1.10);
Characterized in that, the assembly (1) comprises:
Rotor (1.5);
Wherein, said rotor (1.5) is conical tri-wing and bladeless for thrashing the waste.
3. The system for manufacturing wood from mix plastic waste, wherein, said melt compacting assembly (2) as claimed in claim 1 , comprises:
Main stand (2.1),
Anti-vibration jumpers (2.2),
Mold/ die (2.3),
Inlet hopper (2.4),
Outlet hopper (2.5),
Motor (2.6),
Motor pulley (2.6.1),
V-belt (2.7),
Helical gearbox (2.8),
Gear pulley (2.8.1),
Heater (2.9),
Water tank (2.1 1),
Barrel (2.12),
Heater barrel (2.12.1),
Middle barrel (2.12.2),
Gearside barrel (2.12.3),
Inlet hopper barrel (2.12.4);
Characterized in that, the assembly (2) comprises: Screw (2.10);
Wherein, said screw (2.10), is with deep and long pitch grooves; The system for manufacturing wood from mix plastic waste, wherein, the planking assembly (5) as claimed in claim 1, comprises:
Main stand (5.1),
Anti-vibration jumpers (5.2),
Motor (5.3),
Motor plate (5.3.1),
Motor pulley (5.3.2),
Helical gearbox (5.4),
Gear pulley (5.4.1),
Barrel (5.5),
Barrel cover guard (5.5.1),
Hydraulic cylinder (5.6),
Hydraulic oil tank (5.6.1),
V-belt (5.7);
Lower die (5.8);
Lower die support plate (5.8.1);
Upper die (5.9);
Upper die support plate (5.9.1),
Inlet hopper (5.10),
Outlet hopper (5.11),
Heater (5.12);
Characterized in that, the assembly (5) comprises: Screw (5.13);
Wherein, said screw (5.13), is divided in zones. A system for manufacturing wood from mix plastic waste as claimed in claim 1, wherein, a process comprises steps of:
Removing dust using dust removing assembly (1), Removing of moisture and melting the densified material using melt compacting assembly (2),
Preparing compound,
Grinding the mixture,
28
Molding the mixture in the final product using plastic planking assembly (5).
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WO2001068345A1 (en) * | 2000-03-15 | 2001-09-20 | Remaplan Anlagenbau Gmbh | Method for transfer moulding polymer compounds |
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US20170087758A1 (en) * | 2014-04-25 | 2017-03-30 | Rolan Investment Oü | System and method for producing plastic products from recycled mixed plastic waste and plastic product |
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US4772430A (en) * | 1985-01-11 | 1988-09-20 | Jgc Corporation | Process for compacting and solidifying solid waste materials, apparatus for carrying out the process and overall system for disposal of such waste materials |
US5082605A (en) * | 1990-03-14 | 1992-01-21 | Advanced Environmental Recycling Technologies, Inc. | Method for making composite material |
US5088910A (en) * | 1990-03-14 | 1992-02-18 | Advanced Environmental Recycling Technologies, Inc. | System for making synthetic wood products from recycled materials |
WO2001068345A1 (en) * | 2000-03-15 | 2001-09-20 | Remaplan Anlagenbau Gmbh | Method for transfer moulding polymer compounds |
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