Abstract:
A device for breaking glass articles, such as bottles, the device comprising an inlet to receive an article. A conduit links the inlet with a glass-breaking chamber, and the chamber houses a glass-breaking member, said glass-breaking member being rotatably mounted for rotation in a vertical plane, and to impact a bottle as a bottle enters the chamber. A motor is linked via a horizontally rotating axle to rotate the glass-breaking member. An obliquely mounted crusher plate is located such that as the glass-breaking member rotates and impacts a glass article, which is forced against the crusher plate by the glass-breaking member to aid breakage of a glass article. A collector is included in which broken glass is retained ready for removal from the device. An intermediate collector is also included to temporarily retain broken glass, including a release valve allowing broken glass to pass from the intermediate collector to the collector, via an aperture therebetween.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a national stage application filed under 35 U.S.C. 371 of International Application No. PCT/GB2015/053069, filed Oct. 15, 2015, which claims priority from Patent Application No. GB 1418285.1, filed Oct. 15, 2014, each of which is incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is to an improved device for breaking glass and glass-like materials, including ceramic materials, and is particularly suitable for breaking glass bottles such as used to hold wines, spirits, beer or the like. The device is especially suited for use in a bar, nightclub, restaurant or similar establishment, and where limited space is available. 
       BACKGROUND TO THE INVENTION 
       [0003]    In a previous patent application, WO2014/049353, the Applicant disclosed a machine to break glass into small particles, which machine was particularly suitable for use in bars, nightclubs which have a cellar beneath the bar where the glass particles produced could be collected for later disposal. In particular, the glass cullet produced can be removed and made available specifically for remelt. The size of the fragmented particles produced is chosen to ensure the glass is in suitable form for said remelt, allowing new bottles to be formed from the melted material. 
         [0004]    However, such an arrangement is not always suitable or possible and the present invention seeks to provide a machine which can be used where space is more limited. 
         [0005]    In addition, the present invention also includes a valve which is particularly suited for use in controlling the flow of abrasive particulate material, such as the glass particles produced within the device of the current invention, but also more generally. Presently available valves can be easily damaged because of the abrasive nature of particulate material which can especially damage parts of the valve made of softer materials and also can penetrate between moving parts causing the parts to jam together such that the parts can move only with extreme difficulty. 
       SUMMARY OF THE INVENTION 
       [0006]    According to a first aspect of the invention there is provided a device for breaking glass articles, such as bottles, used for wines and spirits, the device comprising; 
         [0007]    an inlet to receive an article, 
         [0008]    a conduit linking the inlet with a glass-breaking chamber, the chamber housing a glass-breaking member, said glass-breaking member being rotatably mounted for rotation in a vertical plane, and to impact a bottle as a bottle enters the chamber; 
         [0009]    a motor linked via a horizontally rotating axle to rotate the glass-breaking member; 
         [0010]    an obliquely mounted crusher plate located such that as the glass-breaking member rotates and impacts a glass article is forced against the crusher plate by the glass-breaking member to aid breakage of a glass article; 
         [0011]    a collector in which broken glass is retained ready for removal from the device; 
         [0012]    an intermediate collector to temporarily retain broken glass, including a release valve allowing broken glass to pass from the intermediate collector to the collector, via an aperture therebetween. 
         [0013]    The above arrangement allows for a more compact machine to be utilised, enabling smaller establishments to utilise the device. 
         [0014]    The crusher plate advantageously includes a rib to assist in the breakage of the glass and especially in shredding of any labels on the glass, which labels can act to hold pieces of glass together and so hinder the breakage process and subsequent passage of broken glass through the release valve. 
         [0015]    Preferably, the glass breaking member includes a blade extending perpendicularly from a mounting plate. Further preferably the blade has a generally rectangular profile. 
         [0016]    Conveniently the blade includes a cut-out of complementary shape to the rib and which in use passes in close spaced-relationship with said rib as the blade rotates. This configuration provides a non-linear path for a glass bottle to traverse as it passes through the device and reduces the risk of over-large particles of glass going through to the container. Yet further conveniently the blade includes a further cut-out along an edge to provide a further, non-linear path for a glass bottle to traverse, which minimises, for example, the risk of a label passing through to the collector without being shredded. 
         [0017]    The device preferably includes an input chute pivotally mounted, such that insertion of a bottle into the chute beyond the mount acts to pivot the chute into a vertically orientated position, releasing the bottle into the conduit. The chute minimises the risk of a person&#39;s hand accidentally being caught in the blade. Further preferably pivoting of the chute to the bottle releasing orientation, activates an inlet closure means to reduce the risk of shards of glass produced exiting the inlet and also to prevent a second bottle being immediately inserted into the device and potentially overloading the device. 
         [0018]    The mass of glass particles can make opening of a valve difficult and also result in rapid wear and tear on conventional valves. The release valve of the present invention is therefore advantageously mounted on rollers to ease the movement of the valve between an open and a closed position. 
         [0019]    Further advantageously the release valve includes a plate element, and yet further advantageously a gripping portion enabling the valve to be operated manually by a user. The plate element enables glass particles to accumulate on its in-use upper surface and to periodically be released to the collector. The device advantageously includes one or more brushes in contact with and extending across the width of the release valve which prevents glass particles from being drawn beyond the edge of the aperture and between the device and the release valve. Damage to the release valve and the device is minimised and the risk of the valve becoming jammed is also minimised. 
         [0020]    Preferably, the plate element includes a ridge across the width of the plate element to prevent the plate element from being pulled too far out of the device. 
         [0021]    The chute in its rest position advantageously opens onto a back retaining wall to prevent a bottle from sliding too far. The back wall is further advantageously formed of a material having a low co-efficient of friction such as Teflon®, HDPE or UHMWPE to minimise the chance of a bottle engaging the back retaining wall too strongly and the resulting frictional force preventing the chute from pivoting. Yet further advantageously the back retaining wall is concavely curved to assist with movement of the bottle. 
         [0022]    Optionally, the conduit comprises sound-insulating material to reduce the noise generated by the device. The sound-insulating material further optionally comprises a perforated metal sheet backed with an absorptive foam or an open-cell material. 
         [0023]    Optionally, the rotation of the glass breaking member is at a speed of from 1000-3000 rpm, the value being set to deliver glass particles of a desired particle distribution. 
         [0024]    Advantageously, the collector includes one or more sensors, to determine the level of glass within the collector, which level is communicated to a user when the level reaches a preset value. The or each sensor is further advantageously an ultrasonic sensor, conveniently mounted on an upper surface of the collector. Optionally the level at which communication to a user is set at 200 mm from the top or 100 mm. 
         [0025]    According to a second aspect of the invention, there is provided a valve for controlling the flow of particulate solid through an aperture, the valve comprising a plate element, moveable between an aperture-spanning position preventing flow and an open position, 
         [0026]    the plate element being housed within a valve housing and mounted on rollers to ease movement, 
         [0027]    one or more brush elements mounted within the housing, the or each brush element engaging a surface of the plate element to prevent movement of particles beyond the brush and so effectively sweep the plate element as the plate element is moved within the housing. 
         [0028]    The risk of the valve jamming is therefore reduced and also damage done to the valve by a particulate material penetrating between the housing and the plate element is reduced. 
         [0029]    Preferably, the plate element includes a ridge, across the width of the plate element to prevent the plate element from being pulled too far out of the device. 
         [0030]    Advantageously, the plate element includes a gripping portion to facilitate operation of the plate element. Optionally, movement of the plate element is actuated by a motor drive unit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    The invention is now described with reference to and as illustrated by the accompanying drawings which show, by way of example only, two embodiments of a device for breaking glass. In the drawing: 
           [0032]      FIG. 1  is a side view of a first embodiment of a device, with the side panel removed, immediately prior to insertion of a bottle; 
           [0033]      FIG. 2  is the side view of the device of  FIG. 1  after insertion of the bottle; 
           [0034]      FIG. 3  is the side view of the device of  FIG. 1 , showing breakage of the bottle; 
           [0035]      FIG. 4  is a first perspective view of the device of  FIG. 1 —side panel removed; 
           [0036]      FIG. 5  is a second perspective view of the device of  FIG. 1 —side panel removed; 
           [0037]      FIG. 6  is a side view of a second embodiment of a device, with the side panel removed, immediately prior to insertion of a bottle; 
           [0038]      FIG. 7  is the side view of the device of  FIG. 1  after insertion of the bottle; 
           [0039]      FIG. 8  is the side view of the device of  FIG. 1 , showing breakage of the bottle; 
           [0040]      FIG. 9  is a first perspective view of the device of  FIG. 1 —side panel removed; 
           [0041]      FIG. 10  is a second perspective view of the device of  FIG. 1 —side panel removed; 
           [0042]      FIGS. 11 a , 11 b    are cut away perspective views, illustrating a valve mechanism in more detail; 
           [0043]      FIGS. 12 a , 12 b    are sectional views showing a valve mechanism in operation; 
           [0044]      FIGS. 13 a , 13 b    illustrate a motor and blade in perspective view and exploded perspective view; 
           [0045]      FIGS. 14 a , 14 b   , illustrate a blade and crusher plate in perspective and top view respectively; 
           [0046]      FIG. 15  illustrates air circulation within the first embodiment of the device; 
           [0047]      FIG. 16  is a perspective view of a two-piece construction for the second embodiment of the device; 
           [0048]      FIGS. 17 a , 17 b    illustrate the device on castors for ease of mobility; and 
           [0049]      FIG. 18  illustrates a silencer. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0050]    The invention as described herein relates to a device to break glass bottles and the like into small particles. The device is particularly suitable for premises such as bars, restaurants in reducing the volume of waste glass produced. This assists in the removal of the glass from the premises and also in the reuse of the glass. The particles produced are of such a size and shape that the overall density is increased over the original bottles which increases the capacity of the device and aids in transportation of the glass from the premises. Moreover, the glass particles are less hazardous to users than larger shards of glass from a broken bottle can be. 
         [0051]    The devices disclosed are primarily for use as a standalone unit in the bar and do not need to be placed above a cellar to allow the collector for the broken glass to be placed there. 
         [0052]    In their most basic aspect, the devices disclosed herein comprise an inlet for a piece of glassware through which the glassware is introduced, the glassware then falls, under gravity into a rotating blade, driven by a motor, the blade acting to break the bottle into small particles typically 5-30 mm in size which is ideal for glass to be remelted for further use. The particulate glass is then collected in a container such as a hopper for ultimate disposal. 
         [0053]    By variation of the speed of the rotation, the shape of the blade etc, the size of the glass particles produced can be varied to suit the end purpose. For example, glass particles below 10 mm in size can be used in water filtration, as part of building aggregate or incorporated into road surfaces. Larger sizes, over 10 mm in size can be recycled and used in the manufacture of new bottles or jars or in glassfibre. 
         [0054]    In order to improve the safety of the devices, cut-out switches for the motor are included to prevent a person coming into contact with the blade whilst the blade is moving. Also indicators can be included to make the user aware of when the storage capacity of the device for the broken glass is reaching its limit and action needs to be taken to empty the container. 
         [0055]    Referring initially to  FIGS. 1 to 5 , these show a first embodiment of a device, generally referenced  10 . The device  10  comprises a housing formed of panels  11  which can be formed of a sheet metal or also of wood which can provide improved sound insulation properties. Set into the top most panel  11   a  is an inlet  12  which opens into a conduit  13  connecting the inlet  12  with a breakage unit  14 . In the embodiment shown, the conduit  13  is openable by means of catches  15  such that in the event of a bottle becoming stuck, the conduit  13  can be opened to assist in clearance of the blockage. 
         [0056]    As the device  10  is intended for usage either in, or in close working proximity to a bar, then minimisation of noise created by the device  10  is important. To this end, the inlet is surrounded by a sound-insulating collar  16 . The collar  16  has a perforated sheet metal outer layer and inner layers formed of absorptive foam or an open cell material such as fibreglass there between. These elements of the collar  16  combine to reduce the level of sound escaping from the device via the open inlet  12 . 
         [0057]    To further reduce the escape of sound and also to reduce the risk of glass escaping out of the inlet  12  from the breakage unit  14 , sprung flaps  17  are mounted within the inlet&#39;s mouth. As a bottle is pushed through the flaps  17 , the flaps  17  are pushed apart enabling the bottle to enter the conduit  13 . Once the bottle has passed through the flaps  17 , springs incorporated in the mounting for the flaps  17  urge the flaps  17  together to close the inlet  12 . 
         [0058]    In order to reduce noise as well as withstand impact from glass shards, the flaps  17  are formed of a thermoplastic elastomer, such as a polyurethane, polyethylene, or a rubber material. 
         [0059]    The conduit  13  opens into the breaking chamber  18  of the breakage unit  14 . The breaking chamber  18  houses the rotably mounted blade  19  and the crusher plate  20  which co-operate together in use to break the bottle as it falls through. 
         [0060]    The bottle is broken down to a particulate material of the required size and the particles then fall into the hopper  21  where they collect until finally emptied through the valve  22  into the transport container  23 . To aid the user in determining the requirement to empty the hopper  21 , a window  24  is included in the panel  11   b  of the device  10 . The window  24  is formed of polycarbonate or a toughened glass to resist scratching by the glass particles, which may impact the window  24  at high energy as they are ejected from the breaking chamber  18 . 
         [0061]    In addition or as an alternative to the window  24 , the device  10  can include level sensors and indicators to determine and display the level of glass accumulating in the hopper  21 . The sensors  151  to  153  (see  FIG. 15 ) can be ultrasonic, infrared, optical, microwave, pendulum/tilt switch or capacitive sensor which can be set, for example, to show that the level of glass is within 200 mm, 100 mm of the top of the hopper. The level is communicated to the user by a visible or audio signal such as LED light  154  perhaps showing different colours depending on the sensor triggered. In the event that the hopper becomes full, a cut-out switch for the device  10  can be activated preventing further use of the device  10  until the hopper level is reduced. Additionally, safety cut-out switches are provided in the event that the door panels  11   c ,  11   d  are opened. This facility can of course be extended to other panels. 
         [0062]    Turning now to the second embodiment of  FIGS. 6 to 10 , the majority of the device  60  shown therein is as for the first embodiment of  FIGS. 1 to 5 . Where this is the case, the same numerals will be used for the same features. The inlet however comprises an alternative inlet feed mechanism which allows for safe delivery of bottles and ensures that bottles cannot be inserted too rapidly into the device  60 , which may cause the device  60  to jam. Also, the inlet feed mechanism functions most effectively when the bottle is inserted base first, which is also the ideal orientation for the bottle to reach the breaking chamber  18 . 
         [0063]    The inlet feed mechanism comprises an inlet  61  leading to a tube  61   a , said tube  61   a  being pivotally mounted on low friction bearings about a horizontally disposed axis  62 . Insertion of a bottle into the tube  61   a  moves the centre of mass of the tube and bottle combined. The balance point of the tube  61   a  is such that the rotation is caused by bottles of all sizes typical in a bar such as ‘mixer’ bottles and champagne bottles. Eventually insertion of the bottle causes the tube  61   a  to pivot in the direction shown by the arrow A in  FIG. 7 , until the tube  61   a  is vertically orientated. The weight of the bottle then causes the bottle to move downwards which opens the flaps  63  leading into the conduit  13  and onwards to the breaking chamber  18 . The bottle is then broken by the blade  19  and the glass particles produces are eventually led into the container  23  in the manner described above for the first embodiment. Once the bottle has dropped from the tube  61   a , the tube  61   a  pivots back returning the tube  61   a  to an orientation ready to receive a further bottle. Typically, the time from the bottle being released into the tube  61   a  and returning to its bottle-receiving orientation is 1-2 seconds. 
         [0064]    In use therefore and referring to the second embodiment, the user connects the device  60  to a mains AC electricity supply. After checking that the container  23  and the hopper  21  are not full, either by viewing through the window  24  or consulting any indicator  154  present, the user inserts a bottle through the inlet into the tube  61   a . Once the bottle is sufficiently within the tube  61   a , the mass of the bottle causes the tube  61   a  to pivot. A flexible retaining wall  64  is mounted at the exit  65  of the tube  61   a  and is fixed at either end such that the retaining wall  64  describes therebetween a curve which follows the path of the exit  65  as the tube  61   a  pivots. The retaining wall  64  is preferably formed of a material having a low co-efficient of friction such as Teflon®, HDPE or UHMWPE to minimise the chance of a bottle engaging the back wall too strongly and the resulting frictional force preventing the tube  61   a  from pivoting. 
         [0065]    In an alternative embodiment, not illustrated, a rigid, angled wall can be used in place of the flexible wall. 
         [0066]    The pivoting action triggers operation of the motor  130  to cause rotation of the blade  19 . Also, as the tube  61   a  pivots, the opening to the tube is moved away from the inlet  61  which prevents a user from inserting or keeping their hand within the tube  61   a . The risk of the user therefore being injured due to rotation of the blade directly or from an inadvertent impact by particles generated by the blade is minimalized. Additionally, the pivoting can cause a cover member  61   b  to be brought across the opening. The inserted bottle passes down the conduit  13  through the breakage unit  14  to be collected in the hopper and eventually the container. If no further bottles are inserted into the device  60 , then the motor is timed to run for an overrun time which can be for example from 5 to 60 seconds. 
         [0067]    The operation of the valve  22  is now described in more detail with reference to  FIGS. 11 and 12 . The valve  22  is mounted between the hopper  21  and the transport container  23 . As bottles are broken in the breakage unit  14 , the particles issuing therefrom are at first collected on the valve plate  110 . Once sufficient glass is collected, the valve plate  110  is moved from the closed position shown in  FIG. 12 a    to the open position in  FIG. 12 b   . The glass particles are released into the container  23 , following which the valve plate  110  is returned to the closed position. To assist opening and closure, the valve plate  110  is provided with a handle or gripping portion  111 . The handle  111  can simply be a fold in the valve plate  110  or can be another type of handle known generally. 
         [0068]    In order to reduce damage to the valve plate  110  and penetration of glass particles into the space  110   a  between the valve plate  110  and the valve plate housing  112 , the valve plate  22  includes additional features which prolong the life of the valve  22  and aid in its operation. It will be appreciated that the risk of glass particle penetration into the valve  22  is greatest when the plate  110  is drawn out in the direction of the Arrow in  FIG. 12 b   , although penetration can take place simply by the momentum of the falling particles, causing the particles to rebound into the space  110   a . To prevent this therefore the valve plate  110  is mounted on rollers  113  which are prevented from coming into contact with the glass by the configuration of the plate  110 . In the embodiment shown, the valve plate  110  is formed along two of its edges into an elongate roller surface  114 . In use therefore the roller surface  114  rests on the rollers  113  which enables the plate  110  to be easily moved. 
         [0069]    Additionally or alternatively, brushes  115   a - c  extending across the width of the plate  110  are suspended from the valve plate housing  112 . Two of the brushes  115   a, b  act firstly to prevent the glass particles from moving off the section of the valve plate  110  onto which the particles fall. Secondly, the brushes  115   b, c  act to sweep the particles towards the aperture connecting the hopper  21  and the container  23  so that the glass particles fall into the container  23  on opening the valve  22 . A slot  116  on the valve plate  110  acts as a stop member for closure of the valve plate  110  and again acts as a further barrier for glass particle penetration. 
         [0070]    Details of the blade  19  and the blade housing to the motor  130  are shown in  FIG. 13 . The motor  130  shown is a three-phase motor which enables firstly smoother and hence quieter and more efficient operation of blade  19  than a single phase motor. A single phase motor can nevertheless be used. Second, the three-phase motor is more easily able to cope with use of the device in which the motor is repeatedly switched on, runs for a short period of time and is then switched off, which is a typical use scenario for the present invention. 
         [0071]    With regard to the blade  19 , this can be seen to have a generally trapezoidal cut-out  131  along its outer edge  132 . It will be appreciated that most bottles which are inserted into the device  60  have their labels still attached. Labels, by virtue of the adhesive used to secure the label to the bottle can adversely affect the breakage process. The labels can moreover result in the valve&#39;s function being substantially sub-optimal. Should the label remain intact, the outlet hole would be required to be much larger, which increases the risk of an increased quantity of airborne matter being released. The device  60  allowing for this to be the case and will simplify the user&#39;s task considerably as a pre-breakage cleaning step to remove the label will not need to be undertaken. The cut-out provides a convoluted path which a bottle needs to traverse through the machine so that the chance of a label passing through flat and avoiding fragmentation of the portion of the bottle to which it is attached is considerably reduced. 
         [0072]    In addition, to aid this process, the blade  19  can also comprise one or more further cut-outs. In the embodiment shown in  FIG. 14 , the further cut-outs  133   a, b  are located on a separate edge to the cut-out  131 . The shape of the further cut-outs  133   a, b  are chosen to be complementary to a rib  134  on the crusher plate  20 . A spacing  135  is included between the blade  19  and the crusher plate  20  and the rib  134  to allow passage of glass particles between these two elements, with the spacing  135  being selected to be large enough such that the glass is not reduced to a particle size which is too small. A typical spacing is 5 to 30 mm, and preferably 5 to 10 mm, depending on the particle size desired. 
         [0073]    In order to reduce dust generation, which can occur on pressure build-up within the breakage unit  14 , an air circulation breather pipe  155  is included linking the outlet of the breakage unit  14  with the conduit  13 . The breather pipe  155  also aids in noise reduction by minimising the opportunity for standing waves to build-up within the machine. 
         [0074]    In  FIG. 16 , an embodiment is shown in which the inlet and breakage units are provided in a first cabinet  161  and the hopper and container units are provided in a second cabinet  162 . This embodiment enables the device to be supplied to the user in more easily handleable packaging with the two units being secured together on site. In an alternative embodiment, not illustrated, the first cabinet  161  can be mounted to a counter top for discharge into a tube. This allows collection of broken glass into containers of different sizes, depending on space available and the wishes of the user. 
         [0075]    In  FIG. 17 a , 17 b    the device, in accordance with the above described embodiments is mounted on castors  170  for ease of manoeuvring between locations. 
         [0076]    In  FIG. 18  a further noise reduction means is disclosed, for use in conjunction with the above-disclosed embodiments. A silencer or baffle box is located beneath the outlet from the breaking chamber  18 . The glass particles exiting from the breaking chamber  18  can have a high velocity due to the action of the blade  19  and gravity. The noise generated as the particles impact the sides of the device can therefore be substantial. 
         [0077]    The silencer  180  acts to decelerate the glass particles, which reduces the noise generated in any impact. The silencer  180  comprises 2 overlapping angled rubber flaps  181  and on impact with these flaps  181 , the particles lose momentum and are deflected away from the sides. It will be appreciated that additional flaps  181  can be utilised if deemed necessary. 
         [0078]    It will be recognised that the invention has not alluded to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention.