Abstract:
A separator is disclosed for mechanically separating objects having one size dimension less that a predetermined threshold size. The present separator comprises a cylindrically- or barrel-shaped device having one or more louvers. The barrel is oriented at a preset angle and rotated about its longitudinal axis (along its circumference) and powered by a motorized drive. A collection of objects (processed materials or heavy metal particles from shredder operation) are introduced into the higher opening in the barrel. As the collection of objects progresses downward through the barrel, a plurality of machined slots or louvers separates the larger objects from the smaller. The present invention separates the collection of objects into two separate paths, comprising two products, which are 1) an overflow path, comprised essentially of objects that exceed the maximum allowable size through the louvers and fall through the lower end of the device; and 2) an underflow path, comprised essentially of objects that are able to pass through the louvers. The objects in the underflow path are collected separately from those in the overflow path.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to an apparatus for separating objects by size and shape. More particularly, the present invention relates to an apparatus for separating objects based on a size threshold, whereby objects measuring less than a predetermined maximum size in any dimension are separated from objects measuring over the predetermined maximum size threshold. Finally, the present invention relates to an apparatus for sorting relatively planar-shaped objects measuring less than a predetermined threshold size in the non-planar dimension from other larger objects. One example of a planar object to be sorted is coinage.  
           [0003]    2. Description of Related Art  
           [0004]    The recovery and separation of multiple components of a mixed sample remains an important operation of any recycling system. In shredder residue metal recycling, specifically automobile shredder residue processing, this is no different. Although successful methods have been developed for distinguishing such items as heavy metals, light metals, organics, rubber, etc., it shall prove beneficial to this industry to further extract specific items from such a broad category of materials.  
           [0005]    Among the categories are mixed heavy metals, and these may be defined as any non-ferrous metallic substance with a specific gravity greater than approximately 2.8, as compared to water (1.0 g/cm 3 ). In automobile shredder residue processing, this may include copper, zinc, stainless steel, etc. Mixed heavy metals will also include all metallic coins. Separating these coins creates an additional separate product of the monies themselves, and does not diminish the value of the mixed heavy metals from which it was derived. In addition the separated coinage product provides an additional revenue source for the user. At the present time, the exclusive way of separating the coins from the mixed heavy metals is achieved by the tedious process of hand sorting from a large volume stream. The coin concentrator, proposed for United States patent, provides the following: a means of concentrating the metallic coins from a portion of mixed heavy metals to substantially reduce the amount of hand sorting required to extract the metallic coins.  
         SUMMARY OF THE INVENTION  
         [0006]    A separator is disclosed for mechanically separating objects having one size dimension less that a predetermined threshold size. The present separator comprises a cylindrically- or barrel-shaped device having one or more louvers. The barrel is oriented at a preset angle and rotated about its longitudinal axis (along its circumference) by means of an drive. A collection of objects (processed materials or heavy metal particles from shredder operation) are introduced into the higher opening in the barrel. As the collection of objects progress downward through the barrel, a plurality of machined slots or louvers, separating the larger objects from the smaller. The present invention produces two products: an overflow, comprised essentially of objects that exceed the maximum allowable size through the louvers and fall through the lower end of the device; and an underflow, comprised essentially of objects that are able to pass through the louvers and are collected separately from the overflow. This separator effectively mechanizes the concentration of coins from the dissimilarly shaped heavy metals. In doing this, not only is the need for costly manual labor reduced, but so is the time required to process the mixed heavy metal material.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    The novel features believed characteristic of the present invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings wherein:  
         [0008]    [0008]FIG. 1 is a side view of a separator in accordance with an exemplary embodiment of the present invention;  
         [0009]    [0009]FIG. 2 is a cross-sectional view of the present separator in accordance with an exemplary embodiment of the present invention;  
         [0010]    [0010]FIG. 3 is a cross-sectional view of a barrel portion of the present separator in accordance with an exemplary embodiment of the present invention; and  
         [0011]    [0011]FIG. 4 is a magnified view of a portion of the cross-sectional view of the present barrel depicted in FIG. 3 including a louver in accordance with an exemplary embodiment of the present invention. 
     
    
       [0012]    Other features of the present invention will be apparent from the accompanying drawings and from the following detailed description.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0013]    The present invention is directed to a separator for effectively mechanizing the concentration of coins from the dissimilarly shaped heavy metals. In doing this, not only does it overcome the prior art&#39;s need to reduce costly manual labor, but it also reduces the time required to process the mixed heavy metal material for sorting coinage from the heavy metals. The objects and advantages of the present separator are better understood with the description of figures below.  
         [0014]    The present invention is described with respect to exemplary embodiments illustrated in FIGS. 1 through 4 which are suitable for separating a concentration of metallic coins from a mixed collection of irregularly-shaped heavy metal objects produced from an automobile shredder operation. The present invention is also suitable for separating various other materials, based on solid particles having a maximum size in any one spatial dimension being less than an opening size in a fabricated louver as will become apparent from the descriptions below.  
         [0015]    [0015]FIG. 1 is a diagram of an exemplary separator for sorting objects by size and shape as viewed from the side. FIG. 2 is a cross-sectional view of the separator as viewed from cross-section I-I depicted in FIG. 1. The present invention will be described with regard to both FIGS. 1 and 2 simultaneously. In accordance with an exemplary embodiment of the present invention, separator  100  comprises two basic subparts: rotated barrel assembly  102 ; and powered base assembly  104 . Rotated barrel assembly  102  is comprised of hollow, substantially cylindrically-shaped barrel  106 , having an essentially rounded cross-sectional shape with openings at either end. Flange  108  is securely fastened to one end of barrel  106  in such a way as to not completely obstruct input opening  110 . The opposite end of barrel  106  from input opening  106  is discharge opening  112 . Longitudinally along barrel  106  are a plurality of slots or louvers  114  which are fabricated in or disposed onto barrel  106 . Louvers may be disposed in a generally longitudinal orientation to barrel  106 , or alternatively may be disposed in a spirally-wound slot fashion about barrel  106  (not shown). The structure of louvers  114  will be discussed in detail below with regard to the longitudinal louver configuration; however, the function of louvers  114 , in either configuration, is to provide a pathway for objects not exceeding a maximum size to exit barrel  106 .  
         [0016]    Briefly, a collection of solid objects is fed into barrel  106  of separator  100  through input opening  110  and the collection is separated in two fractional discharges based on the size of the objects in the collection and the magnitude of an opening in one or more louver(s)  114 . The first fractional output, the “underflow,” comprises objects with a dimension less than the magnitude of the louver&#39;s opening and is extracted mechanically from the collection. The second fractional output, the “overflow,” passes directly through the entire longitudinal extent of barrel  106  and is discharged from discharge opening  112 .  
         [0017]    Powered base assembly  104  provides vertical support and rotational power for barrel assembly  102  and a collection hopper for the underflow objects. In the depicted example, the outer body of barrel  106  rests on four rollers, two positioned on either side of the longitudinal axis A-A of barrel  106  and on each side of one roller disposed toward input opening  110  and the other roller is disposed toward discharge opening  112 . One of ordinary skill in the art would recognize that the rollers may take many forms, but are presently depicted as pneumatic tires  120  and pneumatic tires  124 . The inner face of flange  108  is abutted against pneumatic idler tire  128 . Pneumatic tires  120  are securely mounted on axle  122  and pneumatic tires  124  are mounted on axle  126 . The position of barrel  106  is held relatively constant with respect to powered base assembly  104  by pneumatic idler tire  128  and parallel to the longitudinal axis A-A of barrel  106  by pneumatic tires  120  and pneumatic tires  124 .  
         [0018]    Rotational power is delivered to one or both of axles  122  and  126  from motor  130  by drive  131  which may be implemented as, for example, a belt, chain or gear drive assembly. The rotational power is transferred from one or both of axles  122  and  126  to pneumatic tires  120  and/or pneumatic tires  124  and on to barrel assembly  102  by frictional couplings between pneumatic tires  120  and/or  124  and barrel assembly  102 . Idler tire  124  is not mechanically driven.  
         [0019]    A pair of input end vertical support members  136  provide vertical support for the input ends of axles  122  and  126 , while discharge vertical support members  138  provides vertical support for the discharge ends of axle  122 . Discharge vertical support members  138  are shorter than the aforementioned input vertical support members  136 . Axles  122  and  126  are rotationally supported on vertical supports  136  and  138  by, for example, pillow block bearings  140 . Although not depicted in the present figures, input vertical supports  136  and/or discharge vertical supports  138  may further comprise height adjustment mechanisms for altering the vertical height of the respective support; exemplary adjustment mechanisms include interlocking screw, or hydraulic jacks or the like.  
         [0020]    In the depicted example axles  122  and  126  rotate counterclockwise causing barrel  110  to rotate in a clockwise rotational direction as illustrated by arrow R 1  shown in FIG. 2. Rotation ensures the collection of solid objects fed into barrel  106  which continue on a path essentially perpendicular to louver(s ) 114  and toward discharge opening  112 . Of course, only the overflow objects traverse the full extent of barrel  106  to discharge opening  112 ; underflow objects exit barrel  106  through louvers  114  into collection hopper  132  and finally into discharge  134 . The underflow fraction of objects and the overflow fraction of objects are separated based on a predetermined dimensional size threshold for the objects. The collection of objects traverses the longitudinal extent of barrel  106  by gravity, thus input opening  110  is fixed at a higher relative vertical position, height L, than the vertical position of discharge opening  112 , height LL. Barrel  106  is oriented downward toward discharge opening  112 . Since barrel  106  is supported by pneumatic tires  120  and pneumatic tires  124 , which are mounted on axles  122  and  126 , respectively, axles  122  and  126  are oriented at approximately the same angle as barrel  106 . This is accomplished by maintaining the input end vertical support members  136  at a higher vertical position relative to that of discharge vertical support members  138 . Any object with a dimensional measurement in any spatial plane that is less than that of the opening in louver(s)  114  will be extracted from the collection of objects. The structure and function of louver(s)  114  are directly discussed below.  
         [0021]    [0021]FIGS. 3 and 4 are cross-sectional views of portions of barrel  106  in accordance with exemplary embodiments of the present invention. FIG. 3 is a cross-sectional view of barrel  126  taken from cross-section II-II shown in FIG. 1. FIG. 4 is a magnified view of section  142  of barrel  106  including a portion of louver  114 . In accordance with an exemplary embodiment of the present invention, louver  114  is comprised of a longitudinal slot or louver opening  144  formed by a separation between outer flap  146  and inner flap  148 . Distance O 1  between opposing outer flap  146  and inner flap  148  is based on a maximum dimensional size of objects to be separated. Distance O 1  is equal to the predetermined maximum size alluded to above. Edge  150  is formed on the innermost extent of inner flap  148  and is oriented toward the direction of rotation, i.e. if rotation R 1  is clockwise, then edge  150  points toward the clockwise direction; alternatively, if rotation R 1  is counterclockwise, then edge  150  points toward the clockwise direction. Opening  144  should therefore be oriented toward the direction of rotation. As barrel  106  rotates, edge  150  contacts the lower strata of the collection of objects containing the objects, which, due to gravity, remain in contact with the inner surface of barrel  106 . Objects having a dimensional size less than distance  01  are captured by edge  150  and separated from the collection. Those underflow objects exit barrel  106  through opening  144  and are expelled into hopper  132 .  
         [0022]    Notice also that opening  144  is approximately parallel to the inner surface of barrel  106 . Therefore, in order for an object to be captured by edge  150  into opening  144 , the object must have a dimensional size less than that of opening  144  and that dimension of the object must also be oriented parallel to opening  144 . Here, it should be understood that, in general, the linear magnitude of one dimension of an object must be smaller than the maximum threshold for an object to pass through opening  144  in louver  114 . Irregularly-shaped objects, those objects having one side with a linear measurement less than the predetermined maximum threshold size may not pass through the opening in louver  114  for two possible reasons. First, because one side of the object is smaller than the predetermined maximum threshold size, the object thickens away from the side and therefore will not completely pass through opening  114 . The second reason is due to an object not having a general planar shape, and although a diameter of the object is less than the predetermined threshold amount, the dimension measurement of the object is greater than the threshold due to the nonplanarity of the object. Irregularly-shaped objects may initially enter opening  144  in louver  114  but then become lodged, thus requiring manual removal of the objects. Thus, the size of opening  144  should be determined by the size of object intended for sorting for optimal sorting results. From the foregoing, it should be clear that the present invention is particularly suited for sorting planar objects through the underflow, wherein the opposing outer planar surfaces of the object are separated by less than the predetermined maximum threshold amount. However, in order to be captured by edge  150  into opening  144 , the planar surfaces should be approximately parallel to the inner surface of barrel  106 . In accordance with one exemplary embodiment of the present invention, barrel  106  is comprised of two (2) sets of four (4) louvers  114  that are disposed radially about the barrel. In accordance with one exemplary embodiment, each louver  114  has a longitudinal slit (opening  144 ) in a generally parallel orientation with said longitudinal axis A of barrel  106 . In accordance with another exemplary embodiment of the present invention, barrel  126  opening distance  01  is equal to approximately one eighth inch (0.125″) for separating specific types of planar objects to the underflow path, i.e. coinage minted in the United States. Thus, in a mixed heavy metals system, made up of shredder residue, particularly automobile particulates, monetary metallic coinage concentrate is discharged at opening  114 , while all remaining shredder residue is evacuated from separator  100  at discharge opening  112 . One of ordinary skill in the art would readily appreciate that the magnitude of opening distance O 1  may be adjusted to any distance based on the application of separator  100 .  
         [0023]    Louver(s)  114  may be physically constructed using any one of a plurality of methods. In accordance with one exemplary embodiment, louver  114  is fabricated directly into the wall of barrel  106  using any well-known machine milling and/or grinding process. In accordance with another exemplary embodiment, louver  114  is fashioned from a pair of flaps, outer flap  146  and inner flap  148 , which are affixed to barrel  106  forming opening  144 . Outer flap  146  and inner flap  148  may be permanently affixed across an opening in barrel  106  by welding the flaps directed to barrel  106  or temporarily affixed across an opening in barrel  106  using removable fasteners. Regardless of which method is employed, louver(s)  114  should be constructed from durable materials as the movement of the collection of objects in barrel  106  has a high abrasive effect on the contact surfaces. Additionally, regardless of how louver(s)  114  are affixed to barrel  106 , the inner surfaces of flaps  146  and  148  should maintain a continuous circumference defined by the continuous inner surface of barrel  106 .  
         [0024]    Alternatively, barrel assembly  102  further comprises an axle disposed coaxially with axis A-A within barrel  106  and secured by rigid interior support members to the interior surface of barrel  106  (not shown). The axle extends beyond input opening  110 , on the first end of barrel  106 , and beyond discharge opening  112  on the second end of barrel  106 . In which case, the coaxially positioned axle is rotationally supported near the opening end by a first vertical support member and near the discharge end by a second vertical support member by, for example, pillow block bearings affixed to the respective vertical members (also not shown). Rotational power is delivered to the axle from motor  130  by a belt or gear drive assembly as described above (not shown). Again, the opening end of barrel  106  is maintained at a higher vertical position relative to that of discharge end in order to affect gravity feed of the collection of objects through the barrel. Therefore, the rotational support near the input opening is positioned vertically higher than the rotational support near the discharge opening of barrel  106 .  
         [0025]    It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are effectively attained, and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. It should also be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between.  
         [0026]    The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.