Abstract:
A method and system are presented for grinding and reclaiming of polymer material such as a rubber. The apparatus comprising a stator ( 4 ) and a rotor ( 2 ) in near face-to-face relationship with each other forming an operating zone for rubber grinding and reclaiming therebetween. The stator ( 4 ) has a substantially flat smooth face surface and the rotor ( 2 ) has a concave face surface with a depth gradually decreased from a center to a periphery thereof. The rotor further comprising at least one curved protrusion ( 30 ) with a radius of curvature gradually increased from the center to the periphery of the rotor.

Description:
BACKGROUND 
       [0001]    The present invention relates to a waste rubber processing machine and method, and more particularly to a process and apparatus for grinding and reclaiming rubber or similar material. 
         [0002]    Grinding or size reduction and crumb production of waste cured rubber, including scrap tires, is subject of numerous patents, articles and books. 
         [0003]    There are a lot of plants in the world (ca 1200), which produce rubber crumb from the scrap tires. Most of them are dealing with the treatment of waste rubber by collecting, sorting and breaking it down to the required size as defined by the end user. Yet very few rubber industrialists deal with reclaiming and de-vulcanization. 
         [0004]    However, at present the most acute challenge is what to do with this rubber crumb. According to published data, 51% of crumb is incinerated, 43% is added to asphalt and only 6% are rejuvenated as new raw rubber material. 
         [0005]    Investigations performed at most Rubber Centers, such as Akron Rubber Development (USA), Kharagpur Rubber Institute (India), NIISP (Russia) have shown that main properties of rubber compound decrease linearly as content of ground rubber grows. It indicates obviously that granulated rubber behaves as filler in rubber compounds and cannot be used at high percentages. By data of Smith, upper level of mechanically ground crumb content cannot exceed 2.3% for radial tires and 3.2% for bias tires. It is caused by steep impair of main properties at major contents. 
         [0006]    Various machines and technologies are used for production of cured rubber crumb. 
         [0007]    One of the common known approaches is size reduction of rubber chips at breaking or grinding 2-roll mills. This technique is based on passing rubber chips through tight nip between rollers are widely used in the recycling industry. Technology based on multiple passing of raw rubber material mixed with special additives (modifier) through the narrow nip of 2-roll mills are suitable for devulcanization, too. The following patents: U.S. Pat. No. 3,269,468; U.S. Pat. No. 5,257,742; U.S. Pat. No. 2,211,518; U.S. Pat. No. 1,653,472; U.S. Pat. No. 4,747,550 and U.S. Pat. No. 1,758,010 describe different grinding mills. Low productivity caused by very short time of shear stress in the nip (0.04-0.05 sec) restricts feasibility of this technology. 
         [0008]    Another technique is based on knife cutting as disclosed by patents U.S. Pat. No. 5,695,131; U.S. Pat. No. 5,299,744 and U.S. Pat. No. 7,021,576. Multi-knife shredder or rotor knife mill are widely used in rubber recycling. Though this technique provides relatively high productivity, it yields only rough crumb and, in addition to that, cut crumb is contaminated by metal impurities. 
         [0009]    Technique involving freezing of rubber (cryogenic methods) prior to or during processing in mills are known in the art. U.S. Pat. No. 4,813,614 and GB patent 1559152 disclose cryogenic grinding between two wheels provided by a set of crushing pins. U.S. Pat. No. 4,383,650 discloses grinding of frozen material between two toothed wheels. It is also known cryogenic milling in vibration mill or a rotary blade mill, where the material is maintained cooled below −60 .degree C. by supplying a coolant, particularly liquid nitrogen or carbonic acid. Cryogenic grinding provides rather fine particles with minimum impurities. However, extremely high cost of liquid nitrogen makes cryogenic methods uneconomical. Besides, cryogenic technology does not allow devulcanization by chemical agents, because these reactions do not occur at low temperatures. 
         [0010]    In the last decades use of extruders for rubber grinding has been developed widely, as disclosed in U.S. patent U.S. Pat. No. 6,590,042; U.S. Pat. No. 6,576,680 and U.S. Pat. No. 6,335,377. Extruder could operate within a wide range of temperatures (up to 300° C.) and provides sufficient productivity. The great skill is required for adjusting the mill to achieve optimum results by this technology, because the material is intensely heated during processing in the mill and the extruder. Thus, a great amount of heat energy must be dissipated by water-cooling. Disadvantages of this technique are: lack of possibility for ultra-fine grinding because clearance between screw and walls cannot be performed tightly enough; unfeasibility for effective cooling of solid bulk of processed material; extreme energy consumption. 
         [0011]    Attrition or disc mills for rubber grinding also are known in the art. US patent U.S. Pat. No. 4,535,941 for example, discloses grinding at horizontal mill, similar to those used in pigments industry. Later U.S. patent of the same inventor, U.S. Pat. No. 4,625,922 discloses improved technique, of grinding at elevated temperatures. This technique suffers from unfeasibility of continuous process. In order to overcome this drawback, it was proposed to perform rubber grinding in flow of liquid slurry (water, oil, etc.) as described in US patents U.S. Pat. No. 5,238,194, U.S. Pat. No. 5,411,215 and U.S. Patent Application U.S. 20020086911. Sufficient continuity could be achieved; however necessity in consequent drying of the produced crumb makes such a process impractical. 
         [0012]    Construction of disc mill for grinding rubber between grinding wheel and shroud is also disclosed in US patent U.S. Pat. No. 6,976,646. Setting of uniform clearance between wheel and shroud along entire perimeter of working zone at this design is problematic. 
         [0013]    Therefore, a need still exists for an improved technique of producing commercially reusable rubber material by providing a cost-effective, continuousgenerally ambient temperature process. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    These and other objects are accomplished in a rubber grinding and reclaiming machine and continuous method which operates at generally ambient or moderately elevated temperature and produces fine grain rubber particles or reclaimed rubber material at a low cost. Rubber material advances into a grinding module where the rubber material is ground into rubber particles and/or converts into reclaimed rubber material via a rotating grinding wheel.
 
Thus, finely ground and devulcanized rubber particles are created, which are suitable for incorporation into new rubber products. The rubber particles are produced cheaply and efficiently.
 
These and other features of the present invention are discussed or apparent in the following detailed description of preferred embodiments of the invention. Continuity of process is due to forced advance of material along the entire path from feeder to output and unique smart design of the transition area from screw feeder into the spiral vertical disc. Performance of the process by single pass is due to extended spiral path of the working disc. Preparation of the fine-ground crumb and reclaim is due to easily controlled clearance at the zone of material output. Fine compatibility of crumb and reclaim with rubber compounds due to well-developed surface of the ground particles. Effective heat removal is achieved due to developed working surfaces along the whole path of the processed material. Power economy provides due to pulling material advance instead of pushing, used in conventional extruder dispergators.
 
         [0015]    Thus, according to one general aspect of the present invention, there is provided an apparatus for a polymer material grinding and reclaiming, comprising a stator and a rotor in near face-to-face relationship with each other forming an operating zone for rubber grinding and reclaiming therebetween. The stator has a substantially flat smooth face surface and the rotor has a concave face surface with a depth gradually decreased from a center to a periphery thereof. The rotor further comprising at least one curved protrusion with a radius of curvature gradually increased from the center to the periphery of the rotor. 
         [0016]    According to one general aspect of the present invention, there is provided a method of rubber grinding and reclaiming comprising the steps of forming an operating zone for rubber grinding and reclaiming by providing a stator and a rotor in near face-to-face relationship with each other. The stator has a substantially flat smooth face surface and the rotor has a concave face surface with a depth gradually decreased from a center to a periphery thereof. The rotor further comprising at least one curved protrusion with a radius of curvature gradually increased from the center to the periphery of the rotor 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    In order to understand the invention and to see how it may be carried out in practice, preferred embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which: 
           [0018]      FIG. 1  is a cross-section schematic view of rubber grinding machine of the invention. 
           [0019]      FIG. 2   a  is a face view of a mono-spiral rotor in accordance with one embodiment of the invention; 
           [0020]      FIG. 2   b  is a cross-section view of mono-spiral rotor; 
           [0021]      FIG. 3   a  is a face view of a multi-spiral rotor in accordance with another embodiment of the invention; 
           [0022]      FIG. 3   b  is a cross-section view of multi-spiral rotor; 
           [0023]      FIG. 4  illustrates an example of multi-spiral rotor in accordance with the preferred embodiment of the present invention; 
           [0024]      FIG. 5  is a cross-section view of transition zone between operating zone and feeding-in conveyor of rubber grinding reclaiming machine. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    Referring to  FIG. 1 , a polymer material such as rubber grinding and reclaiming machine LIM includes a rotor  2 , a fixed stator portion  4 , with cooling jacket  6 , a screw feeder  8  having an auger  9 , associated with a hopper  10 . Rotor  2  is rotated by a motor  12  via a gear  14 . The stator  4  is formed by a metal plate having a flat surface in near face-to-face relationship with rotor  2  and is provided with a central bore or opening in the center thereof are further illustrated in  FIG. 5 . The auger  9  of screw feeder  8  may be driven by a drive formed by a gear assembly  18  and a motor  20 . 
         [0026]    In operation, rubber waste in form of pieces of chips or optionally mixture of said pieces with addition of modifier enters from hopper  10  into the screw feeder  8  and travels to a operating zone formed by a gap between stator  4  and rotor  2 . Ready material  24  after processing is evacuated by the belt conveyer  26 . 
         [0027]    Optionally, vibration could be applied towards stator  4  by a vibrator  28  in order to intensify the comminuting process due to the effect of alternating contraction-release of the particles. Rotor  2  also could be provided by cooling jacket (not shown) for cooling. 
         [0028]    Optionally, means for controlling cooling liquid, e.g. water flow trough the cooling jackets  6  and/or rotor&#39;s cooling jacket could be provided so as to provide an optimal working temperature. Preferably, optimal working temperature is within a range of about 40-80 degrees of C. 
         [0029]    Referring to  FIGS. 2   a  and  2   b  and  3   a  and  3   b , and  4  rotor  2  is a metal (steel) disc with gradually increased thickness from central to the periphery portion and having a curved protrusion portion(s) (ridge)  30  ( 30 ′,  30 ″). Spiral protrusion portion could be either in form of mono-spiral  30  ( FIGS. 2   a ,  2   b ) or in form of multi-spiral  30 ′,  30 ″ ( FIGS. 3   a ,  3   b  and  4 ). Rotor  2  is a metal (steel) disc having a concave face surface, formed by gradually increased thickness from central to the periphery portion of the disc. Such configuration of rotor  2  with spiral protrusion portion  30  ( 30 ′,  30 ″) could be formed e.g. using Five-Axis CNC Machine Tools from metal (steel) disc. Profile of protrusion portion(s)  30  ( 30 ′,  30 ″) is made such that its radius gradually increases while height gradually decreases from center to periphery of rotor. Preferably, clearance between rotor  2  and stator  4  is regulated, e.g. by providing adjustable mounting of stator  4  permitting its inward or outward placement with respect to the rotor  2 . Depending upon the desired fineness of the output material, an optimum clearance between rotor  2  and stator  4  can be determined. Material fine comminuting occurs in operating zone of rubber grinding machine during passing the material along spiral groove formed by protrusion portion  30  ( 30 ′,  30 ″) and flat surface of the stator  4 . 
         [0030]    Preferably, in order to provide high level of devulcanization of grinded rubber, raw material is treated in accordance with co-pending PCT application PCT/IL2009/000808 the disclosure of which is incorporated by reference herein. 
         [0031]    In operation of machine, comminuting between flat surface of stator  4  and curved grooves of rotor  2  provides formation of thin and oblong particles with well-developed surface up to 400-600 cm 2  per gram. 
         [0032]    Preferably, the shape of protrusion portion  30  ( 30 ′,  30 ″) could be designed based on two conditions: a) forced and steady advance of material; b) material flow continuity. Both conditions should be fulfilled at the entire tract from center to periphery. 
         [0033]    Forced and steady advance of material is provided when tractive force acting on processed material exceeds the confining force caused by friction. This condition is fulfilled while the angle between tangent to the circle and tangent to a curve of blades profile in the center is taken as 30° (angle is determined experimentally). To this end: 
         [0000]      Δ R   0   /Δt )/[ R   0 /(Δtπ/180)}= tg 30°
 
         [0000]    Where R 0 —radius in the inlet area (mm)
 
Substituting Δt=1/(6n), where n—is angular speed of rotor (rev/min), we obtain (ΔR i *6n)/ πR i =tg30°=0.5773, where R i —current radius of the profile.
 
Hence it follows that ΔR 0 =0.5773 πR 0 /6n
 
Increment of the current radius ΔR i =R (i+1) −R i  is calculated by expression
 
         [0000]      ΔR i   =Q   0 /[1/(6* n )]*{(2π R   i   −Σa )*[ H   i −(Δ H   i   /L   i )*( R   i   −R   0 )]}
 
       Wherein: 
       [0034]    Σa—total width of all blades (mm)
 
H i —clearance between surfaces of stator and rotor in the beginning of area (mm)
 
ΔH i —increment of the clearance between surfaces of stator and rotor in the beginning and the end of area (mm)
 
L i —length of area (mm)
 
Q 0 —volume of the material flow at the inlet of the rotor.
 
         [0000]        Q   0 =[1/(6* n )]*{(2 πR   0   −Σa )*[ H   0 −(Δ H   0   /L   0 )]}
 
         [0000]    Expression [H i −(ΔH i /L i )*(R i −R n )]—reflects influence of area of radial section from clearance between surfaces of stator and rotor.
 
Then next current radius R (i+1) =R i +ΔR i  
 
Volume of the material flow at any arbitrary section of the pathway:
 
         [0000]        Q= 3.14 *R   i   2   *H   i   *n =const 
       Wherein: 
       [0035]    R—current diameter of the rotor (that in the inlet zone—R 0  and that in the outlet zone—R 2 ).
 
H—clearance between the stator and the rotor (that in the inlet zone—H 0  and that in the outlet zone—H 2 ).
 
n—angular speed of the rotor.
 
Material flow continuity (Q=const) could be presented as:
 
         [0000]    
       
      
       H 
       i 
       *R 
       i 
       2 
       =R 
       2 
       2 
       * H 
       2  
      
     
         [0000]    Parameters of the entire profile are determined by condition of material flow continuity. Thus, if diameter and clearance in the outlet zone are assigned, clearance at any arbitrary cross-section is defined by formula: 
         [0000]      H i   =R   2   2   /R   i   2   *H   2    
       EXAMPLE 
       [0036]    If R 0 =50 mm; Σa=4*6=24 mm; H 0 =7.02 mm; L=40 mm; R 2  =500 mm;
 
ΔH=5 mm; H 2 =0.2 mm; n=30 rev/min; Δt=1/6n=1/180 sec; ΔR 0 =0.5773π50/180=0.503˜0.5 mm
 
Then current increment of radius ΔR i =R (i+1) −R i  
 
         [0000]      ΔR i   =Q   0 *[1/(6* n )]*/{(2π Ri− 24)[7.02−4/40*( R   i −50)]}={182700*(1/180)}/{(2π R   i −24)[7.02−4/40*(R i −50)]}=1015/{(2π Ri− 24)[7.02−4/40*(R i −50)]}
 
       Flow Productivity: 
       [0037]        Q   0 =[1/(6 *n )]*{(2π R   0   −Σa )*[H 0 −(Δ H   0   /L   0 )]}==0.5/(1/180)*(2π50−24)*[7−(4/40)*(50−50)]=90*290*7=182.7 cm 3 /sec
 
       And Flow Productivity Per Hour: 
       [0038]    182.7 cm 3 /sec*3600/1000=657 liter/h 
         [0039]    At bulk density 0.4 gr/cm 3  mass productivity is 263 kg per hour. 
         [0040]    Current Height of Blades: 
       H i R 2   2 /R i   2 *H 2 =500 2 /R i   2 *0.2=50000/R i   2  mm. 
       [0041]    Referring to  FIG. 5 , construction of transition zone between screw feeder  8  and operating zone of rubber grinding machine formed by a gap G between rotor  2  and stator  4  is shown. 
         [0042]    According to one preferred embodiment of the invention, the transition zone is formed by curvature surfaces of a stator  4  and a bushing  40  associated with rotor  2 . Screw feeder  8  includes auger  9  associated with bushing  40  via a planar bearing  42  formed from brass or bronze. Planar bearing  42  could be fixedly mounted whether with auger  9  or bushing  40 . 
         [0043]    Configuration of curvature surfaces of transition zone preferably could be defined from condition of constant volume of material (rubber crumb under processing) for any arbitrary cross-section along the transition area. 
         [0044]    Volume amount of material moved by the auger  9  within the feeder  8  per one revolution could be defined as: 
         [0000]        V=F*b , cm 3 /min. 
         [0045]    Wherein, F—is area of ring between outer cover of the feeder  8  and the shaft of the auger  9  in cm 2 ; b—is a pitch of the screw, cm; 
         [0046]    Area of the ring defined by between outer cover of the feeder  8  and the shaft of the auger  9  could be defined as: 
         [0000]        F =3.14( R   0   2   −r   0   2 ), cm 2    
         [0047]    Wherein, R inn —inner radius of the feeder&#39;s  8  tube in cm; R 0 —radius of the auger&#39;s shaft  9  in cm. 
         [0048]    Then the volume of material could be defined as: 
         [0000]        V= 3.14( R   0   2   −r   0   2 )* b  (cm 3 ) 
         [0049]    Table 1 exemplifies dimensions screw feeder  8 . 
         [0000]    
       
         
               
             
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Screw feeder 
               
             
          
           
               
                   
                   
                 Inner 
                   
                   
               
               
                 Radius 
                 Pitch 
                 radius 
                 Distance 
                 Area of the 
               
               
                 of 
                 of the 
                 of the 
                 from 
                 ring cross- 
               
               
                 shaft, 
                 screw, 
                 tube, 
                 shaft to 
                 section, cm 2   
               
               
                 cm 
                 cm 
                 cm 
                 tube, cm 
                 F = 3.14(R 0   2  − 
               
               
                 r 0   
                 a 
                 R 0   
                 m = R 0  − r 0   
                 r 0   2 ) 
               
               
                   
               
               
                 5 
                 5.6 
                 6.5 
                 1.5 
                 54.17 
               
               
                   
               
             
          
         
       
     
         [0050]    Preferably, a curvature surfaces of stator  4  (further inner surface IS) or bushing  40  (further outer surface OS) could be formed with constant radius in order to simplify computation of the transition area. In the present example, inner surface IS has a 5 constant radius S. Distance from the beginning of inner surface IS to desired section plane being a linear variable a. For calculating pitch Δa=0.5 cm and number of section m=1 . . . 13, variable a=0.5*n. 
         [0051]    In that case, radius of curvature of outer surface OS of the transition area could be defined as: 
         [0000]    
       
      
       R 
       out 
       =R 
       inn 
       +s−√s 
       2 
       −a 
       2  
      
     
         [0000]    wherein, R inn  is radius of inner surface of the transition area 
         [0052]    Primarily, volume V 0  of the first layer at the entrance from the feeder to the transition area could to be defined as: 
         [0000]        V   0 =0.5*3.14*( R   0   2   −r   0   2 ) 
         [0053]    Wherein R 0  inner radius of the feeder&#39;s  8  tube in and r 0  is radius of auger&#39;s  9  shaft (see above). 
         [0054]    Area of ring defined by outer and inner surface of the transition area F thus could be defined as: 
         [0000]        F= 3.14 ( R   2   out   −R   2   inn ) 
         [0055]    Wherein R inn —radius of inner surface of the transition area. 
         [0056]    Volume of layer with thickness of 0.5 cm (due to pitch Δa=0.5 cm) will be: 
         [0000]        V= 0.5* F= 0.5*3.14 ( R   2   out   −R   2   inn ) 
         [0057]    Thus, radius of inner surface of the transition area R inn  could be defined as 
         [0000]        R   inn =√( R   2   out   −R   2   0   +r   2   0 )=√[( R   0   +s −√  ( s   2   −a   i   2   )) 2   −R   2   0   +r   2   0 ]
 
         [0058]    Table 2 exemplifies values of radius of outer surface, radius of inner surface and distance therebetween for arbitrary section plane of the transition area for values R 0 =6.5 cm; r 0 =5 cm; s=6.5 cm,. 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                   
                   
                   
                   
                 Distance 
               
               
                   
                 Distance from 
                 Current 
                 Current 
                 between outer 
               
               
                 Radius of 
                 the beginning 
                 radius of 
                 radius  
                 and inner 
               
               
                 the 
                 of stator&#39;s 
                 outer surface 
                 of inner 
                 curves of the 
               
               
                 stator&#39;s 
                 inner curvature 
                 of the 
                 surface of 
                 transition area 
               
               
                 inner 
                 to arbitrary 
                 transition 
                 the transition 
                 perpendicularly 
               
               
                 curvature 
                 section plane 
                 area 
                 area R inn  = 
                 to the axis 
               
               
                 S 
                 a i   
                 R out  = 2 * s− 
                 √R 2   out  − R 2   0   
                 c 1   
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 6.5 
                 0.0 
                 6.50 
                 5.00 
                 1.50 
               
               
                 6.5 
                 0.5 
                 6.52 
                 5.02 
                 1.49 
               
               
                 6.5 
                 1.0 
                 6.58 
                 5.10 
                 1.48 
               
               
                 6.5 
                 1.5 
                 6.68 
                 5.23 
                 1.45 
               
               
                 6.5 
                 2.0 
                 6.82 
                 5.40 
                 1.41 
               
               
                 6.5 
                 2.5 
                 7.00 
                 5.63 
                 1.37 
               
               
                 6.5 
                 3.0 
                 7.23 
                 5.92 
                 1.31 
               
               
                 6.5 
                 3.5 
                 7.52 
                 6.27 
                 1.25 
               
               
                 6.5 
                 4.0 
                 7.88 
                 6.69 
                 1.18 
               
               
                 6.5 
                 4.5 
                 8.31 
                 7.20 
                 1.11 
               
               
                 6.5 
                 5.0 
                 8.85 
                 7.81 
                 1.04 
               
               
                 6.5 
                 5.5 
                 9.54 
                 8.58 
                 0.95 
               
               
                 6.5 
                 6.0 
                 10.50 
                 9.64 
                 0.86 
               
               
                 6.5 
                 6.5 
                 13.00 
                 12.32 
                 0.68 
               
               
                 6.5 
                 6.7 
                   
                 13.00 
               
               
                   
               
             
          
         
       
     
         [0059]    Those skilled in the art will readily appreciate that various modifications and changes can be applied to the embodiments of the invention as hereinbefore described without departing from its scope defined in and by the appended claims.