Abstract:
A polystyrene product remanufacturing apparatus includes a cabinet assembly having four or more side walls, including a front panel, two side panels, and a back panel, a top, and a bottom to create an interior space for used polystyrene products, the front panel includes two hinged doors, first door hinges on a vertical edge of the front panel to provide access to the space for placement of used polystyrene products and the second door hinges proximate a lower horizontal edge of the front panel to retrieve densified polystyrene products; a plurality of radiant heat sources for controlled temperature in the cabinet, positioned proximate the top panel, two side panels, bottom panel, and centered above the bottom panel; and two or more drawers positioned proximate bottom panel and removable through the second door.

Description:
TECHNICAL FIELD 
       [0001]    The disclosure relates generally to an enclosed heat source or oven, and more specifically is related to a heating apparatus for modifying the shape and density of plastic. 
       BACKGROUND 
       [0002]    Polystyrene or Styrofoam products are widely used in the food service industry such as cafeteria&#39;s and lunch rooms for serving food and drink. Presently, in the cafeteria/lunchroom settings used Styrofoam trays and containers are disposed of by dumping the products along with the remaining food left on the product into a garbage bag and dispose of the tray and food content. Despite the suitability of Styrofoam for these purposes, the cost of its disposal along with the environmental impact has become of concern. Polystyrene has beneficial characteristics such as it is light weight and high strength; however, once used it is not easily compressed and does not have enough density to make transportation to a central recycling center economical due to the large space the un-stacked used containers and trays occupy. 
         [0003]    Various cabinets or insulated cabinets with internal heat sources are known in the prior art, for example, there are BBQ grills, cookers or smokers, ventilating and cooling (HVAC) units, and wall ovens. Each cabinet houses a heat source and serves a purpose of efficiently heating an item for a special purpose. 
         [0004]    One such purpose is densification of plastic, polymers, or polymer materials such as polystyrene since expanded polystyrene is a thermoplastic polymer and heat quickly causes the polymer chains to retract or shrink. 
         [0005]    Two processes for densification of polystyrene include compression and melting. Large commercial or industrial recyclers have conveyor delivery system, large hoppers, shredders, heat sources, and compression devices to remanufacture polystyrene. However, such facilities require bulk quantities of polystyrene to be transported to the facility, require substantial space requirements for such equipment, and generate undesirable amounts of fumes. 
         [0006]    Therefore, it is readily apparent that there is a recognizable unmet need for a polystyrene product remanufacturing apparatus and methods of use, which enables remanufacturing of large numbers of expanded polymer container, packaging, or tray at the source of the used items, such as, a single school or cafeteria, fast food restaurant or similar location having a high volume of used expanded polymer containers, packaging or trays resulting in an enormous space when un-stacked, and enables remanufacturing the expanded polystyrene into dense retracted blocks, which are efficient to transport. 
       BRIEF SUMMARY 
       [0007]    Briefly described, in example embodiment, the present apparatus overcomes the above-mentioned disadvantage, and meets the recognized need for a polystyrene product remanufacturing apparatus and methods of use comprising, in general, a cabinet assembly having four or more side walls, including a front panel, two side panels, and a back panel, a top, and a bottom to create an interior space for used polystyrene products, the front panel includes two hinged doors, first door hinges on a vertical edge of the front panel to provide access to the space for placement of used polystyrene products and the second door hinges proximate a lower horizontal edge of the front panel to retrieve densified polystyrene products; a plurality of radiant heat sources for controlled temperature in the cabinet, positioned proximate the top panel, two side panels, bottom panel, and centered above the bottom panel; and two or more drawers positioned proximate bottom panel and removable through the second door, and, thus, functions to enable remanufacturing of large numbers of expanded polymer packaging or trays at the source, such as, a single school or cafeteria, fast food restaurant or similar location having a high volume of used expanded polymer packaging or trays resulting in an enormous space when un-stacked, and remanufacturing the expanded polystyrene into a dense retracted blocks that are efficient to transport. 
         [0008]    According to its major aspects and broadly stated polystyrene product remanufacturing apparatus and methods of use comprising, in general, a polystyrene tray remanufacturing apparatus and methods of use comprising, in general, an cabinet assembly having four or more side walls, including a front panel, two side panels, and a back panel, a top, and a bottom to create a space for used polystyrene products, the front panel includes two hinged doors, first door hinges on a vertical edge of the front panel to provide access to the space placement of used polystyrene products and the second door hinges proximate a lower horizontal edge of the front panel to retrieve densified polystyrene products; a plurality of radiant heat sources for controlled temperature in the cabinet, positioned proximate the top panel, two side panels, bottom panel, and centered above the bottom panel; and two or more drawers positioned proximate bottom panel and removable through the second door. 
         [0009]    In a preferred embodiment, an apparatus for the densification of thermoplastics, the apparatus including a cabinet assembly having a plurality of side walls, a top, and a bottom, the cabinet assembly configured to create an interior space, at least one door configured to provide access to the interior space, a plurality of radiant heat sources configured for controlled temperature in the interior space, and wherein the plurality of radiant heat sources includes one or more upper radiant heat source positioned to radiate heat from an upper portion of the interior space adjacent the top, the plurality of radiant heat sources further includes one or more lower radiant heat source positioned to radiate heat from a lower portion of the interior space adjacent the bottom, and the plurality of radiant heat sources still further includes at least one middle radiant heat source positioned to radiate heat from a center portion of the interior space adjacent a point between the top and the bottom. 
         [0010]    In still a further exemplary embodiment of a method of densification of a plurality of thermoplastics, the method including the steps of obtaining an apparatus having a cabinet assembly configured with a plurality of side walls, a top, and a bottom, the cabinet assembly configured to create an interior space, at least one door configured to provide access to the interior space, a plurality of radiant heat sources configured for controlled temperature in the interior space, wherein the plurality of radiant heat sources includes one or more upper radiant heat source positioned to radiate heat from an upper portion of the interior space adjacent the top, the plurality of radiant heat sources further includes one or more lower radiant heat source positioned to radiate heat from a lower portion of the interior space adjacent the bottom, and the plurality of radiant heat sources still further includes at least one middle radiant heat source positioned to radiate heat from a center portion of the interior space adjacent a point between the top and the bottom, and wherein the interior space includes one or more collector trays, inserting the plurality of thermoplastics therein the interior space, completing one or more pre-operation procedures, powering the plurality of radiant heat sources to achieve a temperature equivalent to the melting point of the plurality of thermoplastics, densifying the plurality of thermoplastics, and collecting the densified plurality of thermoplastics in the collector trays. 
         [0011]    Accordingly, a feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide a front loading access door to enable easy loading of used polystyrene products. 
         [0012]    Another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to have a front retrieval access door to enable easy unloading of densified polystyrene products. 
         [0013]    Still another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide an insulated energy efficient apparatus to for densification of used polystyrene products. 
         [0014]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to integrate a safety control system with solenoid door locks. 
         [0015]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide a small foot print remanufacturing apparatus utilized to densify used polystyrene products at the source such as, a single school or cafeteria, fast food restaurant or similar location having a high volume of used expanded polymer containers, packaging or trays. 
         [0016]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide transportation cost savings by remanufacturing the expanded polystyrene into dense retracted blocks, which are efficient to transport. 
         [0017]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide a remanufacturing apparatus with a control system with three position operation switches. 
         [0018]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to provide a side or back vent for discharge of fumes generated during densification of used polystyrene products. 
         [0019]    Yet another feature of the polystyrene product remanufacturing apparatus and methods of use is its ability to densify or retract the used polystyrene product by approximately ninety percent (90%) reducing the cost to transport and recycle or dispose of the used polystyrene product. 
         [0020]    These and other features of the polystyrene product remanufacturing apparatus and methods of use will become more apparent to one skilled in the art from the following Detailed Description of the Embodiments and Claims when read in light of the accompanying drawing Figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The polystyrene product remanufacturing apparatus and methods of use will be better understood by reading the Detailed Description of the embodiments with reference to the accompanying drawing figures, in which like reference numerals denote similar structure and refer to like elements throughout, and in which: 
           [0022]      FIG. 1  is a perspective view of an example embodiment of polystyrene product remanufacturing apparatus; 
           [0023]      FIG. 2  is a left side, front side, right side, and back side view of the polystyrene product remanufacturing apparatus of  FIG. 1 ; 
           [0024]      FIG. 3  is a perspective view of the polystyrene product remanufacturing apparatus of  FIG. 1 , shown with front panel doors in the open position; 
           [0025]      FIG. 4  is perspective exploded view of polystyrene product remanufacturing apparatus of  FIG. 1 ; 
           [0026]      FIG. 5  is a front view of the polystyrene product remanufacturing apparatus of  FIG. 1 , showing the positioning of the plurality of heating elements; 
           [0027]      FIG. 6  is a side view of the polystyrene product remanufacturing apparatus of  FIG. 1 , showing the positioning of the plurality of heating elements; 
           [0028]      FIG. 7  is a side view of the polystyrene product remanufacturing apparatus of  FIG. 1 , shown with used product positioned therein; 
           [0029]      FIG. 8  is a side view of the polystyrene product remanufacturing apparatus of  FIG. 1 , shown with used product densified and retracted into a melted block; and 
           [0030]      FIG. 9  is a flow diagram of a method of densifying and retracting polystyrene product. 
       
    
    
       [0031]    It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention. 
       DETAILED DESCRIPTION 
       [0032]    In describing the exemplary embodiments of the present disclosure, as illustrated in  FIGS. 1-9  specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples, and are merely examples among other possible examples. 
         [0033]    Referring now to  FIGS. 1-3 , by way of example, and not limitation, there is illustrated an example embodiment of a polystyrene product remanufacturing apparatus  10 . Preferably, remanufacturing apparatus  10  preferably includes cabinet assembly  12  configured of four or more side wall sections and top and bottom, including front panel  25 , two side panels, left side panel  24  and right side panel  22 , back panel  23 , top panel  21 , and bottom panel  26  to create an enclosed and insulated space therein. It is contemplated herein that cabinet assembly  12  may include an internal or external support structure to provide support for side wall sections and a top and bottom. Moreover, assembly of cabinet assembly  12  may be assembled by welding or screwing the component together or other attachment device known to one of ordinary skill in the art. Furthermore, bottom panel  26  preferably includes a plurality of legs or feet, such as foot plate assemblies  40 , including first foot plate assembly  41 , second foot plate assembly  42 , third foot plate assembly  43 , and fourth foot plate assembly  44 . Moreover, foot plate assemblies  40  may include wheels, such as casters to enable repositioning of polystyrene product remanufacturing apparatus  10 . It is further contemplated herein that cabinet assembly  12  preferably includes insulation, such as rock wool to insulate cabinet assembly  12  in an effort to reduce heat transfer, reduce energy consumption, and hot surface safety concerns. It is still further contemplated herein that conduit runs and junction boxes may be positioned internal or external to cabinet assembly  12  to enable power, wiring, sensors, and controls to be positioned therein cabinet assembly  12 . 
         [0034]    Still furthermore, cabinet assembly  12  preferably includes one or more door assemblies  30  releasably hinged thereto front panel  25 , such as first, upper, or top door assembly  32  is preferably releasably hinged to a vertical edge of the front panel  25  and is releasably latched via door latch bracket  52  to front panel  25  and door latch bracket  52  is preferably positioned on an opposite edge of vertical edge of the front panel  25 . Preferably first door assembly  32  provides access to upper interior cabinet space for placement or stacking of used polystyrene products therein cabinet assembly  12 . Second, lower, or bottom door assembly  34  is preferably releasably hinged to front panel  25  and provides access to lower interior cabinet space  74  for insertion and/or removal of pan or tray, such as collector tray  95  therefrom cabinet assembly  12 . Bottom door assembly  34  preferably includes lower door handle  54  for operation of bottom door assembly  34 . 
         [0035]    Cabinet assembly  12  preferably includes one or more access panel  54  positioned preferably on back panel  23 , however any of the other panels of cabinet assembly  12  may include access panel  54 . 
         [0036]    Cabinet assembly  12  is preferably formed of a suitable material, such as stainless steel, aluminum, tin, iron, rigid plastic or plastic with metal inserts for strength, fiber, metal, alloy, steel, or the like, capable of providing structure to polystyrene product remanufacturing apparatus  10 . Preferably, the material includes other suitable characteristics, such as durability, rust-resistance, light weight, heat-resistance, chemical inertness, oxidation resistance, ease of workability, or other beneficial characteristic understood by one skilled in the art. 
         [0037]    It is contemplated herein that sections or integral sections of shaped cabinet assembly  12  may include various configurations, angles, and sizes and such sections or combination sections may be arranged proximate one another to fit together to form cabinet assembly  12 . 
         [0038]    It is further contemplated herein that first, upper, or top door assembly  32  is configured to enable easy loading of used polystyrene products, such as stacked trays ST as shown in  FIG. 7 . 
         [0039]    It is further contemplated herein that second, lower, or bottom door assembly  34  is configured to enable easy unloading or retrieval of densified polystyrene products, such as melted brick MB as shown in  FIG. 8 . 
         [0040]    Referring now to  FIGS. 4-6 , by way of example, and not limitation, there is illustrated an example embodiment of a polystyrene product remanufacturing apparatus  10 . Preferably polystyrene product remanufacturing apparatus  10  further includes control panel assembly  80  having control panel  81  and bottom panel  82 , and positioned therein control housing  83  having control panel cover  84 . Control housing  83  preferably includes controls  86  configured to operate polystyrene product remanufacturing apparatus  10 . Controls  86  preferably include wiring, sensor, regulators, timers, electronics, solenoid door locks, thermostats, communications equipment, lights, key switch, actuators, transformer and the like necessary to operate and control polystyrene product remanufacturing apparatus  10 . Control panel cover  84  preferably includes one or more operators, such as buttons, switches, lights and the like necessary to operate and control polystyrene product remanufacturing apparatus  10 . 
         [0041]    Preferably polystyrene product remanufacturing apparatus  10  further includes ventilation assembly  60  having ventilation conduit  64  and reservoir  62 . Ventilation assembly  60  is preferably positioned with ventilation conduit  64  having access to upper interior cabinet space  72  anywhere on cabinet assembly  12  four or more side wall sections and top and bottom. Preferably ventilation assembly  60  is configured to vent any fumes, gases, or moisture accumulating within upper interior cabinet space and/or lower interior cabinet space  74 . It is contemplated herein that ventilation assembly  60  may include a fan and duct work necessary to vent any fumes, gases, or moisture accumulating within upper interior cabinet space  72  and/or lower interior cabinet space  74  to an exterior position, such as outside a building. 
         [0042]    Preferably polystyrene product remanufacturing apparatus  10  further includes a plurality of radiant heat elements  90  strategically positioned or disposed within upper interior cabinet space  72  and/or lower interior cabinet space  74  of cabinet assembly  12 . Preferably heat elements  90  are configured with controls  86  to regulate and maintain specified temperature within upper interior cabinet space  72  of cabinet assembly  12 . Moreover, heat elements  90  include first upper heat element  91 A and second upper heat element  91 B positioned proximate top panel  21  or bottom panel  82  of control panel assembly  80  or proximate an upper portion of upper interior cabinet space  72 . First upper heat element  91 A and second upper heat element  91 B preferably radiate heat from above upper interior cabinet space  72  and/or lower interior cabinet space  74  to therein such space. Furthermore, first upper heat element  91 A and second upper heat element  91 B preferably include heating element covers, such as first heating element cover  92 A and second heating element cover  92 B to affixed around first upper heat element  91 A and second upper heat element  91 B to prevent debris from contacting first upper heat element  91 A and second upper heat element  91 B. 
         [0043]    Moreover, heat elements  90  include first lower heat element  91 D and second lower heat element  91 E positioned proximate bottom panel  26 . First lower heat element  91 D and second lower heat element  91 E preferably radiate heat from below upper interior cabinet space  72  and/or lower interior cabinet space  74  to therein such space. Furthermore, first lower heat element  91 D and second lower heat element  91 E preferably include heating element covers, holders and/or mounting plates, such as first heating element cover  93 D and second heating element cover  93 E to cover first lower heat element  91 D and second lower heat element  91 E to prevent debris from contacting first lower heat element  91 D and second lower heat element  91 E; including first heating element holder  92 D and second heating element cover  92 E to support first lower heat element  91 D and second lower heat element  91 E; and including first heating element mounting plate  94 D and second heating element mounting plate  94 E to mount first lower heat element  91 D and second lower heat element  91 E thereto. 
         [0044]    Moreover, heat elements  90  include middle heat element  91 C positioned preferably proximate bottom panel  26  and affixed to pan divider  94 C, pan divider  94 C preferably configured to extend therefrom bottom panel  26  into upper interior cabinet space  72  and/or lower interior cabinet space  74 . Middle heat element  91 C preferably radiates heat from below upper interior cabinet space  72  and above lower interior cabinet space  74  to therein such space. Furthermore, middle heat element  91 C preferably includes heating element covers, holders and/or mounting plates, such as heating element cover  93 C to cover middle heat element  91 C to prevent debris from contacting middle heat element  91 C; including middle element holder  92 C to support middle heat element  91 C therefrom pan divider  94 C. Still further, heating element cover  93 C is preferably configured as a center divider of lower interior cabinet space  74  dividing stacked trays ST transitioning to melted brick MB (as shown in  FIGS. 7-8 ) between collector trays  95 , such as first collector tray  95 A and second collector tray  95 B. Moreover, middle heat element  91 C and heating element cover  93 C is preferably configured as a center divider of lower interior cabinet space  74  dividing stacked trays ST transitioning to melted brick MB (as shown in  FIGS. 7-8 ), thus, efficiently transitioning dividing stacked trays ST to melted brick MB by providing a heat source that radiates from upper interior cabinet space  72 . It is further contemplated herein that pan divider  94 C may be of a size capable of positioning middle heat element  91 C anywhere in the center column between first upper heat element  91 A and second upper heat element  91 B, and first lower heat element  91 D and second lower heat element  91 E. 
         [0045]    It is contemplated herein that other collector trays may be configured for cabinet assembly  12 , such as a single tray or the like. 
         [0046]    It is recognized herein that a plurality of radiant heat elements  90  are strategically positioned within upper interior cabinet space  72  to achieve optimum balance of heat throughout upper interior cabinet space  72  and/or lower interior cabinet space  74  of cabinet assembly  12 . 
         [0047]    It is recognized herein that a plurality of radiant heat elements  90  are strategically positioned therein upper interior cabinet space  72  to supply sufficient heat to cause stacked trays ST to retract, densify, or melt into brick MB (as shown in  FIGS. 7-8 ). 
         [0048]    It is recognized herein that a plurality of radiant heat elements  90  are strategically positioned around stacked trays ST (as shown in  FIG. 7 ). 
         [0049]    Preferably polystyrene product remanufacturing apparatus  10  further includes power cord and plug  60  to connect polystyrene product remanufacturing apparatus  10  thereto electric service. 
         [0050]    It is contemplated herein that controls  86  integrated and are in communication with solenoid door locks of door latch bracket  52  to provide safety control system disabling door latch bracket  52  when temperatures exceed a specified level. 
         [0051]    It is contemplated herein that collector tray  95  may be positioned, slid or rolled therein/out of lower interior cabinet space  74  via opening and/or closing of bottom door assembly  34 . 
         [0052]    Referring now to  FIGS. 7-8 , by way of example, and not limitation, there is illustrated cut away of an example embodiment of a polystyrene product remanufacturing apparatus  10 . Preferably polystyrene product remanufacturing apparatus  10  is shown with stacked trays ST inserted therein upper interior cabinet space  72  of cabinet assembly  12 . Stacked trays ST preferably include polymers, polymer materials, thermo plastics, or expanded polymer, such as polystyrene including containers, packaging, or trays. In use a plurality of radiant heat elements  90  strategically positioned or disposed within upper interior cabinet space  72  of radiate heat to achieve a temperature equivalent to the melting point of stacked trays ST, such as approximately 375 degrees Fahrenheit. Such temperature will cause stacked trays ST to retract and densification into melted block MB reducing stacked trays ST volume by approximately ninety percent (90%) reducing the cost to transport and recycle or dispose of the used polystyrene product. 
         [0053]    It is contemplated herein that collector trays  95 , such as first collector tray  95 A and second collector tray  95 B collect or amass densified stacked trays ST or stacked trays ST in a retracted and densification form as melted block MB. 
         [0054]    It is contemplated herein that cabinet assembly  12  configured of four or more side wall sections and top and bottom may include one or more vents to exhaust heat from within cabinet assembly  12  or to discharge fumes generated during densification of used polystyrene products. 
         [0055]    Referring now to  FIG. 9 , there is illustrated a flow diagram  900  of a method densification of polystyrene products, such as stacked trays ST. In block or step  910 , obtaining polystyrene product remanufacturing apparatus  10  as described above in  FIGS. 1-8 . In block or step  915 , inserting one or more polystyrene products, such as stacked trays ST, therein polystyrene product remanufacturing apparatus  10  or more specifically therein upper interior cabinet space  72  of cabinet assembly  12  (loading step). It is contemplated herein that stacked trays ST may be pre-stacked or otherwise non-organized prior to loading. In block or step  920 , completing one or more pre-operation procedure, such as loading collector trays  95 , such as first collector tray  95 A and second collector tray  95 B, closing doors, such as top door assembly  32  and bottom door assembly  34  and setting controls  86  configured to operate polystyrene product remanufacturing apparatus  10 . In block or step  925 , powering heat elements  90  to achieve a temperature equivalent to the melting point of stacked trays ST for a necessary time period set by controls  86 . In block or step  930 , retracting/densifying one or more polystyrene products, such as stacked trays ST into melted block MB. In block or step  935 , collecting densified one or more polystyrene products, such as stacked trays ST in collector trays  95 , such as first collector tray  95 A and second collector tray  95 B. In block or step  940 , removing collector trays  95 , such as first collector tray  95 A and second collector tray  95 B having one or more melted block MB therefrom said lower interior cabinet space  74  or cabinet assembly  12 . In block or step  945 , disposing/recycling of one or more melted block MB. In block or step  950 , reducing the cost to transport, recycle, and/or dispose of the used polystyrene products, such as stacked trays ST. 
         [0056]    The foregoing description and drawings comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments, it should be noted by those ordinarily skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one ordinarily skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Moreover, the present invention has been described in detail; it should be understood that various changes, substitutions and alterations can be made thereto without departing from the spirit and scope of the invention as defined by the appended claims. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.