Patent Description:
In the technical field set out above, it is widely known to produce articles made from polymer material using suitable transforming machines which provide for the formation of the desired article from a polymer blend which is prepared suitably.

For example, in a commonly used method of injection-moulding, the transforming machines, which are supplied by a polymer blend in granular form, provide in a first step for bringing the polymer blend to the molten or semi-molten state, for example, inside an extruder, and then for injecting it inside a mould having the form of the desired article where it is solidified, thus obtaining the final article.

Alternatively, the polymer blend in the molten or semi-molten state can be caused to pass through an extrusion head having a predefined profile which, in this case, also confers on the molten or semi-molten material the desired shape of the article to be obtained.

These blends are configured to confer on the final product chemical/physical or mechanical characteristics which are adequate for the purposes intended for the use thereof and can provide for the combination of a consistent number of materials, including one or more polymer materials and one or more additives which can be both of an organic nature and of an inorganic nature.

In general terms, these materials can differ from each other as a result of any characteristic thereof, such as, for example, the chemical composition or the form thereof or the degree of purity thereof or the origin thereof.

By way of example, the materials to be mixed may be one or more granular polymers, a mineral filler and one or more additives, such as a stabilizing compound, an antioxidant compound or a colouring compound.

Furthermore, the polymers to be mixed may be of the same type, for example, TPU or EVA, but may have different origins, such as, for example, virgin material or recycled material or may have different characteristics, for example, in terms of Shore hardness.

The polymer blends are generally prepared in a weighing and mixing unit, where the different materials are charged in accordance with the intended quantities from a respective recipe which defines the precise relationship between the different materials of each polymer blend and are therefore mixed with each other in a virtually homogeneous manner before being supplied to the transforming machine.

<CIT>, <CIT>, <CIT> and <CIT> each describes production apparatus known in the art.

In this context, the Applicant has observed that some materials which form the polymer blends have high hygroscopic properties and therefore tend to absorb humidity which can, during the moulding or extrusion step, lead to the formation of both structural and aesthetic defects in the final article.

In order to prevent such disadvantages, it is known to process such materials in a suitable heating and drying device before being mixed with the other components of the polymer blend and therefore being supplied to the transforming machine.

However, the Applicant has observed that this arrangement is not particularly effective and has therefore perceived the need for optimizing the configuration of the known apparatuses in order to improve the management and the overall efficiency thereof.

In the present description and the appended claims, the term "granular material" is intended to be understood to be a plurality of solid elements which are different and separate from each other, having suitable dimensions and shape in accordance with the processing to be carried out and the material used, including the powdered or flaked polymer material.

The blend is based on polymer material when at least <NUM>% of the material of the blend is formed by one or more polymer materials, preferably at least <NUM>%. The polymer material may be any material which is suitable for and normally used in processing operations for plastics materials. Preferably, it is a thermoplastic material, such as, for example, polyolefins, polyurethanes, polyesters, polyamides or the copolymers thereof. Preferred examples of polymer materials are ethylene vinyl acetate (EVA) copolymer and thermoplastic polyurethane (TPU).

The object of the present invention is to provide a production apparatus for polymer-based articles which is structurally and functionally configured to at least partially overcome one or more of the disadvantages set out above with reference to the cited prior art.

This object is achieved by the present invention by means of a production apparatus according to independent claim <NUM>; further preferred embodiments are claimed in the dependent claims.

As a result of these characteristics, the apparatus of present invention advantageously allows the polymer blend which is prepared by the weighing and mixing unit to be heated shortly before it is supplied to the transforming machine, preventing the dispersion of heat and the possibility of absorbing fresh humidity before being introduced into the transforming machine.

The apparatus of present invention may have at least one of the preferred features described below.

Preferably, the weighing and mixing unit is positioned at a higher level than the supply hopper so as to allow the transfer of the polymer blend by falling from the weighing and mixing unit to the supply hopper.

More preferably, the weighing and mixing unit is positioned vertically above the supply hopper.

In this manner, the configuration of the apparatus is advantageously optimized, minimizing the overall dimensions thereof and making full use of gravitational force for moving the polymer blend between the various components thereof. In some embodiments, the supply hopper is positioned at a higher level than the transforming machine so as to allow the transfer of the polymer blend by falling from the supply hopper to the transforming machine.

More preferably, the supply hopper is positioned vertically above the transforming machine.

In some embodiments, the weighing and mixing unit is connected to a plurality of storage tanks. Preferably, each storage tank contains a respective material which forms a component of the polymer blend.

The storage tanks have suitable dimensions and are provided in suitable numbers in accordance with the polymer blends to be prepared for the production of the desired articles.

Preferably, the weighing and mixing unit is connected to each storage tank by means of a respective charging line.

Preferably, the materials are of the granular type and the charging line is configured to carry out a pneumatic transport of the materials from the storage tanks to the weighing and mixing unit.

Preferably, the weighing and mixing unit is connected to a charging line for recycled material which originates from waste of the articles.

Preferably, the weighing and mixing unit comprises a mixing hopper which is positioned downstream of the weighing hopper and which is provided with a mixing member which is configured to mix the materials which are contained in the mixing hopper.

In some embodiments, the heating circuit comprises a dehumidifying device which is configured to dehumidify the gas before it is introduced into the supply hopper.

In this manner, the polymer blend in the supply hopper is dried before being introduced into the transforming machine.

This provision is particularly advantageous if one or more materials of the polymer blend is/are hygroscopic.

The transforming machine is preferably an injection-moulding machine or an extruder.

The articles are preferably soles of footwear items.

The features and advantages of the invention will be better understood from the detailed description of a preferred embodiment thereof which is illustrated by example with reference to the appended drawings, in which:.

With reference to the appended Figures, there is generally designated <NUM> a production apparatus for polymer-based articles which is realized according to the present solution.

The apparatus <NUM> is provided to produce soles for footwear and it is particularly provided to simultaneously produce different soles both in terms of form and dimensions and in terms of composition of the polymer blend from which they are produced.

To this end, the apparatus <NUM> comprises three transforming machines <NUM>, in particular of the injection-moulding type, which operate substantially independently of each other.

As a function of the production requirements, therefore, the transforming machines <NUM> can produce articles from the same polymer blend having the same composition or can produce articles from polymer blends having different compositions.

Naturally, the apparatus <NUM> may have a different number of transforming machines <NUM>, including only one.

Each transforming machine <NUM> is supplied by a respective supply hopper <NUM> which is positioned above the transforming machine <NUM> so as to supply the polymer blend to the transforming machine <NUM> by gravitational force through a discharge pipe <NUM>.

The polymer blends which can be used in the transforming machines <NUM> are prepared from materials which are contained in suitable storage tanks <NUM>. The storage tanks <NUM> may differ from one another in shape and dimensions and, in the preferred embodiment considered here, there are four of them.

The materials contained in the storage tanks <NUM> are of the granular type with chemical/physical characteristics which are different from each other and are, for example, granules of virgin polymer materials or recycled polymer materials or granules of additive materials.

In one or more transforming machines <NUM>, it is further possible to use in the polymer blend granules which result from the grinding (and potential regranulation) of waste articles, which is carried out at a grinding machine 3a. In a position vertically above each supply hopper <NUM>, there is further provided a respective weighing and mixing unit <NUM> which is configured to prepare a polymer blend from the materials which are contained in the storage tanks <NUM> or which are obtained in the grinding device 3a.

Each supply hopper is therefore interposed between a weighing and mixing unit <NUM>, from which it is separated by means of a valve 8a, and a transforming machine <NUM>, from which it is separated by means of a valve 8b.

The transfer of the materials which are contained in the storage tanks <NUM> to the different weighing and mixing units <NUM> is brought about by means of a first pneumatic transport circuit.

In particular, each storage tank <NUM> is connected to the different weighing and mixing units <NUM> by means of a respective charging line <NUM> which is provided, at the weighing and mixing unit <NUM>, with a respective container <NUM> where, as a result of the provision of a filter which is positioned at the outlet of the container, the material which is transported in the charging line <NUM> is separated and is caused to fall into the weighing and mixing unit <NUM>.

Downstream of the respective container <NUM>, the charging lines <NUM> are all connected by means of respective shutoff valves to a first intake line <NUM>, which is in turn connected to a first vacuum pump <NUM>.

The apparatus <NUM> further comprises a second pneumatic transport circuit which is provided to transport the recycled material from the grinding machine 3a to one (or more) weighing and mixing unit(s) <NUM>.

In particular, the second transport circuit comprises a transport line <NUM> which is connected to the outlet of the grinding machine 3a and which, in the region of the weighing and mixing unit <NUM>, opens in a container <NUM>, where the recycled material, also due to the provision of a suitable filter positioned at the outlet of the container <NUM>, is separated from the transport gas and caused to fall into the weighing and mixing unit <NUM>.

Downstream of the container <NUM>, the transport line <NUM> is connected by means of respective shutoff valves to a second intake line <NUM> which is in turn connected to a second vacuum pump <NUM>.

The weighing and mixing unit <NUM> is of the gravimetric type and comprises a weighing hopper <NUM> which is configured to receive and weigh the material which is released from time to time by one of the containers <NUM> and <NUM>. To this end, the weighing hopper <NUM> is supported on load cells <NUM> so as to allow the precise measurement of the quantity of material introduced into the weighing hopper <NUM>.

The weighing and mixing unit <NUM> further comprises a mixing hopper <NUM>, which is positioned downstream of the weighing hopper <NUM> and which is provided with a mixing member, for example, of the type with vanes or the type with a screw, which is configured to mix in a substantially homogeneous manner the different materials which are contained in the mixing hopper <NUM>.

Each supply hopper <NUM> is preferably provided with a sensor which controls the quantity of polymer blend which is present inside the supply hopper <NUM>, for example, a level sensor.

Furthermore, each supply hopper <NUM> is connected to a heating and drying circuit <NUM> which is configured to introduce, if required, a hot and dry gas inside the supply hopper <NUM> in order to heat and dry the polymer blend before it is supplied to the transforming machine <NUM>.

The heating and drying circuit <NUM> may be of any suitable type and, for example, may be of the type with compressed air which is dehumidified in a dehumidifying device (for example, having molecular sieves) which is brought to ambient pressure and heated in an electric heater before being introduced into the supply hopper <NUM>.

In the discharge pipe <NUM> of each supply hopper <NUM>, there may further be provided a metering device which is provided to meter one or more additives in the polymer blend being introduced into the transforming machine, for example, colourants and/or stabilizers.

The gravimetric metering device <NUM> further comprises a control unit <NUM> which is suitably programmed to receive instructions concerning the polymer blends to be composed for each transforming machine <NUM> and to control the operation of all the components of the apparatus <NUM>, which operates in the manners described below.

Beforehand, there are inserted or stored in the control unit <NUM> the different polymer blends which can be used by the transforming machines <NUM> in order to obtain the soles desired and there is associated with each transforming machine <NUM> a polymer blend.

At this point, the control unit <NUM> controls the preparation of the different polymer blends in the weighing and mixing units <NUM> which supply each transforming machine <NUM>.

To this end, the pneumatic transport of the individual components of the different polymer blends to the respective weighing and mixing units <NUM> is activated according to methods which are known per se to the person skilled in the art.

Each material is brought near the container <NUM> (or the container <NUM>, if provided) and is discharged, for example, by means of suitable metering valves, into the weighing hopper <NUM>. The material which is introduced into the weighing hopper <NUM> is weighed by the load cells <NUM> and, once the intended quantity is reached, the control unit <NUM> interrupts the further addition of material and controls the discharge of the contents of the weighing hopper <NUM> into the mixing hopper <NUM> underneath.

The same weighing procedure is carried out for each additional material which composes the polymer blend and which is therefore taken from the specific storage tank <NUM> in order to be charged in the container <NUM> of the respective charging line <NUM>, weighed in the weighing hopper <NUM> and added to the mixing hopper <NUM>, where it is mixed with the other materials which compose the polymer blend.

Once the formation of the polymer blend is complete, it is discharged by gravitational force into the supply hopper <NUM>, by opening the shutoff valve 8a. Here, the polymer blend is heated and dried by the hot and dry gas which is introduced into the supply hopper <NUM> by the heating and drying circuit <NUM>.

The polymer blend, once the temperature and drying conditions intended have been reached, is supplied to the transforming machine <NUM> by opening the shutoff valve 8b. Along the discharge pipe <NUM>, there may further be added to the polymer blend one or more additional additives which are supplied by the metering device, if provided.

The polymer blend is therefore molten and moulded in the transforming machine 2a in order to obtain the desired article, for example, a first type of sole for footwear items.

Claim 1:
A production apparatus (<NUM>) for polymer-based articles, particularly for producing soles of footwear items, comprising:
- a weighing and mixing unit (<NUM>) which is configured to prepare at least one polymer blend;
- a supply hopper (<NUM>) which is connected to the weighing and mixing unit (<NUM>) in order to receive the at least one polymer blend from the weighing and mixing unit (<NUM>);
- a transforming machine (<NUM>) which is supplied by the supply hopper (<NUM>) and which is configured to transform the at least one polymer blend which is received from the supply hopper (<NUM>) into one of the polymer-based articles characterised in that the apparatus further comprising a heating circuit (<NUM>) which is connected to the supply hopper (<NUM>) and which is configured to introduce a hot gas inside the supply hopper (<NUM>) in order to heat the polymer blend and in that the that the weighing and mixing unit (<NUM>) comprises a weighing hopper (<NUM>) which is supported on load cells (<NUM>) and in which the materials from the storage tanks (<NUM>) are introduced, wherein the weighing and mixing unit (<NUM>) further comprises a mixing hopper (<NUM>), which is positioned downstream of the weighing hopper (<NUM>) and which is provided with a mixing member which is configured to mix in a substantially homogeneous manner the different materials which are contained in the mixing hopper (<NUM>).