Patent Description:
It is known that in the field of processing and/or recycling plastic materials, a very complex system for the treatment of plastic materials is required. Fundamental components of these systems are the pumps, namely, that part of the systems that can be adapted along the process for plasticising, the feeding of the extruders, but also before or after the filtration units.

The documents <CIT> and <CIT> show a screw pump module for the extrusion of plastic material, which suffer from many of the drawbacks explain in the follow description and which are resolved by the object of the present invention.

The purpose of these pumps is to transfer the molten material to the various operating machines and/or to confer the required pressure at the inlet e.g. for the extruder or the granulator or for transferring the molten material from a rougher unit filter to a finishing filter with adequate pressure.

Although gear pumps were preferable, these were found to be very delicate from the point of view of the molten material to be treated, since they could only admit material with a very low degree of contamination.

Currently the feed unit of an extruder has a long screw inside a cylinder, which rotates, feeding, compressing, and plasticising the incoming material and returning it at the end ready for subsequent processing.

In order to carry out the aforementioned functions, the screw has a helical circumferential profile that can have a variable pitch and height of the threads along the axis of advancement. However, the number of revolutions of the single screw is the same for the entire length of the screw, being constant and impressed at one end by an electric motor using a reduction gear.

Therefore, the screw must be the right size for the torsional stress exerted by the gearmotor, taking into account the length of the screw and the distributed resistances and friction.

The plant engineering complexity of the assembly must also be taken into account, since the plastic material, when it is being processed inside the cylinder, is subjected to high temperatures and significant pressures; it generates gases that must be expelled/released outside the cylinder. Usually this is accomplished using a specially dimensioned degassing operation, but at the same time this considerably complicates the continuity of the cylinder within which the plasticising screw rotates.

The consolidated structuring of a pump as a single element for the aforementioned operations is, therefore, a compromise between performance and features.

Depending on the construction design choices, the size, the length and the diameter of the screw remain fixed and cannot be changed during the entire useful life of the device. In order to make slight variations to these fixed properties, the motor is very often equipped with a variable speed drive, but even in this case it is a compromise between the various functions. Furthermore, the size of the motor must be much more oversized than for normal use, assuming that on some occasions the device can be used well beyond its normal operating parameters.

The values of the actual loads involved are considerable, for screws even several metres long and for material pressures that inside the cylinder can far exceed hundreds of pressure bars, and therefore making the drive motor larger even just by a few percentage points compared to nominal operating values has a very significant impact.

Furthermore, it must also be taken into account that the processed material very often has different characteristics, starting from the degree of pollution to its chemical formulation, to the desired final degree of purity or to the conditions in which the various components are found (percentage of the filter not clogged).

Finally, it should not be forgotten that the molten material must be kept at temperature to allow it to be processed, with enormous energy expenditure for heating along the entire length of the pump. Sometimes, some part must be adjusted to a different temperature and so it is also necessary to use expensive cooling devices, since this must be provided along all or part of the length.

All the aforementioned characteristics, which the pump must in any case have, mean that the entire assembly has a length and height with a linear insertion on the system that would require a site that can contain these considerable dimensions of dozens of metres.

It is quite clear that once everything has been installed, it does not have the flexibility to be adapted, unless everything is completely reworked.

Stopping the pump for maintenance or for unforeseen events requires lengthy and expensive interventions to get it back into working order and fully operational.

The object of the present invention relates to a screw pump module for molten plastic material, which overcomes one or more of the drawbacks of the known art.

A further object of the present invention is to provide a screw pump module for molten plastic material that can be more compact from a dimensional point of view than a traditional solution.

A different object of the present invention is to make available a screw pump module for molten plastic material that is easier to configure than a traditional solution.

Another object of the present invention is to provide a screw pump module for molten plastic material that is less subject to friction and resistance than a traditional solution.

An important object of the present invention is to provide a screw pump module for molten plastic material that can use screws of varying diameters.

Another object of the present invention is to provide a screw pump module for molten plastic material that makes it easy to degas following the plasticisation process.

Another important object of the present invention is to make available a screw pump module for molten plastic material whose power requirements of the motors moving the screw is lower than the corresponding traditional solution.

All the aforesaid objects, and others which will become more apparent from the continuation of the description, are achieved by the features of claim <NUM>.

In particular, this is a screw pump module comprising:.

Advantageously, the object of the invention has a single-function screw, therefore the system can be correctly and precisely dimensioned for said function for which the screw has been designed.

Advantageously, the pump module is compact for the function to be performed, having a flange for the inlet and a flange for the outlet of the molten material arranged on a coinciding axis. Advantageously, the pump module has a terminal support for the end of the screw, consisting of a bushing or a bearing preventing the screw from resting on the inner surface of the cylinder and preventing the sliding friction of the helical thread on the inner surface of the hollow cylinder.

Advantageously, the motor of the pump module is dimensioned precisely, with lower power consumption, since the screw has less friction and has been precisely set for the force required for the function of the screw.

Advantageously, the pump module can be positioned in a flexible manner due to the limited overall dimensions of the assembly.

Advantageously, the pump module can be modularly connected with other pump modules or with other elements of the system by positioning a flanged inlet and outlet at <NUM>° to the main axis of the screw.

Advantageously, each pump module has a modular structure but varies its main characteristics in light of the functions to be performed just by modifying the screw inside the hollow cylinder. Advantageously, each pump module can be adjusted individually and the rotation speed can be varied, independent of the speed of the other modules placed alongside and/or present in the system. Advantageously, the sum of the power consumption of the single motors of each pump module is lower than the power consumption of a single motor that should operate a single device with equivalent processing.

Advantageously, the screw is precisely dimensioned for the function carried out by the single modular element, without oversizing for the additional torsions that would occur in the case of several functions carried out by the continuation of successive screws.

Advantageously, the pump module is easy to inspect and is equally easy to maintain, since both the inlet and outlet of both the module, the cylinder and also the connection duct are open or can be opened by removing suitable caps.

Advantageously, the pump module can easily be adapted to a specific function by inserting a screw with a specific helical thread profile.

The technical characteristics of the invention, according to the aforementioned objects, can be clearly seen from the content of the claims below and the relative results will be apparent in the detailed description that follows with reference to the drawings, which illustrate a purely exemplary and non-limiting embodiment, in which:.

With reference to the drawings, the object of the innovation revolutionises the system of feeding the pump of a screw extruder by optimising energy consumption, which is certainly lower due to there being less friction and taking into consideration the total energy required for a pump made from different corresponding elements placed in series.

Above all, with the system of the invention, it is possible to split what traditionally was the single screw of the pump, which was tasked with the compression, plasticisation, degassing, etc., in various modules, each specifically specialised for a limited set of functions and preferably for a single function.

The object of the invention also allows you, given the modularity of the pump module, to place the various modules in series, and it has not increased the total length, as would have been expected for a number of elements in series, but actually limits its overall length due to the presence of the connection duct, which is a return or recovery duct, that connects the inlet of the module with the initial part of the hollow cylinder, or which connects the outlet with the final part of the hollow body.

By placing the inlet and outlet of the pump module on the same side, the inlet and outlet flanges are kept coaxial.

By placing the screw with the main axis at <NUM>° to the axis of the in-line connection of the inlet and outlet, the system becomes even more compact.

Advantageously, each screw of each pump module is powered by a single motor using a suitable reduction gear, thus it is possible to calculate the power of the motor much more precisely for the required needs, and also it is possible to individually vary the torque and the number of revolutions specifically for the required use and the specific function to be performed.

Structurally, each individual pump module <NUM> can be supported by a suitable support <NUM>, possibly trolley-mounted with wheels <NUM>, which makes it extremely simple and practical to move for an easy and quick installation. Furthermore, a pump module <NUM> supported in this way makes it very inexpensive to maintain and/or replace in the event of breakages or scheduled interventions.

Said support <NUM> comprises a base <NUM> provided with height adjusters <NUM> in order to be able to reach, fix and maintain the pump module <NUM> at the correct height for its installation in the system.

The pump module <NUM> is connected through a spacer collar <NUM> to a gear motor <NUM> directly connected to the screw and driven by a suitable drive motor <NUM>.

An advantage of the system is precisely that of having a dedicated motor <NUM>, so that it can be adjusted according to contingent needs, for example, if installed after an extruder, the pump module can increase the pressure of the molten plastic for the use of the component, whatever it is.

However, this pump module can also be mounted between a rougher filter changer and a finisher filter changer.

The capacity of this pump module is that it can bring the working pressure from a pressure of a few bars, of the molten material leaving the previous machine, to the pressure required by the next machine.

The pump module <NUM> comprises an inlet flange <NUM> for the entry of the molten material, and an outlet flange <NUM> for the exit of the molten material.

Said inlet flange <NUM>, and possibly also the outlet flange <NUM>, is preferably positioned at <NUM>° to the main axis of the compression screw <NUM>, allowing you to significantly limit the space between the inlet and outlet of the material.

Advantageously, said inlet flange <NUM> and said outlet flange <NUM> are positioned with their main axis coinciding, allowing you to maintain the linear implementation and connection of the previous machines and the machines following the pump module.

To obtain the aforementioned characteristic, the pump module <NUM> comprises a connection duct <NUM> which hydraulically connects the inlet flange <NUM> with the inlet <NUM> of the hollow cylinder <NUM> within which the screw <NUM> rotates.

Said connection duct <NUM> feeds the screw <NUM> with the molten material coming from the inlet of the inlet flange <NUM>. It has been found that along said connection duct <NUM>, there is no appreciable increase in pressure or any other form of alteration of the plastic material involved.

To make it easier to maintain the pump module <NUM> near the inlet of the hollow cylinder <NUM>, there is a removable plug (plug towards gear motor) <NUM> for accessing and inspecting the end part of the connection duct <NUM> that opens on the inlet of the hollow cylinder <NUM>.

In this way, said connection duct <NUM> can easily be accessed at its ends even in the event that it becomes obstructed or needs to be inspected.

Preferably, said connection duct <NUM> is parallel and laterally spaced from the screw <NUM>, outside the hollow cylinder, keeping the space occupied by the hollow cylinder <NUM> to a minimum.

This configuration is also optimal for heating, for maintaining the temperature of the molten material and also for reducing heat loss, in fact the outer surface of the module is only slightly higher compared to a configuration that includes only the hollow cylinder, and the temperature of the molten material is kept at the same level for the material present in the connection duct <NUM> and also for the material processed by the screw <NUM> with the various electric heating elements placed on the perimeter surfaces of the pump module <NUM>.

The screw <NUM> located within the hollow cylinder <NUM> has a helical thread <NUM> on the circumference for shifting the material from the inlet of the hollow cylinder <NUM> to the outlet of the hollow cylinder <NUM>.

During this displacement of the molten material, from the inlet to the outlet of the hollow cylinder <NUM>, the plastic material undergoes an increase in pressure and/or plasticisation or other modifications related to the function of the screw itself and to the configuration of the helical thread <NUM>.

These functions can be finely adjusted by modifying the torque and the number of revolutions of the motor <NUM> that rotates the screw <NUM> using the gear motor <NUM>.

This peculiarity of having a motor <NUM> dedicated to the single screw <NUM> inside the pump module not only optimises the result at the outlet from the outlet flange <NUM>, as regards the characteristic parameters of the molten material, such as, for example, temperature, pressure, degree of plasticisation, but also achieves that flexibility and compactness that are the purposes of the invention.

Advantageously, in fact, the motor <NUM> is positioned orthogonally to the axis of the screw and preferably vertically, and has a series of accessory elements that are, given the powers, limited to the motor only, of limited size (electrical panel, cable sizing, etc.).

In fact, a screw <NUM> of limited length, such as the one inside the pump module that is the object of the invention, is not subject to high levels of friction on the hollow cylinder <NUM> and can be supported in a cantilevered position by the spacer collar <NUM>. Advantageously and for greater safety, it is possible to support the end of the screw <NUM> near the outlet of the hollow cylinder <NUM> using a bearing in the cover cap <NUM> of the hollow cylinder <NUM>. Said covering cap <NUM> can easily be removed and allows axial access to the inside of the hollow cylinder <NUM> for any maintenance and/or other inspection operations, or even facilitating the replacement of the screw.

Claim 1:
Screw pump module for the extrusion of plastic materials comprising:
- a drive motor (<NUM>);
- a body (<NUM>) with an inlet (<NUM>) and an outlet (<NUM>) for the molten material;
- a hollow cylinder (<NUM>) with an inlet (<NUM>) and an outlet (<NUM>);
- a screw (<NUM>) with a helical thread (<NUM>) around the circumference;
- a connection conduit (<NUM>) between the inlet (<NUM>) of the hollow cylinder (<NUM>) and the inlet (<NUM>) of the body (<NUM>); or
- a connection conduit (<NUM>) between the outlet (<NUM>) of the hollow
cylinder(<NUM>) and the outlet (<NUM>) of the body (<NUM>); wherein said screw (<NUM>) is rotated by said drive motor (<NUM>) and
wherein inside said hollow cylinder (<NUM>) said screw (<NUM>) with a helical thread (<NUM>) rotates;
wherein the molten material enters from the inlet (<NUM>) of the hollow cylinder (<NUM>) and, following the rotation of said screw (<NUM>) with a helical thread (<NUM>), exits from the outlet (<NUM>) of said hollow cylinder, (<NUM>); characterized in that: said inlet (<NUM>) and said outlet (<NUM>) of the body (<NUM>) are at the same end of said body (<NUM>) and have a common main axis;
wherein said inlet (<NUM>) and said outlet (<NUM>) are respectively equipped with a flange for the inlet and a flange for the outlet of the molten material, and where the flanges are positioned with a coincident axis;
wherein said inlet (<NUM>) and said outlet (<NUM>) are flanged, and are positioned at <NUM>° with respect to the main axis of the screw (<NUM>);
wherein inside said body (<NUM>) is located said connection conduit (<NUM>) through which the molten material that enters from the inle (<NUM>) of the body (<NUM>) reaches the inlet (<NUM>) of the hollow cylinder; or through which the molten material leaving the hollow cylinder (<NUM>) reaches the outlet (<NUM>) of the body (<NUM>), and wherein said connecting conduit (<NUM>) is positioned with its axis parallel to the main axis of the screw (<NUM>).