Patent Application
20080299243
Many types of products are extruded from dies and cut to certain lengths after being extruded through the die. Such products include, but are not limited to, catalyst, human and animal foods, fertilizer, medication, various types of plastic and or other polymer products, fiber reinforced products, metal, glass, etc. For some types of products (e.g., medication, fertilizer, catalyst, etc.) the cut extruded product should be as uniform as possible. The rate at which a certain product is extruded through a particular die can at least partially depend on a variety of factors such as the wearing of the die components, the wearing of the auger, the density of the product, whether the auger is starved of feed material, plugging of one or more die inserts, etc. As a result of one or more of these variable factors and/or other factors, the rate at which a particular product extrudes through one or more dies can periodically vary. This varying of the rate of product extrusion commonly results in the cut extruded product being of a non-uniform length, thereby resulting in a significant percent of the product to be disposed of.
Products formed for the medical and catalyst industry are highly sensitive to product uniformity. The uniform size of a catalyst is used to control certain types of chemical reactions. In some types of chemical reactions, a large tolerance as to size variations was acceptable for the catalyst in these chemical reactions. Due to these large acceptable tolerances as to catalyst size, the catalyst could be extruded and cut using conventional technology and about 65-85% of the cut catalyst would be acceptable for use. However, when the tolerances for the size of the catalyst are small when the catalyst is used in other types of chemical reactions, the amount of wasted cut catalyst significantly increases, thereby increasing product costs. In the medical industry, the tolerance for the size of the medical catalyst is very low so as to ensure that essentially the same dosage of medicine is present in each pill. As such, most drug manufacturers use a pill manufacturing process. Pill machines are also used to form some types of catalyst that require a low tolerance to the size of the catalyst. Although the pill manufacturing process produces a large percentage of medication and catalyst having a desired size, the pill manufacturing process is very expensive as compared with most extrusion processed, and also has extremely slow through-puts, thereby resulting in low output over time and significantly increased manufacturing costs. Such high costs are cost prohibitive for many types of products.
In view of the current state of the art, there is a need for extrusion hardware and a cutting device that can be used to cut an extruded product in a more uniform manner.
The present invention relates to extrusion hardware, and more particularly to die plates, extruder die inserts, and cutting devices for use in an extruder system. In one non-limiting embodiment of the invention, there is provided specially designed extruder die inserts and die plates that can to used to extrude a wide variety of different materials. The extruder/die inserts and die plates of the present invention are designed to improve the throughput by an extruder, improve the durability of the die plate and/or extruder/die insert, improve the ease of use of the extruder/die insert in combination with the die plate, and/or improve the quality of the material extruded by the extruder system. In yet another and/or alternative non-limiting embodiment of the invention, there is provided a cutting assembly to cut materials that have been extruded through one or more extruder/die inserts that are positioned in a die plate. The extrusion hardware of the present invention is particularly directed to the extrusion and cutting of an extruded catalyst; however, the extrusion hardware can be used to cut many other types of extruded material.
In one non-limiting aspect of the present invention, there is provided a cutting assembly that is designed to cut materials on one or more types of materials that have been extruded through one or more die plates that may or may not include one or more extruder/die inserts. The improved cutting assembly is designed to improve the product quality of cut extruded material by cutting the extruded material within low tolerances to a certain specified length. In many types of businesses such as, but not limited to, the catalyst business, etc., the size of the extruded material must be maintained to comply with certain criteria. For instance, the size of the catalyst can affect the rate of reaction that takes place when using the catalyst. An extruded catalyst that is cut too large or too small could adversely affect a chemical reaction that involves the use of the catalyst. The proper cutting of other materials (e.g., foods, fertilizers, etc.) can affect the product quality and/or effectiveness of the cut product. The improved cutting assembly of the present invention is designed to cut an extruded product from a die plate to form a cut product that more closely matches the desired length of the product. In addition, the improved cutting assembly of the present invention can be used to cut products that are currently extruded through die plates and thereby significantly reduce the amount of waste of such extruded product that historically has to be disposed of since the extruded product did not meet the size tolerance parameters of the extruded product. As such, one non-limiting aspect of the present invention is thus directed to an extrusion cutting assembly which can increase the quantity of cut product.
In another and/or alternative non-limiting embodiment of the invention, the cutting assembly of the present invention includes a fluid cutting arrangement to cut and/or break material that is extruded through a die plate and/or one or more extruder/die inserts in a die plate. The fluid can be a liquid and/or a gas. In one non-limiting embodiment of the invention, the fluid is a gas. Non-limiting gasses include, but are not limited to, air, nitrogen, stream, noble gasses, etc. In another and/or alternative non-limiting embodiment of the invention, a high pressure fluid is at least partially used to cut and/or break material that is extruded through a die plate and/or one or more extruder/die inserts in a die plate. As defined in herein, high pressure is a pressure of about 20 psig or greater. In one non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is at least about 25 psig. In another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is at least about 50 psig. In still another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is at least about 60 psig. In still yet another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is less than about 10,000 psig. In another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is less than about 1,000 psig. In still another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is less than about 500 psig. In still another and/or alternative non-limiting aspect of this embodiment, the high pressure fluid used by the cutting assembly of the present invention is less than about 200 psig. In still another and/or alternative non-limiting embodiment of the invention, a super heated steam can be used solely as the high pressure fluid or be combined with one or more other high pressure fluids (e.g., air, noble gas, etc.). The super heated steam is defined as steam having a temperature of over 110° C., generally over about 150° C., typically at least about 200° C., and more typically at least about 250° C. As can be appreciated, higher temperature super heated steam can be used. The super heated steam, when used, can be used to facilitate in the drying of the material that is extruded through a die plate and/or one or more extruder/die inserts in a die plate. The super heated steam can also or alternatively be used to increase the PV and/or CS of the material that is extruded through a die plate and/or one or more extruder die inserts in a die plate.
In still another and/or alternative non-limiting aspect of the present invention, the cutting assembly of the present invention includes an improved control arrangement which can vary the fluid pressure (e.g., adjust the fluid pressure and/or flowrate, pulse the fluid to/in the cutting assembly, maintain a constant fluid pressure and/or flowrate, etc.) to account for the type of material being extruded through the die plate and/or extruder/die insert, and/or to account for any pressure differentials applied to the material being extruded through the die plate and/or extruder/die insert; however, this is not required. For instance, when the pressure on the extruded material increases, the material typically travels at a faster rate through the die plate and/or extruder/die insert. Conversely, when the pressure on the extruded material reduces, the extruded material typically passes at a slower rate through the die plate and/or extruder/die insert. By detecting the pressure of the material prior to entering one or more openings in the die plate and/or extruder/die insert, and/or as the material enters and/or passes through one or more openings in the die plate and/or extruder/die insert, it can be determined whether the material is accelerating, decelerating, or maintaining a constant velocity through the die plate and/or extruder/die insert. If it is determined that the speed of the material (e.g., via pressure reading, via visual detection, via flow meters, etc.) passing through one or more openings in the die plate and/or extruder/die insert has decreased or increased and/or is going to decrease or increase, adjustments can be made to the fluid pressure of the cutting assembly to account for the change in speed at which the material is exiting the outer surface or face of the die plate and/or extruder/die insert. Furthermore, if it is determined that the speed of the material passing through one or more openings in the die plate and/or extruder/die insert has remained constant and/or is going to remain constant, the fluid pressure of the cutting assembly can also be maintained. Furthermore, the material passing through one or more openings in the die plate and/or extruder/die insert can have different physical properties (e.g., hardness, brittleness, elasticity, density, etc.) which can require different fluid pressure levels and/or different fluid flow characteristics (e.g., pulsed flow, variable flow, constant flow, etc.) to properly cut and/or break the material passing through one or more openings in the die plate and/or extruder die insert. As a result, the fluid pressure and/or flow can be used to cut and/or break the material that has been extruded through one or more openings in the die plate and/or extruder/die insert so as to maintain a desired cut length of the cut extruded material. In still another and/or alternative non-limiting embodiment of the invention, an electronic control system is used to control the rate at which the fluid flows from the cutting assembly so as to cut and/or break the material being extruded from one or more die plates and/or extruder/die inserts. In one non-limiting aspect of this embodiment, a manual and/or electronic fluid control valve is used to control the rate at which the fluid flows from the cutting assembly as the material is extruded from one or more die plates and/or extruder/die inserts. As can be appreciated, other or additional control systems can be used to control the fluid flow from the cutting assembly.
In yet another and/or alternative non-limiting aspect of the present invention, the detected pressure prior to one or more of the openings of the die plate and/or extruder/die insert and/or in one or more of the openings of the die plate and/or extruder/die insert, can also or alternatively be used to set off alarms (i.e., used to indicate one or more operations of the extruder not operating within one or more parameters, etc.) and/or shut down one or more components of the extruder system so as to reduce or prevent damage to one or more components of the extruder system; however, this is not required. In one non-limiting embodiment of the invention, the one or more pressure sensors generate a signal that can be used to activate an alarm to indicate that the detected pressure is below and/or above a desired value. This alarm can be used to detect and/or notify an operator of clogged die openings, worn components (e.g., worn/damaged auger blade, worn/damaged wiper blade, worn/damaged die plate, worn/damaged die/extruder insert, worn/damaged die pins, damaged/malfunctioning pressure sensors, etc.), insufficient feeding of material to be extruded, etc. In another and/or alternative embodiment of the invention, the improved cutting assembly can include a storage system that stores data regarding, but not limited to, a) the detected pressures over a period of time, b) the flow pressure by the cutting assembly, c) the fluid flowrate by the cutting assembly, d) the change out frequency of extruder components (e.g., wiper blade, auger blade, die plate, extruder/die insert, die pins, etc.), e) speed of rotation of the auger blade, f) the type/size of components used in the extruder, g) the type of feed material, h) the rate of material fed to the auger blade, i) the type of fluid used by the cutting assembly, j) the average size of the cut and/or broken extrudate, and/or k) the change out frequency of the cutting assembly components. As can be appreciated, other or additional information can be recorded by the cutting assembly. This data can be used to facilitate in determining whether one or more components of the extruder and/or cutting assembly were operating properly during an extrusion process. The data can also or alternatively be used to control the operation of the cutting assembly. The data can be tagged to a time and/or date period; however, this is not required. This data can be designed to be accessed at real time and/or in other manners. The collected data can be used to activate one or more alarms to indicate an existing or potential problem with one or more components of the extruder and/or cutting assembly; however, this is not required. The collected data can be used to activate one or more alarms to indicate that a component change out is due for one or more components of the extruder and/or cutting assembly; however, this is not required. The collected data can be used to profile the operation of one or more components of the extruder and/or cutting assembly; however, this is not required.
In still yet another and/or alternative non-limiting embodiment of the invention, the improved cutting assembly includes one or more sensors other than a pressure sensor that can be used to affect the fluid pressure and/or the fluid flowrate of the cutting assembly and/or activate one or more alarms; however, this is not required. Such other sensors can include, but are not limited to, temperature sensors, flow sensors, composition sensors, auger rotation speed indicators, fluid pressure of the cutting assembly, fluid flowrate of the cutting assembly, die opening plug detectors, product quality detectors, die plate pressure detectors, product length detectors, etc. These one or more sensors can be located in one or more openings in the die plate and/or extruder/die insert, and/or spaced from one or more openings in the die plate and/or extruder die insert and/or be part of the cutting assembly. The data from one or more of these sensors can be recorded; however, this is not required. The data can be tagged to a time and/or date period; however, this is not required. The data from one or more of the sensors can also or alternatively be used to control the operation of one or more components of the cutting assembly (e.g., fluid pressure, fluid flowrate, etc.) and/or one or more components of the extruder (e.g., auger rotation speed, material feedrate into auger, etc.). The collected data can be also or alternatively be used to activate one or more alarms to indicate that a component change out is due for one or more components of the extruder, and/or the cutting assembly and/or one or more components of the extruder are not working properly; however, this is not required. The collected data can be used to profile the operation of one or more components of the extruder and/or cutting assembly; however, this is not required. In another and/or alternative embodiment of the invention, additional data can be used by the cutting assembly to monitor and/or control one or more components of the extruder and/or cutting assembly. Such data can include, but is not limited to, die plate size, die plate opening configuration, die plate opening size, material of the die plate, thickness of the die plate, die/extruder insert size, die/extruder insert shape, die/extruder insert thickness, die/extruder insert material, type of insert pins, shape of insert pins, material of pins, type of auger blade, material of auger blade, shape of auger blade, size of auger blade, type of feed material, cutting assembly diffuser, type of fluid used by the cutting assembly, flowrate of fluid from and/or to the cutting assembly, fluid pressure from and/or to the cutting assembly, type and/or size of spacer used by the cutting assembly, number of blades on wiper blade, type of wiper blade, spacing of wiper blade from die plate and/or die/extruder insert, wiper blade material, recommended change-out/maintenance for one or more components of the extruder and/or cutting system, recommended operational parameters of one or more components of the extruder and/or cutting system, quality of extruded product, time of usage of one or more components of the extruder and/or cutting system, etc. As can be appreciated, other or additional data can be collected, stored, proceeded, monitored and/or other uses by the cutting assembly. As can also be appreciated, the data that is collected, stored, processed, etc. by the cutting assembly can be used to optimize the operation of the extruder system to produce a higher quality of extruded material. As can be appreciated, any data that can be collected, stored, proceeded, monitored and/or other uses by the cutting assembly can be made available to an operator onsite so that the operator can monitor and/or control one or more operations of the extruder and/or cutting assembly. As can further be appreciated, any data that can be collected, stored, proceeded, monitored and/or other uses by the cutting assembly can also be transmitted to a remote location (e.g., control and/or monitoring station, etc.) so that an operator can monitor and/or control one or more operations of the extruder and/or cutting assembly at a remote location.
In a further and/or alternative non-limiting embodiment of the invention, the improved cutting assembly includes a diffuser that is designed to direct fluid at some angle relative to the plane at which material is being extruded through one or more openings in the die plate and/or extruder/die insert. In one non-limiting embodiment of the invention, the diffuser directs fluid at about 1-90° relative to the plane at which material is being extruded through one or more openings in the die plate and or extruder/die insert. In one non-limiting aspect of this embodiment, the diffuser directs fluid at about 10-90° relative to the plane at which material is being extruded through one or more openings in the die plate and/or extruder/die insert. In another and/or alternative non-limiting aspect of this embodiment, the diffuser directs fluid at about 25-90° relative to the plane at which material is being extruded through one or more openings in the die plate and/or extruder/die insert. In still another and/or alternative non-limiting aspect of this embodiment, the diffuser directs fluid at about 45-90° relative to the plane at which material is being extruded through one or more openings in the die plate and/or extruder/die insert. In another and/or alternative non-limiting embodiment of the invention, the diffuser includes one or more openings that are used to direct fluid at the material as it is being extruded through one or more openings in the die plate and/or extruder/die insert. In one non-limiting aspect of this embodiment, the size of the two or more openings in the diffuser used to direct fluid at the material as it is being extruded through one or more openings in the die plate and/or extruder/die insert can be the same or different. In still another and/or alternative non-limiting aspect of this embodiment, the shape of the two or more openings in the diffuser used to direct fluid at the material is being extruded through one or more openings in the die plate and/or extruder/die insert can be the same or different. In yet another and/or alternative non-limiting aspect of this embodiment, the shape of one or more openings in the diffuser used to direct fluid at the material as it is being extruded through one or more openings in the die plate and/or extruder/die insert can be selected to create a desired fluid flowrate and/or flow profile as the fluid flows through the one or more openings and toward the material as it is being extruded through one or more openings in the die plate and/or extruder/die insert; however, this is not required. In still yet another and/or alternative non-limiting aspect of this embodiment, the number of openings in the diffuser used to direct fluid at the material as it is being extruded through one or more openings in the die plate and/or extruder/die insert is generally at least the same or greater than the number of openings in the die plate and/or extruder/die insert; however, this is not required. In another and/or alternative non-limiting embodiment of the invention, the diffuser can include one or more angled surfaces to cause fluid flowing from the diffuser to contact material that is being extruded through one or more openings in the die plate and/or extruder/die insert at a predefined angle so as to facilitate in the breaking and or cutting of the material from the die plate and/or extruder die insert.
In still another and/or alternative non-limiting embodiment of the invention, the diffuser of the cutting assembly includes one or more inlet openings designed to receive fluid from a pressurized fluid source. The opening can include a connector (e.g., quick connector, threaded connector, etc.) to connect a pressure hose to the opening; however, this is not required.
In still yet another and/or alternative non-limiting embodiment of the invention, the cutting assembly directs high pressure fluid at some point that is spaced from the point that the material is extruded through one or more openings in the die plate and/or extruder/die insert; however, this is not required. This spaced application of high pressure fluid allows material to be extruded at some distance out from the one or more openings in the die plate and/or extruder/die insert prior to encountering the high pressure fluid from the cutting assembly. The control of the space results in controlling the length of the cut and/or broken extruded material. In one non-limiting embodiment of the invention, one or more spacers can be used to direct high pressure fluid at some point that is spaced from the point that the material is extruded through one or more openings in the die plate and/or extruder/die insert; however, it can be appreciated that other or additional arrangements (e.g., die plate designed, diffuser design, etc.) can be used to direct high pressure fluid at some point that is spaced from the point that the material is extruded through one or more openings in the die plate and/or extruder/die insert. Many different distances at which high pressure fluid is directed at some spaced point from the point that the material is extruded through one or more openings in the die plate and/or extruder/die insert can be selected. In one non-limiting design, the distance at which high pressure fluid is directed at some spaced point from the point that the material is extruded through one or more openings in the die plate and/or extruder/die is generally about 0-5 inches. In another non-limiting design, the distance at which high pressure fluid is directed at some spaced point from the point that the material is extruded through one or more openings in the die plate and/or extruder/die is generally about 0-2 inches. In still another non-limiting design, the distance at which high pressure fluid is directed at some spaced point from the point that the material is extruded through one or more openings in the die plate and/or extruder/die is generally about 0-1 inches. As can be appreciated; other distances can be used.
In another and/or alternative non-limiting embodiment of the invention, there is provided a specially designed die plate that is used in association with the cutting assembly of the present invention, which die plate enables the cutting assembly to be connected to the die plate in close proximity to the material being extruded through one or more openings in the die plate and/or extruder/die.
In still another and/or alternative non-limiting embodiment of the invention, the cutting assembly can include one or more operational modes; however, this is not required. In one non-limiting embodiment of the invention, one mode of the cutting assembly can be a manual mode wherein the flowrate and/or fluid pressure to the cutting assembly is set and maintained substantially constant throughout an extrusion process. In another and/or alternative non-limiting embodiment of the invention, the cutting assembly can include an automatic mode wherein a) flowrate and/or fluid pressure to the cutting assembly can be controlled, b) flowrate and/or fluid pressure from one or more openings in the diffuser can be controlled, c) the angle at which the high pressure fluid is directed at the material being extruded through one or more openings in the die plate and/or extruder/die insert, and/or d) the amount of space that high pressure fluid is directed from the point that the material is extruded through one or more openings in the die plate and/or extruder/die insert can be controlled. The control of the cutting assembly in the automatic mode can be based on one or more set and/or detected parameters (e.g., current weather conditions, time of day, time of year, geographic location, type of extruder, extruder configuration, type of feeder for extruder, die plate temperature, auger blade temperature, material to be extruded temperature, material to be extruded flowrate, material to be extruded composition, material to be extruded density, time period required for material to move through one or more openings in die plate and/or die/extruder insert, time period required for material to move along auger blade at a certain auger blade rotation speed, auger blade rotation speed, die plate and/or die/extruder insert opening plug detection, product quality detection, die plate pressure detection, pressure in one or more openings of die plate and/or die/extruder insert, temperature in one or more openings of die plate and/or die/extruder insert, time of use for die/extruder inserts, time of use for die plate, time of use for die pins, time of use for auger blade, time of use for liner, type of liner, material of liner, shape of liner, die plate size, die plate opening configuration, die plate opening size, material of the die plate, thickness of the die plate, die/extruder insert size, die/extruder insert shape, die/extruder insert thickness, die/extruder insert material, die extruder insert hole profile, type of insert pins, shape of insert pins, material of insert pins, type of auger blade, material of auger blade, size/shape of auger blade, type of feed material, type of high pressure fluid from the cutting assembly, flowrate of high pressure fluid from the cutting assembly, flow profile of high pressure fluid from the cutting assembly, type of diffuser of the cutting assembly, the spacing of the high pressure fluid from the point that the material is extruded through one or more openings in the die plate and/or extruder die insert, the angle at which the high pressure fluid is directed to the material being extruded through one or more openings in the die plate and/or extruder/die insert, number of blades on wiper blade, type of wiper blade, spacing of wiper blade from die plate and/or die/extruder insert, wiper blade material, calculated and/or detected wear rates and/or information of one or more components of the extruder and/or cutting assembly, etc.) so as to obtain the desired cut material length and/or product quality of the extruded and cut material. As mentioned above, one or more of these parameters can be recorded by the cutting assembly and/or one or more other components of the extruder, manually and/or automatically input into the cutting assembly and/or one or more other components of the extruder, and/or transmitted to and/or received from a remote location.
In still yet another and/or alternative non-limiting embodiment of the invention, the improved cutting assembly can include one or more detectors (e.g., camera [video camera, standard camera, etc.], light sensor, radio frequency sensor, sound wave sensor, electromagnetic wave sensor for non-visible electromagnetic waves [X-rays, infrared light, ultraviolet light, gamma waves, etc.], etc.) to monitor the length of the extruded material prior to, during, and/or after the cutting process. This monitored information can be used to provide data on the quality of the material being cut, the percentage of the material being cut that is within an acceptable length, and/or to control the fluid flowrate and/or fluid pressure through the cutting assembly to better obtain a desired cut length of the material. As can be appreciated, the detection of the length of the cut material can be monitored at the location of the cutting assembly and/or at some period after the material has been cut (e.g., when the cut material is being conveyed to a drying location, etc.). In one non-limiting embodiment of the invention, a video monitor or other device can be used to monitor the material being cut and/or conveyed and a software program or other type of statistical device can be used to determine the length of the cut product, and then send such information to one or more controllers (e.g., pressure and/or flowrate controller, etc.) to be used to adjust the fluid flowrate and/or fluid pressure from the cutting assembly based upon the determined length for the cut product and/or provide quality control data regarding the cut product. As can be appreciated, other or additional control systems can be used. In another and/or alternative non-limiting embodiment of the invention, a closed loop system could be used to further simplify the control system (e.g., reduce the number of control switches an operator uses) and/or facilitate in obtaining the desired product quality.
In a further and/or alternative non-limiting embodiment of the invention, the cutting assembly can be ergonomically designed so as to facilitate in the operation of the cutting assembly and/or to facilitate in the repair and maintenance of the cutting assembly. In one non-limiting embodiment of the invention, the cutting assembly allows the operator to easily access various connectors, bolts, switches, etc. which are required for periodic operation and/or maintenance of the cutting assembly. As a result of this ergonomic design, the need for special tools is reduced or eliminated and/or the operation and/or maintenance of the cutting assembly is simplified, thereby reducing the time and/or cost of maintenance and repair.
One non-limiting object of the present invention is the provision of a method and process for forming more uniform cut lengths of an extruded product.
Another and/or alternative non-limiting object of the present invention is the provision of a method and process for a cutting assembly that can be used to improve the forming of more uniform cut lengths of an extruded product.
Still another and/or alternative non-limiting object of the present invention is the provision of a method and process for a cutting assembly that uses high pressure fluid to cut lengths of an extruded product.
These and other advantages will become apparent to those skilled in the art upon the reading and following of this description taken together with the accompanying drawings.
Reference may now be made to the drawings, which illustrate various embodiments that the invention may take in physical form and in certain parts and arrangements of parts wherein:
Referring now to the drawings wherein the showing is for the purpose of illustrating preferred embodiments of the invention only and not for the purpose of limiting the same,
Die plate 11 includes at least one die insert cavity 11a when extruder/die inserts are used with the die plate. The extruder/die inserts can have many different cross-sectional shapes (e.g., diamond shaped, triangular shaped, circular shaped, etc.). The extruder die inserts typically have one or more openings through the extruder die insert that are used to form the shape of the material being extruded through the die plate. Pins can also be inserted in one or more openings in the extruder/die inserts to create the shape of the material being extruded through the die plate. The extruder/die inserts are typically formed of a polymer material; however, other or additional materials can be used (e.g., metal, ceramic, etc.). The die plate and clamping ring are typically formed of a metal material; however, other materials can be used.
Die plate 11 also includes a front cavity 11b. The cavity 11b has sloped sides that align with the sloped sides of the clamping ring as illustrated in
In general, the extruder system includes an auger blade, not shown, or other or additional device that is designed to move material, not shown, to be extruded toward the die plate 1. The die plate 11 generally has a plurality of openings 11a that are each designed to receive a die/extruder insert 15. The material that is transported by the auger blade is designed to become an extruded product such as, but not limited to, a catalyst. As can be appreciated, the present invention can be used to form many types of products other than catalyst. Although not shown, the opposite end of the auger blade is connected to a motor that is designed to rotate the auger blade. The use of such a motor, and the configuration of the motor and the necessary connection between the motor and auger blade are well known in the art, thus will not be further described. Also not shown is the feed section for the auger blade that feeds material to the auger blade, which in turn transports the material to the die plate. Many different auger blade feed arrangements can be used, and many of these feed arrangements are well known in the art and will not be further described.
The auger blade that is used in the extruder system can have many different configurations. Two non-limiting configurations for the auger blade are a single flight configuration or a dual flight configuration. The front end of the auger blade can include a connection arrangement that is designed to secure a wiper blade to the front end of the auger blade; however, this is not required. When a wiper blade is not to be connected to the front end of the auger blade, the connection arrangement can be eliminated. The connection arrangement can be designed in many different ways to facilitate in the connection of a wiper blade to the front end of the auger. In one non-limiting arrangement, the connection arrangement can include a cavity and a threaded opening. The auger blade, when used, is typically housed in an auger housing or liner, not shown, that defines a generally cylindrical opening through which the material to be extruded travels. As can be appreciated, other housing or liner shapes can be used. The use of an auger housing or liner in conjunction with an auger blade for various types of extruder applications is well known in the art, thus will not be further described.
Die plate 11 is a generally circular plate having a plurality of insert openings 11a that are formed in the die plate. As can be appreciated, the die plate need not be circular (e.g., oval, polygonal, etc.). The insert openings 11a in the die plate can have a variety of configurations and/or shapes. The insert opening can have a generally triangular shape or diamond shape. As can be appreciated, other or additional insert shapes can be used (e.g., oval, circular, square, pentagonal, hexagonal, rectangular, rhombus shaped, trapezoidal, etc.). The size and shape of the insert openings on each die plate is generally the same, however, this is not required. As such, a die plate can have different sized openings and/or different shaped openings on the die plate. Many different configurations of openings for the inserts can be used. As such, many opening configurations and/or numbers of opening can be used on the die plates. The extruder die inserts can also have a variety of interior configurations, not shown, to facilitate in receiving certain shaped die/extruder inserts. The die plates can also include one or more mount holes that are designed to receive a bolt and/or other type of connector to facilitate in mounting the die plate to the extruder system; however, this is not required. The front and/or back face of the die plate can have one or more recessed portions; however, this is not required. The die plates can include one or more orientation structures that are designed to facilitate in the proper placement of the die/extruder insert into the die opening; however, this is not required.
Referring again to
Referring now to
As illustrated in
Referring now to
One or more spacer disks 14 can be used to control the length of extruded material that is cut or broken by the fluid flow from the diffuser.
Referring now to
Die plate 11 includes at least one die insert cavity 11a when extruder/die inserts 15 are used with the die plate. The extruder/die inserts can have many different cross-sectional shapes (e.g., diamond shaped, triangular shaped, circular shaped, etc.). The extruder/die inserts typically have one or more openings through the extruder/die insert that are used to form the shape of the material being extruded through the die plate. Pins can also be inserted in one or more openings in the extruder/die inserts to create the shape of the material being extruded through the die plate. The extruder/die inserts are typically formed of a polymer material; however, other or additional materials can be used (e.g., metal, ceramic, etc.). The die plate and clamping ring are typically formed of a metal material; however, other materials can be used.
Die plate 11 also includes a front cavity 11b. The cavity 11b has sloped sides that align with the sloped sides of the clamping ring as illustrated in
Referring again to
Referring now to
Die plate 11 includes at least one die insert cavity 11b when extruder/die inserts 15 are used with the die plate. The extruder/die inserts can have many different cross-sectional shapes (e.g., diamond shaped, triangular shaped, circular shaped, etc.). The extruder/die inserts typically have one or more openings through the extruder/die insert that are used to form the shape of the material being extruded through the die plate. Pins can also be inserted in one or more openings in the extruder/die inserts to create the shape of the material being extruded through the die plate. The extruder/die inserts are typically formed of a polymer material; however, other or additional materials can be used (e.g., metal, ceramic, etc.). The die plate and clamping ring are typically formed of a metal material; however, other materials can be used.
Die plate 11 also includes a front cavity 11c. The cavity 111 can have sloped sides that align with the sloped sides of a clamping ring, not shown; however, this is not required. As can also be appreciated, cavity 11 need not have sloped sides. As can also be appreciated, die plate 11 does not need to have a cavity 11c. Positioned about the middle of the die plate are three openings 11d that are designed to enable a screw 13 to be secured to a portion of the cutting assembly 20 as will be described in more detail below. As can be appreciated, the die plate can include a large or smaller number of openings 11d. As can also be appreciated, openings 11d can be positioned on other regions of the die plate. As can be appreciated, the die plate can be connected to the cutting assembly in other or additional manners (e.g., bolt, rivet, etc.). The die plate 11 can be designed in one non-limiting arrangement such that front cavity 11c has a depth such that the bottom surface of the front cavity is closely or substantially flush with an end of an extruder/die insert when an extruder/die insert is inserted in the die plate as illustrated in
Referring again to
One or more spacer disks 14 can be used to control the length of extruded material that is cut or broken by the fluid flow from the diffuser.
As can be appreciated, a flow controller can be used that pulses the flow of fluid to the diffuser so as to facilitate in the cutting or breaking of material at certain lengths that is extruded from the extruder/die inserts; however, this is not required. In such an arrangement, the use of the spacer disk can be eliminated; however, this is not required. Any number of control systems and/or arrangements can be used to pulse the flow of fluid through the diffuser of the cutting assembly. The control systems and/or arrangements can be manually and/or automatically set. The control systems and/or arrangements can be adjusted by feedback control systems and/or other types of control systems; however, this is not required.
High pressure fluid is generally directed to the diffuser. Such pressures generally are about 25-150 psig; however, other pressures can be used.
Although not shown, various types of detectors can be used (e.g., pressure detectors, temperature detectors, vibration detectors, chemical analysis detectors, etc.) can be used to control the quality and consistency of the cut or break length of the extruded material; however, this is not required. For example, one or more pressure transducers can be supplied in the die plate; however, this is not required. The pressure transducers can be designed to communicate with a controller, not shown, which communicates with an auger motor, not shown, fluid flow controller to the diffuser, not shown, etc. If it is detected that the pressure has decreased/increased, various components of the extruder (e.g., rate at which the auger blade rotates, fluid flow and/or pressure to the diffuser, etc.) can be controlled as a function of the detected pressure. As can be appreciated, the controlled parameters can be at least partially controlled by other or additional factors (e.g., current weather conditions, time of day, time of year, geographic location, type of extruder, extruder configuration, type of feeder for extruder, die plate temperature, auger blade temperature, material to be extruded temperature, material to be extruded flowrate, material to be extruded composition, material to be extruded density, time period required for material to move through one or more openings in die plate and/or die/extruder insert, time period required for material to move along auger blade at a certain auger blade rotation speed, auger blade rotation speed, diffuser configuration, die plate and/or die/extruder insert opening plug detection, product quality detection, die plate pressure detection, pressure in one or more openings of die plate and/or die/extruder insert, temperature in one or more openings of die plate and/or die/extruder insert, time of use for die/extruder inserts, time of use for die plate, time of use for die pins, time of use for auger blade, time of use for liner, type of liner, material of liner, shape of liner, die plate size, die plate opening configuration, die plate opening size, material of the die plate, thickness of the die plate, die/extruder insert size, die/extruder insert shape, die/extruder insert thickness, die/extruder insert material, die/extruder insert hole profile, type of insert pins, shape of insert pins, material of insert pins, type of auger blade, material of auger blade, size/shape of auger blade, type of feed material, type of fluid flowing to the diffuser, fluid flow to the diffuser, pressure of fluid to the diffuser, number of blades on wiper blade, type of wiper blade, spacing of wiper blade from die plate and/or die/extruder insert, wiper blade material, calculated and/or detected wear rates and/or information of one or more components of the extruder and/or cutting assembly, etc.).
A sensor arrangement can also be supplied to check the length of the cut or broken extruded material; however, this is not required. For example, the sensor can be in the form of a camera, or the like, that can detect the dimensions of the cut or broken extruded material. The sensor arrangement can be designed to communicate with one or more controllers; however, this is not required. The sensor arrangement can send a signal to the one or more controllers, not shown, in response to the detected dimensions of the cut or broken extruded material. Based at least partially on the detected dimensions of the cut product, operation and/or parameters of various of the extruder and/or cutting assembly can be adjusted to control the length of the cut or broken extruded material.
The cutting assembly can also include a mode control; however, this is not required. The mode control, not shown, can be in communication with one or more controllers, not shown. For instance, the cutting assembly can include an automatic mode wherein the fluid flowrate and/or fluid pressure to the diffuser is adjusted based upon the detection of one or more parameters (e.g., pressure of the material prior to and/or as it is being extruded through the die plate and/or die/extruder insert; the detected velocity of the material prior to, during, and/or after being extruded through the die plate and/or die/extruder insert; detection of the length of the cut material and/or calculating the length of the cut material; current weather conditions; type of extruder; extruder configuration; type of feeder for extruder; die plate temperature; die/extruder insert temperature; auger blade temperature; material to be extruded temperature; material to be extruded flowrate; material to be extruded composition; material to be extruded density; time period required for material to move through one or more openings in die plate and/or die/extruder insert; time period required for material to move along auger blade at a certain auger blade rotation speed; auger blade rotation speed; type of diffuser; type of fluid to diffuser; pressure of fluid to diffuser; die plate and/or die/extruder insert opening plug detection; product quality detection; type of liner; material of liner; shape of liner; die plate size; die plate opening configuration; die plate opening size; material of the die plate; thickness of the die plate; die/extruder insert size; die/extruder insert shape; die/extruder insert thickness; die/extruder insert material; die/extruder insert hole profile; type of auger blade; material of auger blade; size/shape of auger blade; number of blades on wiper blade; type of wiper blade; spacing of wiper blade from die plate and/or die/extruder insert; wiper blade material; vibration detection of one or more components of the extruder; cavitation detection of material to be extruded; detection of amount of material being fed by auger blade; calculated and/or detected wear rates and/or information of one or more components of the extruder and/or cutting assembly, etc.). The cutting assembly can include one or more measured and/or adjustable parameters to adjust the length of the extruded material being cut and/or broken so as to obtain a desired length of the cut material, etc.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween. The invention has been described with reference to the preferred embodiments. These and other modifications of the preferred embodiments as well as other embodiments of the invention will be obvious from the disclosure herein, whereby the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.
The present invention claims priority on U.S. Provisional Application Ser. No. 60/932,295 filed May 30, 2007 entitled “Extrusion Cutting Apparatus”, all of which is incorporated herein by reference. The present invention also claims priority on U.S. Provisional Application Ser. No. 60/961,081 filed Jul. 18, 2007 entitled “Extrusion Cutting Apparatus”, all of which is incorporated herein by reference. The present invention relates to extrusion hardware, and more particularly to die plates, die plate inserts and cutting devices for use in an extruder system. The following patents and patent applications are incorporated herein by reference to provide background information relating to extruder technology and can be used in and, or with the present invention, namely U.S. Pat. Nos. D442,612; D444,487; D446,794; D450,732; D452,257; D469,116; D469,117; D469,452; D469,453; D469,454; D470,869; D470,870; D472,252; D485,286; D494,198; D496,377: D497,376; D523,452; D531,197; D534,562; D544,005; D544,006; D544,506; D544,891; D562,364; D562,370; D562,857; D562,858; D562,859: D562,860; D562,861; D563,441; D563,442; D564,549; D564,550; D564,551; D565,067; D565,068; D565,610; D565,611; D565,612; D565,613; D565,614; D565,615; D566,145; D568,349; D569,885; and U.S. Patent Application Ser. Nos. 60/548,693 filed Feb. 27, 2004; 11/062,220 filed Feb. 18, 2005; 29/242,613 filed Nov. 10, 2005; 29/242,779 filed Nov. 15, 2005; 29/242,881 filed Nov. 15, 2005; 29/263,364 filed Jul. 14, 2006; 11/651,063 filed Jan. 8, 2007; 29/272,847 filed Feb. 20, 2007; 29/285,094 filed Mar. 21, 2007; 29/285,095 filed Mar. 21, 2007; 29/285.099 filed Mar. 21, 2007; 29/285,108 filed Mar. 21, 2007; 29/285,112 filed Mar. 21, 2007; 29/285/115 filed Mar. 21, 2007; and PCT Application Serial Nos. PCT/US2006/005731 filed Feb. 17, 2006 and PCT/US2007/000300 filed Jan. 8, 2007; and European Patent Nos. 556030-01/04; 556006-001/013; 556022-01/04; and European Patent Application Serial No. 000556022 filed Jul. 4, 2006.
| Number | Date | Country | |
|---|---|---|---|
| 60932295 | May 2007 | US | |
| 60961081 | Jul 2007 | US |
