MXPA00010483A - High molecular weight elastomer processing system for chewing gum - Google Patents

Abstract

A process and apparatus for melting and processing a high molecular weight elastomeric material for a gum base or chewing gum product is disclosed. The solid elastomeric material, which preferably is polyisobutylene, is heated and melted into a liquid material which is then transported to an extruder. The apparatus has a heated housing section (14) which includes sets (26) of heated plate members arranged in fan-type groupings. Heated diverter members (32A, 32B, 32C) are positioned beneath the sets of fan-type plates. A heated angled conduit section (16) is positioned below the housing section and a heated storage section (18) is attached to the angled conveyance section. A valve and pump system is used to discharge the liquid elastomeric material from the holding section to the gum base or chewing gum extruder. Accurate metering and feeding of the liquified elastomeric material to a continuous extrusion process is achieved.

Description

SYSTEM OF PROCESSING OF ELASTOMEROS OF HIGH MOLECULAR WEIGHT FOR MASCARA Field of the Invention The invention is directed to an apparatus and method for processing highly viscous elastomeric materials, such as polyisobutylene, for chewing gum and chewing gum bases. Background of the Invention Elastomers are one of the main ingredients of a base of chewing gum and thus turn one of the main ingredients of a final chewing gum product. Typically, a chewing gum base is made separately from the final chewing gum, although there are some systems that are capable of producing a final chewing gum product in a continuous process.

A chewing gum composition typically comprises a water-soluble bulky portion, a water-insoluble chewing gum base portion, and typically water-insoluble flavoring agents. The insoluble gum base generally comprises elastomers, elastomer solvents, plasticizers, waxes, emulsifiers, and inorganic fillers. The water soluble portion dissipates with a portion of the flavoring agent for a period of time during the chewed The base portion of gum is retained in the mouth for as long as the product is chewed. The batch method for producing chewing gums has long been considered the standard for producing chewing gums as well as gum bases, on a commercial scale. Batch processes, however, which typically use Sigma sheet mixers, tend to be busy and produce chewing gums of varying consistency. Various efforts have been undertaken to try to simplify and reduce the time required for the manufacture of the gum base and chewing gum, as well as to prepare gum and gum base products having better and more consistent properties. For example, the use of continuous extruders to manufacture a final chewing gum product is shown in US Patent No. 5,135,760 for Degady et al., US Patent No. 5,045,325 for Lesko et al., And US Patent No. 4,555,407 issued. for Kramer et al. Also, there are various processes in the art to continuously produce a chewing gum base with the use of a continuous extrusion machine. This is described, for example, in U.S. Patent Nos. 5,419,919 and 5,486,366, both to Song et al. The continuous processes for gum base and the processes for chewing gum product described in these patents typically use a continuous extrusion machine, such as a double screw extruder. Continuous extrusion machines that can be used to produce a chewing gum base or a final chewing gum product or both, include extruders from Japan Steel Works, Leistriztz, Werner & Pfleiderer Corp., and Buss Mfg. Co., WLS Togum and Baker Perkins. These extruders typically have several different feed inlets where the ingredients are added, and the screws extended inside the extruder barrels are removed with different types of mixing and blending elements. While different equipment manufacturers manufacture different types of screw elements, the most common types include conducting elements, compression elements, reverse conduction elements, homogenization elements (such as elements of cutting discs and toothed elements), and discs of kneader and kneader blocks. These various types of elements, and other elements typically used in extrusion machines, especially double screw extruders, are well known in the art and commercially available. The elements are often designed specifically for the particular type of extruders used. In this regard, the elements intended for similar functions will vary in design depending on the type of extruder for which they are intended. Whether a batch processor or a continuous extruder-type processor is used to produce the gum and gum base products, it is important to provide the various ingredients for these products in an optimal form and condition. This improves the speed and efficiency of the final processing. In this regard, ingredients such as fillers, elastomers, plasticizers, oils, waxes, and the like, often require special handling or preparation before being included in the batch or extrusion process. The preparation of the ingredients is especially important where a continuous extrusion processor is used. The ingredients supplied to the continuous extrusion apparatus are preferably provided in the optimum size, shape, condition and temperature for ease of handling, insertion and intermixing with the other ingredients in the extruder. Also, due to the properties of some of the various ingredient materials, it is necessary to pre-prepare or pre-mix them to allow them to be inserted into the extruder in the best possible condition. As indicated, an important component of a gum base is the elastomeric portion which may include natural elastomers, synthetic elastomers, or combinations thereof. These elements of the rubber base are important because they provide the insoluble body with elasticity to recover from the deformation caused when chewing. In preparing the gum base, it is important that other components which are included in the base composition to carry out various characteristics of the resulting gum, are mix thoroughly with the elastomeric portion so that the complete gum base product will retain the proper elasticity as a homogeneous phase. Solid elastomers suitable for use in the final chewing gum and chewing gum base products include synthetic gums or elastomers such as butadiene-styrene copolymer, polyisobutylene, and isobutylene-isoprene copolymer, as well as natural gums or elastomers such as chewing gum, natural rubber, gelitongo, balata, gutta-percha, lechi, caspi, sorva or mixtures thereof. Polyisobutylene is commonly used as one of the elastomer components for the gum base. Polyisobutylene adds "chewiness" to the final rubber product since many elastomeric materials, such as rubber, are chewing hard. The polyisobutylene materials are commercially available, for example, from Ritchem Corp, and Exxon Corp. (VISTANEX®). Polyisobutylene and other elastomeric materials having high molecular weights, for example greater than 30,000 are difficult to work within a commercial process. These materials are difficult to handle, melt, grind and cut into small pieces due to their viscosity, consistency and characteristics. The difficulties in processing these materials are combined when a continuous extrusion process is used in where the materials need to be added in a predetermined amount and in a predetermined state and temperature. When these elastomeric materials, such as polyisobutylene, are melted and processed, it is important not to trap air in the molten or liquefied materials. The trapped air prevents accurate and efficient measurement of the material inside a continuous extruder. Trapped air also stimulates undesirable oxidation of the material. In batch processes, high molecular weight elastomeric materials can be used more easily than with extruders. In batch processes, the bales, slabs, or cylinders of the materials are simply inserted into the batch mixer tank and allowed to melt over time and mix with the other components in the tank. To melt these materials, it is typically necessary to heat them in excess of 121.11-148.88 ° C (250-300 ° F). In order to use these materials in a chewing gum or gum base processing system using a continuous extrusion apparatus, it is necessary to also maintain them at such elevated temperatures so that they are in a liquid condition. Such elevated temperatures, however, if used for any amount of time in the main extruder, can adversely affect other ingredients in the system. It is a general object of the present invention to provide an improved method and apparatus for the production of chewing gum products and gum base products.

It is also an object of the present invention to provide an improved method and apparatus for the preparation of high molecular weight elastomer materials, such as polnosobutylene, to facilitate the improved processing of gum and gum base products. It is still another object of the invention. The present invention provides a method and apparatus for continuously melting and storing elastomer materials, such as polnosobutylene. It is another object of the present invention to provide an improved process and apparatus for feeding high molecular weight elastomer materials, such as polnosobutylene in a liquid or molten condition. within a chewing gum or gum base processing system which uses a continuous extruder These and other objects, benefits and advantages are satisfied by the present invention which is detailed in preferred form in the following description Brief Description of the Invention The present invention provides an improved apparatus and process for producing a gum base and the final chewing gum product. A novel process and apparatus is used to melt and supply certain high molecular weight elastomer materials, such as polnosobutylene. , which are used as some of the ingredients of the rubber based product Preferably, the present invention is used with elastomeric materials having molecular weights in excess of 30,000. Where a continuous extrusion machine is used, elastomer materials prepared and supplied in accordance with the present invention can be fed and inserted directly into the barrel of the extrusion machine during // the operation of a rubber base extrusion process of stabilized, continuous state According to the present invention, a solid part of the elastomepco material is placed as a whole or groups of heated plates arranged in fan-like considerations The plates are heated internally such as by circulating hot oil, to reach the temperatures necessary to melt the material. A plurality of heated diverting members are placed immediately below the heated melting plates. The melting plates and the diverting members are placed in a lodging which is maintains at an elevated temperature or jackets heated with steam The housing in turn is connected to a heated corrugated conduit, which directs molten and liquefied matepal into a hot sensing tank. The angled conduit and the holding tank are chamfered in its external surfaces with steam spirals In this way the duct and the holding tank are heated to temperatures above the melting point of the elastomep material in the housing The elastomeric material placed on the fusion plates in the housing slowly heats and melts and passes through fan-like plates on the biasing members. The molten material in turn is directed by gravity and without agitation or formation of air bubbles through the conduit at an angle and into the holding tank. The liquefied material is discharged from the holding tank by a pump mechanism and isolation valve. With the present invention high weight elastomeric materials, such as polyisobutylene, are melted and contained as a liquid with a minimum of trapped air and oxidation. The material is in a condition and temperature to be introduced directly into a continuous process of extrusion type and to be measured precisely within it. Other features, benefits and advantages of the present invention will become apparent when the following description is seen in accordance with the accompanying drawings and the appended claims.

Brief Description of the Drawings FIGURE 1 is a schematic diagram of an elastomer processing system according to the present invention; FIGURE 2 is a side cross-sectional view of the processing system shown in Figure 1; FIGURE 3 is a top view of the processing system as shown in Figures 1 and 2; FIGURE 4 represents a preferred array arrangement of heated fusion plates according to the present invention; and FIGURE 5 is a schematic diagram illustrating the use of the present invention with a continuous extrusion process of gum base or chewing gum.

Best or Best Modes of Practicing the Invention The present invention is particularly suitable for processing high molecular weight elastomeric products and materials, such as polyisobutylene, which are used as some of the ingredients in the products of chewing gum bases and gum bases. chew. One of the commercial designations for polyisobutylene is Vistanex®, a product of Exxon Corp. Other commercially available polyisobutylene materials are available from Ritchem Corp. Preferably, the present invention is used with elastomeric materials having molecular weights in excess of 30,000. In general, the present invention provides an apparatus and method for melting, storing and feeding high molecular weight elastomeric materials to facilitate their introduction and use of a continuous process to produce a chewing gum base product or chewing gum. In this regard, you must It is to be understood that the present invention can be used to prepare polyisobutylene or other elastomeric component of a chewing gum base or a final chewing gum product and can be used with a batch-type system or a continuous extruder-type system. In the preferred embodiment of the present invention, and for use to illustrate the present invention, the present is described with reference to its use in a continuous gum base manufacturing system which utilizes an extruder. In particular, for use as a continuous rubber base process, the present invention facilitates the feeding and intermixing of certain elastomeric components of the gum base with other ingredients and components of the gum base product. A schematic illustration of the apparatus according to the present invention is shown in Figure 1 and is referred to by the reference number 10. Figures 2 and 3 are side and top views, respectively, of the apparatus 10, with Figure 2 being in a partial cross section. Figure 4 is an enlarged view of the preferred fan-shaped fusion plates used with the present invention. Figure 5 is a schematic diagram of the use of the present invention with a continuous gum base manufacturing process using a continuous extruder 12. Elastomers are one of the main ingredients of a chewing gum base and thus in turn one of the main ingredients of \? final chewing gum product A typical chewing gum base includes one or more elastomers, along with one or more fillers, elastomer solvents, plasticizers and optionally, polymers, waxes, emulsifiers, and various colors, flavors and antioxidants The elastome portion of the product may include natural products, synthetic elastomers, or combinations thereof Solid elastomers suitable for use in chewing gum bases and the final chewing gum product include synthetic gums or elastomers, such as butadiene-styrene copolymer, polnsobutylene , and copolymer of isobutylene-isoprene, as well as natural gums or elastomers such as chewing gum, natural rubber, balata gelitongo, gutta-percha lechi caspi, sorva or mixtures thereof The elastomepco element of the gum base provides the insoluble body with elasticity to recover of the deformation caused when chewing With many rubber bases and rubber products, other products elastomepcos, such as polnsobutylene, are added to increase the "chewiness" of the rubber. Many of these elastomer materials, however, are difficult to handle and process. In particular, due to their low viscosity, high molecular weight and resulting properties and properties these materials do not easily or quickly change from a solid to a liquid. Furthermore, these materials are difficult to precisely measure and introduce in a consistent way the Gum base or chewing gum product often resulting in inconsistent and inconsistent results Whether a batch process or a continuous extruder type is used to produce the gum and gum base products, it is important to provide the various ingredients for those products in the best shape and condition This improves the speed and efficiency of the final processing, and ensures consistency and uniformity from batch to batch and from product to product In this regard the ingredients such as fillers, elastomers, plasticizers, oils, Waxes, and the like, frequently require special handling and preparation before being included in the batch or extrusion process. The preparation of the ingredients is especially important where a continuous extrusion processor is used. The ingredients that are supplied to a continuous extrusion apparatus are They provide preferably in the size, shape, condition (solid, liquid, etc) and optimum temperatures for ease of insertion and intermixing with the other ingredients in the extruder Also, the properties of many of the various ingredient materials require premixing with other materials or being solidified, broken into particles, or liquefied to be inserted into the extruder in the best possible condition Also, it is important to precisely control the amount of material that is added to the continuous extrusion processor to provide uniformity and consistency in the Final product. Frequently, when elastomers, such as polyisobutylene, and other ingredients melt and liquefy, air is trapped in them, or other impurities are imbedded in them, which affects the unit of weight and the volume unit of the materials. Air also causes undesirable oxidation of materials. These factors in turn affect the quality, uniformity and consistency of the final products. The present invention provides an apparatus and method which melts and processes highly viscous high molecular weight elastomeric materials such as polyisobutylene, in an optimum form for possible use in a continuous extrusion type system. Preferably, the present invention is used with elastomeric materials having molecular weights in excess of 30,000. The material melts uniformly in a heated tank and has a gravity transition from the tank to a retention area of the apparatus. This ensures constant melting conditions and melting temperature for the material, and also eliminates entrapment of air and other impurities entering the system. As shown in Figures 1-3, the apparatus 10 includes a housing section 14, an angled conveyance or section 16, and a retainer tank section 18. Each of the three sections 14, 16 and 18 are heated around their outer peripheries to maintain an internally desired temperature in all sections of the Apparatus 10 In this regard, housing 14, as well as sections 16 and 18, are externally chapped with steam coils 20. These jackets have passageways and conduits for the circulation of a heated fluid, such as steam, and are placed on or around of the outer peripheries of the housing and adjacent sections Steam coil members 20 are of conventional design and are supplied with steam from conventional sources (not shown) with appropriate temperature and supply controls One or more load cells 24 are placed preferably at various points on the apparatus for measuring the weight thereof and determining the amount of material heated and liquefied in the apparatus. In this respect, Figure 2 represents a load cell 24, although it should be understood that a plurality of load cells may provided in accordance with professional practice Various assemblies 26 of heated fusion plates 28 are located in the housing 14 The plates 28 are placed in the assemblies 26 of the arrays or fan-like groupings as shown in Figures 1, 2 and 4 The plates have larger openings or gaps G at their upper ends and smaller openings or gaps H its lower ends Also, as shown in Figure 4, the upper and lower extended edges 30 and 31 of each of the plates 28 have dotted ends One or more deflection members are placed immediately below the assemblies 26 of heated fusion plates 28. In this respect the embodiment of the invention shown in Figures 1 and 2 has three deflection members 32A 32B and 32C. These correspond to the assemblies 26 of heated melting plates The plates 32A 32B and 32C are of different lengths and are used to deflect molten or liquefied material flowing through the plate assemblies towards the surface or angled surfaces of the conduit section 16. This is shown by arrows 34 in Figures 1 and 2 The housing and the sections of the apparatus as well as the fusion plates and the biasing members, are each preferably made of a stainless steel material. The fusion plates and the biasing members have cavities internal and heated internally by the circulation of hot oil Preferably the plates and members comprise two sheets of material sold The oil is heated and supplied by a conventional agent (not shown) Section 18 of the receiving tank of the apparatus 10 is used to accommodate and store a quantity of the liquefied elastomer material As shown in Figure 2, the material is melted and proceeds down the sloping side 42 of the angled conduction section 16 that forms a batch of molten material 40 in the holding tank section The elastomeric material is introduced into the apparatus 10 through the upper opening 15 of the housing section 14. The elastomeric material can be supplied in any conventional solid form, such as slabs, bales, or cylinders, and can be introduced into the housing manually or by any conventional automatic mechanism, such as a mobile crane type apparatus. In this regard, a plurality of cylinders 50 are shown in phantom lines in Figures 1 and 2 as being representative of the elastomeric materials used with the present invention. The solid pieces of material 50 are placed directly on the upper ends 30 of the heated plate members 28. Preferably, the temperatures of the steam heated coils in the housing 14 and sections 16 and 18, as well as the temperatures in the heated melting plates 28 and deflection members 32A-C, are maintained above the melting temperature of the material elastomeric used in the process. For example, with polyisobutylene, the temperature of the various components of the apparatus 10 is maintained at temperatures up to 260 ° C (500 ° F). Due to the high temperatures in the apparatus 10, the elastomeric material placed on the fusion plates 28 in the housing section 14 melts in a slow and uniform manner. The material melts by gravity downwards through the fan-like groupings of heated plates 28, along the deflection members 32A, 32B and 32C heated at an angle, and against the angled heated side 42 of the conduction section 16. The molten material then flows by gravity into section 18 of the storage or retention tank. To use the liquefied material for further processing, the apparatus 10 is provided with a valve mechanism 60 and a pump mechanism 62. The valve and pump mechanisms 60 and 62 are controlled by a conventional control and delivery system 64 to discharge an appropriate amount of liquid elastomer material 40 when required for the chewing gum or rubber base processing system. In this regard, a pipe or conduit 66 is attached to the valve mechanism 60 to provide the liquid material 40 to the extruder 12.

Referring now to Figure 5, the extruder 12 includes an extended barrel section 70 and a motor and control section 72. The barrel 70 has one or more elongated screw members 74 positioned in which it processes the ingredients of the gum base and advances them in a homogenous melt to the discharge end 76 where the mass is discharged into the appropriate containers 78. The extruder 12 has a number of input ports, three of which (80, 82 and 84) are shown. It is also possible that there is a larger or smaller number in input ports for the extruder 12. In the representative extruder device 12 illustrated in Figure 5, the elastomeric material Liquid from the apparatus 10 is introduced into the barrel 70 of the extruder through the inlet port 82. In order to melt and process an adequate amount of elastomeric material for a rubber based commercial process, the apparatus 10 must have substantial apparatus and capacity. In this regard, for illustration, the housing section 12 may be several feet in size along each of its sides. Preferably, a system according to the present invention has a melting tank apparatus that melts the elastomeric material at a temperature as high as 260 ° C (500 ° F). For commercial purposes, the apparatus 10 preferably has the ability to melt several hundred pounds per hour of the molten material and retain it at the desired delivery temperature. The supply system feeds the molten material to the processor or extruder consistently and at a specified feed rate and pressure. The present invention facilitates this by allowing the molten material to flow by gravity and have a gravitational transition from the melting plates 28 to the retaining section 18 of the apparatus, eliminating trapped air. The system according to the present invention also preferably has several hundred square feet of melting surface area in the heated melting plate members 28. In addition, the supply melt pump 62 is heated by steam and controlled in a conventional manner to Supply the molten material at a consistent speed for commercial production. Although what is currently believed to be the preferred embodiments of the invention has been described, those skilled in the art will review that changes and modifications can be made thereto without departing from the spirit and scope of the invention, and it is intended to claim all of such changes and modifications as fall within the scope of the invention as defined and covered by the following claims.

Claims (18)

1. CLAIMS 1. An apparatus for diffusing and processing a high molecular weight elastomeric material, said apparatus is characterized in that it comprises: a housing, a section of conduction with angle attached to and operatively associated with the housing; a storage section attached to and operatively associated with the driving section; a plurality of heated plate members positioned in the housing; and at least one deflection member positioned in the housing immediately adjacent the heated plate members.
2. 2. The method according to claim 1, characterized in that the deflection members are heated.
3. 3. The method according to claim 1, characterized in that the plurality of heated plate members are arranged in at least one fan-shaped array. The method according to claim 1, characterized in that the housing, the conduit section and the storage section are heated by steam coils. The method according to claim 1, characterized in that the plate members and the diverting members are heated by the circulation of hot oil 6. The method according to claim 1, further characterized in that it comprises a pump and valve mechanism for removing material from the storage section 7 The method according to claim 1, characterized in that the apparatus is supported on at least one load cell 8 The method according to claim 1, characterized in that the heated plate members are placed in at least two sets of arrays in the shape of a fan 9 The method according to claim 8, characterized in that a deflection member is provided separately for each of the fan-shaped groupings. The method according to claim 1, characterized because the diversion members are placed to direct the m aterial by gravity towards an angled surface of the conduit section 11 The method according to claim 1, characterized in that the elastomepco material is polnsobutylene 12. The method according to claim 1, characterized in that the elastomeric material has a molecular weight in excess of 30,000. 13. A system for introducing a liquefied elastomeric material into a continuous gum base manufacturing process, the process includes an extruder with a plurality of ports, the system is characterized in that it comprises: an apparatus for converting a solid elastomeric material into a liquid, the apparatus having a heated housing, a heated conducting section, a heated storage section, and a plurality of heated plate members placed in the housing to melt the material; removing means for removing the heated liquid elastomeric material from the apparatus; and driving means for transporting the liquid elastomeric material to one of the ports in the extruder. The method according to claim 13, characterized in that the apparatus further comprises at least one biasing member for directing the molten material by gravity from the heated plate members to the conduction section. 15. The method according to claim 14, characterized in that the deflection members are heated. 16. The method according to claim 13, characterized in that the elastomeric material is polyisobutylene. 17. The method according to claim 13, characterized in that the elastomeric material has a molecular weight in excess of 30,000. 18. The method according to claim 13, characterized in that the liquefied material travels by gravity from the heated plate members to the storage section, where air entrapped in the liquid material is minimized.