RU2298474C2 - Method and the device used for manufacture of the laminated products - Google Patents

Abstract

FIELD: chemical industry; methods and devices used for manufacture of laminated products.

SUBSTANCE: the invention is pertaining to the method and the device used for manufacture of the high-viscosity products, in particular, for production of the soaps with a set of the color layers having unique features, for example, additives or odor. The device contains at least two extruders, in which the pastes having the different characteristics are fed. In the place of the extruders joint there is at least one head for the pastes stirring with each other. The head contains the mounted there nozzle having the separate inlets, the separate cameras and one common outlet for the separate pastes. The pastes are fed into the separate inlets and extruded from one outlet with production of the laminated billet. The device additionally contains the squeezer for molding and cutting of the billet by pressing in the form of the lumps of the laminated product. The squeezer is made with capability of variation of the angle between the axis of the billet and the axis of the squeezer. The change of the indicated angle is conducted after the first pressing of the billet. Then conduct the following pressing of the billet for creation of the various visual effects on the lump of the laminated product. The different visual effects are achieved by adjustment of the angles of the layers of the product to the axis of the lump of the laminated product. The invention also presents the description of the article produced by this method. The invention allows to manufacture the laminated article with the layers of the different colors, odors and additives in combination with the special configuration and in the determined numbers using the low-cost method.

EFFECT: the invention ensures production of the laminated article with the layers of the different colors, odors and additives in combination with the special configuration and in the determined numbers using the low-cost method.

17 cl, 29 dwg

Description

The invention relates to a method and device used for the manufacture of highly viscous products, which then harden, in particular soaps with many colored layers having characteristic features, for example additives or aromas, and products made in this way.

In the traditional production of soap, the soap composition is formed on the presses after it is converted into a soap mass and the addition of flavors and dyes, and then packaged. In this way a uniform, uniformly colored bar of soap is obtained. Ordinary pieces of soap are packed one after another or together in two, three, four or more pieces.

The present invention allows the production of striped and aromatic bars of soap having two or more colors.

The traditional method of making soap (the so-called Marseille method) contains four stages: saponification, washing, curing and drying.

The saponification stage is based on a reaction with sodium hydroxide. At the washing stage, glycerin, which is an important by-product in the production of soap, is removed. At the curing stage, saponification is carried out, and at the drying stage, a bar of soap takes its final shape.

These stages are well known in the manufacture of soap, and the modern soap industry is based on the continuous and automatic application of these stages. After these stages, soap bars are formed in the final stages of processing, which consist of drying, kneading, molding, labeling and finally packaging.

At the kneading stage, additives or fillers, such as flavorings, colorants, binders, deodorants, are added to the soap mass. The types and quantities of such additives may vary depending on the specific purpose of the soap, namely, toilet soap, bath soap, bactericidal soap, etc.

However, one-color types of soap do not meet the desire of customers to have a variety of products. Therefore, various methods and devices for making striped soap have been developed in the prior art.

US Pat. No. 3,884,605 describes a method for manufacturing multi-colored and striped pieces of soap by mixing various colored soap pastes coming out of two spiral augers arranged parallel to each other by means of an injector with parallel tubes.

On the other hand, US Pat. No. 3,890,419 describes a device for producing a bar of soap having colored stripes on its outer surface made by introducing a coloring matter into the soap mass in the extruder region.

In addition, another US patent 3923438 describes a device for the manufacture of a bar of soap with one strip. Several screws are provided in the extruder of this device, and the coloring matter is introduced into the soap mass when passing through these screws.

US Pat. No. 4,094,946 provides two mutually eccentric and transverse helical screws. Soap paste having a different color is introduced into each screw, and pastes of different colors are mixed in an extruder, as a result of which a bar of soap is obtained.

US Pat. No. 4,127,372 describes a device used for the same purpose, in which the paste passes through one spiral screw in the second, and a coloring agent interferes with the dye from several openings at the end of the second spiral screw.

In US Pat. No. 4,196,163, colored striped soap is made using the special shape part that the extruder is provided with.

However, all of the above technical solutions provide soap bars having strips only on their outer surface. After a short use, the strips disappear. If the strips penetrate deeper into the piece, then these strips tend to crack or delaminate along the lines soon.

The objective of the invention is to create a product, for example, a bar of soap having two soap masses connected to each other with a special configuration and in a certain amount, with layers of different colors, aromas, additives.

Another objective of the invention is the provision of combining with each other various soap pastes having different contents of flavors, dyes and additives, resulting in an outwardly attractive and diverse product.

Another objective of the invention is to ensure the mixing of soap pastes without cracks and delamination by the manufacture of layered soaps in an inexpensive and expedient manner.

The objectives of the invention are solved by a device for the manufacture of pieces of a layered product from a highly viscous material that hardens in a dry state, containing at least two (screw) extruders, into which pastes having different characteristics, and at least one head located at the junction of the extruders are fed for mixing pastes with each other; moreover, a nozzle having separate entrances, separate chambers and one common outlet for individual pastes supplied to separate entrances is installed in said head for extruding them from the indicated one outlet to obtain a layered preform, the device further comprising a press for molding and cutting the preform by pressing , in the form of pieces of a layered product, said press being configured to change the angle between the axis of the workpiece and the axis of the press to create various visual effects on the piece m different angles of the product layers to the axis of the piece of the layered product.

Accordingly, the invention also provides a method for producing slices of a layered product from a highly viscous material that hardens in a dry state using the above-described device, comprising feeding pastes having different characteristics through extruders, extruding them through one outlet to obtain a layered preform, molding and cutting the preform by pressing it in the press, and after the first pressing, the angle is changed between the axis of the workpiece and the axis of the press, and the following compressing the workpiece to create various visual effects on a piece of layered product.

The invention also relates to a layered product obtained by the method according to the invention. Preferably, this layered product is obtained from soap pastes, which may have the same or different characteristics.

The invention is further described by examples with reference to the accompanying drawings, in which:

Figure 1 - schematic view of the device from above,

Figure 2 is a top view of the nozzle,

Figure 3 is a front view of the nozzle,

Figure 4 is a side view of the nozzle,

5 is a view in section of a nozzle along aa,

6 is a view in section of a piece of soap made using this nozzle,

7 is a top view of a bar of soap made with this nozzle,

Fig. 8 is a plan view of a second embodiment of a nozzle,

Fig.9 is a side view of a second embodiment of the nozzle,

Figure 10 is a front view of a second embodiment of a nozzle,

11 is a view in section of a second embodiment of a nozzle in BB,

12 is a sectional view of a bar of soap made with a second embodiment of the nozzle,

13 is a top view of a bar of soap made with a second embodiment of the nozzle,

Fig. 14 is a plan view of a third embodiment of a nozzle,

Fig - front view of a third embodiment of the nozzle,

Fig is a side view of a third embodiment of the nozzle,

17 is a sectional view of a third embodiment of a nozzle in CC,

Fig. 18 is a cross-sectional view of a bar of soap made with a third embodiment of the nozzle,

Fig is a top view of a piece of soap made with a third embodiment of the nozzle,

Figure 20 is a plan view of a fourth embodiment of a nozzle,

21 is a front view of a fourth embodiment of a nozzle,

Fig. 22 is a side view of a fourth embodiment of a nozzle;

23 is a cross-sectional view of a fourth embodiment of a nozzle according to D-D,

24 is a cross-sectional view of a bar of soap made with a fourth embodiment of the nozzle,

Fig - top view of a piece of soap made with the fourth

nozzle option

26 is a front view of a nozzle cap,

Fig.27 is a view in section of a cover,

Fig - top view of the press and the workpiece,

Fig is a perspective view of the soap.

Parts of the device are listed below:

1. Device

2. Extruder

3. Extruder head

4. Nozzle (nozzle)

5. Login

6. Camera

7. Exit

8. Press

9. Conveyor

10. Separator

11. Soap

12. Layer

13. Cover

14. Case

15. The wall

The term "layered product" in this description means a product in the form of a piece consisting of several layers (12), which in the same product have different characteristics, such as color, aroma, additive, pattern. When the product is in its viscous state, it has the form of a paste, and after molding and drying it hardens. Although this product may be a food product, a cleaning agent, or the like, this product is preferably a bar of soap, including a bar of soap, known as “striped” soap. Soap is called “striped” because its bar contains several stripes or lines of different patterns and colors.

The device according to the invention contains at least one extruder (2), which serves soap paste. A spiral auger (not shown) rotates around the axis and provides advancement of the soap paste. At the end of the extruder, a head is provided for mixing different soap pastes. The device according to the invention is characterized in that the nozzle (4) is provided in the head (3) for passing separated soap pastes entering through different inlets (5) through different chambers (6) and extruding them with mixing in the form of one paste through one outlet ( 7). Soap paste (10) leaves the nozzle (4) in the form of a blank having several layers and is transferred by conveyor (9) to the press (8), on which it is molded, prepared for packaging.

Each chamber (6) faces a separate input (5) and is connected to a common output (7). The chambers (6) have a cross section of the manufactured bar (2) of soap.

Another embodiment of the invention is shown in FIG. 2-5, where it is shown that the nozzle (4) has the shape of a cylinder with a round, rectangular or elliptical base. This cylinder has two inlets, one on the base and the other on the side wall. The inlets are preferably circular in shape to facilitate the flow of soap paste. Each of these inputs (5a and 5b) opens into a separate chamber (6a and 6b) in the cylinder. These chambers are separated from each other by a wall (15), starting from the inner side of the side wall and ending immediately before the exit. The wall sections near the entrances are tapered, which facilitates flow in the X and Y directions. The soap paste takes a rectangular, elliptical or similar shape when it flows through the chambers. Due to the continuous flow through the extruder, the paste inside the cylinder is directed from the inlet (5) to the outlet (7).

Soap (11) made according to this embodiment is shown in FIGS. 6 and 7. This soap contains two layers having different characteristics and located one on top of the other. The dividing line connecting the layers is in the center of the cross section of the soap.

Another embodiment of the invention is shown in FIGS. In this embodiment, the nozzle (4) is preferably in the form of a cylinder with a rectangular base. The inner cavity of the cylinder is divided into four chambers (6a, 6b, 6c, 6d) with a vertical wall (15a) and two horizontal walls (15b and 15c). Two chambers (6a and 6b) open at the inlets located at the base of the cylinder. Two other chambers (6c and 6d) open in two separate entrances (5c and 5d) in the side wall of the cylinder. In a preferred embodiment, a soap composition having one characteristic flows into the first two chambers from one extruder, and a soap base different from it flows into the other chambers from the second extruder.

In this way, a bar of soap is made having a cross-section (see FIGS. 12 and 13).

On Fig-17 shows another embodiment, in which the nozzle (4) is made preferably in the form of a cylinder having a rectangular base. The internal cavity of this cylinder has three separate chambers (6a, 6b, 6c), opening in three separate entrances (5a, 5b, 5c). Two of the chambers (6b and 6c) open into the entrances (5b and 5c) on the side wall. Another chamber (6a) opens into the inlet (5a) located on the base of the cylinder. Two chambers (6b and 6c) protrude into the chamber (6c) at the inlet (5a) and, thus, the chamber has an H-shaped cross section. The soap (2) made according to this embodiment has separate layers (12b and 12c) on and below the middle layer (12a). The upper and lower layers (12b and 12c) can be the same width as the middle layer (12a) or differ from it in width.

In another embodiment, shown in FIGS. 20 and 21, the nozzle (4) is preferably in the form of a cylinder having a rectangular base. The inner cavity of the cylinder contains a main chamber (6a) opening into the inlet (5a) located on the base of the cylinder. The main chamber is surrounded by chambers (6b, 6c, 6d, 6e, 6f, 6g, 6h, 6i) opening to the inlets (5b, 5c, 5d, 5e, 5f, 5g, 5h, 5i) located in the side walls of the cylinder. The chambers (6b, 6c, 6d, 6e, 6f, 6g, 6h, 6i) with holes in the side walls protrude into the main chamber like the teeth of a comb.

The soap (11) made according to this embodiment has layers of various colors (12b and 12i) on and under the middle layer (12a) (Figs. 24 and 25).

The outlet (7) is closed by a lid (13) bearing a housing (14) for forming a blank from the paste exiting the nozzle. Thus formed, the workpiece has a cross section of the housing (14) (Fig.26 and 27).

In a preferred embodiment, a wedge-shaped separator (10) is located outside the nozzle wall to guide the paste leaving the extruder (2) into separate inlets. This separator (10) preferably has a cross section of an isosceles triangle. When the paste reaches the top of the triangle, it flows equally up and down to the entrances (5) of the chamber.

Soap exiting the nozzle (4) in the form of a billet having various layers is conveyed by a conveyor under a press for cutting into preformed pieces ready for packaging. Here, the angle (α) of the axis of the workpiece (T9) and the angle of the axis of the press (P) can be varied to create various visual effects on a bar of soap by changing the angle of the layers of soap with respect to the axis of the soap. For example, an angle from 0 to 89 ° between the axis of the workpiece and the axis of the press provides a diagonal layer on the bar of soap. If this angle is 90 °, the layers have the same angle to the axis of the soap (Fig. 28).

In another embodiment, the pieces of soap can pass through the press two or more times, after they are rotated through an angle (in the direction of M1 or M2) after the first stage of pressing. Thus, more complex layers can be obtained (FIG. 29). Soap pastes resulting from separate extruders can have the same or different characteristics, for example, humidity, saturation of fatty acids, etc.

Despite the fact that the device according to the invention has been described with specific reference to soap, it can be used for other products mentioned here.

The components of the device can be manufactured at the same time or separately.

Industrial applicability

The soap base is in the liquid phase, having a moisture content of 30-32% and a temperature of 80-85 ° C. After the neutralization step, several additives are added to the soap and the acidity (pH) is adjusted. Then the soap paste is pressed out and sent to the drying unit.

In a drying installation, toilet soap varieties are dried to a moisture content of 15-16%, and bath soap varieties are dried to 24-25%. Then the soap is planed and extruded from a drying extruder.

When passing through the lattice of the drying extruder, the soap becomes pasty due to the action of the knife in the form of a rotating blade. Then the soap paste enters the tank and is poured into the upper spiral auger of the automatic machine. The sensor of the device prevents leaks and loading of excessive quantities.

In the upper spiral screw of the apparatus, the soap is moved by the pressure created by the rotation of the spiral screw and mixed, while dye, flavoring and other additives are added to it. Soap paste is also squeezed out of the grate at the end of the spiral auger under pressure.

A knife in the form of a blade in front of this grate cuts the paste, which takes the form of sticks having a certain size. During these stages, flavoring, coloring and other additives are added and mixed thoroughly. Soap paste in the form of sticks becomes more uniform and suitable for the continuation of the process.

The resulting soap paste passes through two nozzles, respectively, is discharged onto a carrier conveyor at the outlet of the apparatus and enters the upper nozzle of the extruder (2).

Here, the paste is mixed in the same way under the influence of the driving force and the rotation force of the spiral screws and acquires a uniform structure. The paste passes through the grate at the end of the upper nozzle and is cut with a knife in the form of a blade at the end of the grate, and the third time is a soap paste in the form of sticks of the same size. This paste is poured into the lower nozzle of the extruder (2), which is under vacuum.

Exposure to vacuum at this stage of the process is very important so that the air entering the soap paste is removed by vacuum, thus preventing the formation of bubbles, cracks, crevices and deformations due to air ingress. Again, in the same way, the soap is mixed under the influence of the driving force and the rotation force of the spiral augers and moves on. At this stage there is no grill and knife in the form of a blade. Soap paste passes through the upper and lower nozzles of the apparatus and the upper and lower nozzles of the extruder.

At the last stage, namely at the exit of the lower nozzle of the extruder (2), there is an oil heater. This heater heats the soap paste to a temperature of 70-80 ° C. Soap paste, including flavoring, dye and additives, flows into the head at the exit of the extruder under the influence of temperature and vacuum created during continuous operation.

The same process as described above is repeated in a different apparatus and extruder (2) in the same way for a second soap paste having a different flavor, color and additives than the first soap paste.

The second apparatus and the extruder are installed at an angle of 90 ° to the first apparatus and the extruder. Directly at the point of their connection, a nozzle is located at an angle of 90 °, through which soap pastes with different aromas, colors and additives are mixed.

Two soap pastes having different colors and aromas pass through separate heads (3) of the extruders and are found in the nozzle according to the invention, and this nozzle, due to its unique design, mixes the soap pastes to obtain a soap blank having multi-colored strips with a special pattern.

Soap paste coming out of the drying containers, first entering the automatic apparatus in the “X” direction and passing through the extruder, is mixed with another soap paste, moved in the “Y” direction, at the “XY” junction.

For mixing, one of the soap pastes, which is heated to a temperature of 60-80 ° C and moves under vacuum with a spiral screw in the X direction, enters the inlet (5a) and fills one of the chambers (6a) and quickly passes under vacuum in the X direction.

Soap paste having a different color, aroma and additives flows from the inlets in the upper and lower walls of the nozzle into the chambers (6b-6i) protruding into the main chamber (6a).

Soap flowing in the “X” direction hits the walls of the chambers (6b-6i), which are closed to the soap paste coming in the X direction, but are open on the other side. Therefore, when soap paste enters these chambers, cavities are formed in the soap paste, the volume of which is equal to the chamber. These cavities are filled with another soap paste coming from another extruder and side chambers (6b-6i). Thanks to the heaters of the extruder heads, soap pastes heated to 60-80 ° C are mixed due to the presence of vacuum in the chambers.

Since the system operates continuously, the soap passes on at a constant speed and mixes in the outlet (7) under vacuum and leaves the outlet in the form of a colored striped soap blank.

The distance between the chambers opening to the side walls in horizontal and vertical directions is of great importance, since it affects the thickness of the layers of soap and can cause the formation of cracks and crevices at the junction of the layers.

In the case of combining vertically located chambers, the layers delaminate, since the layers arriving in the X direction will lose contact with each other. Preferably, the distance between the cameras in the horizontal and vertical directions is from 0.1 to 5 cm.

Striped soap can combine soap containing cream and at the same time a fragrant soap, and the user can receive a softening and nourishing effect, as well as enjoy the aroma. When used, namely, when soap is washed under the influence of water, all mixed layers (2) are washed and dissolved the same way. Striped soap acts in the same way as regular soap with respect to cleaning, removing dirt, and does not have a harmful effect on the skin.

In addition, the user enjoys the appearance of striped soap.

No additive, binder or intermediate layer is used to combine the individual colored layers of soap.

Claims (17)

1. Device for the manufacture of a layered product from a highly viscous material that hardens in a dry state, containing at least two extruders (2), which are pastes having different characteristics, and at least one head (3) located at the junction extruders for mixing the pastes with each other, moreover, a nozzle (4) is installed in the said head, having separate entrances (5), separate chambers (6) and one common outlet for the individual pastes supplied to the individual entrances (5), for extruding them from indicated one output to obtain a layered preform, characterized in that the device further comprises a press (8) for molding and cutting the preform by pressing in the form of pieces of a layered product, said press being configured to change the angle between the axis of the preform and the axis of the press (8) to create different visual effects on a piece by adjusting various angles of the product layers to the axis of the piece of the layered product. 2. The device according to claim 1, characterized in that each of the chambers (6) opens into a separate entrance (5), and all of them are connected in a common outlet having a cross section corresponding to the desired shape of the product (11). 3. The device according to claim 1 or 2, characterized in that the chambers (6a and 6b) are separated from each other by a wall (15) in the form of a cylinder having at least two inlets, one of which is located on the base (5a), and the other starts in the inner part of the side wall of the cylinder and passes to a place immediately before the exit. 4. The device according to claim 3, characterized in that in the wall (15) the area near the entrances is tapered, and the area near the exit is flat. 5. The device according to claim 1 or 2, characterized in that the nozzle (4) has the shape of a cylinder with a rectangular base, the inner cavity of which is divided into four chambers (6a, 6b, 6c and 6d) by means of a vertical (15a) and two horizontal walls (15b and 15c), with two chambers (6a and 6b) opening into the entrances (5a and 5b) provided on the base of the cylinder, and two other chambers (6c and 6d) opening into two separate entrances (5c and 5d) provided side walls of the cylinder. 6. The device according to claim 1 or 2, characterized in that the nozzle (4) has the shape of a cylinder with a rectangular base, the inner cavity of which is divided into three separate chambers (6a, 6b, 6c), opening in three separate entrances (5a, 5b 5c), while two of the chambers (6b and 6c) open into the inlets (5b and 5c) provided on the side walls of the cylinder, and the last chamber (6a) opens into the inlet (5a) provided on the base of the cylinder, two of chambers (6b and 6c) protrude into the chamber (6a), which opens into the entrance on the base (5a), and thus form a cross section in pho rme "H". 7. The device according to claim 1 or 2, characterized in that the nozzle is in the form of a cylinder with a rectangular base, comprising a main chamber (6a) opening into the inlet (5a) provided on the base of the cylinder and several chambers (6b, 6c, 6d , 6e, 6f, 6h, 6i), protruding into the main chamber like the teeth of a comb and opening into the entrances provided on the side walls of the cylinder. 8. The device according to claim 1 or 2, characterized in that the outlet (7) is closed by a lid (13) supporting the corresponding housing (14). 9. The device according to claim 1 or 2, characterized in that the nozzle has a wedge-shaped separator (10) located outside the side wall to evenly direct the paste coming from the extruder (2) into separate entrances. 10. The device according to claim 1 or 2, characterized in that the nozzle contains a separator having a cross section in the form of an isosceles triangle. 11. The device according to claim 1 or 2, characterized in that it contains a conveyor (9) for transferring the workpiece (11) obtained from the nozzle, which has different layers, to the press. 12. A method of obtaining pieces of a layered product from a highly viscous material that hardens in a dry state, using the device according to claim 1, which provides for the supply of pastes having different characteristics through extruders, extruding them through one exit to obtain a layered preform, molding and cutting the preform by pressing it in the press, and after the first pressing, the angle is changed between the axis of the workpiece and the axis of the press and the next pressing of the workpiece is carried out to create different visas flax effects on a piece of layered product. 13. The method according to item 12, in which the stage of changing the angle includes turning a piece around its axis by a certain angle. 14. The method according to item 12 or 13, in which the pastes served from different extruders are the same with respect to such characteristics as humidity, saturation of fatty acids, color, additives and aroma. 15. The method according to item 12 or 13, in which the pastes served from different extruders differ in respect to such characteristics as humidity, saturation of fatty acids, color, additives and aroma. 16. The product obtained by the method according to any one of paragraphs.12-15. 17. The product according to clause 16, obtained from a soap paste.

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