WO2016181376A1

WO2016181376A1 - Extruder equipment arrangement for producing three layers sheet of colored resin with the material composition of each layer is enhanced

Info

Publication number: WO2016181376A1
Application number: PCT/ID2016/000001
Authority: WO
Inventors: Fumiyuki KOZAWA
Original assignee: Pt. Topla Abadi Jaya
Priority date: 2015-05-12
Filing date: 2016-03-01
Publication date: 2016-11-17

Abstract

This invention relates to an arrangement of extruder equipment for producing three layers sheet of colored resin, accordingly the invention comprising components as following: first extruder (1) placed in a position which align with the path of the sheet to be treated and second extruder (2) placed in an oblique position to the path of the sheet and third extruder (3) placed in an oblique position to the treated sheet path which respectively extruded from each different material, wherein; - the first extruder (1) having a mixture materials from HIPS resin as a pure raw material that having thickness from 5% up to 20%, which is filled through a hoper (18a) and previously through an automatic coloring unit towards the mold by means of connector block (8) and feeder block (10) towards mold T, second extruder (2) having a recycle material with thickness from 25% up to 40%, which is filled through a hoper (18b) and distributed through connector block (8) and feeder block (10) towards mold T, and third extruder (3) having a HIPS resin with an aisen resin that having a thickness from 70% up to 40%, which is filled through a hoper (18c) and distributed through connector block (8) and feeder block (10) towards mold T, wherein the tilt angle of the second extruder (2) and the third extruder (3) against the first extruder (1) is 65° (α = 65°).

Description

EXTRUDER EQUIPMENT ARRANGEMENT FOR PRODUCING THREE LAYERS SHEET OF COLORED RESIN WITH THE MATERIAL COMPOSITION OF EACH LAYER IS ENHANCED

Field of Invention

This invention in general relates with an enhanced extruder equipment arrangement for colored sheet product having three layers, specifically this invention relates with an enhanced extruder equipment for colored sheet having three layers which preferably;

a. First layer comprising a pure resin raw material HIPS or ESCR with thickness from 5% up to 20%, second layer comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material HIPS or ESCR with thickness from 70% up to 40%, preferably;

b. First layer comprising a pure resin raw material HIPS or ESCR with thickness from 20% up to 33%, second layer comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 60% up to 34% and the third layer is comprising pure resin raw material HIPS or ESCR with thickness from 20% up to 33%, more preferably;

c. First layer is comprising pure resin raw material HIPS or ESCR with thickness from 5% up to 20% added with 1% up to 20% rubbe , the second layer is comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material HIPS or ESCR with thickness from 70% up to 40% added with 1% up to 20% rubber, more preferably;

d. First layer is comprising pure resin raw material ABS with thickness from 5% up to 20%, the second layer is comprising pure raw material ABS added with ABS recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material ABS with thickness from 70% up to 40%, more preferably;

e. First layer is comprising pure resin raw material ABS with thickness from 20% up to 33%, the second layer is comprising pure raw material ABS added with ABS recycle material with thickness from 60% up to 34% and the third layer is comprising pure resin raw material ABS with thickness from 20% up to 33%.

Background of Invention

As we know, that at this point in making a resin sheet material using an extruder usually with one layer only, wherein the resulting product has a limited color and can not have had a more varied color again.

To produce the color is by using a dyes automatic unit dyes, which can mix various colors for pellet resin, before being put into hoper feeder material, wherein with the heating can serve to alter the pellet resin into the shape of the melting / gel and then inserted into the tank.

Extruder machine is a machine that uses screws to suppress resin which has been heated in paste form, which is printed by die-T or mold form T, or hereinafter mold T, the mold of the adapter then connector block and block feeder is then processed with rollers polishing to flatten these factors.

Factors that make it difficult to create a three layers resin layer is due to the influence of an extruder machine that is used to create a layer of the three layers resin sheet.

The second factor is, in making the resin sheet is usually dye cannot vary because the coloring process that often occurs is to change the color of the resin sheet is extruded by an extruder machine.

The third factor is the contamination from dirt into the resin sheet is printed, so that will make the product has a low quality. The fourth factor is the lack of precision dimensional measurement, which resulted in the failure from sheets of resin product .

The fifth factor is the layer from three layers sheet that is not unified, so it will be detached from one another because it is not integrated into one.

The sixth factor is the short bank or spots on the of resin sheet product of three layers, thus making the product becomes inferior.

The seventh factor is in the manufacture of of resin three layers - sheet product using an extruder machine, frequent breakdowns because of the products produced are often broken, so that it becomes a failed product.

Based on the weaknesses mentioned above that occur in the manufacture of products with the extruder machine, it can result in high costs in the manufacture of this three layers of resin sheet.

In a making process, the step of processing may comprising:

Material comprising the genuine HIPS, the recycle HIPS and the pure HIPS are inserted respectively to the container tank for the subsequent coloring process in the coloring unit, by using suction pipe which will go down into the mixing tank in the coloring unit.

Furthermore, after the unit coloring, then it will go into the hoper for each individual from extruder machine that is driven through the screw and exit through the heater to melt the raw materials stage to filter out impurities with the using a sieve (screen changer) and further connector blocks (block junction) and a block feeder (feeder block), which serves to unify the three types of resins from 3 material into a single entity, so that out of the connector blocks to be leveled by the mold-T. Plastic gel which has become an integral color is then entered into the polishing unit roller (roll polishing unit) . The next stage is the result of polishing with using rollers are cooled by a conveyor, with the help of a cooling fan and drawn using the pickup roller (take-up roll) .

The next stage of the product into the cutting unit, to cut materials that are tailored to the size of product orders, carried out by the mower unit.

The last stage is packing or arrangement of the compilers units by the operator, where the sheets that have been cut are arranged from table sheet to be stacked to the pile of sheets are packaged for sale.

Results pieces from scraps or waste materials are destroyed again with the shredder for recycling.

Based on the process flow of work, the manufacture of the product resin layer of three layers, in accordance with the present invention designed specifically for extruder machine better, so that the shape of the mold and the result of the unification of material into one can produce a quality product of a sheet of resin in accordance with the invention the colors are varied and do not fade.

Based on the manufacture and arrangement of the equipment should be able to overcome the problems mentioned above, the inventors tried to make an arrangement of equipment extruder to overcome the problems mentioned above, taking into account the following aspects:

The first aspect, the inventors made an arrangement of equipment extruder to produce colored sheets of resin three layers, such as by making extruder which were united from extruder first, extruder second and extruder third, using each extruder which has a different diameter to become one , from the filling to the filter adapter from the third extruder machine, through a strainer to put together into a connection block and transmitted to block feeder, to be inserted into the mold-T in gel form for further processing.

The second aspect, the inventors made an arrangement of equipment extruder to produce sheets of colored resins three layers, using extruders of different diameter which are 90 mm, 115 mm and a diameter extruder of 65 mm, each of which is useful to unify resin material into unity in connector blocks.

The third aspect, the inventors made an arrangement of equipment extruder to produce a of resin colored three layers using an extruder placed with a slope of 65 degrees to the x- axis of first extruder, to filter with the each adapter of extruder, to put in a conduction block and block feeder to the mold-T comes out in the form of a gel, which was then the material of the mold is polished with the rollers to make a sheet form.

The fourth aspect, the inventors made an arrangement of equipment extruder to produce a of resin colored three layers using an extruder arranged in a certain order, to produce a printout of the unity and avoid contamination, because the material is filtered in the unit extruder, the resulting sheet product of resin three layers of high quality.

Fifth aspect, the inventors made an arrangement of equipment colored of resin extruder to produce three layers by making good coloring, before entering into the extruder using automatic coloring (Autocolor) .

Sixth aspect, the inventors made an arrangement of equipment extruder to produce colored resins three layers with the make the arrangement of equipment with the degree of slope is determined, to produce a mixture of ingredients into a single unit of each equipment extruder so as one that cannot be separated or into a single layer with the other layers.

Seventh aspects, the inventors made an arrangement of equipment extruder with the each extruder is filled with the raw material of resin different of resin raw materials native and materials resin raw materials native with the recycled raw materials and original raw materials, with the a greater thickness to produce sheet three layers of resin.

The term "HIPS VIRGIN" is referring to a pure resin material to make the three layers sheet product. The term "SCRAP" is referring to a recycle raw material to make the three layers sheet product.

The term "screen changer" is referring to a tool to filter the extruded material so that can be contaminant free.

The term "adapter" is referring to an adjuster for a channel toward connector block from the extruder equipment arrangement to produce the three layers sheet product.

The term "feed block" or feeder block is referring to a block that feeding the unification results from the three extruder machine in order to became a single layer and channeled towards mold "T".

Summary of Invention

The object of the invention is to provide an arrangement of equipment extruder to produce colored sheets of resin three layers, such as by making extruder which were united from extruder first, extruder second and extruder third, using each extruder which has a different cylindrical diameter to become one, from the filling to the filter adapter from the third extruder machine, through a strainer to put together into a connection block and transmitted to block feeder, to be inserted into the mold-T in gel form for further processing.

Furthermore, object of the invention is to provide an arrangement of equipment extruder to produce sheets of colored resins three layers, using extruders of different diameters which are 90 mm, 115 mm and a diameter extruder of 65 mm, each of which is useful to unify resin material into unity in the adapter according to the arrangement of equipment extruder to produce colored sheets of resin three layers of this invention.

Another object of the invention is to provide an arrangement of equipment extruder to produce a of resin colored three layers using an extruder placed with a slope of 65 degrees to the x-axis of first extruder, to filter with the each adapter of extruder, to put in a conduction block and block feeder to the mold-T comes out in the form of a gel, which was then the material of the mold is polished with the rollers to make a sheet form according to the arrangement of equipment extruder to produce colored sheets of resin three layers of this invention.

The next object of the invention is to provide an arrangement of equipment extruder to produce a of resin colored three layers using an extruder arranged in a certain order, to produce a printout of the unity and avoid contamination, because the material is filtered in the unit extruder and the resulting sheet product of resin three layers is having a high quality. The arrangement of equipment extruder to produce colored sheets of resin three layers of this invention.

The objects, features and advantages from this invention is to make an arrangement of equipment extruder to produce colored sheets of resin three layers, by making an arrangement of equipment with a predetermined degree of slope to produce a unify mixture of materials from each extruder equipment, and becoming one that cannot be separated or into a single layer with other layers, by using the arrangement of equipment extruder of colored sheets of resin three layers of this invention .

The term "T" is referring to a mold that forming layer in gel resin form, from the three extruder becoming one, and polished with the rollers to make three layers sheet form.

Brief Description of Drawings

To clarify the invention intended, hereby the following attached drawings as reference.

Figure 1 is the arrangement of equipment extruder of colored sheets of resin three layers according to this invention.

Figure 2 is a flow charts production of the three layers resin product by using the arrangement of equipment extruder for the colored sheets of resin three layers according to this invention. Detailed Description of Invention

Referring to figure 1 is an arrangement of equipment extruder of colored sheets of resin three layers according to this invention, comprising a first extruder (1) having a diameter 115 mm which is placed align with the axis of box terminal (12a) by means of distributing resin material through hoper (18a) to filling the colored resin pellets to be inserted in the first extruder (1) by means of heat exchange (21), materials extruded with force that being distributed from AC or DC (22) motor owning 150 - 160 kw power, through gear box that rotate the screw extrusion (24) which able to extrude resin material towards the mold (T) , through filler sieve (6) with head (5) that distributed by adapter (7) towards the connector block (8) and continued to the feeder block (10), and further the resin material being molded by using the mold-T. The mixture of HIPS or ESCR resin as the pure material with thickness from 5% up to 20%.

Furthermore, for the second extruder (2) which has a 65 degrees slope position against x-axis with extruder that having diameter 90 mm and a filler hole with hoper (18b) and box terminal (12b) which is moved by AC (20) motor through gear box with filler sieve (9) that served the extruded material screening with adapter (4) towards the connector block (8) and the feeder block (10) , and afterwards to the mold-T, which having a pure HIPS or ESCR materials added with the HIPS or ESCR recycle material with thickness from 25% up to 40%.

Furthermore, the third extruder (3) which has a 65 degrees slope position against x-axis with extruder that having diameter 65 mm, smaller than the first extruder (1); wherein the second extruder (2) is moved by AC (11), wherein the resin material is inserted from the feeder hoper (18c) to be extruded with the screw extrusion (not shown) and distributed by the sieve (filtering the dirt) through adapter and supplied towards the connector block (17), from the adapter to the connector block (8) and proceed to the feeder block (10), henceforth the resin material molded by using the mold-T with a pure HIPS or ESCR resin with thickness from 70% up to 40%.

Hereinafter, in the molding process, all three of them; whether first extruder (1), second extruder (2) and the third extruder (3), respectively extruding material being incorporated in the connector block (8) to the feeder block (10), for the next placed in the mold-T, so all of the materials are incorporated become a single gel material which is ready to be polished with rolls, in order to produce the high quality of three layers sheet.

As seen in the Figure 2, which is a flow chart extrusion to produce three layers colored sheet materials, first by filling material and coloring in the dye unit (A) material, which is colored before inserted to the first extruder (1), wherein the material is in accordance with the desired color from any color which is inserted to the hoper, to be extruded by using the screw extrusion (24) that able to extract the material towards the mold-T and material from the second extruder (2) and material from the third extruder (3), which all of them moving and incorporating to be one in the connector block and feeder block, so the material becoming unify and inseparable towards the polisher (B) , and will be used as the three layer sheet, which is convey by the belt conveyor to the cutting unit (C) , the sheet that being cut placed in working table unit (E) , wherein operator will able to stack the sheet in one pile of results product, whilst the scrap cut will be pelletize in palletization machine unit (D) which transported to the scrap tank unit (F) and furthermore reprocessed to become palletization material. According to what is conducted in the first making process of the three layers sheet colored resin, so the waste material will not be discarded and able to be re used.

Best way to perform the invention:

First, the arrangement of extruder equipment for the colored resin sheet, comprising; First extruder (1) placed in a position which align with the path of the sheet to be treated and second extruder (2) placed in an oblique position to the path of the sheet, and third extruder (3) placed in an oblique position to the treated sheet path which respectively extruded from each different material, wherein; the first extruder (1) having a mixture materials from HIPS resin as a pure raw material that having thickness from 20% up to 33%, which is filled through a hoper (18a) and previously through an automatic coloring unit towards the mold by means of connector block (8) and feeder block (10) towards mold T, second extruder (2) having a recycle material with thickness from 60% up to 34%, which is filled through a hoper (18b) and distributed through connector block (8) and feeder block (10) towards mold T, and third extruder (3) having a HIPS resin with resin that having a thickness from 20% up to 33%, which is filled through a hoper (18c) and distributed through connector block (8) and feeder block (10) towards mold T, characterized with the tilt angle of the second extruder (2) and the third extruder (3) against the first extruder (1) is 65° (a = 65°) .

Second, the arrangement of extruder equipment for the colored resin sheet, comprising;

First extruder (1) having a diameter of 115 mm to extruding pure resin material with thickness from 5% up to 20%, added with 1% up to 20% rubber;

Third, the arrangement of extruder equipment to produce three layers sheet colored resin according to the invention, wherein the second extruder (2) having a diameter of 90 mm to extruding pure HIPS or ESCR material added with HIPS or ESCR recycle material, with thickness from 25% up to 40%.

Fourth, the arrangement of extruder equipment to produce three layers sheet colored resin according to the . invention, wherein the third extruder (3) having a diameter of 65 mm to extruding pure HIPS or ESCR material with thickness from 70% up to 40%. Fifth, the arrangement of extruder equipment to produce three layers sheet colored resin according to the invention, wherein the first extruder (1), second extruder (2) and third extruder (3) material is unify all of the components becoming one, in order to produce the three layers sheet colored resin.

Sixth, the arrangement of extruder equipment to produce three layers sheet colored resin according to the invention, wherein the first extruder (1), second extruder (2) and third extruder (3) material is filtered with sieve (screen changer), in order to make the resulted resin-gel free from contamination .

To clarify the invention, hereby the referring number according the attached figures;

I. First extruder

2. Second extruder

3. Third extruder

4. Adapter

5. Head

6. Sieve (screen changer)

7. Adapter

8. Connector block (junction block)

9. Sieve (screen changer)

10. Feeder block

II. AC motor

12. a) box terminal

12. b) box terminal

13. Chiller conveyor unit

14. Mold-T

15. Polishing unit

16. Rail

17. Sieve (screen changer)

18. a) hoper

18. b) hoper

18. c) hoper

19. Motor serve unit 20. AC motor

21. Heat exchanger

22. AC/DC motor 150-160 KW

23. Gear box

24. Screw extrusion

A. Automatic coloring unit

B. Polishing roll unit

C. Cutting unit

D. Palletization machine unit

E. Working table unit

F. Scrap tank unit (recycle)

Modification and variation that conducted by the person skilled in the art e.g., making an arrangement of extruder equipment to produce three layers sheet colored resin according to the invention with another arrangement but the extruder being used are having precise size, wherein that is still in the scope and nature of the invention, as covered in the attached claims as follow.

Claims

Claims :

1. An extruder equipment arrangement for producing colored resin sheet, comprising the following components:

- first extruder (1) placed in a position which align with the path of the sheet to be treated;

second extruder (2) placed in an oblique position to the path of the sheet;

third extruder (3) placed in an oblique position to the treated sheet path which, respectively extruded from each different material, wherein;

the first extruder (1) having a mixture materials from HIPS resin as a pure raw material that having thickness from 5%. up to 20%, which is filled through a hoper (18a) and previously through an automatic coloring unit towards the mold by means of connector block (8) and feeder block (10) towards mold T,

second extruder (2) having a recycle material with thickness from 25% up to 40%, which is filled through a hoper (18b) and distributed through connector block (8) and feeder block (10) towards mold T, and

third extruder (3) having a HIPS resin with resin that having a thickness from 20% up to 33%, which is filled through a hoper (18c) and distributed through connector block (8) and feeder block (10) towards mold T, characterized with the tilt angle of the second extruder (2) and the third extruder (3) against the first extruder (1) is 65° (a = 65°) .

2. An extruder equipment arrangement for producing colored resin sheet according to claim 1, wherein the first extruder (1) having a diameter of 115 mm to extruding pure resin material with thickness from 5% up to 20%.

3. An extruder equipment arrangement for producing colored resin sheet according to claim 1, wherein the second extruder (2) having a diameter of 90 mm to extruding recycle resin material with thickness from 25% up to 40%.

4. An extruder equipment arrangement for producing colored resin sheet according to claim 1, wherein the third extruder

(3) having a diameter of 65 mm to extruding pure resin material with thickness from 70% up to 40%.

5. A composition of three layers sheet colored-resin material product, which is produced by the extruder equipment arrangement according to claim 1, wherein the first layer is comprising pure resin raw material HIPS or ESCR with thickness from 5% up to 20%, the second layer is comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material HIPS or ESCR with thickness from 70% up to 40%.

6. A composition of three layers sheet colored-resin material product, which is produced by the extruder equipment arrangement according to claim 1, wherein the first layer is comprising pure resin raw material HIPS or ESCR with thickness from 20% up to 33%, the second layer is comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 60% up to 34% and the third layer is comprising pure resin raw material HIPS or ESCR with thickness from 20% up to 33%.

7. A composition of three layers sheet colored-resin material product, which is produced by the extruder equipment arrangement according to claim 1, wherein the first layer is comprising pure resin raw material HIPS or ESCR with thickness from 5% up to 20% added with 1% up to 20% rubber, the second layer is comprising pure raw material HIPS or ESCR added with HIPS or ESCR recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material HIPS or ESCR with _. thickness from 70% up to 40% added with 1% up to 20% rubber.

8. A composition of three layers sheet colored-resin material product, which is produced by the extruder equipment arrangement according to claim 1, wherein the first layer is comprising pure resin raw material ABS with thickness from 5% up to 20%, the second layer is comprising pure raw material ABS added with ABS recycle material with thickness from 25% up to 40% and the third layer is comprising pure resin raw material ABS with thickness from 70% up to 40%.

9. A composition of three layers sheet colored-resin material product, which is produced by the extruder equipment arrangement according to claim 1, wherein the first layer is comprising pure resin raw material ABS with thickness from 20% up to 33%, the second layer is comprising pure raw material ABS added with ABS recycle material with thickness from 60% up to 34% and the third layer is comprising pure resin raw material ABS with thickness from 20% up to 33%.