METHOD AND APPARATUS FOR PROCESSING A CONTAINER COMPRISING A REST TJE OF THE ORTGINAL CONTENTS
The present invention relates to a method and apparatus for processing a container comprising a residue of the original contents, a kit of parts forming the apparatus and a control system for the method and/or apparatus. The present invention has numerous applications in the waste management sector, especially in view of increasing concern about the environment. In particular the invention has applications in processing of used ink cartridges for the bulk printing industry and used oil or chemical containers.
Recyclable containers are increasingly used in industry for many purposes. These containers may contain a residue of the original contents when they have been used and this presents problems for recycling, because it pollutes the material which is to be recycled. In the past this has often led to the whole container being treated as refuse rather than recycling material. Such empty containers are bulky and thus expensive to dispose of.
Attempts have been made to cut the used containers into manageable sections so that at least the cost of disposal is reduced. However use of shredders for this can be unsuccessful due to the nature of the material forming the container and/or certain more rigid, bulkier parts of the container which make shredding difficult. This is particularly true for used printer cartridges in the printing industry which are formed from polypropylene or other similar non- compactible material and include an open end and a closed head end. The closed head end incorporates an aperture for dispensing closed by a cap or one way valve and a piston which has been pushed through the container to the dispensing aperture and is received in the head with a residue of printing ink between the piston and dispensing aperture.
In this case, use of a standard shredder has been found to shatter the polypropylene due to the blade speed and characteristics of the material. Furthermore the head of the cartridge can jam the shredder blades or damage them due to its construction and the additional bulk of the piston.
Thus there is a need for an apparatus and a process which allow recycling of at least those portions of containers which have substantially no residue of the content and for compaction of the waste and/or recycling material produced.
The above problem is solved by the present invention.
In its broadest aspect there is provided according to the present invention a method for processing a container comprising a residue of the original contents, having two ends and a body and retaining substantially all of the residue in a first portion and substantially none of the residue in a second portion, wherein the method comprises a step of sectioning the second portion into sections occupying a reduced combined volume with respect to that of the second portion and a step of separation of the first and second portions.
The present invention is based on the surprising discovery that waste management and environmental issues relating to containers comprising a residue of the original contents can be simply addressed firstly by separating a first portion holding substantially all of the residue from a second portion, holding substantially none of the residue. These two portions can then be disposed of separately, one for immediate and easy recycling and one for possible recycling after processing into lower grade applications or alternatively as refuse. Secondly, the method according to the present invention also includes a step of sectioning the second portion holding substantially none of the residue into manageable sections occupying a
reduced combined volume. Thus transport, storage and processing of the non- contaminated portion is facilitated.
For example, in an ink cartridge as previously described the closed end may be treated as refuse or be recycled as lower grade polypropylene. The manageable sections of the second portion can be stored and transported for immediate recycling into higher grade use.
A container for processing may be of any non-compactible material selected from synthetics, metals, alloys and natural products, most advantageously from thermoplastic rigid synthetics, preferably polypropylene and copolymers thereof.
Reference herein to an end of a container is to a position or portion which is peripheral to the body of the container and which may be an end location or portion.
According to the present invention the second portion of the container is sectioned. The first portion may also be sectioned. This allows easier transport, storage and further processing of the portion holding substantially all of the residue as well as the portion holding substantially none of the residue.
The method according to the present invention is suited for processing a container of which the first and second portions of the container may be any two portions of the container, one of which holds substantially all of the residue and the second of which holds substantially none.
According to a preferred embodiment, the end comprises the first portion and the body comprises a second portion. This is the case for example in an ink cartridge where the piston has moved down through the body of the container to its closed end to eject ink from a dispensing aperture and a residue is retained there between.
Alternatively, the body may comprise the first and second portions. This is the case where the residue is retained along the length of the body and not at one or other end.
The separation and sectioning step may be carried out simultaneously or sequentially in any order. Preferably, the separation follows the sectioning step. This gives the advantage that the container may remain in one piece until the separation step which may act to separate the first and second portions such that this separation also completes the sectioning step of the second portion sections from each other.
The sectioning step may comprise any sectioning which reduces the second portion into sections occupying a reduced combined volume as hereinbefore defined. The manageable sections may be of any shape. Advantageously the sectioning step comprises sectioning into strips. Those strips may then be further sectioned into smaller pieces if required. Strips have the advantage of being easily produced with parallel cutters in a elongate container.
The sectioning may be carried out at any orientation to the body which produces a reduced combined volume as hereinbefore defined. Preferably the sectioning step comprises sectioning longitudinally along the body of the container and optionally further sectioning as described above. Such longitudinal sectioning allows simple use of parallel cutters and obviates
problems caused by cutting laterally across the body in many sections, such as with elastic bodies and the like.
The separation step is determined by the position of the first portion in the container. In the preferred embodiment as described above, the separation step may be effected by separation of one end from the container. In the alternative embodiment, where the body comprises the first and second portions, the separation step can be effected by discarding one section produced by the sectioning step.
The sectioning step is determined by the shape of container. In the container of the preferred embodiment with one open end and one closed end, the sectioning step preferably comprises advancing the body of the container from the open end longitudinally through a die which divides the container into strips. This is a simple, effective form of sectioning which also has the advantages of good controllability and positioning of the container.
If the container is advanced and the die stationary, the container can be positioned for subsequent allocation of the sections and first portion into respective collection areas. The rate of advance of the container with respect to the die may be selected in accordance with the material of the container. For example for a polypropylene container the rate of advance is set at between 0.005 and 0.03, preferably 0.01 metres per second to avoid problems caused by shattering of polypropylene with high speed cutters.
The separation step may be carried out in any direction to separate the first and second portions. Preferably the separation step comprises movement of a cutter laterally across the body of the container. As previously mentioned, this may also act to complete sectioning of the sections from each other.
The separation step may comprise movement of the first and second portions away from each other. Preferably the separation step comprises allocation of the first and second portions to respective collection areas. Thus the portions are separated according to their subsequent paths in recycling.
The separation step may include gravity feed or ejection of the manageable sections and/or first portion.
Preferably the separation step allows the section to fall into a collection area. This is by means of a simple gravity feed. Preferably an ejection step follows the separation step to eject the first portion into a collection area. Thus advantageously ejection and gravity feed may be used for separation of the first and second portions.
In the preferred embodiment as described above the closed end of the container is ejected in an opposite direction from the original advance of the container to fall into a collection area.
In a further aspect of the invention there is provided an apparatus for carrying out the method as hereinbefore described, specifically there is provided an apparatus for processing a container as hereinbefore described comprising a residue of the original contents and having two ends and a body and holding substantially all of the residue in a first portion and substantially none of the residue in a second portion, comprising sectioning means for sectioning the second portion into sections occupying a reduced combined volume with respect to that of the second portion and separation means for separation of the first and second portions.
The apparatus corresponds to the process as hereinbefore described and corresponding features of the apparatus have the same advantages as the corresponding method steps.
According to the present invention sectioning means are provided for sectioning the second portion. Means may also be provided for sectioning the first portion. This allows easier transport, storage and further processing of the portion holding substantially of the residue as well as the portion holding substantially none of the residue.
Means may be provided to carry out the separation and sectioning steps simultaneously or sequentially in any order. Preferably, advancing means are provided to actuate the sectioning means and traversing means are provided to actuate the separation means after actuation of the sectioning means.
This gives the advantage that the contain may remain in one piece until the separation step, which acts to separate the first and second portion, such that this separation also completes the sectioning step of the second portion sections from each other.
The sectioning means may section in any way to reduce the second portion into sections occupying a reduced combined volume as hereinbefore defined. Thus the means may act to produce manageable sections of any shape. Advantageously, the sectioning means sections the portion into strips. Means may also be provided to section further into smaller pieces if required. Strips have the advantage of being easily produced with parallel cutters in an elongate container.
The sectioning means may act at any orientation to the body which produces a reduced combined volume as hereinbefore defined. Preferably the sectioning means sections longitudinally along the body of the container. Optional means for further sectioning are provided as described above. Such longitudinal sectioning allows simple use of parallel cutters as sectioning means and obviates problems caused by cutting laterally across the body in may sections, such as with elastic bodies and the like.
The action of the separation means is determined by the position of the first portion in the container. In the preferred embodiment as described above, the separation means act to separate one end from the container. In the alternative embodiment, where the body comprises the first and second portions, the separation means comprise means for discarding one section.
The action of the sectioning means is determined by the shape of container. In the container of the preferred embodiment with one open end and one closed end, the sectioning means comprises a die and an advancing means which acts on the closed end to advance the body of the container from the open end with respect to the die, which divides the container into strips.
The die may have any suitable arrangement of apertures and blades and preferably comprises a central aperture and peripheral apertures which act to section the container as it is advanced through the die.
This is a simple, effective form of sectioning which also has the advantages of good controllability and positioning of the container. If the container is advanced and the die stationary, the container can be positioned for subsequent or simultaneous allocation of the sections and first portion into respective collection areas.
The advancing means may be in the form of rams or may be constructed to any other design. The function of all rams described herein may be controlled by a CPU in response to the input of sensors and timing and logic circuits.
In particular, means may be provided to control the rate of advance of the container with respect to the die. The rate is selected in accordance with the material of the container.
Means may be provided to control the advancing distance, such as proximity sensors or abutment means, so that the advancing means stop short of sectioning the first portion. Means may be provided to detect the final position of the advancing means; these means may trigger the separation means.
The separation means may act in any direction to separate the first and second portions. Preferably, separation means comprises a cutter and traversing means which moves the cutter laterally across the body of the container. As previously mentioned, means may also be provided to complete sectioning of the sections from each other.
The cutter may be in the form of a knife with cutting surfaces and a tip formed from steel, stainless steel or any other suitable cutting material. The traversing means may be in the form of a pneumatic or other ram acting on the knife.
The separation means may also comprise means for movement of the first and second portions away from each other. Preferably the separation means comprises means for allocation of the first and second portions to respective
collection areas. Thus the portions are separated according to their subsequent paths in recycling.
The separation means may function using gravity feed or ejection of the manageable sections and/or first portion. Preferably, the separation means comprises means which allow the sections to fall into a collection area. Thus the sections are held in position only by their connection to the first portion. Separation allows a simply gravity feed of the sections.
Preferably ejection means are provided to eject the first portion into a collection area. Thus advantageously means ejection and gravity feed may be used for the separation of the first and second portion.
In the preferred embodiment as described above, means are provided to eject the closed end of the container in an opposite direction from the original advance of the container to fall into a collection area.
Ejection means may comprise an ejection ram which is preferably pneumatic and an ejection portion which is inserted through the central aperture of the die.
The process may be partially or fully automated. For example containers may be fed individually by conveyor to the apparatus and means provided to close guards when a correctly positioned cartridge is detected. The sections of the second portion and the first portion may be manually or automatically removed from their respective collections areas by use of conveyors or the like. The cycles, container or separated portions and sections may be counted using sensors if there is no automatic removal of the sections and closed head end, so that the operator can be alerted when their removal becomes necessary. Guards may be situated at the entry point of the container into the apparatus
and at the exit points of the first and second portions. They may also be situated wherever access is required.
In a further aspect of the invention there is provided a kit of parts which may be assembled to form the apparatus as herein described.
In a further aspect there is provided a processed container in the form of sections and separated portions as hereinbefore described obtained by the method or with use of the apparatus as hereinbefore described.
In a yet further aspect of the invention there is provided a control system for the method as herein described or the apparatus as herein described comprising a central processing unit controlling means adapted to monitor and adjust parameters of the method or application as hereinbefore defined e.g. by means of sensor means to detect the positions of the working components as well as a safety sensor to detect guard positions.
In a further aspect of the invention there is provided the use of the method as herein described or the apparatus as herein described for waste management or as part of a recycling processor.
The method and apparatus of the present invention have many varied applications, which all permit the user to allow recycling of containers comprising a residue of the original contents. Thus, applications are not restricted to cartridges for printing machines but include oil drums, chemical containers and any other containers comprising a residue which is not easy to recycle with the container.
The invention is now illustrated in non-limiting manner with reference to figures 1 to 8.
Figure 1 shows a cartridge used in the method and apparatus according to the invention.
Figure 2 shows a simplified sectional isometric view of the apparatus with cut away portions to reveal working components of the apparatus.
Figure 3 shows a side section through the apparatus.
Figure 4 shows the main working components of the apparatus in a first position, with a cartridge in position, ready for processing.
Figure 5 shows the main working components of the apparatus in a second position, with the cartridge pushed through the die by a main ram.
Figure 6 shows the main working components of the apparatus in a third position, after separation of the sections from the closed end of the cartridge by a knife.
Figure 7 shows the main working components of the apparatus in a fourth position, after ejection of the closed end of the cartridge from the die.
In figure 1 is shown shows a cartridge (1) which is to be processed using the method and apparatus according to the invention. The cartridge 1 presents a closed end (2) and an open end (3) as well as a piston (4), which has been forced through the cartridge to dispense the original contents through the dispensing aperture (5).
The cartridge (1) is of substantially circular cross section and of elongate shape. It is formed from polypropylene or other suitable plastic and presents flexible walls and a more rigid closed head end.
Cartridge (1) is normally used in colour offset printing in printing shops and is suitable for any ink delivery method in offset printing. The cartridge is inserted head first into a pneumatically operated dispensing device. The device forces the piston through the cartridge to dispense ink.
After dispensing, a residue of the original contents is retained between the piston and dispensing opening at gap (23). Gap (23) is shown much exaggerated for ease of understanding, but will always be present between piston (4) and dispensing aperture (5). Dispensing aperture (5) is formed by crossed slits (24) in the inner end wall. The cartridge has been closed with a cap (6) after use to prevent spillage of the residue.
Thus substantially all of the residue is retained in closed head end (2) of the cartridge and this comprises the first portion (26) and substantially none of the residue is retained in the body and open end of the cartridge and this comprises second portion (27).
The method and apparatus of the present invention act to section the cartridge body, including open end (3) and to separate the first portion 26 and second portion (27).
In figures 2 and 3 are shown simplified sectional views of the apparatus. Figure 2 shows an isometric view and figure 3 a side elevation. The apparatus as seen in figures 2 and 3 comprises a frame (7), a cover and access
doors/guards (not shown), a CPU (15) and control panel (16), a standard air line and voltage supply (not shown) and working components as further detailed below.
There are three main assemblies, each comprising a ram or piston (8,12, 13). The main ram sections the cartridge(l) body by advancing it through a die (20). The traversing ram (12) separates the closed head end (2) of the cartridge (1) from the body by traversing a knife (17) through the body and an ejection ram (12) ejects the closed head end of the cartridge from the die.
All the rams (8, 12, 13) are pneumatic rams in the example. The main ram is shown at (8) and acts as advancing means to advance the cartridge substantially horizontally through die (10). Main ram (8) has a nylon head receiving portion into which the closed head end of the cartridge fits. The cartridge is supported by cradle (14), which is made up of a plurality of bars.
The die (10) presents a central aperture (18) and peripheral apertures (19). These act to section the cartridge as it is advanced through die (10). The die is positioned in a substantially vertical plane at right angles to the advancing direction of the main ram and cartridge and supported by frame (7).
Knife (11) which acts as a separation means is adjacent to the die and in a substantially parallel plane to it positioned beyond the die in the advancing direction. It has a resting position below die (10) and is traversed up through the frame by traversing ram (12) to a top position, covering the apertures (18, 19) of die (10). Knife (11) comprises a pointed tip (20) which pierces the cartridge initially and cutting surfaces (21) extending downwards and outwards away from the tip. Steel knife (10) is supported at its vertical edges in two runners for its substantially vertical travel.
Ejection ram (13) and ejector (17) are the ejecting means used to remove the closed head of the cartridge once the knife has retracted from its top position. The ejector is moved in the opposite direction to the advancing direction by the ejection ram and passes through central aperture (18) of die (10) to eject the head.
Once the knife (11) has separated the sections of the body from the closed head end, it retracts and the ejection ram (13) pushes ejector (17) through central aperture (18) of die (10) to eject the closed head end (2) which is held in the die (10) by friction.
Figures 4, 5, 6 and 7, show simplified representations of the main working components of the apparatus and illustrate the stages involved in processing a cartridge according to Fig 1, in an apparatus as shown in Figures 2 & 3.
Figure 4 shows the initial position. The cartridge (1) has been inserted into the apparatus and rests on cradle (14) with its closed head end received in the head receiving portion (9) and its open end adjacent to die (10). The head receiving portion (9) is adjustable in the longitudinal direction to allow for variations in the position of the piston (4) in the closed head end (2) and/or in the length of the cartridge (1). Thus for a longer cartridge or a cartridge with the piston (4) not fully pushed into the closed head end, leaving a larger (gap 23), the head receiving portion can be positioned further from the die.
Figure 5 shows the main ram (8) in its advanced position. It has advanced cartridge (1) through die (10) to create sections (22) of the cartridge body. The advancing distance of the ram is adjustable as is its speed of advance. These parameters may be controlled through the CPU (15) or manually. The
advancing distance is controlled by abutment of the head receiving portion (9) against the substantially vertical inner surface of die (10), or by other means so that the ram stops short of pushing the closed head end (2) into the die.
The final position of the ram is detected by a magnetic or other sensor. It remains in position after detection, which triggers the knife 11 to traverse to its top position.
Figure 6 shows the knife (11) in its top position. The sections (22) of cartridge body have fallen into a collection area (26) (shown in figures 2 and 3).
In figure 7, the main ram (8) and knife (11) have been retracted to return to their original positions. Figure 7 shows the ejection ram (13) in extended position, with the ejector (17) inserted through the central aperture (18) of die (10) to eject closed head end (2) from the die. The closed head end (2) is poised to fall into a collection area (27) (shown in figures 2 and 3). The cradle is constructed so that its length or spaces between its bars allow the closed head end to fall into the collection area after ejection. Retraction of ejection ram (13) after ejection means that all working components have returned to their original positions for the next cycle.
In figure 8 is shown a flow chart illustrating the control system of the invention as shown in Figures 1 to 7. The process is controlled by a CPU or can also be valve controlled.
A letter (A-S) represents each step of the flow chart. Some steps are depicted as operator functions but may be either automatic or manual.
In a first step A, the cartridge is placed on the ram cradle. Subsequently there is a check to see whether the emergency stop has been activated B, if so, it is switched off. Next the air supply is switched on and a check C is made to determine the position of the guards and close them E if necessary.
The apparatus is started at stage F and the advance of the main ram timed G. When the ram reaches its final position H, the knife is traversed K. If it does not reach its final position in a certain time, the operation times out J and the knife is traversed K.
After a check to see if the main ram and knife have fully retracted L, followed by a time out M and emergency stop N if they are not, the control sequence continues with ejection of the closed head end O. After a check for retraction of the ejection ram P the cycle may be complete Q or the sequence times out R. If the sequence times out then the guards are opened for investigations.
Further advantages of the invention will be apparent from the foregoing.
Cartridge
Closed head end of cartridge
Open end of cartridge
Cartridge Piston
Dispensing aperture of cartridge
Cap of cartridge
Support frame
Main ram (is advancing means)
Head receiving portion
Die
Knife (separation means or cutter)
Traversing ram (traversing means)
Ejection ram (ejection means)
Ram cradle
Central Processing Unit
Control panel
Ejector
Central aperture of die
Peripheral apertures of die
Pointed tip of knife
Cutting surfaces of knife
Sections of container body
Gap between piston and dispensing opening in cartridge
Inner end surface of cartridge
Runners
Collection area for sections
Collection area for head ends