Note: Descriptions are shown in the official language in which they were submitted.
Wo 95/13875 ~ PCTIUS93111223
2~ 7633~
MULTI-FLAIL GLASS PUIVERIZEl~
Field of the Invention
The invention is in the field of apparatus for
comminuting materials. More spf~c;flr~lly, the invention is
a glass pulverizer that employs two drum-shaped ho~1c; n~q
oriented in a side-by-side contiguous fashion. Within each
housing is a rotatable flail assembly comprising a central
rotor to which a plurality of fl~o~ihl~ flail members are
attached in a spiral configuration.
Backqround of the Invçntion
Numerous r~^h;n~,c have been developed specifically for
comminuting empty glass containers. By breaking the
containers into fragments, the recycling or disposal of the
glass material is facilitated. Machines developed for this
purpose typically include an inlet opening through which
the glass containers are inserted and an outlet opening
through which the broken glass fragments and glass dust are
ejected. To accomplish the breaking of the glass, these
~-rhin~q usually employ either a crushing apparatus or a
h -rm; 11 form of breaker apparatus.
A significant problem with prior art r~h;nf.c that
employ a crusher-type apparatus is a susceptibility of the
machine to jamming when metal or plastic is inadvertently
dropped into the machine ' s inlet . To UV~lUI '' this
difficulty, the machine will either have the ability to
crush the metal, or it will include an automatic dump
~ Wo gS/l387s ~ i7 ~ 3 3 5 PC~IUS93111223 ~
apparatus that allows the machine to purge its contents
when the anvil of the crushing ---h;ln; Fm meets an unusual
resistance. Both of these solutions add an undesirable
measure of ~ 1 ~Y; ty and expense to the device.
In r ~r~h; n~R that employ a h: ; 11 type of breaking
apparatus, frequent and expensive maintenance is often
required. The h: ' 1 l is usually comprised of a number
of rigid me~ al "ham.mers" that are mounted on the exterior
surface of a central rotatable shaf t . Each hammer must be
sharp and straight for the machine to operate efficiently.
However, during use the individual hammers rapidly become
dulled. In addition, when metal objects are inadvertently
fed into the device, these objects can bend or break some
of the hammers, which would necessitate the machine being
placed out of service until the damaged hammers can be
repaired or replaced.
One m~dification that has been used somewhat
successfull~ in vveLl ; n~ the failings of the prior art
h: ; 11 q is the use of flexible hammers in lieu of rigid
hammers. The fl~;hl~ hammers are typically in the form of
movable chains that are attached to the machine ' s central
shaf t in a spaced-apart conf iguration . The chains break
the glass and allow any metal fragments or metal containers
to rapidly pass through the device without causing any
damage .
The chain-type of flexible hammermills, while
providing a number of advantages over the prior art rigid
breaker bar h: ~~ ;llq, still suffer a number of failings.
=
~ WO 9S/13875 ~ 7 6 3 3 5
Firstly, the degree of comminution is uncontrolled, and as
a result relatively large diameter fragments of glass are
often ejected from the device's outlet. Since the
outputted material ; nr~ ri~q these large glass shards or
fr~,; LS mixed with the smaller glass particles, the
material cannot be easily recycled and is difficult to
handle. For example, a major use of pulverized glass is in
road construction where the pulverized glass is mixed with
asphalt or similar materials. The large glass fr~3 ~~ Ls
would make the mixture unsuitable for this application.
A second problem with prior art chain-type hammermills
is that the layout of the device normally required either
a gravity or blower induced flow of material through the
device in order to prevent the material from clogging the
unit. As a result, the machine would require a large
foundation. In addition, when a blower is used to enhance
flow through the device, a significant increase in
operating and maintenance costs is produced.
A third problem with prior art devices is that the
flowpath of the material within the machine is inefficient
and uncontrolled. This results in the high speed ejection
Of minir~lly broken material from the device's outlet.
This high speed material can cause damage to whatever
container or surf ace is being used to receive the broken
glass .
Lastly, the present methods of fastening the
chain-type of flail hammers to the rotatable shaft can
cause premature wear in both the attachment end of each
PCr/US93/11223 ~
flail and in the shaft itself. This can necessitate early
rPrlAC t of the flails and/or replA~ t or ~ hin;nrJ
of the shaf .
$ummarv of the Invention
The in~ention is a glass pulverizer that employs
two multi-f_ail ~c- ~l;es. Each assembly is located in a
separate drlm-shaped housing with the two housings having
contiguous side edges. The unit has a feed inlet situated
on a top surface of one of the housings and an outlet
located on a bottom surface of the other housing. Each
multi-flail assembly comprises a rotatable shaft that is
oriented along the associated housing ' s longitudinal axis .
In the area where the two hollc;n~c are joined together,
complementary orr~n;nr~c in the two housings form a conduit
to allow the initially broken glass to pass back and forth
between the two hr llc; n~C and their associated flail
as..~ c.
Each of the two housings are supported on a common
foundation and are parallel to each other. The two
housings are identical in diameter but have distinctly
different lengths. The second housing extends outwardly
past the f rst housing and it is in the bottom of the
outwardly extending portion in which the device's outlet is
located .
Preferably, each housing includes an interior liner of
a plastic material such as polyurethane. The liner is
expendable ~nd is primarily designed to absorb the impact
~ WO95/13875 ~ r ~ ij t 2 ~ 76335 PCT/USg3~ll223
and cutting forces caused by the inputted materials as they
rebound off the interior surface of the housings. In this
manner, the liner protects the interior surface of the
associated housing. The end of each housing is removable
to facilitate rPrl ~ t of the lining . In addition, when
the end of a housing is removed, the housing' s flail
assembly can be easily removed through the end of the
housing .
The two multi-flail assemblies are oriented in a
parallel manner and are centered within their associated
housing . Attached to the rotatable shaf t of each f lail
assembly are a plurality of separate, flexible flails. The
flails are oriented on the shaft in a spiral fashion so
that when the shaft is sp;nn;n~, the flails extend away
from the shaft and assume a spiral configuration about the
shaft. The spiral orientation causes the assemblies to
also function as an auger to move the broken glass through
the device in the direction of the outlet.
The flails can be in the form of multi-link chains,
wire ropes or pivotable links to which pivotable hammer
members may be attached. Optionally, the flails can be
encased in a plastic material to reduce wear and prevent
direct contact between the flail ' s flexible connection
points and the glass particles.
In addition, the flails may be in the form of a
flexible three piece unit. The disclosed flail includes a
specially designed member for attachment to the shaft. The
attachment member is fastened to the shaft using a fastener
W09S/13875 ~ ~ ~ ! `. 2 ~ 7~335 PCT/US93/1~223
., ~ ,,
assembly. The shaft has a flat surface or spot face
wherein when the fastener is properly tightened down on
this spot face, the flail will naturally assume a correct
orientation. The attachment member is pivotally engaged to
one end of a rigid link. The outer end of the link
;nrl--tlt~c a Fivotally engaged hammer member.
Each f lail is secured to its associated rotatable
shaft using a removable fastener. The shaft includes a
slot at each location where a flail is attached. Each slot
has a smooth bottom surface and rounded end and is
complementary in shape to the end portion of the flail.
Placing the flail in the slot assures the correct
orientation in the spiral for the proper function as an
auger. sy ~rigidly securing the end of the flail, the
incidence oi wear at the end of the flail and in the shaft
is significantly reduced.
The layout of the device is uniquely adapted to
control the through-flow and degree of pulverization of the
glass. When the glass initially enters the first housing,
it is rapidly broken into large pieces by the first flail
assembly. The glass fragments are then directed into an
"impact zone" located in the area where the two hr1lci n,Jc
are joined. In this area, the glass bounces back and forth
between the first and second flail assemblies until the
fragments have been reduced in size with approximately
ninety-five percent of the particles having a diameter
between 10 millimeters and 0.1 millimeters. At the same
time, the pulverized glass is drawn by the auger-type
~ Wo95/13875 ~ r r ~ 2 t 76335 YCIIIIS93111~23
action of the flail ~c~ ; es toward the outer end of the
device and eventually to the extreme outer end of the
second housing where the outlet is located.
By the time the fragments reach the machine's outlet,
they have been pulverized so that they form a non-sharp
cubic aggregate. The aggregate is moving at a relatively
low speed and in a controlled f ashion . The material then
exits the machine via the outlet and falls into a collector
placed below the device. In lieu of a col 1ector, the
material may be directed onto a conveyer which brings the
aggregate to another machine for further processing.
The invention optionally ; nr~ llld~.C a water spray unit
that directs a stream of water onto the glass as it enters
the first housing and is initially broken. The water does
not adversely affect the comminution process and functions
to reduce the ; nri~ nre of airborne glass dust that would
otherwise be produced by the unit.
~ o rotate the flail assA ' 1i,~c, a single motor is
connected to both rotatable shafts via a belt and pulley
system. The belts and pulleys are arLal~ged so that both
shafts and therefore both chain flail ~CSPmhl 1es spin in
the same direction. Alternatively, each flail assembly can
be provided with its own motor.
Due to the design of the device, gravity or blowers
are not required to move the pulverized glass through the
unit. This allows the user to .1; cpF-nSe with the significant
structure normally required to support the unit and also to
avoid the cost of devices dedicated to the moving of the
W0 95/1387~ , ~, r~ 3 $ PCI'NS93/11223 ~
glass .
8rief DescriPtion of the Drawinqs
Figure 1 is an elevational view of the invention.
Figure 2 is a plan view of the invention shown in
f igure 1 .
Figure 3 is an end view of the invention shown in
figure 1. A liquid spray system that can optionally be
added to the invention is shown in phantom in this f igure .
Figure 4 is a partially cross-sectioned elevational
view of the invention of figure 1 taken through the first
hous ing .
Figure 5 is a cross-section elevational view of the
invention shown in figure 1 taken through the second
housing .
Figure 6 is a cross-sectional end view of the
invention shown in f igure 1 taken at a point proximate the
end of the h~nlc;n~c shown in figure 3.
Figure 7 is a side view of an end portion of one of
the flail assemblies shown in figure 5.
Figure 8 is an end view of the flail assembly portion
shown in f i~ure 7 .
Figure 9 is a side view of an alternate embodiment of
a flail.
Figure 10 is a side view of another alternate
embodiment of a flail.
Figure 11 is a top view of the flail shown in figure
10.
:
9S/13875 .i~ 2 1 7633~ PCrlUS93111223
Detailed DescriPtion of the Drawinqs
Referring now to the drawings in greater detail,
- wherein like reference characters refer to like parts
throughout the several f igures, there is shown by the
numeral 1 a glass pulverizer unit . The unit ; nrl ll~lPC a
support rL .l~rk 2 upon which the pulverizer apparatus 6
rests .
As can be seen in f igures 1 and 2, the pulverizer
apparatus comprises a first cylindrical drum-like housing
8 that ;nrllltlPc a top mounted inlet structure 10. The
inlet structure has a central opening 12 that is riulL~,u~lded
by a funnel-shaped wall structure 14. Contiguous to the
first drum-shaped housing 8 is a second cylindrical
drum-like housing 16.
The second housing 16 is oriented wherein its
longitudinal axis is parallel to the longitudinal axis of
the first housing. Located on the bottom surface of the
second housing is an outlet structure 20. The outlet
; nclllflPR a circular wall structure 22 that ~UlL~.lUII~S a
central opening 24.
Figure 3 provides an end view of the apparatus in
which the unit ' s drive mechanism can be seen . The drive
-h~ni~m ;nrlu~pc a top mounted motor 26 that is connected
by a first belt 28 to a pulley 30 that is mounted on a
rotatable shaft 32. A second belt 34 connects the motor to
a pulley 36 that is mounted on a second rotatable shaft 38.
When the motor is operating, the belts cause shafts 32 and
38 to turn in the same dilection. Alternatively, but not
WO95113875 r C~ 2 ~ 76335 PCr/US93/11223 ~
shown, two motors may be employed with one motor connected
by pulley and belt to shaft 32 and the other motor
connected by pulley and belt to shaft 38.
Figure 14 provides a cross-sectional view of the first
housing 8 shown at a time when the shaf t is spinning .
Within the housing is a flail assembly 39 comprising the
center shafl: 32 that is located proximate the housing's
longitudinal axis and supported at each end by bearings 40.
The bearings are secured to the housing. The flail
assembly further comprises a plurality of flexible flails
42 that are each removably attached to shaf t 32 by
removable fasteners (detailed in figure 7). In the
embodiment shown, the flails are in the form of multi-link
lengths of chain. Each flail is attached to the shaft so
that it is spaced from any adjacent flails by both a
vertical and horizontal distance. The flails are thereby
located so that when the shaft is rotating, the centrifugal
force causes the flails to extend outwardly and form a
spiral/auge I shape.
The spiral shape formed by the flail assembly when it
is rotating performs two functions. Firstly, it causes an
effective and controlled comminution of the inputted glass
containers and/or glass ragments. Secondly, it causes the
glass to move toward an outer end 44 of the housing in a
direction parallel to the housing ' s longitudinal axis .
Also lccated within the housing is a removable plastic
liner 45. The liner fits snugly against the interior
surface of l:he housing and protects it from being damaged
WO95/13875 ~ i; .i i 2 1 7 6 335 PCT/US93)112~3
11
by direct contact with the high speed glass and/or metal
f ragments .
- Figure 5 provides a cross-sectional view of the second
housing 16 shown at a time when the shaft is spinning. In
this view, one can see a flail assembly 46 located within
housing 16 that is substantially identical to flail
assembly 39 except that it is longer. This second flail
assembly includes the rotatable shaft 38 (supported at each
end by housing-attached bearings 47 ) and a plurality of
flexible flails 50 removably secured to the shaft. The
flails are alldnyed and secured to the shaft so that they
will produce a spiral configuration when the shaft is
rotating in the same manner as employed in flail assembly
39 and having the same functionality. In addition, the
auger action of flail assembly 46 will move the pulverized
glass toward an outlet 20 that is located on the outer end
52 of the housing 16.
A removable plastic liner 51 is located within housing
16 and protects the interior surface of the housing from
flying pieces of glass or metal. It should be noted that
the liners 45 and 51 may be removed from their associated
housing by removing bolts 53 from the end portions 44 and
52 respectively and then removing the sheet metal screws 55
that fasten the liners to their associated housings.
Figure 6 provides a cross-sectional view taken across
the width of the device. In this view, the shafts and
individual flails can be seen as well as a contact zone 54
located between the two housings. Housing 8 has a long,
WO9511387~ 6:~35 PCT/US93/112~3
12
basically rectangular opening 56 located in its side. The
opening is contiguous to a similarly shaped opening s8 in
the side of housing 16. These two openings join the
interior of the two housings together and allow glass
fragments to bounce between the two hr- l~inqq and be
impacted by the flails of each of the two flail assemblies.
This causes the glass fragments to become completely
pulverized as they move toward the outer ends of the
housings under the auger type action of the flai
assemblies. When the glass reaches the outer end 44 of the
shorter hou~ing 8 ~ it bounces into the longer housing 16
where it is moved in a controlled manner by flail assembly
46 to the outer end 52 of the housing. Once the fully
pulverized llass reaches outlet 20, it falls through the
outlet l s center hole into a removable container or drum
(not shown) or onto a ~ veye:L (not shown).
To aid in reducing the amount of airborne glass
particles that are sometimes released from the device a
water spray system may optionally be included. The spray
system is shown in phantom in f igure 3 wherein a hose or
pipe 60 is connected to a source of water 62. A valve 64
is located in the hose adjacent the unit and functions to
control the volume of water passing through the hose.
Att ched to the outlet of the valve and mounted to
the side of the device l s inlet 1 o is a spray nozzle 66 .
A fine spray of liquid introduced as glass is inserted into
the device or at any other point is effective. This
wetting ac~ on causes ~e ~ ne glass par~c es o a~ere ~o
o 95/13875 ,~ 2 1 7 PCI IUS9311 1223
13
larger glass frA5 ts and thereby the amount of ~;rhnrne
glass dust at the outlet 20. The operation of the overall
device is for the most part unaffected by the added liquid.
Figures 7-9 provide detailed views of the structure of
the flail assemblies when said ~SA '1;PS are at rest. In
figures 7 and 8, an end portion of flail assembly 39 is
shown. It should be noted that a view of an end portion of
flail assembly 46 would be identical to the portion shown
in f igures 7 and 8 .
In the shaf t portion shown in f igures 7 and 8, the
attachment structure for the flails 42 may be readily seen.
Each of the flails is in the form of a length of chain that
has an inner end link 70 that is fitted into a
complementary slot 72 on the shaft. The slot has a flat
bottom surface 73 and has a width approximately equal to
the width of link 70. A fastener 74 extends through the
center opening of link 70 and a head portion 76 of the
fastener contacts the outer surface of the link to hold the
link into the slot. In this manner, link 70 is rigidly
fixed to the shaft with its bottom surface in full contact
with surface 73 of the slot. It should be noted that the
link of the flail adjacent to link 70 can pivot on link 70
and thereby maintain the flexibility of the flail. By
immovably fixing link 70 to the shaft, the shaft will not
become worn as the rest o~ the flail pivots and moves on
the end of link 70. It should also be noted that the slots
72 are rounded on one end and located in a staggered manner
to enable the previously described spiral orientation of
WO95/13875 ~ $ ! ~ 2 1 ~6~35 PCT/US93/llZZ3
14
the flails hhen the shaft is spinning.
Figure 9 shows a second embodiment of a flexible flail
80 which could be substituted or one or all of flails 42
or 50 descri ~ed in the primary ~ ' '; t . As shown, flail
80 incl~ld~fi a plurality of interconnected links 82 that are
contained within an elongated polyurethane or rubber cover
84. The col er is flexible and unctions to protect the
enclosed links and to minimize the amount of pulverized
glass that collects on the links. By eliminating the
direct contact between the glass particles and the links,
the wear life of the links are extended.
As also shown, a rotatable hammer 86 is located at the
distal end ( furthest from the connection point to the
shaft) of the flail 80. The hammer is made from an
?l y hard material such as hardened steel, ceramic or
carbide and is movably connected to the adjacent link 87.
The connect- on is provided by the end of link 87 being
received within an aperture 88 of the hammer. A pin 92 is
inserted through the hammer 86 and the adjacent link 87 to
secure the link 87 in place. The movable hammer is
especially useful when a non-frangible item has been
entered into the machine. When the hammer contacts the
item, the connection allows the hammer to rotate about its
connection to the adjacent link of the flail ana thereby
not become ( amaged or excessively worn by the impact with
the item.
Figures 10 and 11 show another embodiment of a
flexible flail 94 that can be substituted for one or all of
WO 95/13X75 ~ ~ ~ 2 1 7 6 3 3 5 PCIIUS93111~23
flails 42 or 50. The flail includes a connector 96 that is
designed to be secured to the shaft 32 or 38 of the flail
- assembly by a bolt or similar fastener 99 that would extend
through aperture 98. The fastener 99 is designed to be
threadably engaged to a complementary threaded bore ( such
as 74) in the shaft. The fastener 99 thereby functions to
secure and correctly position the connector 96 on the
shaft's surface. In this manner, each flail can be secured
to the shaft to obtain the desired spiral orientation of
the flails.
Attached to the connector 96 is a link 100 that is
pref erably made of a hardened steel material . The
attachment is made using a press-fit pin 102 that extends
through apertures 104 in the connector and which only
loosely fits through an aperture 106 in the link. In this
manner, the rod is able to pivot about pin 102. A plastic
bushing can be used to protect the pin 102. The outer or
distal end of the rod has a pivotally attached hammer 108.
The hammer member is preferably made of a hardened steel
material and is connected to the rod by a pivot pin 110.
The pin is press- fit into apertures 112 of the hammer and
loosely fits through an aperture 114 of the rod. Plastic
bushings 113 at four locations, keep the link 100 from
contacting and wearing the connector 96 and the hammer 108.
In this manner, the hammer can pivot on the end of the rod
thereby providing the hammer with a second pivot point
relative to the shaf t .
To summarize the operation of the unit, the user
WO 95/13875 ~ L; r,i, ~ 2 1 7 6:3 3 5 PCT/US93111223
16
inputs glass containers through the inlet 10. The
containers break as they contact the flf~x;hle flails that
are moving below the inlet . The resultant f ragments of
broken glass are then swept by the flails into the impact
zone 54 between the two housings. The fragments bounce
back and forth between the individual flails of the two
flail assemblies and thereby become fully comminuted into
small particles and reach a size wherein approximately
ninety-five percent of the particles are between 1 and 0.1
millimeter in diameter. During the comminution process,
the auger action of the two flail assemblies causes the
glass particles to move toward the outer ends of each
housing. When the particles reach the outer end 44 of the
shorter housing 8, they are swept into the flails of the
longer housing where they are then propelled in a
controlled fashion toward the outlet 20. The particles
then fall hrough the outlet's center hole 24 into a
removable drum or similar container (not shown) or onto a
cul.veye. (nût shown).
The em 70diments disclosed herein have been .li sC-lcce~l
for the pur-70se of f.~ rizing the reader with the novel
aspects of the invention. Although preferred: ~ ~ir ts
of the invention have been shown and described, many
changes, mo(~ifications and substitutions may be made by one
having ordinary skill in the art without necessarily
departing from the spirit and scope of the invention as
described in the following claims.
