Polymer powder blending apparatus

Abstract

An apparatus for blending polymer powder and pigment inside of a blender that heats the polymer through agitation of the blending process. The apparatus includes a control scheme that monitors the condition of the powder and discharges the powder from the blender just before the powder reaches its melting point. The apparatus monitors the flowability of the powder as well as the temperature. As an additional method of controlling the temperature inside of the blender, the blending speed can be varied by virtue of a variable speed motor that is attached to the blender.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates generally to the field of polymeric powder conditioning. More specifically, the present invention relates to an apparatus and system for polishing and coloring powdered resins, including polymer powders of all types.

[0003] 2. Description of Related Art

[0004] Pulverized resins, particularly resins intended for use in thermoplastic molding and shaping operations, are typically sold as fine powders, with particle sizes between 200 to 500 microns. These polymer powders are further conditioned prior to use to improve their flowability and optionally add pigment. The conditioning process usually involves stirring or blending the powder (with or without pigment) inside of a large drum with rotating rods having spaced blades. The rotation of the blades not only agitates and mixes, but also heats the powder, sometimes approaching the melting point of the resin. Because it is undesirable to melt the powder inside the drum, the powder is monitored, usually manually. One of the many problems that exist with manual observation of this process is the uncontrolled results that can often occur when different personnel perform the monitoring process. Even the same person can produce different results on different days.

[0005] When the polymer powder conditioning includes pigmenting, the traditional methods include admixing the polymer powder with the pigment which electrostatically clings the pigment to the outer surface of the polymer powder particles. However, electrostatically attaching the pigment to the polymer has some disadvantages. Pigment applied in this manner can be easily removed by contact with solvents or friction caused handling the pigmented powder. Further, admixing pigment with the polymer powders results reduced structural strength of objects formed from those polymers.

[0006] Therefore, there exists a need whereby polymer powders can be conditioned to improve their flowability and ability for pigmenting in a repeatable fashion without the threat of overheating and thus melting the polymer. A need also exists for a pigmented polymer that does not easily shed its color and whose structural integrity is not compromised by coloring.

BRIEF SUMMARY OF THE INVENTION

[0007] Disclosed herein is a method and apparatus for conditioning thermoplastic resin. According to this invention, set point data is pre programmed into a controller, where the set point data comprises flowability data and powder outletflow data. During operation a specified amount of powder and a specified amount of pigment is directed into a container. The contents of the container is continuously mixed which heats the powder that is inside of the container. The powder has a flowability value that changes in proportion to changes in powder temperature. During the mixing process, the controller directs the system to discharge a fraction of the powder within the container onto a flowability meter where the flowability of the powder being discharged from the container is measured. The measured value of the flowability is then transmitted to the controller where it is compared to the flowability data pre programmed into the controller. The powder remaining in the container is discharged from the container when the evaluated flowability of the powder being discharged from the container is equal to the flowability data pre programmed into the controller.

[0008] The pigment impregnates the outer surface of the polymer powder particles and adheres in such a way that the pigment cannot readily be separated from the powders.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0009] FIG. 1 provides a schematic view of the Continuous Blending Apparatus of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0010] FIG. 1 depicts a schematic view of a Continuous Blending Apparatus 1 according to this invention. In general, the Continuous Blending Apparatus 1 comprises a powder feed 10, a pigment feed 20, a continuous blender 30, a controller 40, a motor 55, and a flowability meter 50. The continuous blender 30 is preferably an apparatus housing one or more drums having stirrers mounted therein for mixing together the drum contents. The powder feed 10 is operatively attached to the continuous blender 30 for transferring powder from the powder feed 10 to the continuous blender 30. It is preferred that the powder feed 10 consist of a stationary tank raised above the continuous blender 30 to facilitate transfer of the contents of the powder feed 10 to the continuous blender 30. Powder enters the continuous blender 30 from the powder feed 10 through the powder feed inlet 31; the powder flow is controlled by the powder feed control valve 11. It is envisioned that the powder generally used in conjunction with this invention comprise polymeric powders such as polyolefins including polyethylene, polypropylene, and other like materials including all thermoplastic materials. However, the powder processed by the invention disclosed herein can include any powder whose flowability and ability to be pigmented is enhanced by heating.

[0011] Likewise, the pigment feed 20 is also preferably situated above the continuous blender 30 for ease of entry of the pigment into the continuous blender 30. The pigment feed 20 can comprise any type of container suitable for storing and transferring pigment without undue spillage or leakage. Pigment enters the continuous blender 30 from the pigment feed 20 via the pigment feed inlet 32 and control of the pigment flowing from the pigment feed 20 to the continuous blender 30 is achieved by the pigment feed control valve 21.

[0012] Mechanically connected to the continuous blender 30 is a motor 55 that provides rotational energy to the stirrers (not shown). It is preferred that the motor 55 be electric and have the capability to operate at more than one rotational velocity. Therefore, shown connected to the motor 55 is a motor speed controller 56 in conjunction with a power supply 57. The motor speed controller 56 comprises a variable resistor for varying the electrical current supplied to the motor 55, however one skilled in the art can readily appreciate that many alternatives exist for varying the rotational speed of the motor 55. The power supply 57 can provide either alternating or direct current.

[0013] A powder outlet 33 is included on the continuous blender 30 which provides for the transfer of the powder out of the continuous blender 30 to the flowability meter 50 via a transfer line. The flow of powder from the powder outlet 33 is controlled by the continuous blender outlet control valve 34. The temperature of the powder exiting the continuous blender 30 is monitored by the temperature element 43, and possibly others, which can be attached to the outer or the inner surface of the transfer line. Accordingly, the temperature element 43 can be a thermocouple adhered to the transfer line, or a probe inserted through the transfer line either at the outer edge of the powder flow or in the powder flow stream. Alternatively a temperature probe can be situated in various positions in the turbulent powder flow within the continuous blender 30.

[0014] The flowability meter 50 measures the ability of the powder to flow (the powder flowability) as it exits from the continuous blender 30. The preferred flowability units are based on ASTM D 1895-96 which are based on the period of time required for 100 grams of powder to pass through a 10 mm funnel orifice. While a typical powder takes 25-35 seconds to pass through the orifice, a polished powder could be less than 20 seconds. One method to determine flowability of the present invention involves measuring the mass flow rate of the powder exiting the continuous blender 30 as an indicator of how well the powder is flowing. A low mass flow rate would intimate a low flowability, whereas a high mass flow rate indicates high flowability. The flowability meter 50 illustrated in FIG. 1 utilizes the correlation of powder mass flow rate to the flowability by detecting the powder mass flow rate with a load cell 51. The load cell 51 creates a signal in response to the instantaneous mass of the powder flowing across the flowability meter 50, that signal is transmitted to the controller 40 where the signal is processed into flow data. It is appreciated that one skilled in the art can develop a numerical scale whereby signals received and processed by the controller 40 from the flowability meter 50 provide a reading reflecting the flowability of the powder flowing across the flowability meter 50. One of the many advantages of monitoring the powder flowability in addition to only powder temperature is that the melting temperature of the powder can change from batch to batch and grade to grade.

[0015] After the powder flows across the flowability meter 50 it is deposited onto the fluid bed 60 for cooling. The fluid bed 60 is a fluidized air driven bed unit which can lower the powder temperature by 30° C. or more. Traditional powder cooling techniques involve passing the warm powder through an air stream, however the additional use of air in this environment increases the chances for color contamination of similarly located processes or devices. The powder sieve 65 illustrated is a simple vibratory sieve device used to screen out any melted lumps or hairs of powder that may have formed during the heating process. Located under the powder sieve 65 is a selector valve 70 that can alternatively direct powder flow from the powder sieve 65 to the cooled powder bin 80 or the off spec bin 90.

[0016] Before a particular batch of powder is conditioned, the controller 40 is pre programmed with set points that pertain to the batch being conditioned. As is well known in the art, the controller 40 can consist of a single microchip or an entire computer system, both of which are capable of receiving and storing data as well as transmitting signals to process equipment. The set points can comprise maximum powder temperature, flowability values, flow control ranges, and current/voltage values. These set points will vary depending on powder material, pigment type, batch quantities, and desired product. Therefore, the operation of preprogramming set points into the controller 40 will be determined by process operators and it is appreciated that it is obvious to those skilled in the art.

[0017] In operation, the start up procedures involve a warm up step where powder from the powder feed 10 is dosed into the continuous blender 30 until a specified amount has entered the continuous blender 30. The dosing procedure can be accomplished by programming the controller 40 to actuate the powder feed control valve 11 open until the desired amount of powder has flowed into the continuous blender 30. The amount of powder added to the continuous blender 30 will depend on the size of the continuous blender 30 and the powder used. However, the amount of powder allowed to flow across the powder feed control valve will be apparent to one skilled in the art.

[0018] While the powder is being dosed into the continuous blender 30, pigment is added into the continuous blender 30 with the powder. The pigment can be in either powder form, or can be a liquid dispersed pigment. During this time the stirrers (not shown) continuously rotate and thoroughly mix the powder with the pigment. The stirring action not only mixes the powder with the pigment, but also adds heat to the powder because of friction forces produced by the mixing. As the powder is heated, the powder particles become softer which enhances pigment adhesion to the powder particles. While the pigment is mixed with the powder, the powder is constantly monitored to ensure that its temperature does not reach its melting point. Obviously, because the powders composed of different materials will in all likelihood have different melting points, the melting point for each specific powder must be known and the memory of the controller 40 must be adjusted accordingly. Flowability and temperature values of the powder both indicate when the powder is close to melting. One of the many advantages of the present invention provides continuous monitoring of the flowability and the temperature of the powder being colored in the continuous blender 30. During mixing, small doses of powder are released from the continuous blender 30 through the continuous blender outlet control valve 34. Actuation of the continuous blender outlet control valve 34 can be directed by signals from the controller 40 in response to set points pre programmed into the controller 40. As described above, the flowability of the small doses of powder exiting the continuous blender 30 is measured by the flowability meter 50 and transmitted to the controller 40. When the flowability data monitored by the controller 40 indicates that the powder is approaching its melting point, the controller 40 is pre programmed to activate the continuous blender outlet control valve 34 to empty the powder from the continuous blender 50. Alternatively, the temperature of the powder can be tracked by the temperature element 43 in conjunction with the controller 40. The temperature element 43 transmits a signal to the controller 40 representative of the powder temperature, the controller is designed and configured to convert the signal from the temperature element 43 and compare it to set point data stored in the controller 40. When the controller 40 senses that the powder is close to melting, it can direct the continuous blender outlet control valve 34 open to empty the powder from the continuous blender 30.

[0019] If desired, the continuous blending apparatus 1 can affect the powder temperature in the continuous blender 30 by altering the rotational speed of the motor 55. The controller 40 should be capable of being programed to adjust the motor speed, via its cooperation with the motor speed controller 56, based on data input from either the flowability meter 51 or the temperature element 43. The option of adjusting motor speed provides additional flexibility in establishing an optimum powder mixing temperature.

[0020] Because some of the powder exiting the continuous blender 50 has not been adequately colored, some of the powder will be repigmented or reblended before it is passed on for further processing. For example, the powder that is dosed out of the continuous blender 50 before the powder has reached a satisfactory temperature for pigment adhesion will be considered off spec. This off spec powder is forwarded by the selector valve 70, under control by the controller 40, to the off spec bin 90. Likewise, powder that has been successfully pigmented will be forwarded by the selector valve 70 to the cooled powder bin 80 where it is stored for further processing.

[0021] Mixing the pigment with the powder, when the powder is close to its melting point, glues the pigment to the outer surface of the individual powder particles. Because the pigment is now actually embedded or partially encapsulated in the polymer, the pigment adheres to the polymer and will not easily be removed from the polymer, even with solvents. Other added benefits of this process include increased color strength and intensity of the pigmented polymer, and added structural strength of the objects formed by polymers pigmented by the process. Additionally, due to the enhanced coloring effect achieved by the process disclosed herein, less pigment is now required than what is required in prior art processes.

[0022] While the control valves (powder feed inlet control valve 11, pigment feed control valve 21, and continuous blender outlet control valve 34) are disclosed as typical gate type valves with diaphram actuated controls, these can consist of other types of control devices obvious to those skilled in the art. Further, existing polymer processing apparatus that are modified to monitor flowability data of powder exiting a powder conditioning device; and use that data to determine when conditioning is complete, are considered a part of this invention. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.

Claims

1. A method of conditioning polymer powder comprising the steps of:

preprogramming set point data into a controller, where the set point data comprises flowability data and powder outletflow data;

feeding a specified amount of powder into a container; where said powder has a flowability value that changes in proportion to changes in powder temperature;

stirring said powder inside of said container at a rate sufficient to heat said powder;

discharging a fraction of said powder within the container and measuring the flowability of said fraction with a flowability meter that is in data communication with said controller;

comparing the measured flowability of said fraction with the flowability data pre programmed into said controller; and

when the evaluated flowability of the powder being discharged from the container is equal to the flowability data pre programmed into said controller, discharging the powder remaining in the container.

2. The method of claim 1 further comprising adding a specified amount of pigment to said powder within the container.

3. The method of claim 1 further comprising the step of cooperatively adapting a load cell to said flowability meter and measuring the flowability of the discharging powder with the flowability meter adapted to include a load cell.

4. The method of claim 1 further comprising the step of preprogramming a temperature set point into said controller, measuring the actual temperature of the powder being discharged from the container, and discharging all powder remaining in the container when the actual temperature of the powder being discharged from the container is equal to the temperature set point.

5. The method of claim 1 further comprising the step of adding another specified amount of powder to the container after all of the powder has been discharged from the container.

6. The method of claim 5 further comprising the step of adding another specified amount of pigment to the container after all of the powder has been discharged from the container.

7. The method of claim 1 further comprising the step of preprogramming said controller with a flowability value that corresponds to an optimum temperature for mixing said powder with said pigment.

8. The method of claim 1 further comprising controlling the temperature of said powder by controlling the rate of rotation of said container.

9. The method of claim 1 further comprising cooling said discharged powder by forcing the powder through a fluidized air driven bed unit.

10. The method of claim 9 further comprising separating off-spec material from said cooled powder.

11. The method of claim 10 further comprising selectively directing off-spec material to an off-spec container and directing said cooled powder to a product container.

12. Apparatus for blending pigment with particulate polyolefin resin, said apparatus comprising:

a continuous blender adapted to receive powder at a controlled rate of feed through a powder inlet, adapted to receive pigment at a controlled rate of feed through a pigment feed inlet, and a powder outlet;

one or more stirrers attached within said continuous blender to blend the powder and pigment residing inside of said continuous blender;

a pigment feed flow control device in communication with said pigment fee inlet;

a powder outletflow control device in communication with said powder outlet capable of regulating the amount of powder flowing from said powder outlet;

a flowability meter positioned to receive powder flowing from said powder outletflow control device; and

a controller in communication with said flowability meter and said powder outletflow control device, where said controller receives flow data from said flowability meter, compares the flow data to pre programmed flow data set points within the controller memory, calculates the flow control data required in the powder outletflow control device, and transmits the flow control data to said powder outletflow control device.

13. The blending apparatus of claim 12, further comprising a powder feed flow control device in communication with said powder feed inlet.

14. The blending apparatus of claim 13, wherein said controller also calculates the flow control data required in the powder feed flow control device, and transmits the flow control data amount to said powder feed flow control device.

15. The blending apparatus of claim 14, wherein said powder feed flow control device regulates powder flow into said continuous blender based on flow control data received from said controller.

16. The blending apparatus of claim 15, further comprising a pigment feed flow control device in communication with said pigment feed inlet.

17. The blending apparatus of claim 16, wherein said controller also calculates the flow control data required in the pigment feed flow control device, and transmits the flow control data to said pigment feed flow control device.

18. The blending apparatus of claim 17, wherein said pigment feed flow control device regulates pigment flow into said continuous blender based on flow control data received from said controller.

19. A pigmented polymer particulate conditioned in accordance with the method of claim 1 comprising:

a polymer powder particle impregnated with pigment along its outer surface, where said pigment is encapsulated within the outer crust of said polymer powder particle material such that said pigment adheres to said polymer powder particle.

20. The pigmented polymer particulate of claim 19, wherein said polymer powder particle is selected from the group comprising, polyethylene, and polypropylene.

21. The pigmented polymer particulate of claim 19, wherein said pigment is in powder form.

22. The pigmented polymer particulate of claim 19, wherein said pigment is in liquid dispersed form.