AU2024326375B2

AU2024326375B2 - Improvements in and relating to methods and apparatus for the manufacture of plastics and products therefrom, including parts and components therefor

Info

Publication number: AU2024326375B2
Application number: AU2024326375A
Authority: AU
Inventors: Dallas Rex James; Peter Graham NORTHIN; Zachary Luke SMITH; Jason Lee WALKER; Leith Evan WANSBROUGH
Original assignee: Meltix Ltd
Current assignee: Meltix Ltd
Priority date: 2023-11-02
Filing date: 2024-11-04
Publication date: 2026-01-08
Anticipated expiration: 2044-11-04
Also published as: AU2025234248A1; WO2025095797A1; AU2024326375A1

Abstract

A plastic frictional melting mixer apparatus (FMMA) comprising: - a housing which has a cylindrical bore; wherein the cylindrical bore includes an internal surface having a series of longitudinal toothed regions (LATRs) comprising a plurality of longitudinally aligned and spaced apart teeth (LATR teeth) projecting inwardly from the internal surface; and - a rotor located in the cylindrical bore, wherein the rotor includes: • a tipped region comprising plurality of circumferentially and longitudinally spaced apart and offset tips; - a motor arrangement which can rotate the rotor so the tip/RTR tooth speed is 6m/s; and - a feed arrangement to deliver plastic beads/shreds to the rotor; and - wherein the gap between the rotor and the cylindrical bore is sufficient to allow for radial acceleration, in-use, of beads/shreds of plastic from the rotor into the inner surface of the cylindrical bore, given the 6 m/s tip speed.

Description

JAWSRef: JAWS Ref: 323359PCT 323359PCT

IMPROVEMENTSIN IMPROVEMENTS IN AND AND RELATING RELATING TO TO METHODS METHODSAND ANDAPPARATUS APPARATUS FOR FOR THE THE MANUFACTURE MANUFACTURE OFOFPLASTICS PLASTICSAND ANDPRODUCTS PRODUCTS THEREFROM, THEREFROM, INCLUDING INCLUDING PARTS AND PARTS AND COMPONENTS COMPONENTS THEREFOR THEREFOR TECHNICALFIELD TECHNICAL FIELD

Thepresent The presentinvention inventionrelates relates to to improvements improvements ininand and relatingtoto methods relating methods and and apparatus apparatus for for

the manufacture the manufacture ofofplastics plastics and andproducts productstherefrom, therefrom,including includingparts parts and andcomponents components therefor. therefor.

In In particular, particular,the present the presentinvention relates invention to to relates a machine a machineand andcomponents therefor together components therefor together with improved with methods, improved methods, which which cancan melt melt plastic plastic beads beads or or shreds, shreds, viavia friction, to friction, to make make

productstherefrom products therefrom - without - without the need the need for additional for additional heating heating elements elements to melt theto melt the plastic plastic beads/shreds. beads/shreds.

Thepresent The present invention invention is primarily is primarily although although not limited not limited to the to the melting melting of recycled of recycled plastic plastic beads beads or shreds. or shreds.

BACKGROUND ART BACKGROUND ART

Plastic pollution Plastic pollutionisis aamajor majorworldwide worldwide problem. problem.

As many As many plasticsare plastics arenotnot biodegradable biodegradable there there is aisreal a real needneed to find to find waysways of recycling of recycling and and repurposingused repurposing usedplastic. plastic.

For example, For example, it it hashas previously previously been been estimated estimated around around 1.1 to 8.81.1 to 8.8tonnes million million of tonnes of plastic waste plastic waste

enters the enters the ocean year¹[1]. eachyear ocean each

Plastic is recycled Plastic is recycledfor forrepurposing repurposing in most in most instances, instances, bytransforming by first first transforming a plasticaarticle plasticinto article into either beads either or shreds. beads or shreds. Machines Machinesforfor meltingplastic melting plasticbeads beadsororshreds shreds areknown. are known.

However,these However, thesemachines machines all all require require additionalheating additional heatingelements elements to to melt melt thethe plasticbeads plastic beads or or

shreds. This shreds. Thisincreases increases thethe carbon carbon footprint footprint of of plastic plastic recycling recycling as as it itincreases increases thethe energy energy

requiredtotomelt required meltthethe plastic. plastic. Additionally, Additionally, it increases it increases the costs the costs involved involved with recycling with recycling and re- and re- purposingplastic. purposing plastic. These These machines machines are also are also relatively relatively complicated complicated andexpensive and thus thus expensive to to manufactureand manufacture and maintain. maintain.

It would It would be useful if be useful if there therecould could be be provided provided a machinewhich a machine which could could address address one one or more or more of of theseissues, these issues,to to assist assist with with recycling recycling and and re-purposing re-purposing used used plastic. plastic.

It would It alsobebeuseful would also usefulififthere therecould couldbe be provided provided an alternative an alternative machine machine and alternative and alternative method method for mixing for mixing and melting recycled and melting recycled plastic plastic beads or shreds. beads or shreds.

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In In particular, particular, it itwould alsobebeuseful would also useful to to provide provide alternative alternative low-cost low-cost processes processes for recycling for recycling and and repurposing repurposing plastic. plastic.

It would It would further furtherbe beuseful usefulif if there could there be be could provided a machine provided a machineor ormethod method which could produce which could produce moltenplastic molten plasticwithout without thethe useuse of heating of heating elements elements at the at theorsame, same, or preferably preferably anrate an increased increased rate of production of production than knownmethods. than known methods.

It would It would also also be be useful useful if ifthere therecould couldbe be provided provided a a machine ormethod machine or method which which diddid notnot require require

sequentially increasing sequentially increasing continual continual compression compression totomelt meltthe theplastic/beads. plastic/beads.

It would It would also also be be useful useful ififthere could there couldbe beprovided providednew new parts for foraamelter/mixer melter/mixer which which does not does not

requireheating require heating elements elements to heat to heat the plastic. the plastic.

It would It alsobebeuseful would also useful if ifthere therecould could be be provided provided a machine a machine or process or process which which could could mix plastic mix plastic beadsororshreds beads shredsininaa more moreeffective effectiveway waytotoproduce producea aplastic plasticextrusion extrusionwhich whichhas hassignificantly significantly less air less air pockets therein pockets therein than than plastic plastic extruded extruded from from a conventional a conventional extruder extruder for recycling for recycling plastic. plastic.

All references, All including references, including anyany patents patents or patent or patent applications applications cited incited this in this specification specification are are herebyincorporated hereby incorporatedbybyreference. reference.NoNo admission admission is made is made thatthat any any reference reference constitutes constitutes prior prior

art. The art. discussionof The discussion of the the references states what references states whattheir their authors assert, and authors assert, the applicants and the applicants

reservethe reserve theright righttotochallenge challenge the the accuracy accuracy and pertinency and pertinency of the of the cited cited documents. documents. It will be It will be clearly understood clearly understood that, that, although although a number a number of priorofart prior art publications publications are to are referred referred herein, to herein, this this reference does reference doesnot notconstitute constitute an an admission admissionthat thatany anyofofthese thesedocuments documents form form part part of of thethe common common general general knowledge knowledge in the in the art,art, in in New New Zealand Zealand orany or in in any other other country. country.

Throughoutthis Throughout thisspecification, specification, the the word word "comprises", or variations thereof "comprises", or thereof such such as as "comprise" "comprise"

or "comprising", or "comprising", willbebe will understood understood to imply to imply the inclusion the inclusion of a element, of a stated stated element, integer orinteger step, or step, or group or groupofofelements elements integers integers or steps, or steps, butthenot but not the exclusion exclusion of any of any other otherinteger element, element, or integer or step, or step, or group groupofofelements, elements, integers integers or steps. or steps.

Further aspects Further aspectsand andadvantages advantagesof of thethe present present invention invention willbecome will become apparent apparent fromfrom the the

ensuingdescription ensuing description which whichisis given given by by way wayofofexample example only. only.

SUMMARYOF SUMMARY INVENTION OFINVENTION

Rotor Rotor

According According to to oneone aspect aspect ofpresent of the the present invention invention there isthere is provided provided a arotor a rotor for for plastic a plastic frictional melting frictional meltingmixer mixerapparatus apparatus (FMMA) which (FMMA) which comprises: comprises:

• aa tipped tippedregion region comprising comprising plurality plurality of circumferentially of circumferentially and longitudinally and longitudinally

spaced spaced apart apart andand offset offset tips.tips.

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In In some embodimentsthe some embodiments therotor rotor may include aa rotor mayinclude rotor toothed toothed region region(RTR) (RTR)including includinga a plurality of plurality of RTR teeth. RTR teeth.

Although, in Although, in a a preferred preferred embodiment the embodiment the rotormay rotor may solelycomprise solely comprise a tipped a tipped region. region.

In embodiments where embodiments where there there is is provided provided both both a tipped a tipped region region andand an an RTR, RTR, the the tipped tipped region region

and RTR and RTR may may be be located located at either at either anan upstream upstream or downstream or downstream end end of theofrotor the rotor with with respect respect

to one to another. one another.

TheRTR The RTR of the of the rotor rotor may may include include a plurality a plurality of circumferentially of circumferentially spaced spaced apart apartrotor elongate elongate rotor teeththereon teeth thereon projecting projecting outwardly, outwardly, the rotor the rotor teeth teeth all ahave all have a longitudinal longitudinal axistooth axis (rotor (rotor tooth axis), wherein axis), whereinsaid said rotor rotor tooth tooth axes axes may may all be all be substantially substantially parallelparallel to one another. to one another.

Preferably, therotor Preferably, the rotortooth tooth axis axis maymay have have an of an angle angle of substantially substantially 39todegrees 39 degrees the to the longitudinalaxis longitudinal axisofofthe therotor. rotor.

Thetipped The tipped region region may may include include a series a series of longitudinally of longitudinally spaced spaced apart apart tip-sections. tip-sections.

Each tipsection Each tip sectionmaymay havehave a plurality a plurality of thereon. of tips tips thereon.

Preferably, each Preferably, each tip-section tip-section of the of the series series maysix may have have tipssix tips thereon, thereon, andeach and wherein wherein tip- each tip- sectionmay section may have have spirally spirally offset offset tips tips withwith respect respect to adjacent to adjacent tip-section(s). tip-section(s).

Preferably, each Preferably, each tip-section tip-section may may be in be thein theofform form ofplate a hex a hexmounted plate to mounted a rotatortoshaft. a rotator shaft.

Preferably, where there is where there is no RTRononthe no RTR therotor, rotor, the the rotor rotor may comprisea aplurality may comprise plurality of of adjacent adjacent

spirally offset spirally hexplates offset hex platesmounted mounted to rotator to the the rotator shaft.shaft.

Preferably, thetips Preferably, the tipsininuse usemaymay be rotated be rotated at aspeed at a tip tip speed of 6m/s. of 6m/s.

According According to to a further a further aspect aspect of present of the the present invention invention there isthere is provided provided a rotor a rotor for for a a plastic plastic frictional melting frictional meltingmixer mixerapparatus apparatus (FMMA) which (FMMA) which comprises: comprises:

- - a tipped a tippedregion; region; wherein: wherein:

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-- the tipped the tippedregion regionis is located located at aatpredominantly: a predominantly: an an upstream,midstream, upstream, midstream,oror downstream, downstream, position; position;

or or - -- a combination, a combination, or or partial partial combination, combination, of positions; of said said positions; onthe on therotor; rotor; with respect with respectto: to: - a rotor a rotor toothed toothed region region (RTR); (RTR);

wherein wherein

-- the RTR the RTR isislocated locatedat at aa predominantly: predominantly:an anupstream, upstream, midstream,orordownstream, midstream, downstream, position; position;

or or - - a combination, a combination, or or partial partial combination, combination, of positions; of said said positions; on, the on, therotor; rotor; or or - the tipped the tipped region region and RTR,ifif both and RTR, both are are present present on onthe the rotor together, rotor together,areare respectively respectively located, located, atofone at one a of a predominantly:an predominantly: anupstream, upstream,midstream midstream or downstream or downstream

positionononthe position therotor, rotor,ororother other non-overlapping non-overlapping

combination combination of of these these relative relative positions. positions.

As will As will be be understood fromthe understood from theabove aboveparagraphs paragraphsthethe inventor inventor hashas found found that that thethe rotorcan rotor can functionallyoperate functionally operate with with either either a tipped a tipped region region or a rotor or a rotor toothed toothed region, region, or or both in both in combination. combination.

Theinventor The inventor has hasalso alsofound foundthe therotor rotor can can functionally functionally operate with both operate with both a tipped tipped region region and a and a

rotor toothed rotor toothedregion. region.

According According to to a further a further aspect aspect of present of the the present invention invention there isthere is provided provided a rotor a rotor and and housing housing arrangementfor arrangement foraaplastic plastic frictional frictional melting meltingmixer mixerapparatus apparatus (FMMA) wherein (FMMA) wherein thereisis there

provided aa rotor provided rotor substantially substantiallyas as described described above including aa working above including workingsection, section, which whichcan, can,in- in- use: use:

- - radially accelerate radially accelerate shreds shreds or or beads towardsananinternal beads towards internal surface surface of of the the

cylindrical bore cylindrical boreofofthe thehousing, housing, wherein wherein the internal the internal surface surface has aofseries has a series of longitudinaltoothed longitudinal toothed regions regions (LATRs) (LATRs) comprising comprising a plurality a plurality of longitudinally of longitudinally

aligned and aligned andspaced spacedapart apartteeth teeth(LATR (LATR teeth) teeth) projectinginwardly projecting inwardlyfrom fromthe the internal surface; internal surface;

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-- drive the drive the shreds or beads shreds or forwardin beads forward in aa downstream downstream directionand direction and forcethe force the plastic shreds plastic shreds or or beads throughreduced beads through reduceddiameter diameter gaps gaps between between the tips the tips or or RTR teethononthe RTR teeth therotor rotor and andthe theLATR LATR teeth teeth which which periodicallyoccur periodically occur and and

disappearas disappear asaaconsequence consequence of the of the rotationofofthe rotation therotor; rotor; -- therebyalternating thereby alternating between between radialradial acceleration acceleration and the and theof forcing forcing of the the plastic plastic shredsor shreds or beads beadsduring duringaxial axial travel travel long long the the rotor rotorfrom from upstream to upstream to

downstream; downstream; soso asas toto

- - mix plastic mix plastic shreds shreds or or beads; and/or beads; and/or

- -- melt plastic melt plastic shreds shreds or or beads; beads;

whereinthe wherein theworking workingsection sectioncomprises: comprises:

- -- tippedregion; tipped region; and/or and/or

- - a rotor a rotor toothed toothed region region (RTR); and (RTR); and

- - (optionally) (optionally) aadischarge discharge region. region.

Preferably, Preferably, the the discharge region may discharge region maybebelocated locatedatatan andownstream downstreamend end of the of the rotor; rotor; andand whereinthe wherein theRTR RTR may may be be adjacent adjacent the the tipped tipped region, region, andand either either thethe RTRRTR or the or the tipped tipped region region

may beadjacent may be adjacentthe thedischarge discharge region. region.

Again,asasabove Again, above the the inventor inventor has found has found that thethat thecanrotor rotor can functionally functionally operate operate with either with a either a tippedregion tipped regionorora rotor a rotor toothed toothed region. region. The inventor The inventor has alsohas also found thefound thefunctionally rotor can rotor can functionally operatewith operate with both both a tipped a tipped region region and aand a toothed rotor rotor toothed region. region.

In In one one embodiment, thetipped embodiment, the tippedregion regionmay may be be adjacent adjacent thethe discharge discharge region. region.

In another another embodiment embodiment thethe toothed toothed region region (RTR) (RTR) may may be adjacent be adjacent the discharge the discharge region. region.

Accordingtoto another According anotheraspect aspectofofthe thepresent presentinvention inventionthere thereis is provided provided aa rotor rotor for foran an FMMA FMMA

whereinthethe wherein discharge discharge region region is in is inform the the of: forman of: an increased increased diameter diameter section section of the of rotator the rotator shaft, or shaft, or aa ring-shaped ring-shaped section section which which is mounted is mounted to the shaft, to the rotator rotatorwherein shaft,the wherein outer the outer surfaceofofthe surface thedischarge discharge region region when when viewed viewed in cross in cross sectional sectional profile is profile circularisin circular shape. in shape.

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Housing Housing

According According to to a further a further aspect aspect of present of the the present invention invention there isthere is provided provided a housing afor housing for a plastic a plastic frictional melting frictional meltingmixer mixerapparatus apparatus (FMMA) which (FMMA) which includes: includes:

-- aa cylindrical cylindrical bore borewhich whichin in useuse can can househouse a rotora therein; rotor therein;

whereinthethe wherein internal internal surface surface of the of the cylindrical cylindrical bore bore (bore)(bore) has a of has a series series of longitudinal longitudinal aligned aligned toothed regions toothed regions (LATRs), (LATRs),wherein wherein a LATR a LATR comprises comprises a plurality a plurality of of longitudinallyaligned longitudinally alignedand and spacedapart spaced apartteeth teeth(LATR (LATR teeth)projecting teeth) projectinginwardly inwardlyfrom fromthe theinternal internal surface. surface.

In In some embodiments some embodiments the the LATR LATR teethteeth of the of the toothed toothed regions regions may have may have a longitudinal a longitudinal axis axis

(tooth axis) (tooth axis)which whichis is angled angled withwith respect respect tolongitudinal to the the longitudinal axis ofaxis the of the(bore bore boreaxis). (bore axis).

In In alternate alternate embodiments theLATR embodiments the LATR teeth teeth maymay havehave a longitudinal a longitudinal axisaxis which which is substantially is substantially

parallel to parallel to the the bore boreaxis. axis.

In aa preferred preferred embodiment theLATR embodiment the LATR teeth teeth have have a tooth a tooth axis axis with with an an angle angle of of substantially3939 substantially

degreestoto the degrees the bore boreaxis. axis.

In In one one preferred preferred embodiment the embodiment the LATR LATR teeth teeth may may project project inwardly inwardly 5mm 5mm frominternal from the the internal surfaceofofthe surface thebore. bore.

A housing A housingsubstantially substantially as as described describedabove abovewherein wherein thethe bore bore hashas at at least least one one discharge discharge port port

whichisiscoaxial which coaxial with with cylindrical cylindrical bore. bore.

A housing A housingsubstantially substantially as as described describedabove abovewherein wherein thethe bore bore hashas a discharge a discharge portport which which

provides for provides for radial radialegress egress of ofmolten molten plastic plasticfrom fromaadownstream endofofthe downstream end thebore. bore.

A housing A housingsubstantially substantially as as described describedabove abovewherein wherein thethe bore bore hashas a projection a projection radially radially

extendingtowards extending towardsthe thecentre centreofofthe the bore borewherein whereinsaid saidprojection projectionis is adjacent adjacent aa downstream downstream edgeofofthe edge theport port relative relative thethe rotational rotational fluid fluid flow flow of the of the molten molten plastic plastic imparted imparted by the by the rotor. rotor.

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Housingand Housing andRotor Rotor

According According to to a further a further aspect aspect of the of the present present invention invention there there is is provided provided a provided a provided housing housing and and rotor arrangement rotor for aa plastic arrangement for plastic frictional frictionalmelting mixer melting apparatus mixer apparatus(FMMA) whereinthe (FMMA) wherein thehousing housing and rotor and rotor arrangement includes: arrangement includes:

- - a housing a housing which which has has a cylindrical a cylindrical bore;bore; wherein wherein the cylindrical the cylindrical bore an bore includes includes an internal surface internal surface having having a a series series of oflongitudinal longitudinaltoothed toothedregions regions(LATRs) (LATRs) comprising comprising aa

plurality of plurality of longitudinally alignedandand longitudinally aligned spaced spaced apart apart teeth teeth (LATRprojecting (LATR teeth) teeth) projecting inwardlyfrom inwardly fromthethe internal internal surface; surface; and and

- aa rotor - rotor located inthe located in thecylindrical cylindricalbore, bore, wherein wherein the rotor the rotor includes: includes:

spaced spaced apart apart andand offset offset tips.tips.

According According to to a further a further aspect aspect of the of the present present invention invention there there is is provided provided a provided a provided housing housing and and rotor arrangement rotor for aa plastic arrangement for plastic frictional frictionalmelting mixer melting apparatus mixer apparatus(FMMA) whereinthe (FMMA) wherein the housing housing and rotor and rotor arrangement includes: arrangement includes:

• aa rotor rotor toothed toothedregion region(RTR) (RTR) including including a plurality a plurality of RTR of RTR teeth, teeth, instead instead of, orof, or

in combination in with combination with a tipped a tipped region. region.

In In some embodiments some embodiments the the LATR LATR teethteeth of the of the toothed toothed regions regions may may have have a longitudinal a longitudinal axis axis

(tooth axis) which (tooth axis) whichis is angled angled withwith respect respect tolongitudinal to the the longitudinal axis ofaxis the of the(bore bore boreaxis). (bore axis).

parallel to parallel to the the bore boreaxis. axis.

In In aa preferred preferred embodiment theLATR embodiment the LATR teeth teeth have have a tooth a tooth axis axis with with an an angle angle of of substantially3939 substantially

degreestoto the degrees the bore boreaxis. axis.

In In one one preferred preferred embodiment when embodiment when the the beads/shreds beads/shreds at least at least one one width width or height or height dimension dimension

greater equal greater to, or equal to, or above, above, 3mm butbelow 3mm but below7mmthe 7mmthe LATRLATR teeth teeth may project may project inwardly inwardly 5mm 5mm fromthe from theinternal internalsurface surface of the of the bore. bore.

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In another another preferred preferred embodiment when embodiment when the the beads/shreds beads/shreds at least at least one one width width or height or height

dimensiongreater dimension greaterequal equalto, to, or or above, above,1mm 1mm – 2mm - 2mm the LATR the LATR teeth teeth may project may project inwardly inwardly

6mm 6mm from from the the internalsurface internal surfaceofofthe the bore. bore. In In a a preferred preferred embodiment the embodiment the rotormay rotor may solely solely

compriseaatipped comprise tippedregion region

In an an another embodiment, another embodiment, where where there there is is provided provided both both a tipped a tipped region region andand RTR, RTR, the the tipped tipped

region and region and RTR RTR may may be be located located at either at either anan upstream upstream or downstream or downstream end end of theofrotor the rotor with with

respect to respect to one another. one another.

Preferably,each Preferably, each tip-section tip-section of the of the series series maysix may have have tipssix tips thereon, thereon, andeach and wherein wherein tip- each tip- sectionmay section may have have spirally spirally offset offset tips tips withwith respect respect to adjacent to adjacent tip-section(s). tip-section(s).

Preferably,each Preferably, each tip-section tip-section may may be in be thein theofform form ofplate a hex a hexmounted plate to mounted a rotatortoshaft. a rotator shaft.

A housing A housingsubstantially substantially as as described describedabove abovewherein wherein thethe bore bore hashas at at leastone least one discharge discharge port port

whichisisco-axial which co-axialwith with cylindrical cylindrical bore. bore.

extendingtowards extending towardsthe thecentre centreofofthe the bore borewherein whereinsaid saidprojection projectionis is adjacent adjacent downstream downstream mostedge most edge of the of the portport relative relative the rotational the rotational fluid fluid flow flow ofmolten of the the molten plasticplastic imparted imparted by the by the rotor. rotor.

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According According to to a further a further aspect aspect of present of the the present invention invention there isthere is provided provided a housing a housing and rotor and rotor arrangementfor arrangement foraaplastic plastic frictional frictional melting meltingmixer mixerapparatus apparatus (FMMA) wherein (FMMA) wherein thehousing the housing andand

rotor arrangement rotor includes: arrangement includes:

- aa cylindrical - cylindrical bore which, in bore which, in use, use, can can house house aarotor rotor therein; therein; and and

whereinthethe wherein internal internal surface surface of the of the cylindrical cylindrical bore bore (bore)(bore) has a of has a series series of longitudinal toothed longitudinal toothed regions regions (LATRs); and (LATRs); and

whereinaaLATR wherein LATR comprises comprises a pluralityofoflongitudinally a plurality longitudinally aligned aligned and andspaced spaced apartteeth apart teeth(LATR (LATR teeth) teeth) projecting projecting inwardly inwardly from from the the internal internal surface; surface;

and and

- aa rotor, - rotor,wherein whereinthe the rotor rotor includes: includes:

- - a tipped a tippedregion; region; wherein: wherein:

- - the tipped the tippedregion regionis is located located at aatpredominantly: a predominantly: an an upstream,midstream, upstream, midstream,oror downstream, downstream, position; position;

or or - - a combination, a combination, or or partial partial combination, combination, of positions; of said said positions; onthe on therotor; rotor;

or or - - a rotor a rotor toothed toothed region region (RTR); (RTR);

wherein wherein

- - the RTR the RTR isislocated locatedat at aa predominantly: predominantly:an anupstream, upstream, midstream,orordownstream, midstream, downstream, position; position;

or or - - a combination, a combination, or or partial partial combination, combination, of positions; of said said positions; on, the on, therotor; rotor; or or - - the tipped the tipped region region and RTR,ifif both and RTR, both are are present present on onthe the rotor together, rotor together,are arerespectively respectively located, located, at of at one onea of a predominantly:an predominantly: anupstream, upstream, midstream midstream or downstream or downstream

.

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. Preferably, therotor Preferably, the rotorteeth teeth of of thethe RTRRTR may may all allahave have a longitudinal longitudinal axis (RTRaxis (RTR tooth axis)tooth which axis) which

havethe have thesame same angle angle in relation in relation toanother to one one another with to with respect respect to the longitudinal the longitudinal axis of theaxis of the rotor (rotor rotor (rotor axis). axis).

In In some embodiments some embodiments the the LATR LATR teethteeth mayhave may all all have a longitudinal a longitudinal axisaxis (LATR (LATR toothtooth axis)axis)

havingthe having thesame same angle angle in relation in relation to onetoanother one another with to with respect respect to the longitudinal the longitudinal axis of theaxis of the bore(rotor bore (rotoraxis). axis).

In In aa preferred preferred embodiment theLATR embodiment the LATR tooth tooth axis axis maymay havehave an angle an angle of substantially of substantially 39 39

degrees degrees to to thethe longitudinal longitudinal axisaxis of the of the rotor/bore rotor/bore from either from either a left a toleft to right right perspective perspective or a or a right totoleft right perspective left and perspective andwherein whereinthe theRTR tooth axis RTR tooth axis may haveananangle may have angleofofsubstantially substantially 39degrees 39 degreesto to thethe longitudinal longitudinal axis axis of rotor/bore of the the rotor/bore from afrom rightato right leftto left perspective perspective or a leftortoa left to right right perspective: perspective: provided provided the the respective respective LATR andRTR LATR and RTR axes axes intersect. intersect. Thus, Thus, ensuring ensuring thethe

respective LATR respective LATRtooth toothaxis axisand andRTR RTR tooth tooth axis axis cross cross over over oneone another. another.

In In one one embodiment embodiment thethe housing housing andand rotor rotor arrangement arrangement for FMMA for an an FMMA the the gap gap between between the the rotor teeth rotor teeth and and the the LATR teethmay LATR teeth maybebe substantially1mm. substantially 1mm.

Scraper Scraper

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a for a housing housing a for a plastic frictional plastic frictionalmelting mixer melting apparatus(FMMA) mixer whichincludes: apparatus(FMMA) which includes: - - a cylindrical a cylindrical bore borewhich whichin in useuse can can househouse a rotora therein; rotor therein; whereinthethe wherein cylindrical cylindrical bore bore includes includes an outlet an outlet port having port having a radially a radially directeddirected delivery delivery axis axis from the from the bore bore and andlocated locatedatat aa downstream downstream endend thereof; thereof;

whereinthe wherein thecylindrical cylindrical bore bore includes includes aa scraper scraper element whichprojects element which projectsfrom fromthe theinner inner surface surface of the of the bore bore and is located and is located adjacent adjacent a a downstream inneredge downstream inner edge of of outletport outlet portat at an an inclined inclined anglerelative angle relativetotooutlet outletport portaxis. axis.

Feed Port Feed Port

According According to to a stillanother a still another aspect aspect of present of the the present invention invention there there is is provided provided a feed a feed port for a port for a friction mixer friction mixermelting meltingapparatus apparatus (FMMA) wherein (FMMA) wherein thethe feed feed portcomprises port comprises a plate a plate which which has: has:

- aa plurality - plurality of of apertures therein apertures therein wherein wherein the the apertures apertures are circumferentially are circumferentially arranged;arranged; or . or .

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- at - at least least two circumferentially two circumferentially arranged arranged elongate elongate arc profiled arc profiled apertures apertures (EAPAs) collectively (EAPAs) collectively

forming aa ring-shape; forming ring-shape; - wherein - whereinthe theinside inside diameter diameterof of ring ring shape formedvia shape formed viathe theplurality plurality of ofapertures apertures or orthe theEAPAs EAPAs

is sized is sized to tohave have the the same minimum same minimum diameter diameter and/or and/or a greater a greater diameter, diameter, in use, in use, than than that that of of

an adjacent an adjacent section section of of the the rotor rotor in inthe theFMMA; FMMA;

suchthat such thatthe thefeed feed port port cancan - via - via the the plurality plurality of apertures of apertures or theorEAPAs the EAPAs - deliver- plastic deliver plastic beadsororshreds beads shredstotobe bemix/melted, mix/melted,from froma afeed feedsource source and and feed feed delivery delivery arrangement, arrangement, to the to the

outside surface outside surface of of aa rotor rotorforming forming part partofofthe theFMMA. FMMA.

In In one one preferred preferred embodiment the embodiment the feed feed portincludes port includesthree threecircumferentially circumferentiallyarranged arrangedelongate elongate arc profiled arc profiledapertures apertures (EAPAs) (EAPAs) collectively collectively forming forming a ringinshape a ring shape in the the plate. plate.

In In one one further further preferred preferred embodiment platemay embodiment plate maybebe substantiallycircular substantially circular shaped. shaped.

Preferably the port Preferably the port is ismade from polytetrafluoroethylene made from polytetrafluoroethylene (PTFE) (PTFE)(also (alsoknown knownby by itstrade its trade mark TeflonTM)which markTeflonTM) whichisis at at least 5mm 5mm toto10mm 10mmin in thickness. thickness.

In In alternate alternate example the port example the port may bemade may be made from from steel steel andand thethe port port may may be be liquid liquid jacketed. jacketed.

In In a further alternative a further alternativeexample, example,the the portport may comprise may comprise two layers: two layers:

- aa first - first layer layer adjacent therotor adjacent the rotorwhich which is steel; is steel;

- aa second - layeradjacent second layer adjacentthe theproduct productfeed feedauger augerwhich which is ispolytetrafluoroethylene polytetrafluoroethylene (PTFE). (PTFE).

A key A key function function of of the the port port isistoto provide a thermal provide a thermalbarrier barrierbetween betweenthe theFMMA andthe FMMA and thefeed feed source/delivery arrangement, source/delivery arrangement,totoprevent preventpremature premature heat heat transfermelting transfer meltingincoming incoming beads/shredsand beads/shreds and congesting/blocking congesting/blocking thethe apparatus apparatus fromfrom continuously continuously melting melting plastic plastic

beads/shredsuntil beads/shreds until aa clogged cloggedfeed feedport portis, is, decongested, orreplaced. decongested, or replaced.

FMMA FMMA

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer apparatus melting mixer apparatus(FMMA) (FMMA) comprising: comprising:

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- aa housing - which housing which has has a cylindrical a cylindrical bore;bore; wherein wherein the cylindrical the cylindrical bore bore includes includes an internal an internal surface surface having having a a series series of of longitudinal longitudinaltoothed toothedregions regions(LATRs) (LATRs)

comprisingaaplurality comprising plurality ofoflongitudinally aligned longitudinally and aligned spaced and spaced apart apartteeth teeth(LATR (LATR

teeth) projecting teeth) projectinginwardly inwardly from from the the internal internal surface; surface; and and

- aa rotor - locatedininthe rotor located thecylindrical cylindricalbore, bore, wherein wherein the rotor the rotor includes: includes:

• aa tipped tippedregion region comprising comprising plurality plurality of circumferentially of circumferentially and and longitudinallyspaced longitudinally spaced apart apart and and offset offset tips;tips; and/or and/or

• aa rotor rotor toothed toothedregion region (RTR) (RTR) including including a plurality a plurality of RTRof RTR teeth; teeth;

- a - a motor arrangement motor arrangement which which cancan rotate rotate thethe rotorsosothe rotor thetip/RTR tip/RTR toothspeed tooth speed is is

substantially 6m/s; substantially 6m/s; and and

- aa feed - feedarrangement arrangement to deliver to deliver plastic plastic beads/shreds beads/shreds to the to the rotor; rotor;

whereinthethe wherein gapgap between between thetipped the rotor rotor region tippedand region and the cylindrical the cylindrical bore istosufficient bore is sufficient allow to allow for radial for radial acceleration, acceleration,in-use, in-use, of of beads/shreds beads/shreds of plastic of plastic from from the theinto rotor rotor the into innerthe inner surface surface of the of the cylindrical cylindrical bore, bore,given giventhethe 6 m/s 6 m/s tip tip speed speed. .

It It isistotobe beunderstood the present understood the present invention invention as asdescribed describedabove above maymay operate operate with with either either a a tipped region tipped region alone, alone, or or aa RTR alone.Alternatively, RTR alone. Alternatively, the the present invention as present invention as described above described above

mayoperate may operatewith withboth botha atipped tippedregion regionand andananRTR. RTR.

Thefeed The feedarrangement arrangementmaymay be any be any feedfeed arrangement arrangement as known as known in the in thefor art artdelivering for delivering plastic plastic

beadstoto aa conventional beads conventionalrotational rotational melter/extruder apparatus. melter/extruder apparatus.

In preferred embodiments In preferred thefeed embodiments the feedarrangement arrangement may may include include a hopper a hopper and auger and auger

arrangement. arrangement.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above wherein wherein the between the gap gap between the rotor the rotor and andthe thecylindrical cylindrical bore boreisissufficient sufficient to to allow allow for for radial radial acceleration, acceleration, in-use, in-use, of of beads/shreds beads/shreds of plastic of plastic fromfrom the rotor the rotor intoinner into the the inner surfacesurface of the cylindrical of the cylindrical bore, bore, given the given the 6 m/s 6 tip/RTRtooth m/s tip/RTR tooth speed. speed.

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According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above wherein wherein the between the gap gap between the: the:

- tips/RTR - tips/RTR teeth; teeth; and and

- the - the LATR teeth; LATR teeth;

when when both both areare aligned aligned is significantly is significantly lessless than than thebetween the gap gap between the tips the tipsinner and the and the inner surface surface of cylindrical of cylindrical bore borewhen whenthe the tipstips and and teethteeth arealigned. are not not aligned.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above wherein wherein the between the gap gap between the tips/RTR the teeth and tips/RTR teeth andthe the LATR LATR teethwhen teeth when both both aligned aligned is is substantially400% substantially 400% less less than than thethe

gapbetween gap betweenthe the rotorrotor andcylindrical and the the cylindrical bore. bore.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting apparatus(FMMA) mixer apparatus (FMMA) substantially substantially as as described described above above wherein wherein during during rotation rotation

of the of rotor, when the rotor, when thethe tips tips areare aligned aligned with with LATR LATR teeth, teeth, there there is is agap a radial radial of: gap of:

• substantially 2.5mm substantially when 2.5mm when mixing/melting mixing/melting beads/shreds beads/shreds having having at least at least one one width width or or height dimension height greaterequal dimension greater equalto, to, or or above, above, 3mm 3mmbutbut below below 7mm; 7mm; or or

• substantially 1.5mm substantially when 1.5mm when mixing/melting mixing/melting beads/shreds beads/shreds having having at least at least one one width width or or height dimension height greaterofof around dimension greater around1mm 1mm - 2mm. - 2mm.

Accordingtotoa astill According still further further aspect aspectofofthethepresent present invention invention there there is provided is provided an an FMMA FMMA substantially as substantially describedabove as described above wherein wherein during during rotation rotation of rotor, of the the rotor, when when theare the tips tips are positionedintermediate positioned intermediate to (i.e., to (i.e., maximally maximally non-aligned non-aligned therewith) therewith) the LATRthe LATR teeth teeth the the radial gap radial gap betweenthe between thetipped tippedregion regionand andthe theLATR LATR teeth teeth is:is:

• substantially 11.5mm substantially when 11.5mm when mixing/melting mixing/melting beads/shreds beads/shreds having having at least at least one one

width or width or height height dimension greaterequal dimension greater equaltoto or or above above3mm 3mmbutbut below below 7mm; 7mm; or or

• substantially 10.5mmwhen substantially mixing/melting 10.5mmwhen mixing/melting beads/shreds beads/shreds having having at least at least one one width or width or height height dimension greaterof dimension greater of around around1mm 1mm - 2mm. - 2mm.

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In some further embodiments some further embodiments thethe radial radial gapgap between between the tips/RTR the tips/RTR teethteeth and aligned and aligned LATR LATR

teeth may teeth maybebe substantially1mm1mm substantially for afor a upstream upstream section section of the of the adjacent rotor rotor adjacent where where the the beads/shreds beads/shreds ofofplastic plastic are are introduced introducedtotothe thecylindrical cylindrical bore androtor bore and rotor arrangement arrangement before before

the radial the radial gap gap between thetips/RTR between the tips/RTRteeth teethand andaligned alignedLATR LATR teeth teeth increases increases to substantially to substantially

2.5mmtotomaintain 2.5mm maintaina ahigher higherrate rateofofflow flowof of beads/shreds/molten beads/shreds/molten plasticthan plastic thanwould would occur occur if ifa a

radial gap radial of 1mm gap of between 1mm between the the tips/RTR tips/RTR teeth teeth and and aligned aligned LATR LATR teeth teeth was was maintained maintained for for the entire the entirelength lengthofofthe therotor/cylinder. rotor/cylinder.

Accordingtoto aa further According further aspect of the aspect of the present present invention invention there there is isprovided providedan an FMMA FMMA

substantially as substantially as described described above whereinduring above wherein duringrotation rotationof of the the rotor, rotor, when the tips/ when the tips/ RTR RTR

teeth are teeth are positioned positioned intermediate to (i.e., intermediate to (i.e., maximally maximallynon-aligned non-aligned therewith) therewith)the theLATR teeth LATR teeth

the radial the radial gap gap between thetipped between the tippedregion/RTR region/ RTR andand thethe internal internal surface surface of of thecylindrical the cylindrical bore bore may besubstantially may be substantially 10.6mm 10.6mm – 11.5mm. - 11.5mm.

Accordingtoto aa further According further aspect of the aspect of the present present invention invention there there is isprovided provided an an FMMA FMMA

substantiallyasasdescribed substantially described above above wherein wherein theregion the tipped tippedofregion of rotoraincludes rotor includes series of a series of longitudinally spaced longitudinally spaced apart apart tip-sections, tip-sections, wherein wherein each tip-section each tip-section of thehasseries of the series has six tips six tips

thereon,and thereon, and wherein wherein each each tip-section tip-section has spirally has spirally offset offset tips tips with with respect respect to adjacent to adjacent tip- tip- section(s). section(s).

substantiallyasasdescribed substantially described above above wherein wherein each tip-section each tip-section is in the is in the form of a form of a hex plate hex plate mounted mounted to to a rotor a rotor shaft. shaft.

substantiallyasasdescribed substantially described above above wherein wherein during rotation during rotation of the of the rotor, rotor, when when the tips the are tips are aligned with aligned with the the LATR teeth, the LATR teeth, the radial radial gap between: gap between:

- flat - flatsections of aa hex sections of hexplate plateintermediate intermediate the the tips;tips; and and - the - internal surface the internal surfaceofofthe thecylindrical cylindrical bore; bore;

is substantially is substantially16.5mm. 16.5mm.

According According to to a further a further aspect aspect therethere is provided is provided a plastic a plastic frictional frictional meltingmelting mixer apparatus mixer apparatus

(FMMA) substantiallyasasdescribed (FMMA) substantially describedabove above wherein wherein neither neither thethe LATRs LATRs nor tipped nor tipped region, region,

RTRs have RTRs have mutually mutually engaging engaging profiles. profiles.

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In In particular, particular,there is is there no no threaded, nor threaded, helical, nor engagement helical, engagementbetween the LATRs between the LATRsand and thethe

tippedregion tipped regionoror RTR, RTR, suchsuch as found as found in a single in a single or twin or twinplastic screw screwextruder. plastic extruder.

Consequently,the Consequently, thetipped tippedregion/RTR region/RTRcancan rotate rotate freelyatatany freely anyspeed speed - particularly at - particularly at high high

revolutions per revolutions per minute (RPM),for minute (RPM), for example, example,those thoserequired requiredtotoachieve achievea a6m/s 6m/s tip/RTR tip/RTR tooth tooth

speed-- without speed without impediment impedimentbyby theLATRs the LATRs themselves. themselves.

A problem A problemwith withthreaded/helical threaded/helicalengagement engagement is twofold. is twofold. First,over First, overan anextended extended longitudinal longitudinal

axis at axis at high highRPMs RPMsthe the rotorrotor whichwhich is essentially is essentially a screwa fitting screw into fitting into the the helical helical threadedthreaded

cylindrical aperture cylindrical apertureof ofthe thebody bodywill willbebeprone pronetoto binding and binding andseizing. seizing.This Thisconsequence consequence

occurringdue occurring due to to thethe vibrational vibrational effect effect of radial of radial oscillations oscillations increasing increasing the longer the longer the the longitudinalaxis longitudinal axisofofthe therotor. rotor.ThisThis whatwhat couldcould be termed be termed wobble wobble like effectlike effect increasing increasing - in - in termsofofradial terms radialdeviance deviance - the - the further further along along the length the length of the of the you rotor rotor you away extend extend from away the from the proximal end proximal end of of thethe rotor rotor connected connected to theto the means drive drive of means of the the rotor e.g.rotor e.g. motor/gear. motor/gear.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above wherein wherein the rotor the rotor has has a a non-taperedlongitudinal non-tapered longitudinal diameter. diameter.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above which which does does not ahave not have a mechanicalcompression mechanical compression section section wherein wherein the the relative relative gapgap distance distance between between the rotor the rotor and and the the internal surface internal surfaceofofthe thecylinder cylinder gradually gradually decreases decreases along along the the axial axial flow flow direction direction so to so to continually compact continually thebeads/shreds compact the beads/shreds due due to to the the reduced reduced radial radial area area through through which which the the

beads/shredsare beads/shreds arebeing beingforced. forced.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above which which further further includes: includes:

- - a source a sourceofofplastic plasticbeads/shreds beads/shreds (plastic); (plastic);

- - a feed a arrangementconfigured feed arrangement configured toto move move thethe plasticfrom plastic from the the source source to to the the

housing. housing.

According According to to a stillfurther a still furtheraspect aspectof of thethe present present invention invention there there is provided is provided a frictional a plastic plastic frictional melting mixer melting mixer apparatus apparatus(FMMA) (FMMA) substantially substantially as as described described above above wherein wherein the FMMA the FMMA does does notinclude not includeanyany additional additional heating heating elements elements to melt to or melt orwith assist assist withthe melting melting the plastic. plastic.

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Theheating The heatingelements elements referredtotoabove referred above notrequired not requiredtotobebeutilised utilised by by the the present present invention invention may may bebe those those heated, heated, directly directly or indirectly, or indirectly, by steam, by steam, electricity, electricity, solar solar or orexternal other other external sourceof source of energy energyfor for providing providing heat. heat.

Thepresent The present invention invention onlyonly requires requires frictional frictional heat produced heat produced from operation from operation of the rotorofwithin the rotor within the cylinder the cylindertotoprovide providethethe heat heat necessary necessary to melttothe melt the plastic. plastic.

Theapplicant The applicant has hasalso alsofound foundthe thearrangement arrangementof of LATR LATR teeth teeth and and tips/RTR tips/RTR teethteeth are effective are effective

at thoroughly at mixing thoroughly mixing the the plastic plastic beads beads and resultant and resultant molten molten plastic. plastic.

- - a rotor a rotor and and cylindrical cylindricalbore borearrangement whichtogether arrangement which togetherare areconfigured configuredtoto providea atortuous provide tortuous path path axially axially along along the rotor the rotor and cylindrical and cylindrical bore bore arrangement arrangement to the to the outlet outlet port. port.

It It will willbe beappreciated in some appreciated in some embodiments embodiments the tortuous the tortuous path will path itself itselfallow will allow for radial for radial

accelerationofofthe acceleration thebeads/shreds beads/shreds and/or and/or resultant resultant plastic. plastic.

Method Method

A method A methodofofmelting meltingand andmixing mixing plasticshreds plastic shredsororbeads beads comprising comprising thethe steps steps of:of:

a) introducing a) introducingthethe shreds shreds or beads or beads to a rotor to a rotor with tips/teeth with tips/teeth locatedlocated within awithin a cylindrical boreprovided cylindrical bore provided with with internally internally radially radially projected projected obstacles obstacles on the on the

inner surface inner surfacethereof; thereof; wherein wherein said said cylinder cylinder andprovide and rotor rotor provide sufficient sufficient gap to gap to allowin-use, allow in-use,for forradial radialacceleration acceleration of the of the beads/shreds beads/shreds away away from the from rotor;the rotor; b) rotating b) rotatingthe therotor rotorsosothethe tips/teeth tips /teeth have have a rotational a rotational speedspeed of substantially of substantially

6m/s; 6m/s;

c) radially c) radiallyaccelerating acceleratingthe theshreds shredsor orbeads beads away fromthe away from the rotor rotor towards the inner towards the inner surfaceofofthe surface thecylinder; cylinder; whereinduring wherein duringtravel travel along along the the cylinder/rotor cylinder/rotor beads/shreds andany beads/shreds and anymolten moltenplastic plasticformed formed will be will radially forced be radially forcedagainst againstthethe internally internally radially radially projected projected obstacles obstacles on the on thesurface inner inner surface of the of cylindrical bore the cylindrical boreasas well well as as longitudinally longitudinally forced forced between between the obstacles the obstacles and tips/teeth and tips/teeth of of the rotor. the rotor.

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Theinternally The internallyradially radiallyprojected projected obstacles obstacles may may be be form in the in the of form teeth,ofridges, teeth, castellations, ridges, castellations, that are that arecircumferentially circumferentially spaced spaced apartapart and extend and extend longitudinally longitudinally along thealong thesurface internal internal of surface of the cylindrical the cylindricalbore. bore.

A method A methodsubstantially substantiallyas asdescribed describedabove above wherein wherein thethe beads/shreds beads/shreds are melted are melted without: without:

- - additional heating additional heating elements to increase elements to increase the the temperature temperatureofofthe thecylinder; cylinder; nor nor

- - sequentially increasing sequentially increasing sustained compression sustained compression during during axialtravel axial travelof of the the beads/shreds; beads/shreds;

required. being required. being

A method A methodsubstantially substantially as as described describedabove abovewherein wherein the the melting melting isisachieved achievedbybyrotational rotational speed speed of the of rotor. the rotor.

A method A methodsubstantially substantiallyas asdescribed describedabove above wherein wherein thethe melting melting is is achieved achieved by by a rotational a rotational

speedofoftips/teeth speed tips/teeth being being substantially substantially 6 6 m/s. m/s.

A method A methodsubstantially substantiallyas asdescribed describedabove above wherein wherein thethe resultant resultant plasticcreated plastic createdbybythe the mixingand mixing and melting melting process process has significantly has significantly less less air air pockets pockets visible visible by by the the naked eye.naked eye.

Accordingtoto aa further According further aspect of the aspect of the present present invention invention there there is isprovided provided aamethod of melting method of melting

and mixing and mixingplastic plastic shreds or beads shreds or beadsvia viathe the step step of of subjecting subjecting the the beads/shreds toboth: beads/shreds to both: a) radial a) radial acceleration; acceleration;andand b) aa tortuous b) tortuousororsemi-tortuous semi-tortuous axial axial path;path;

as part as part of of the the melting melting process; process; and and

subjectingthe subjecting theresultant resultant molten molten plastic plastic to both: to both:

a) radial a) radial acceleration; acceleration;andand b) aa tortuous b) tortuousororsemi-tortuous semi-tortuous axial axial path.path.

provideda aworking provided working section section of a of a rotor rotor whichwhich can, in-use: can, in-use:

cylindrical boreofofthe cylindrical bore thehousing housing wherein wherein the internal the internal surface surface has aofseries of has a series

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longitudinaltoothed longitudinal toothed regions regions (LATRs) (LATRs) comprising comprising a plurality a plurality of longitudinally of longitudinally

aligned and aligned and spaced spacedapart apartteeth teeth(LATR (LATR teeth) teeth) projectinginwardly projecting inwardlyfrom fromthe the internal surface; internal surface; -- drive the drive the shreds or beads shreds or forwardin beads forward in aa downstream downstream directionand direction and forcethe force the plastic shreds plastic shreds or or beads throughreduced beads through reduceddiameter diameter gaps gaps between between the tips the tips on on the rotor the rotor and and the the LATR teethwhich LATR teeth whichperiodically periodically align align and moveaway and move away as as a a consequence consequence of rotation of the the rotation ofrotor; of the the rotor; -- thereby alternating thereby alternating between: between:

▪ radial acceleration(i.e., radial acceleration (i.e.,when whenthethe tips tips andand LATR LATR are notare not

substantially aligned substantially aligned and and

▪ forcing the forcing the plastic plasticshreds shreds or orbeads beads through reduceddiameter through reduced diameter gaps-- between gaps betweenthe thealigned alignedtips tips and andLATR LATR - duringaxial - during axialtravel travel long the long the rotor rotor from from upstream to downstream; upstream to downstream; soso asas to: to:

o mix plastic mix plastic shreds shreds or or beads; and/or beads; and/or

o melt plastic melt plastic shreds shreds or or beads; beads;

whereinthe wherein theworking workingsection sectioncomprises: comprises:

-- a tipped a tippedregion region formed formed by aby a plurality plurality of adjacent of adjacent spirally spirally offsetoffset hexagonal hexagonal

plates. plates.

New Aspectsof New Aspects of Latest Latest Machine andMethodology Machine and Methodology

Restrictor Restrictor -- Plate Plate and OutletNozzle and Outlet Nozzle Assembly Assembly

Accordingtotofurther According further aspect aspectofofthe thepresent presentinvention inventionthere thereisisprovided provided an an outlet outlet nozzle nozzle andand

restrictor-plate assembly restrictor-plate for a aplastic assembly for plasticfrictional frictional melting meltingmixer mixerapparatus apparatus (FMMA) (FMMA) which which includes: includes:

- -- an outlet an outlet nozzle nozzle which includes aa conical which includes conical throat throat leading leading to to aareduced reduced diameter diameter

exit port exit conduit; port conduit;

- -- a restrictor-plate a restrictor-platefor anan for outlet endend outlet nozzle assembly nozzle assembly of ofan anFMMA which FMMA which

includes: includes:

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-- anaperture an aperture co-axially co-axially aligned aligned in-use in-use with with a conical a conical

projectionextending projection extendingfromfrom the output the output end ofend of a cylindrical a cylindrical

bore; bore;

-- - a plurality a plurality of of circumferentially spaced circumferentially spaced apart apart slotsslots whichwhich

extend respectively extend respectively inwardly inwardly from from the the edge edgeofofthe the aperture; aperture;

said aperture said aperture providing providing a close a close tolerance tolerance gap gap with with outside outside surface surface of of the the conical conical projectionleaving projection leaving a sufficient a sufficient distance distance to allow to allow for free for free rotation rotation ofconical of the the conical projectionyet projection yetstill still form form aarestricted restrictedcircumferential circumferential barrier barrier to effectively to effectively close close the the outlet, but outlet, for, the but for, closetolerance the close tolerancegapgap between between the aperture the aperture and and outer outerofsurface surface the of the conical projection conical projection and and the the gap providedby gap provided bycircumferentially circumferentially spaced apartslots spaced apart slots which which also still also still allow thethe allow passage passageofofatat least some least somematerial materialfrom froma amelt meltmix mixchamber from chamber from

whichthe which the conical conical projection projection extends; or extends; or

whereinthe wherein theedge edgeofofthe theaperture aperturecan canin-use in-usealso alsobebemoved moved away away fromfrom the the surface surface of of the conical the conicalprojection projection(or(or vice vice versa) versa) to increase to increase thetherebetween the gap gap therebetween to effectively to effectively

openthe open theoutlet outlet towards anopen towards an openposition. position.

According According to to further further aspect aspect of present of the the present invention invention there there is is provided provided an outlet an outlet nozzle andnozzle and restrictor plate restrictor plateassembly assembly substantially substantiallyas asdescribed described above whereinthe above wherein theclose closetolerance tolerancegap gapisis substantially 1mm - –2mm substantially 1mm 2mm when when the the outlet outlet is is effectivelyclosed effectively closedand andwherein wherein thethe gapgap between between

the edge the of the edge of the aperture aperture and andthe the surface surfaceof of the the conical conical projection projection is is6mm whenthe 6mm when theoutlet outletis is in the in openposition. the open position.

Restrictor Plate Restrictor Plate

According According to to further further aspect aspect of present of the the present invention invention there there is is provided provided a restrictor-plate a restrictor-plate for a for a plastic frictional plastic frictionalmelting mixer melting apparatus mixer apparatus(FMMA) whichincludes: (FMMA) which includes:

- - anaperture an aperture aligned aligned in-use in-use with with a conical a conical projection projection locatedlocated at theend at the output output of theend of the cylindrical bore; cylindrical bore;

- - a plurality a plurality of of circumferentially spaced circumferentially spaced apart apart slotsslots whichwhich aroundaround the edgethe edge of the of the aperture; aperture;

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whereinsaid wherein saidaperture aperturehas hascircumferential circumferentialdimensions dimensions such such that that theedge the edge of of thetheaperture, aperture,isis larger than, larger than,but butwithin withina aclose close tolerance tolerance of, the of, the outerouter dimensions dimensions of the of of the surface surface of the the conical conical projection,totoallow projection, allowfor forfree freerotation rotationofofthethe conical conical projection projection whilst whilst stillstill effectively effectively providing providing a a circumferentialbarrier circumferential barrier to to close close thethe outlet outlet sizesize whenwhen required, required, that isthat is otherwise otherwise provided provided by by said aperture said whenininthe aperture when the open openposition positionaaset set distance distance away awayfrom fromsaid saidsurface surfaceofofthe theconical conical projection. projection.

restrictor plate restrictor assembly plate assembly or or restrictor restrictor plate plate substantially substantially as described as described above wherein, above wherein, the edge the edge

of the of aperture,isistapered the aperture, taperedto to correspond correspond to angle to angle of theof the surface outer outer surface of the projection. of the conical conical projection.

Methods Methods

According According to to further further aspect aspect of present of the the present invention invention there there is is provided provided an method an of method of controlling controlling the amount the amountofofmaterial materialininthe theform formofofplastic plastic beads/shreds, beads/shreds,partially partially molten moltenbeads/shreds beads/shredsor or flowable fully flowable fully molten molten plastic, plastic,which which can can exit exit aa melting melting and mixing chamber and mixing chamber which which includes includes a a rotor, aa conical rotor, projectionextending conical projection extending fromfrom said said rotor rotor beyondbeyond the edgethe of edge of theand the melting melting mixing and mixing chambertowards chamber towardsanan outletnozzle, outlet nozzle,the themethod method comprising comprising thethe steps steps of of moving moving a restrictorplate a restrictor plate towardsororaway towards away from from the the conical conical projection projection (or (or vice vice versa) versa) in order in order to restrict to restrict thethe flow flow of of materialexiting material exitingorormaximise maximise the flow the flow of material of material exiting. exiting.

According According to to further further aspect aspect of present of the the present invention invention there there is is provided provided a method a method of of controlling controlling the melting the meltingandand mixing mixing of plastic of plastic beads/shreds beads/shreds in a plastic in a plastic frictional frictional melting melting mixer apparatus mixer apparatus

(FMMA) (FMMA) soso asas toto createa aflowable create flowablemolten molten plasticthe plastic themethod method comprising comprising thethe step step of of controllingthe controlling thesize sizeofofthe theeffective effective outlet outlet aperture/conduit/orifice aperture/conduit/orifice via: via:

o o movement movement of aof a restrictor-plate restrictor-plate relative relative to a to a conical conical projection projection (orversa) (or vice vice -versa) - at the at the terminal terminal end end of of chamber whichmelts/mixes chamber which melts/mixes the the plasticbeads plastic beads- -totochange change the the

size of size of the theeffective effectiveoutlet; outlet;oror o o movement movement ofleast of at at least one restrictor one restrictor plate plate relative relative to another to another restrictor restrictor plate plate bothofofwhich both which include include a plurality a plurality of separated of separated slots slots therein therein which which can caninto brought brought into alignment alignment or or outout of of alignment, alignment, or brought or brought into partial into partial alignment. alignment.

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Accordingtotofurther According further aspect aspect of of the the present present invention invention there there is is provided a method provided a methodofofcontrolling controlling the melting the melting and andmixing mixingofofplastic plastic beads/shreds beads/shredsinina aplastic plastic frictional frictional melting meltingmixer mixer apparatus apparatus

(FMMA) (FMMA) - via - via frictionalheat frictional heatgenerated generated from from beads/shreds beads/shreds beingbeing impacted/compressed impacted/compressed via via tips of tips of aa rotor, rotor,and LATR - –soso and LATR asas to to form form a uniformly a uniformly flowable flowable moldable moldable molten molten plastic plastic the the methodcomprising method comprisingthethe step step of of retardingthetheexit retarding exitofofbeads/shreds beads/shreds from from an an outlet outlet ( toachieve ( to achieve aneffectively an effectivelyclosed closed position) position) for for a cylindrical a cylindrical bore/rotor bore/rotor arrangement arrangement until theuntil theplastic molten molten plastic achievesa amolten achieves molten temperature temperature thatthat willwill – according - according to the to the typetype of plastic of plastic beads/shreds, beads/shreds, - -

achievea auniform achieve uniform flowflow of molten of molten plastic plastic from from the outlet, the outlet, at which at which point point the exitthe of exit of plastic molten molten plastic fromananoutlet from outletisisincreased increased (to (to achieve achieve a fully a fully open open position). position).

A method A methodsubstantially substantiallyas asdescribed describedabove above wherein wherein if thebeads if the beads to to be be melted melted andand mixed mixed are are polyethylene polyethylene (PE) (PE) if the if the temperature temperature toaform to form a uniformly uniformly flowable flowable molten molten plastic is plastic is substantially 190C -– 210C. substantially 190C 210C.

Accordingtotofurther According further aspect of the aspect of the present present invention invention there there is is provided a method provided a methodofofcontrolling controlling the heat the heat in in aa plastic plastic frictional frictional melting meltingmixer mixer apparatus (FMMA) apparatus (FMMA) thethe method method comprising comprising the the stepsof: steps of: - - increasing the increasing the RPM RPMofofa afeed feedauger auger deliveringplastic delivering plastic beads/shreds beads/shredsfrom from a a hopperto hopper to reduce reducethe thetemperature temperatureofofthe therotor rotorand andcylinder/housing, cylinder/housing,ifif the the temperature temperature

of the of the flowable flowablemolten molten plastic plastic is too is too hot;hot;

- - decreasingthe decreasing theRPM RPMof of a feed a feed auger auger delivering delivering plasticbeads/shreds plastic beads/shreds from from a a hoppertotoincrease hopper increase the the temperature temperature of the of theand rotor rotor and cylinder/housing, cylinder/housing, if just if just starting starting the apparatus the after aa period apparatus after period of of non-use or where non-use or wherethe thetemperature temperatureofofthe theflowable flowable moltenplastic molten plasticisistoo toocold. cold.

D EFINITIONS DEFINITIONS

Theuse The useofofaa "/" “/” between the terms between the terms'tips ‘tips and and RTR teeth’ or RTR teeth' or grammatical grammaticalvariants variantsthereof, thereof, for for example'tips/RTR example ‘tips/RTRteeth' teeth’as asused usedherein hereinmerely merely indicatesthat indicates thateither either tips tips may beused may be usedonon their own, their own, or or RTR teeth may RTR teeth maybebeused used on on theirown, their own, oror boththe both thetips tipsand andRTR RTR teeth teeth maymay be be usedtogether. used together. It It therefore therefore also alsofollows followsthat whenever that the ‘/’ whenever the '/'symbol symbolisis used usedbetween between adjacent adjacent

otherterms other termsin in the the specification, specification, this this indicates indicates either: either: a separate a separate use of use of a a term term separated separated by by the ‘/’ the '/'symbol, symbol,or orcombination combination where both terms where both termsthe theseparated withthe separatedwith the'/' ‘/’ symbol are used symbol are used together. Theuse together. The useofofaa'/" ‘/” elsewhere in this elsewhere in this specification specificationsuch suchas aswith withbeads/shreds has the beads/shreds has the samemeaning. same meaning.

Theterms The terms ‘tooth’ 'tooth' or or “teeth’ "teeth" when when used used in relation in relation to theto the refers rotor rotor refers to RTR to RTR teeth. teeth.

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Theterm The term'RTR ‘RTRteeth' teeth’oror'RTR ‘RTRtooth' tooth’when when used used herein herein refers refers toto aa non-continuous non-continuous discrete discrete

projectionororridge projection ridgeororsetsetofofprojections projections or ridges or ridges whichwhich extendextend away away from from surface the outer the outer surface on the on the rotor rotor as as opposed to aa continuous opposed to continuousprojection projectionsuch suchasasa amale maleororfemale female screw screw thread. thread.

Theterm The term'LATR ‘LATR teeth’oror'LATR teeth" ‘LATR tooth’when tooth' when used used herein herein refers refers to to a a non-continuous non-continuous discrete discrete

projectionororridge; projection ridge;ororset setofofprojections projections or ridges; or ridges; which which extend extend away away from the from inner the inner surface surface of the of the cylindrical cylindrical bore boreasasopposed opposed to aa continuous projection such continuous projection as aa male such as maleor or female femalescrew screw thread. thread.

Theterm The term ‘tip’oror'tips' 'tip' ‘tips’ when whenused used herein herein refers refers to radial to radial points points circumferentially circumferentially spaced spaced apart apart on the on the rotor rotor forming forming an an apex havingaagreater apex having greaterradius radius than thanthe the surfaces surfacesleading leadingto to the the apex. apex.

The term'feed Theterm ‘feed arrangement" arrangement’asasused used herein herein refers refers totoa amechanism mechanism which which can control can control the the (i.e. (i.e.increase increaseorordecrease) decrease) the the rate rateatatwhich whichbeads/shreds are provided beads/shreds are provided to to the the melt melt mix mix

chamber. chamber.

Theterm The term'melt ‘melt mix mixchamber' chamber’asasused used herein herein refers refers totothe thecombination combinationof of a a cylindrical bore cylindrical bore androtor and rotorwhich whichis is used used to frictionally to frictionally meltmelt as well as well asincoming as mix mix incoming plastic plastic beads/shreds. beads/shreds.

Theterm The term'motor ‘motorarrangement" arrangement’as as used used herein herein refers refers to to a a motor motor andand anyany associated associated gears, gears, or or otherelements, other elements, required required to provide to provide a rotational a rotational drive either drive either a rotor, a rotor, or auger, or auger, at the required at the required

numberofofrevolutions number revolutionsper perminute minute(RPM). (RPM).

B DESCRIPTIONOF RIEF DESCRIPTION BRIEF DRAWINGS OFDRAWINGS

Further aspects of Further aspects of the the present invention will present invention willbecome apparentfrom become apparent fromthe theensuing ensuing description description

whichis which is given by way given by wayof of example exampleonly onlyand and withreference with reference toto theaccompanying the accompanying drawings drawings in in which: which:

Figure11 Figure shows shows a perspective a perspective view view of a rotor of a rotor for a for a plastic plastic frictional frictional melting melting mixer mixer apparatus(FMMA) apparatus (FMMA)in in accordance accordance withwith one one aspect aspect of the of the present present invention invention

accordingto according to one onepreferred preferredembodiment embodiment thereof; thereof;

Figure22 Figure shows shows side side view view of the of the rotor rotor in Figure in Figure 1; 1;

Figure Figure 33 shows shows a plan a plan view view of rotor of the the rotor in Figures in Figures 1 and 1 2;and 2;

Figure Figure 44 showsananend shows endonon view view of of therotor the Figures11-– 3; rotorinin Figures 3;

Figure55 Figure showsa aperspective shows perspectiveview viewofofa ahousing housingininaccordance accordance with with oneone aspect aspect of the of the

present invention present invention according accordingto to one onepreferred preferredembodiment embodiment thereof; thereof;

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Figure Figure 66 showsa aplan shows planview viewofofthe thehousing housingininFigure Figure5;5;

Figure Figure 77 showsananend shows endonon view view of of thehousing the housing in in Figures Figures 5 5 and and 6; 6;

Figure88 Figure showsa aside shows sideview viewofofthe the housing Figures55-–7; housingininFigures 7;

Figure Figure 99 showsa aperspective shows perspectiveview viewofofa ahousing housing and and rotorarrangement rotor arrangement for for a plastic a plastic

frictional melting frictional meltingmixer mixerapparatus apparatus (FMMA) comprising (FMMA) comprising the the rotorofofFigures rotor Figures11-- 44 and housing and Figures55-–8;8; housingofofFigures

Figure 10 Figure 10 showsananend shows endonon view view of of a a housing housing andand rotor rotor arrangement arrangement for for a plastic a plastic

frictional melting frictional meltingmixer mixerapparatus apparatus (FMMA) (FMMA) asasshown shownin in Figure Figure 9; 9;

Figure 11 Figure 11 showsa-plan shows a planview viewofofthe therotor rotor shown shownininFigures Figures99and and10; 10;

Figure 12 Figure 12 showsa aplan shows planview viewofofthe theFMMA FMMA shown shown in Figures in Figures 9 –and 9 - 11 11 details and details various various

sectionallines: sectional lines:C-C, C-C, D-D D-D and and E-Etoused E-E used to illustrate illustrate furtherfurther cross-sectional cross-sectional

views of views of the the FMMA FMMA in in theFigures the Figures below; below;

Figure 13 Figure 13 showsa across-sectional shows cross-sectionalview viewalong alongline lineC-C C-CininFigure Figure12; 12;

Figure Figure 14 14 showsa across-sectional shows cross-sectionalview viewalong alongline lineD-D D-DininFigure Figure12; 12;

Figure 15 Figure 15 showsa across-sectional shows cross-sectionalview viewalong alongline lineE-E E-EininFigure Figure12 12and andshows showsthethe RTRRTR

within the within thehousing; housing;

Figure 16 Figure 16 showsananend shows end view view of of aa hex hex plateasasshown plate shown in in Figure Figure 14;14;

Figure 17 Figure 17 showsananend shows end view view of of aa feedport feed portininaccordance accordance with with one one aspect aspect of of thethe present present

invention according invention to one according to one preferred preferred embodiment embodiment thereof; thereof;

Figure 18 Figure 18 showsofofperspective shows perspectiveview viewofofthe theport port shown shownininFigure Figure17; 17;and and

Figure 19 Figure 19 showsa aside shows sideview viewofofthe the port port shown shownininFigures Figures1717and and18; 18;

Figure 20 Figure 20 showsa across-sectional shows cross-sectionalside sideview viewofofaa FMMA FMMAin in accordance accordance withwith one one embodiment embodiment of of thepresent the present invention; invention;

Figure 21 Figure 21 showsa across-sectional shows cross-sectionalside sideview viewofofaa FMMA FMMAin in accordance accordance withwith another another

embodiment embodiment of of thepresent the present invention; invention;

Figure 22 Figure 22 showsa across-sectional shows cross-sectionalside sideview viewofofaa FMMA FMMAin in accordance accordance withwith a preferred a preferred

embodiment embodiment of of thepresent the present invention; invention;

Figure 23 Figure 23 showsa aperspective shows perspectiveview viewofofthe thefeed feedauger augerininFigure Figure22; 22;

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Figure 24 Figure 24 shows shows a perspective a perspective view view of theofrotor the rotor in Figure in Figure 22; 22;

Figure 25 Figure 25 showsa aperspective shows perspectiveview viewofofthe thedischarge dischargeauger auger in in Figure22; Figure 22;

Figure 26 Figure 26 showsa across-sectional shows cross-sectionalview viewofofthe thetipped tipped region region and andhousing housingofofFigure Figure2222 whenthe when thetips tips and andLATR LATR teeth teeth are are aligned; aligned;

Figure 27 Figure 27 showsa across-sectional shows cross-sectionalview viewofofthe thetipped tipped region region and andhousing housingofofFigure Figure2222 whenthe when thetips tips and andLATR LATR teeth teeth are are notaligned; not aligned;

Figure 28 Figure 28 shows shows an an enlarged enlarged partial partial view view of Figure of Figure 22 illustrating 22 illustrating the tortuous the tortuous path path of the of the beads/shredsand beads/shreds and resultantmolten resultant molten plastic; plastic;

Figure 29 Figure 29 is aa photograph is showingthe photograph showing theplastic plastic formed formedbybythe themachine/process machine/process of the of the

presentinvention present invention andand thatthat produced produced by aart by a prior prior art extruder; extruder;

Figure 30 Figure 30 showsa across-sectional shows cross-sectionalview viewofofan anFMMA FMMA which which has has been been recently recently developed developed

and represents and representsone onepreferred preferredembodiment embodiment of the of the present present invention invention and and shows shows

the FMMA the with FMMA with anan open open outlet outlet position;Figure position; Figure30A 30A shows shows the the openopen outlet outlet

position and position howachieved and how achievedininmore more detailand detail andFigure Figure30B 30B shows shows the the closed closed

positionofofthe position theoutlet outletininmore more detail. detail.

Figure 31 Figure 31 is aa perspective is longitudinal perspective longitudinal cross-sectional cross-sectional view view of of Figure Figure 30; 30;

Figure 32 Figure 32 is aa plan is plan view view of ofthe theFMMA shown FMMA shown in in Figure Figure 30; 30;

Figure 33 Figure 33 is aa perspective is perspective view view of of the the apparatus shownininFigures apparatus shown Figures30-32; 30-32;

Figure 34 Figure 34 is aa perspective is view perspective view of of thethe restrictor restrictor plate plate shown shown in Figures in Figures 30 30 and 31; and 31;

Figure 35 Figure 35 is aa plan is viewofofthe plan view therestrictor restrictorplate plate shown shown in Figure in Figure 34; 34;

Figure 36 Figure 36 is aa perspective is perspective view view of of the the rotor rotorshown shown in in Figures 30 – Figures 30 - 33 33 above; above;

Figure 37 Figure 37 is aa side is viewofofthe side view therotor rotorshown shown in Figure in Figure 36; 36;

Figure 38 Figure 38 is aa cross-sectional is cross-sectional view view of ofthe themelting meltingmix mixchamber shown chamber shown ininFigures Figures3030-33; -33;

Figure 39 Figure 39 is aa perspective is perspective view view of of aa removable panelused removable panel usedininthe thehousing housingofofthe themelt meltmix mix chambershown chamber shown in in Figure Figure 38;38;

Figure Figure 40 40 is aa transverse is transverse cross-sectional cross-sectional view view of of the the removable panelshown removable panel shownininFigure Figure 39 39

Figure 41 Figure 41 is perspective is cut-awayview perspective cut-away viewshowing showingthethe rotorand rotor and conical conical projection projection

extendingfrom extending fromthe thefeed feedhousing; housing;

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Figure 42 Figure 42 is aa longitudinal is longitudinalcross-sectional cross-sectionalview viewshowing showing the the feed feed housing andauger housing and augerand and melt mix melt mix chamber chamberinterface interfaceand andthe thethermal thermal breaks breaks therebetween. therebetween.

B BEST MODESAND EST MODES ILLUSTRATIVEALTERNATE ANDILLUSTRATIVE ALTERNATE MODES MODES FOR FOR CARRYING CARRYING OUTOUT THETHE IINVENTION NVENTION

Rotor Rotor

Withrespect With respectto to Figures Figures 1 - 1 – 4 there 4 there is shown is shown a rotora100 rotor for 100 for a frictional a plastic plastic frictional melting melting mixer mixer apparatus(FMMA) apparatus (FMMA) – (not - (not shown) shown) which which has has a tipped a tipped region region 101 aand 101 and a rotor rotor toothed toothed region region

(RTR)inin the (RTR) the form form of of a a ring ring 102. Therotor 102. The rotor 100 tipped region 100 tipped region 101 101and andRTR RTR102102 areare allall made made

frommild from mildsteel. steel.

TheRTR The RTR 102 102 is is located located atatthe theupstream upstreamendend of of thethe rotor100 rotor 100 and and there there is is aa discharge discharge region region

103 inthe 103 in theform formof of a ring a ring having having a central a central aperture aperture 104inwhich 104 which in use, therein, use, receives receivesand therein, is and is attachedto, attached to, aa rotator rotatorshaft shaft104a 104a (which (which is isshown cutawayinin Figure shown cutaway Figure1). 1). The rotator shaft The rotator shaft 104a 104a

being connected being connectedtotoa amotor motor(not (notshown). shown).

TheRTR The RTR 102 102 hashas a pluralityofofcircumferentially a plurality circumferentially spaced spacedapart apartelongate elongaterotor rotorteeth teeth 105 105 thereon.TheThe thereon. rotor rotor teeth teeth 105 have 105 each eacha have a longitudinal longitudinal axis axis (rotor (rotor tooth tooth axis) axis) by indicated indicated by dashedline dashed line X-X X-Xsee seeFigure Figure3.3.The The angle angle of of thethe rotortooth rotor toothaxis axisX-X X-Xisis substantially substantially 39 39

degrees degrees to to thethe longitudinal longitudinal axisaxis of the of the rotorrotor shaftshaft Z-Z Figure Z-Z -see -see Figure 3. beAsseen 3. As can cantheberotor seen the rotor toothaxes tooth axesofofthethe rotor rotor teeth teeth areare all all parallel parallel relative relative to one to one another. another.

Thetipped The tipped region region 101 101 has ahas a series series of longitudinally of longitudinally spaced spaced apart apart tip-sections tip-sections in the formin ofthe form of hex plates hex plates 106, 106, wherein whereineach eachtip-section tip-sectionof of the the series series has six tips has six tips107 107 thereon, thereon, and and wherein wherein

eachtip-section each tip-section 106106 has has spirally spirally offset offset tips tips 107 respect 107 with with respect to adjacent to adjacent tip-section(s). tip-section(s).

Correspondingtips Corresponding tips107 107ononadjacent adjacent tip-sectionsare tip-sections arespirally spirally offset offset by by around around 12 degreessee 12 degrees see Figure1.1. Figure

In In use, therotor use, the rotor100 100is is rotated rotated so so the the tipstips 107 107 have have a of a speed speed 6m/s.of 6m/s.

Thus, in Thus, in this this particular particularembodiment the hex embodiment the hexplates plates have haveaadistance distanceofof90mm 90mm between between non-non-

adjacent opposed adjacent opposed tips-–see tips seedouble double headed headed arrow arrow R inRFigure in Figure 16 -16 - the the shaft shaft is is rotatedatat rotated

around1100 around 1100rpm. rpm. The The hexhex plates plates 106106 also also have have a central a central circular circular aperture aperture forreceiving for receivingthe the rotor shaft rotor shaft 104a. 104a.

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In In the the above-described embodiment, above-described embodiment, thethe ring ring 103 103 of of thethe discharge discharge region region of of thethe rotoralso rotor also has aa diameter has diameterofof around around78mm. 78mm.

Similarly, the Similarly, thediameter diameter of ofthe theRTR 102is RTR 102 is also around 78mm. around 78mm. The The rotor rotor teeth105 teeth 105 of of theRTR the RTR extendabove extend abovethe theouter outersurface surfaceofofthe theRTR RTR 102 102 around around 7.5mm. 7.5mm. So,overall So, the the overall diameter diameter of of the RTR the 102,ifif you RTR 102, you include include opposed opposed rotorteeth rotor teethisis 93mm. 93mm.

Thedischarge The dischargeregion region103, 103,tipped tippedregion region101, 101,and and RTR RTR 102 102 are are all all connected connected to rotator to rotator shaft shaft

104a byaakeyway 104a by keyway attachment attachment (not (not shown) shown) utilisinga akeyseat utilising keyseat on on thethe shaft shaft 104a, 104a, a keyway a keyway on on

eachof each of the the hex hex plates plates 106 106of of the the tipped tipped region region 101, 101, and the respective and the respective rings rings of of the the RTR 102 RTR 102

anddischarge and discharge region region 103; 103; into which into which a key a key (not (notisshown) shown) is slid slid into into place. place. This This enables theenables the shaft 104a shaft 104ato to transmit transmit torque torque to rotor to the the rotor 100. 100.

Further, therotor Further, the rotor100 100is is axially axially secured secured to rotator to the the rotator shaftshaft 104a 104a via via aatweld a weld at each end each end

thereof (not thereof (not shown) or aa locating shown) or locating bolt boltor orlocking lockingkey keyarrangement. arrangement.

Housing Housing

Withrespect With respectto to Figures Figures 5 - 5 – 8 there 8 there is shown is shown a housing a housing 500 for a 500 for a plastic plastic frictional frictional melting melting mixer apparatus mixer apparatus(FMMA) (FMMA) – (not - (not shown) shown) in the in the form form ofcylinder of a a cylinder having having a cylindricalbore a cylindrical bore indicated by indicated by arrow 501. In, arrow 501. In, use use the the bore 501 houses bore 501 housesa arotor rotorsuch suchasasshown shownin in Figures Figures – 4. 1 -1 4.

In In this thisparticular particularembodiment, embodiment, the the bore bore 501 has an 501 has aninternal internal diameter of 105mm. diameter of 105mm.

Thecylindrical The cylindricalbore bore (cylinder) (cylinder) 501 501 has has an an internal internal surface surface 502 502 which haswhich hasofa a series series of longitudinally aligned longitudinally alignedtoothed toothed regions regions (LATRs) asindicated (LATRs) as indicated by byarrow arrow503 503which which have have a a plurality of plurality of longitudinally alignedandand longitudinally aligned spaced spaced apart apart teeth teeth (LATR504 (LATR teeth) teeth) 504 projecting projecting inwardly inwardly from the from the internal internal surface surface 502. In this 502. In thisembodiment theLATR embodiment the LATR teeth teeth areare inserted inserted through through holes holes

cut into cut into the thecylinder cylinderofof the housing the housingand andwelded welded in in place place or or alternately alternatelymay may be be machined from machined from

solid in solid in two ormore two or more pieces. pieces.

As can As canbe beseen seenininFigure Figure5 5the theindividual individual LATR LATRteeth teeth504 504are arearranged arranged along along longitudinal longitudinal

axes 503 axes 503and andtransverse transverse circumferentialaxes circumferential axesC.C. TheThe LATR LATR teethteeth are aligned are all all aligned atset at a a set angletotothe angle therespective respective longitudinal longitudinal or transverse or transverse axes. axes.

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Whereinall Wherein all LATR LATR teethonona alongitudinal teeth longitudinalor or transverse transverseaxis axis have havethe thesame samesetset OL θor angle angle L or

θ withrespect OTTwith respectto to each each axisaxis and and thus thus the located the teeth teeth located on the on the same axissame axis are all are all parallel to parallel to oneanother. one another.

TheLATR The LATR teeth teeth 504 504 each each have have a longitudinal a longitudinal axis axis (cylinder (cylinder toothaxis) tooth axis)indicated indicatedbybydashed dashed line Y-Y line Y-Y see Figure 11. see Figure 11. The Theangle angleofofthe theLATR LATR tooth tooth axis axis shown shown by line by line Y-YY-Y is is substantially substantially

39 degrees 39 degreestotothe thecommon common longitudinal longitudinal axis axis ofof thebore the boreaxis axisand androtor rotorshaft shaftshown shownbyby line line Z- Z- Z. Thus, Z. Thus,thethe tooth tooth axes axes Y-Y Y-Y of theofLATR theteeth LATR 504teeth in a 504 inare series a series are allrelative all parallel paralleltorelative each to each other and other andcircumferentially circumferentially adjacent adjacent LATR LATR teeth teeth alsohave also have paralleltooth parallel toothaxes. axes.

TheLATR The LATR teeth teeth 504 504 project project inwardly inwardly substantially5mm substantially 5mm from from the the internal internal surface surface 502502 of of thethe

cylinder501. cylinder 501.

Thecylinder The cylinder 501 501has hasaadischarge dischargeport port505 505which which allows allows molten molten plastictotobebedischarged plastic dischargedin in a a lateral (i.e. lateral (i.e. radial) radial) direction direction shown shown byby arrow arrow LD6Fig LD Fig and 67.and 7. Adjacent Adjacent the port the port 505, at a 505, at a downstream downstream edge edge of theofport the505 port 505 relative relative the rotational the rotational fluid fluid flow flow - as - as shown by shown arrow C by arrow - of C - of the molten the molten plastic plastic imparted imparted byrotor by the the rotor (not shown) (not shown) is a projection is a projection 506.projection 506. In use, In use, projection 506functions 506 functionsas as a scraper a scraper whichwhich directs directs molten molten plastic plastic out outcylinder of the of the cylinder 501505. 501 via port via port 505.

In this In this embodiment embodiment the the scraper scraper 506 projects 506 projects a distance a distance from surface from the inner the inner surface if the if the cylinder cylinder 501 which 501 whichleaves leavesa agap gapofofsubstantially substantially 0.25mm 0.25mm -0.5mm -0.5mm fromfrom the outer the outer surface surface of the of the

dischargesection discharge section103 103ofofthe the rotor rotor 100. 100.

Rotor and Rotor and Housing Housing

In relation In Figures9 9– -15 relationtotoFigures 15there thereisis shown shownaaFMMA housing FMMA housing and and rotorarrangement rotor arrangement 800 800 for for a a plastic mixer plastic mixer frictional frictionalmelter melterapparatus apparatus(FMMA) shownininFigure (FMMA) shown Figure2020below. below.

TheFMMA The FMMA housing housing and and rotorrotor arrangement arrangement 800a has 800 has a housing housing 500 500 with with a cylindrical a cylindrical bore bore (cylinder) 501 (cylinder) 501 in inwhich which there there is isa arotor 100. rotor The 100. Thecylinder cylinder501 501has hasaadischarge discharge port port505 505 which which

allowsmolten allows molten plastic plastic to to be be discharged discharged in a lateral in a lateral (radial) (radial) direction direction shown shown by arrow by LD.arrow LD.

In this In thispreferred preferredembodiment thecylinder embodiment the cylinder 500 500shown shown has has an an internaldiameter internal diameter of of 105mm 105mm and and the rotor the rotor teeth teeth 105 105 and LATRteeth and LATR teeth504 504have have a gap a gap of of 1mm1mm there there between between – best - seen seenin best in Figure 20. Figure 20.

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The FMMA The FMMA housingand housing androtor rotor arrangement arrangement 800 800 has has an an upstream end UE upstream end UE and and aa downstream downstream end DE- –Figure end DE Figure9.9.

As can As canbe beseen seenininFigure Figure1111the therotor rotor teeth teeth 105 105have havea alongitudinal longitudinal axis axis axes axesX-X X-Xand andthe the LATRteeth LATR teeth504 504have have a longitudinalaxis a longitudinal axisY-Y Y-Yand and the the respective respective X-X X-X andand Y-YY-Y axesaxes cross cross overover

oneanother. one another.Both Boththe therotor rotor tooth tooth axes X-Xand axes X-X andLATR LATR tooth tooth axes axes Y-YY-Y intersect intersect thethe common common

longitudinalaxis longitudinal axisZ-Z Z-Zof of thethe cylinder cylinder and and rotorrotor shaft, shaft, at substantially at substantially 39 degrees 39 degrees as shown as by shown by Xº and X° andY°. Yº.

In In Figures Figures 12 to 15 12 to 15 there there is isshown shown aa FMMA FMMA housing housing and and rotor rotor arrangement arrangement 800 looking 800 looking at at various cross-sectional various cross-sectional views views along alongsectional sectional lines lines C-C, D-Dand C-C, D-D andE-E E-Eshown shown in in Figure Figure 12.12.

In Figure In 13there Figure 13 there is is shown shown the discharge the discharge region region in the in the form of form of ring ring 103 103 of the of the rotor 101 rotor 101 inside housing inside 500at housing 500 at the the downstream downstream endend of of thethe FMMA FMMA housing housing and rotor and rotor arrangement arrangement 800. 800. Thering The ring 103 103being beingconnected connectedto to rotatorshaft rotator shaft 104a. 104a.

Scraper Scraper

Figure 13 Figure 13 shows showsthat thatthe thehorizontal horizontal discharge dischargeport port 505 505from frombore bore501 501 has has a scraper a scraper 506506

adjacent aa lower adjacent lower inner inner edge edgethereof. thereof. The Thescraper scraper 506 506 being being downwardly downwardly inclined inclined towards towards

said edge said of the edge of the discharge dischargeport port 505. 505. sosomolten moltenplastic plasticcan canbebedischarged discharged viathe via theoutlet outletport port 505ininthe 505 thedirection directionofofarrow arrow O. O.

Figure 14 Figure 14 shows showsa ahex hexplate plate106 106ofofthe thetipped tippedregion region101 101ofofrotor rotor 100 100within within housing housing500. 500. Thehex The hexplate plate106 106has hasa acentral centralaperture aperture108 108which which isisconnected connectedto to rotatorshaft rotator shaft104a. 104a.

Figure1414illustrates Figure illustratesthe thesize size of of thethe gapgap between between the107tips the tips of 107 of theregion the tipped tipped101region (shown101 (shown in Figure in Figure 1) 1) and and the LATR teeth504. LATR teeth 504.

In Figure In Figure 15, 15, there there is isshown shown the the RTR 102which RTR 102 which has has a central a central aperture aperture 109 109 which which is is connectedtotorotator connected rotator shaft shaft 104a. TheRTR 104a. The RTR 102 102 hashas rotor rotor teeth teeth 105 105 projecting projecting therefrom. therefrom.

Similarly, Figure Similarly, Figure 15 15 shows the size shows the size of of the the gap gap between therotor between the rotor teeth teeth 105 105 and andthe thecylinder cylinder teeth 504. teeth 504.

Figure 16 Figure 16 shows showsininthis this embodiment embodiment a hex a hex plate plate 106106 as as shown shown in Figure in Figure 14 and 14 and showsshows the the distance shown distance shownbybydouble double headed headed arrow arrow R between R between opposed opposed tips tips 107 is107 is 90mm. 90mm. The hex The hex

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plate 106 plate has aa central 106 has central aperture 160 into aperture 160 into which the shaft which the shaft 104a (not shown) 104a (not shown)isis slid. slid. The gap The gap

betweenthe between thetips tips 107 107and andthe theLATR LATR teeth teeth 504504 is is 2.5mm. 2.5mm.

Thepassage The passageofof plasticbeads/shreds plastic beads/shreds moves moves along along the the rotor rotor past: past:

- - the tips the tips 107 107 and LATR504; and LATR 504;

and/or and/or

- - the rotor the rotor teeth teeth105 105 and and LATR teeth504; LATR teeth 504;

subjects the subjects the plastic plastic beads or plastic beads or plasticshreds shreds to tofrictional forces frictional andand forces impact and impact andcompression compression

forces; and forces; and

subjectsthe subjects therotor rotortotofrictional frictionalforces forcesas as it it rotates rotates against against the the massmass of theof the plastic plastic

beads/shreds. beads/shreds.

Together Together thethe above above forces forces alltoact all act to heat heat the plastic the plastic beads beads or or as shreds, shreds, well asas well the as the cylinder cylinder and rotor. and rotor. Once Oncethe thecylinder cylinderand androtor rotor become become sufficientlyheated sufficiently heated(e.g. (e.g. around around220° 220ºC), C),via via continualrotation continual rotationofofthe the rotor rotor and and exposure exposure to frictional to frictional forces, forces, the cylinder the cylinder andcanrotor and rotor can then also then also further further melt melt the the plastic plasticbeads beads shreds shreds as as they they travel traveltotothe thedownstream endofof the downstream end the FMMA. FMMA.

Feed Port Feed Port

In In Figures Figures 17 to 19 17 to 19 there there is isshown shown aa feed feed port port 1200 for aa FMMA 1200 for which FMMA which is is made made of of

polytetrafluoroethylene polytetrafluoroethylene (PTFE) andwhich (PTFE) and whichisissubstantially substantially 10mm 10mm in in thickness.The thickness. The feed feed port port

1200 hasananupstream 1200 has upstream surface surface (side) (side) 1202 1202 andand a downstream a downstream surface surface (side)(side) 1203 1203 - – Figure19. Figure19.

Thefeed The feedport port 1200 1200isis situated situated in in between anupstream between an upstream open open endend of the of the FMMA FMMA housing housing and and rotor arrangement rotor 800and arrangement 800 andanan auger auger feed feed arrangement arrangement (see (see Figure Figure 20). 20).

Thefeed The feedport port 1200 1200has hasthree threecircumferentially circumferentially arranged arrangedelongate elongate arcprofiled arc profiledapertures apertures (EAPAs)1204 (EAPAs) 1204 – Figs.1717 - Figs. and and 18.18.

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Thefeed The feed port port 1200 1200 alsoalso has ahas a central central aperture aperture 1205 1205 which which in use has in use has a first a first bearing bearing fitted fitted therein (not therein (not shown) onthe shown) on the upstream upstreamside side1202 1202forfor receivingthe receiving theend endofofthe theauger auger(shown (shownin in

Figure 20) Figure 20) which whichfeeds feedsthe theplastic plastic beads or shreds beads or shredsto to the the FMMA FMMA housing housing and and rotor rotor

arrangement800. arrangement 800. The The auger auger is is attached attached to to a second a second motor motor (not(not shown). shown).

In one one embodiment embodiment thethe centralaperture central aperture1205 1205 also, also, ininuse, use,has hasa asecond second bearing bearing fitted fitted

therein (not therein (not shown) onthe shown) on the downstream downstream side side 1203 1203 for for receiving receiving thethe end end of of thethe rotatorshaft rotator shaft 104a (shownininFigure 104a (shown Figure20) 20)totowhich whichthe therotor rotor 100 100isis attached. attached.

FMMA FMMA

In In relation relationtotoFigure Figure20 20there thereisis provided ananFMMA provided 2000which FMMA 2000 which has has a housing-and-rotor a housing-and-rotor

arrangement800 arrangement 800 and and a feed a feed arrangement arrangement 2001.2001. The housing-and-rotor The housing-and-rotor arrangement arrangement 800 800 and feed and feedarrangement arrangement 2001 2001 areare separated separated fromfrom one one another another via avia a feed feed port port 1200 1200 having having

EAPAs 1204 EAPAs 1204 (of(of which which only only oneone cancan be seen). be seen).

Thefeed The feedarrangement arrangement 2001 2001 has has a source a source of plastic of plastic beads beads or shreds or shreds in ainhopper a hopper (not(not shown) shown)

whichprovides which providesthe thebeads beadsororshreds shredstotoa afeed-housing feed-housing 2002 2002 viavia inletport inlet port2003. 2003.

Within feed-housing Within feed-housing2003 2003isisananauger auger2004 2004 which which is is attached attached viavia shaft shaft portion2005 portion 2005to to the the

secondmotor second motor(not (notshown) shown)as as previously previously mentioned. mentioned.

Therotation The rotation of of the the auger auger 2004 is such 2004 is as to such as to move thebeads/shreds move the beads/shreds - indirection - in direction shown shownbyby

arrowsDD-- to arrows to the the housing androtor housing and rotor arrangement arrangement800 800 viavia EAPAs EAPAs 12041204 (of which (of which only only one one can can be seen. be seen.

Therotor The rotor 100 100 has hasaacentral central shaft shaft 104a whichisis attached 104a which attachedto to first first motor motor (not (notshown) shown) at at one one

end thereof end thereof and andheld heldwithin within aa bearing bearing (not (not shown) shown)located locatedinin the the feed feed port port 1200 1200at at the the other other end thereof. end thereof.

Therotor The rotor 100 100 has hasananRTR RTR102102 with with rotor rotor teeth105 teeth 105 thereon, thereon, a tipped a tipped region region 101, 101, and and a a dischargeregion discharge region103. 103.The Thehousing housing 500 500 hashas a bore a bore 501501 withwith LATRLATR teethteeth 504. 504.

In In this thisembodiment of the embodiment of the FMMA FMMA 2000 2000 thebore thebore has has an internal an internal diameter diameter of 105mm of 105mm and and wherein: wherein:

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- - the LATR the teeth504 LATR teeth 504project project5mm, 5mm,thethe tips107 tips 107 ofof thetipped the tippedregion region101 101have have a radius a radius

of 45mm of from 45mm from thecentre the centreofofthe therotator rotator shaft shaft 104a. Thus,the 104a. Thus, the gap gapbetween betweenthethe LATR LATR

teeth 504 teeth andtips 504 and tips 107 is 2.5mm; 107 is and 2.5mm; and

-- the RTR the 102 RTR 102 has has a 78mm a 78mm diameter diameter androtor and the the rotor teethteeth 105 105 project project 7.5mm 7.5mm therefrom. therefrom.

Thus, the Thus, the gap gapbetween between the the rotorteeth rotor teeth105 105and and theLATR the LATR teeth teeth 504504 is 1mm. is 1mm.

Asdetailed As detailedabove, above, in use, in use, the the rotorrotor 100 rotating 100 rotating withinwithin the501 the bore bore 501the crushes crushes plasticthe plastic beads/shredsbeing beads/shreds beingfed fedinto intothe thehousing-and-rotor housing-and-rotorarrangement arrangement800800 via via feedfeed arrangement arrangement

2001, which 2001, whichinin turn turn causes therotor causes the rotor 100 100 and andhousing housing500 500 to to heatupup heat due due to to thefrictional the frictional forces involved forces involved with with crushing and/or compressing crushing and/or compressing theplastic the plasticbeads/shreds. beads/shreds.

Theinventor The inventorhashas found found that that altering altering the speed the speed of the rotation of the rotation of the of the auger to auger tothe increase increase the speedatat which speed whichbeads/shreds beads/shredsareare fedfed to to thehousing-and-rotor the housing-and-rotor arrangement arrangement 800 800 canused can be be used to cool to cool the the temperature of the temperature of the rotor rotor 100 100 and and housing 500.Conversely, housing 500. Conversely, decreasing decreasing rate rate of of supply of supply of beads/shreds beads/shreds bybyreducing reducing thespeed the speed of of thethe auger auger cancan heat heat up up thethe rotor rotor 100100 andand

housing500. housing 500.

In In other other words, words, the the auger speedofof rotation auger speed rotation depends depends ononthe theplastics plastics material material and andwhat's what’s happeningwith happening withthe themelt meltonona agiven givenday. day.Generally, Generally, therange the range of of rotationspeed rotation speedofofthe theauger auger is around is 120rpm. around 120 rpm.

Theinventor The inventor has hasfound foundwhen when melting melting polyethylene polyethylene beads beads the the operating operating temperature temperature of of the the FMMA 2000 FMMA 2000 isisaround around220°C. 220ºC.

In In Figure Figure 21 21 there there is isprovided provided an an FMMA 20001 FMMA 20001 which which is aisfurther a further embodiment embodiment whichwhich does does

not require not require bearings in the bearings in the feed feed port port12001 as does 12001 as doesthe the embodiment embodiment shown shown in Figure in Figure 20. 20. For For easeof ease of reference reference the the same samereference reference numerals numerals as as used used in Figure in Figure 20 have 20 have beenbeen used used for for like like parts. parts.

In In relation to Figure relation to Figure2121thethe discussion discussion will will now now focus focus on differences on differences over whatover whatinis shown in is shown

Figure 20. Figure 20.

Theauger The auger20041 20041hashas a flush a flush downstream downstream end 20041f end 20041f - see - Figure see Figure 21 -lacks 21 - and and lacks the the protrusion 2004p protrusion whichfits 2004p which fits within within the the bearing bearing located located in infeed feed port port1200 1200 as as shown and shown and

described described in in relation relation to to Figure Figure 20. 20.

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Therotor The rotor 1001 1001also alsohas hasaaflush flush upstream upstreamend end 1001f 1001f – see - see Figure Figure 21 21 – which - which lacks lacks the the shaft shaft

104ap protrudingtherefrom 104ap protruding therefromtotolocate locatewithin within aa bearing bearing in in the the feed feed port port 1200 1200 as shownasas as shown

described described in in relation relation to to Figure Figure 20. 20.

Thefeed The feedport port 12001 12001ininFigure Figure2121thus thusdoes doesnot notrequire requireaperture aperture1205 1205as as shown shown in Figures in Figures

17 and18 17 and 18which whichisisused usedtotohouse housethe therespective respectiveauger auger and and rotor rotor bearings bearings of of theembodiment the embodiment describedin described in Figure Figure 20. 20.

In In relation relationtotoFigure Figure22 22there thereisis provided ananFMMA provided 22001which FMMA 22001 which is is thepreferred the preferredembodiment embodiment of the of the present present invention. invention. For For ease of reference ease of reference the the same samereference referencenumerals numerals as as used used in in Figure 20 have Figure 20 havebeen beenused used forfor likeparts. like parts. The Thekey keycomponent component parts parts of the of the FMAFMA 22001 22001 in in Figure 22areare Figure 22 shown shown in Figures in Figures 23 -25. 23 3-25.

TheFMMA The FMMAhas has a housing-and-rotor a housing-and-rotor arrangement arrangement 800 800 and and aarrangement a feed feed arrangement 2001. 2001.

Thefeed The feedarrangement arrangement 2001 2001 having having a feed-housing a feed-housing 2002 2002 andauger and feed feed auger 2004. 2004. The feedThe feed arrangementalso arrangement alsohas has a a source source of of plasticbeads plastic beadsoror shreds shreds in in a ahopper hopper (notshown) (not shown) which which

provides the provides the beads beadsororshreds shredstotothe thefeed feedarrangement arrangement 2001 2001 via via inletport inlet port2003. 2003.

Thefeed The feedauger auger2004 2004is isattached attachedvia viashaft shaftportion portion2005 2005totoaafirst first motor motor (not (not shown) via aa shown) via

toothed gear toothed gear20051. 20051.

arrowsDD-- to arrows to the the housing androtor housing and rotor arrangement arrangement800. 800.

Thefeed The feedhousing housing2002 2002is is connected connected to to thethe housing housing 500500 of the of the housing-and-rotor housing-and-rotor

arrangement800 arrangement 800 viavia a a thermal thermal break break in in theform the formofofTEFLON TEFLONringTM20090. ring 20090.

Therotor The rotor 100 100 has hasaacentral central shaft shaft 104a whichisis attached 104a which attachedto to aa second secondmotor motor (notshown) (not shown)viavia

toothed gear toothed gear20052 20052atatone oneend end thereof. thereof.

Therotor The rotor 100 100 in in the the Figure Figure 22 embodiment 22 embodiment only only comprises comprises a tipped a tipped region region 101. 101. The The tipped tipped

region 101 region 101 being beingupstream upstreamofof a adischarge discharge auger auger 220220 andand a discharge a discharge portport 221.221. The The dischargeauger discharge augerhas hasa ashaft shaft222 222which whichisisattached attachedvia viatoothed toothedgear gear223 223 to to a a thirdmotor third motornot not shown. shown.

Thehousing The housing500 500 has has a cylindricalbore a cylindrical bore501 501with withLATR LATR teeth teeth 504. 504.

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In In this thisembodiment of the embodiment of the FMMA FMMA 22001 22001 the the borebore has has an internal an internal diameter diameter of 150 of 150 mm and mm and

wherein: wherein:

- - the LATR the teeth504 LATR teeth 504project project5mm, 5mm, - - the tips the tips 107 107ofofthe thetipped tipped region region 101 101 - in -the in form the form of aplate of a hex hex -plate have -a have radiusaof radius of 67.5mm 67.5mm from from thethe centre centre ofof therotator the rotatorshaft shaft 104a 104atotowhich whichthey theyare areattached. attached.

Thus, the Thus, thegap gapbetween between the the LATRLATR teeth teeth 504 504 and and tips 107tips 107 when when both both are circumferentially are circumferentially

aligned with aligned with one other is one other is 2.5mm seeFigure 2.5mm see Figure26. 26.

Thefeed The feedauger auger2004 2004is isrotated rotatedatataaspeed speedofofsubstantially substantially 30 30 -- 40 rpm. 40 rpm.

Therotor The rotor 100 100is is rotated rotated at at a a speed of substantially speed of substantially 830 rpm-- 850 830 rpm 850rpm rpmtotoprovide providea atip tip speed speed of substantially of substantially6m/s. 6m/s.

Thedischarge The dischargeauger auger220 220 is is rotatedatataaspeed rotated speedofofsubstantially 30-– 40 substantially 30 40rpm. rpm.

Figures Figures 2626 and and 27 illustrate 27 illustrate how how rotation rotation of theofrotor the rotor 100 in100 in direction direction Z causesZ the causes the plastic plastic

beads/shreds(not beads/shreds (notshown) shown) and and resultant resultant molten molten plastic(also plastic (alsonot notshown) shown)to to bebe substantially substantially

radially accelerated radially accelerated towards the inner towards the inner surface surface of of the the cylindrical cylindricalbore asasshown bore shown by by arrows arrows R. R.

Althoughnot Although notshown shown thebeads/shreds the beads/shreds and and resultant resultant molten molten plastic plastic alsoalso have have a a circumferentialacceleration circumferential acceleration caused caused by rotation by rotation of the of the100 rotor rotor and 100 tips and tips 107 in the107 in the direction direction shownbybyarrow shown arrowZ.Z.

In In Figure Figure 26 26 when thetips when the tips 107 are aligned 107 are aligned with with LATR LATRteeth teeth504 504 thereisisaaradial there radial gap gap between between the teeth the teeth 504 andtips 504 and tips 107 of substantially 107 of substantially 2.5mm. 2.5mm.

In In Figure Figure 27 27 when thetips when the tips 107 are positioned 107 are positioned intermediate intermediatethe theLATR LATR teeth teeth 504 504 (i.e. (i.e.

maximallynon-aligned) maximally non-aligned)the thegap gapbetween between thethe tips tips 107 107 andand thethe internalsurface internal surface 502 502 of of thethe cylindrical bore cylindrical boreisis10.6mm – 11.5mm. 10.6mm - 11.5mm.

Figure 28 shows Figure 28 showsthe thepath pathofofthe theplastic plastic beads fromthe beads from theauger augerininthe the direction direction of of arrow arrow D and D and

then the then the tortuous tortuous path generally shown path generally shown bybyarrow arrowX X around around thethe tips107 tips 107 and and thethe LATR LATR teeth teeth

504. 504.

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Figure 29 shows Figure 29 showshow howthethe melter/mixer melter/mixer process process andand apparatus apparatus of the of the present present invention invention

described described herein herein produces produces plastic plastic which which has nodiscernible has no readily readily discernible visible airvisible pocketsair to pockets the to the nakedeye naked eye- -as ascan canbebeseen seenininthe theend endview viewofofa arectangular rectangularbeam beam – taken B -Btaken from from a mould a mould

into into which which the the apparatus of the apparatus of the present invention directly present invention directlyextruded extruded the the molten molten recycled recycled

plastic. plastic.

As can As canbe beseen seenthe therectangular rectangularbeam beam B and B and its its lack lack of of airpockets air pocketscan canbebe usefullycompared usefully compared to the to the prior prior art art recycled recycledproduct, product, in in thethe form form of aof a circular circular post post C, which C, which was was made made with a with a conventional conventional plastic plastic extruder extruder (i.e., (i.e., which which uses uses heating heating elements elements to plastic to melt the melt the plastic beads). beads).

Best Best Modes Modes Embodiment Embodiment

Figure 30 shows Figure 30 showsthere thereisisprovided providedananFMMA FMMA 30001 30001 whichwhich is ayet is yet a further further embodiment embodiment of theof the

present invention. present invention. For For ease easeofofreference referencewhere where possible possible thesame the same reference reference numerals numerals as as usedin used in Figures Figures 20 20 and and2121have havebeen been used used for for likeparts. like parts.

In In relation to Figure relation to Figure3030thethe discussion discussion will will now now primarily primarily focus focus on differences on differences over whatover is what is shownininFigures shown Figures2020and and21. 21.

TheFMMA The FMMA 30001 30001 has has a a housing-and housing-and rotor-arrangement rotor-arrangement 8001 8001 and andarrangement a feed a feed arrangement 3001 3001 whichhas which hasaahopper hopper3003 3003 andand an an auger auger 30043004 whichwhich are separated are separated by thermal by thermal barrier barrier 300 on300 on the rotor the rotor and and a a thermal thermal barrier barrier 300a 300a in in the the housing housing made made ofofpolytetrafluoroethylene polytetrafluoroethylene(aka (aka TeflonTM). Both TeflonTM) Boththermal thermalbarriers barriers300 300and and 300a 300a have have ringring shaped shaped transverse transverse cross-sectional cross-sectional

section profile-–see sectionprofile see also also Figures Figures 4142. 41 and and 42.

Thehousing-and-rotor The housing-and-rotorarrangement arrangement 8001 8001 in-use in-use formform a melting a melting and and mixing mixing chamber chamber for for transforming plastic transforming plastic beads/shreds into flowable beads/shreds into flowable uniform uniformmolten moltenplastic plastic which whichcan canbebemolded. molded.

Thefeed The feedarrangement arrangement 3001 3001 has has a feed-housing a feed-housing 3002 3002 and a and a source source of plastic of plastic beadsbeads or or shredswhich shreds whichare areheld heldinin aa hopper hopper3003 3003 which which is is connected connected to to an an inlet-aperture3040 inlet-aperture 3040 in in the the

feed-housing3002. feed-housing 3002.

Theauger The auger3004 3004isisa ahollow hollowand andisisdriven drivenbybygears gearsofofwhich whichonly onlygear gear3005 3005 connected connected to the to the

auger is auger is shown andisisrotationally shown and rotationally supported by bearings supported by bearings1042. 1042.TheThe gear gear 3005 3005 (and(and

unshown unshown driveshaft drive shaftgear) gear)are arelocated locatedinin aa gear-housing gear-housing3005a 3005a attached attached to to a drive a drive shaft shaft

3006of 3006 of aa 1.5kW 1.5kWmotor motor 3007. 3007. Rotation Rotation of of thethe auger auger 3004 3004 delivers delivers beads/shreds beads/shreds to the to the

housing-androtor-arrangement housing-and rotor-arrangement 8001. 8001.

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Thefeed The feedarrangement arrangement 3001 3001 has has an electronically an electronically operable operable valve valve (not (not shown) shown) which which can can movedbetween moved between open open or shut or shut positions positions to to allow/stop allow/stop delivery delivery ofofbeads/shreds beads/shredsto to thethe auger auger

via the via the inlet-aperture inlet-aperture3004a. 3004a.

Theauger The auger3004 3004isisconnected connectedto to the the motor motor 3007 3007 via via an an arrangement arrangement whichwhich allows allows the auger the auger

to have to havea avariable variable speed speed to control to control the of the rate rate of of flow flow of plastic plastic beads/shreds beads/shreds to the housing-and to the housing-and

rotor-arrangement 8001. rotor-arrangement 8001.

Therotor The rotor 1001 1001has hasa ahollow hollowdrive driveshaft shaft 1040 1040which whichisisheld heldwithin within aa pair pair of of spaced apart spaced apart

bearings1041located bearings1041 locatedininthe thegear gearhousing housing3009. 3009.

Therotor The rotor 1001 1001has hasa ahollow hollowdrive driveshaft shaft 1040 1040which whichisisdriven drivenby bygears gears3008, 3008,3008a 3008a located located in in a gear-housing a 3009attached gear-housing 3009 attached to to a a 15kW 15kW motor motor 30103010 via avia a drive drive shaft shaft 3011. 3011.

bearings1041 locatedininthe bearings1041 located thegear gearhousing housing3009. 3009.

Therotor The rotor1001 1001 shown shown in theinFigures the Figures 30 - 3130 – 31 - and in and in greater greater detail indetail in 36 Figures Figures and 37 36 and 37 comprisesa atipped comprises tippedregion region1010 1010formed formed from from 9 hexagonal 9 hexagonal plates plates 106 106 which which have have a central a central

aperture into aperture into which the central which the central drive driveshaft shaft1040 1040 can can pass. pass. The hexagonalplates The hexagonal plates106 106 are are non- non-

rotationally connected rotationally connected to to the the hollow hollow drive drive shaft shaft1040 1040 via viaaagrooved grooved keyway arrangement keyway arrangement (not (not

shown)and shown) andcirclips circlips (not (not shown). Otherways shown). Other waysofofconnecting connectingasas known known by those by those skilled skilled in in the the

art are art are envisaged. envisaged.

Thetipped The tippedregion region1010 1010has hassix sixtips tips 107 107on oneach eachofofthe thehex hexplates plates106. 106.The The tips107 tips 107 onon each each

adjacenthexhex adjacent plate plate 106 106 are longitudinally are longitudinally spacedspaced apart apart (with (withtorespect respect to the longitudinal the longitudinal axis of axis of the rotor) the rotor) shown by dashed shown by lineAA-–A. dashedline A.AsAscan can bebe seen seen thethe tipsonon tips adjacent adjacent hexhex plates plates 106106

are also are alsooffset offsetwith withrespect respect to to thethe tipstips 107107 on adjacent on adjacent hex 106. hex plates plates 106.

Thetipped The tippedregion region1010 1010being beingupstream upstream of of a conical a conical projection301 projection 301 and and outletnozzle outlet nozzle 305. 305.

Theconical The conical projection projection 301 301 projects projects out out from the rotor from the rotor beyond the downstream beyond the downstream edge edge of the of the

cylindrical bore cylindrical bore501. 501.

Therotor The rotor housing housing5001 5001has hasa a cylindrical bore cylindrical bore501 501with withLATR LATR teeth teeth 504. 504.

As mentioned As mentionedabove above thethe rotorhousing rotor housing 5001 5001 has has a conical a conical projection projection 301301 which which has has a solid a solid

shaft 302 shaft 302connected connected to antoelectric an electric linear linear actuator actuator (not shown) (not shown) situated situated within within actuator- actuator-

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housing3020. housing 3020.The The linearactuator linear actuatorenables enables the the conicalprojection conical projectiontotobe bemoved moved forward forward or or backward as backward as shown shownby by double double headed arrow X. headed arrow X. This This movement shownby movement shown bydouble double headed headed arrow XXenables arrow enablesthe theconical conicalprojection projection to to move towardororaway move toward away from from a restrictorplate a restrictor plate303. 303.

Theconical The conical projection projection 301 301 and andshaft shaft302 302are areco-axially co-axially aligned aligned with with the the aperture aperture 303 of the 303 of the

restrictor plate restrictor 303. plate 303.

Therestrictor-plate The restrictor-plate303303 is is fixed fixed in in a stationary a stationary relationship relationship located located betweenbetween a 304 a shoulder shoulder 304 on an on an outlet outlet nozzle nozzle 305 andthe 305 and theforward forwardedge edgeofofthe thehousing housing5001. 5001. Thus, Thus, it ismovement it is movementof of the conical the conical projection projection 301 301 toward andaway toward and awayfrom from the the restrictor plate restrictor plate as shownbybyarrow as shown arrowX X whicheffectively which effectivelyopens opens or closes or closes the outlet the outlet from from the the cylindrical cylindrical bore bore 501 501toleading leading to the the outlet outlet nozzle 305. nozzle 305. This This is is shown more shown more clearlyinin Figures clearly Figures30A 30Aand and 30B. 30B.

As can As canbe beseen seenthe theedge edgeof of theangle the angleofofthe thetapered taperedaperture aperture311 311 of of therestrictor the restrictor plate plate 303 303

substantiallycorresponds substantially corresponds to angle to the the angle of theof the surface outer outer surface of projection of conical conical projection 301. 301.

In In the the open position shown open position in Figures shown in Figures30 30and and30A 30A theconical the conicalprojection projectionwhich whichcan can move move in in

the direction the directionofofdouble double headed headed arrow arrow X is inXaisfully in a retracted fully retracted position position relativerelative to melting to melting mix mix chamberwhich chamber which is isdefined definedbybythe therotor rotorhousing housing5001 5001 which which comprises comprises the the cylindrical cylindrical bore bore 501501

and tipped and tipped region region 8001. 8001.

When When thethe conical conical projection projection is inis in fully the the fully retracted retracted position position in Figure in Figure 30A 30A (i.e. (i.e. when thewhen the outlet 307 outlet 307isiseffectively effectivelyopen open position) position) the the distance distance between between the edge the closest closest edge of311aperture of aperture 311 and the and the outer outer surface surface 301a 301aofofthe the conical conical projection projection 301 is substantially 301 is substantially6mm asshown 6mm as shownbyby

doublearrow double arrowY.Y.

Conversely, Conversely, when when the conical the conical projection projection is in is in the theextended fully fully extended position position in Figure in Figure 30B (i.e. 30B (i.e. whenthe when theoutlet outlet307307 is is effectivelyininaaclosed effectively closedposition) position)the thedistance distance between between the closest the closest edge ofedge of aperture 311 aperture 311and andthe theouter outersurface 301aofofthe surface301a the conical conical projection projection 301 is substantially 301 is substantially1mm 1mm --

2mmasasshown 2mm shownbybyarrow arrowZ. Z.

As can As canbe beseen seenininFigures Figures30A 30A and and 30B30B the the outer outer surface surface 301a 301a of the of the conical conical surface surface

changesfrom changes frombeing being angled angled with with respect respect to to thelongitudinal the longitudinalaxis axis 302 302totobecome become parallel parallel

thereto 301b. thereto In the 301b. In the embodiment embodiment shown shown in Figures in Figures 30, 30, 30A 30A and 30B, and 30B, this this change change in profile in profile of of the conical projection the projection at at301b 301b works together with works together with a a modified terminal hex modified terminal nut 106a hex nut 106awhich which has aa lipped has lipped portion portion 1060 whichin-use 1060 which in-useprojects projects downstream downstream – see - see also also Figures Figures 36 36 and and 37. 37.

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Thiscombination This combination of the of the flattened flattened section section of theof the conical conical projection projection 301b and301b and the the lipped lipped portion portion 1060 whichoverlays 1060 which overlaysthe theflattened flattenedsection section of of the the conical conical projection 301b – projection 301b - helps helps ensure that ensure that

moltenplastic molten plasticwill willnot notget getininbehind behind the the conical conical projection projection and prevent and prevent it being itretracted. being retracted.

Figures 36 and Figures 36 and3737show showin in greaterdetail greater detail lipped lipped portion portion 1060 hasaatapered 1060 has tapereddownstream downstream edge1060T edge 1060T which which in-use in-use helps helps directmolten direct molten plastic(not plastic (notshown) shown) through through thethe aperture aperture andand

slots of slots of the the restrictor restrictor plate platetowards towards outlet outlet 307. 307.

Therotor The rotor and and tipped tipped region region 101 101including including the the terminal terminal hex hex nut nut 106a 106aisis also also shown shownininFigures Figures 36 and 36 and37. 37.

As can As canbe beseen seenininFigures Figures3636and and3737 the the tipped tipped region101 region 101 hashas thethe tips107 tips 107 are are offset offset

relative tototips relative 107 tips 107on onadjacent adjacenthex hex plates plates106 106 by by twisting twistingeach each upstream hexplate upstream hex plate 106 106byby substantially 10 substantially 10 degrees in aa clockwise degrees in direction relative clockwise direction relativetoto each eachadjacent adjacentdownstream hex downstream hex

plate 106. plate 106.

Theoutlet The outlet nozzle 305has nozzle 305 hasaatapered taperedthroat throat306 306leading leadingtotoananoutlet outlet 307 307from fromwhich whichmaterial material can exit can exit the the rotor rotorand and housing housing assembly. The assembly. The amount amount of material of material exiting exiting therotor the rotorand and housingassembly housing assembly depends depends on the on the temperature temperature and/or and/or visual visual appearance appearance or physical or physical

characteristicsofofthe characteristics thematerial material exiting. exiting. ThisThis can can be be generalised generalised as being as being fully fully molten molten plastic plastic with no with novisible visiblebeads beadsbutbut is also is also moremore fully fully described described below. below.

Whena aflowable When flowablemoldable moldable molten molten plastic plastic is is detected,the detected, theoutlet outletis is moved movedtotothe thefully fully opened opened

positiontotomaximise position maximisethe the flowflow rate rate (output (output of theofapparatus). the apparatus).

In In one one example this occurs example this occursonce oncea atemperature temperatureto to form form a uniformly a uniformly flowable flowable molten molten plastic plastic

has been has beenachieved. achieved.

Thecontrol The controlofofun-melted un-melted plastic plastic or partially or partially melted melted plastic, plastic, on theon onethe oneandhand, hand, and the the molten molten plastic, on plastic, theother on the otherhand, hand, exiting exiting the the rotor/housing rotor/housing assembly assembly is controlled is controlled by: by: - - the restrictor-plate the restrictor-plateand and controlling controlling itsits relative relative proximity proximity to the to the outer outer surface surface of theof the conicalprojection; conical projection; -- the temperature the of the temperature of the molten moltenmoldable moldableplastic plasticisis dependent dependentonon thetype the typeofofplastic plastic beads/shredsbeing beads/shreds beingprocessed processed (i.e.,melt (i.e., meltmixed) mixed)bybythe thepresent presentinvention invention

In In general, if individual general, if individualbeads, beads,or or small small groups groups of partially of partially melted melted beads, beads, or helical or helical stream of stream of

moltenplastic, molten plastic,are are exiting exiting thethe outlet outlet 307: 307: instead instead of, aof, a uniform uniform cylindrical cylindrical or nearorcylindrical near cylindrical

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moltenstream molten streamofofplastic, plastic, the the desired desired temperature to achieve temperature to achieveaa uniformly uniformly flowable flowable molten molten moldable moldable plastic plastic hashas not not beenbeen achieved. achieved. This is generally This is generally evident ifevident if the the molten molten plastic plastic exiting exiting the melting the meltingchamber chamber via outlet via outlet 307a has 307 has a substantially substantially consistent consistent tube, or tube-like, tube, or tube-like, cross- cross- section. section.

Theinventors The inventorshave have observed, observed, if ifthe thebeads/shreds beads/shreds being being melted melted are are polyethylene polyethylene the the desired desired

temperaturetotoachieve temperature achievea auniformly uniformlyflowable flowablemouldable mouldable molten molten plastic,,isis generally plastic,, generally achieved achieved at aa temperature at between temperature between substantially190C substantially 190Cto to 210C 210C - inthe - in theapparatus apparatus of of thethepresent present invention,. invention,.

Theoperation The operationofof the the FMMA FMMA 30001 30001 is controlled is controlled by by a suitably a suitably programmed programmed PLCshown). PLC (not (not shown).

As can As canbe beseen seenininFigures Figures3434and and3535 the the restrictor-plate 303 restrictor-plate 303has hasaacentral central aperture aperture311 311 whichhas which has a plurality a plurality of of circumferentially circumferentially spaced spaced apart312 apart slots slots 312the around around the thereof. perimeter perimeter thereof. Theedge The edge313 313ofof theaperture the apertureisistapered taperedtotocorrespond correspondtotothe theangle angleofofthe theouter outersurface surfaceof of the the conicalprojection conical projection 301. 301.

Whenthe When thebeads beads have have at least at least oneone width width or or height height dimension dimension greater greater equal equal to, to, or or above, above,

3mm 3mm butbut below below 7mm 7mm then then the the width of width of the the slots 312 slots in the312 in the restrictor restrictor plate plate 303 is 303 is substantially substantially

3mm. 3mm.

Whenthe When thebeads beads have have at least at least oneone width width or or height height dimension dimension greater greater equal equal to, to, or or above, above, 1mm1mm

-– 2mm, 2mm, then then the the width width of slots of the the slots 312 312 in the in the restrictor restrictor plate plate is is substantially substantially 2mm.In 2mm.In Figure 38 Figure 38 there is there is shown shown aa melt melt mix mixchamber chamber having having a housing a housing 5001 5001 withwith a cylindrical a cylindrical bore bore 501501 forming forming

part of part of an an FMMA 30001. FMMA 30001.

Thebore The bore501 501has hasanan internalsurface internal surface502 502with withananinternal internaldiameter diameterofof150 150mmmm andand wherein: wherein:

- - the LATR the teeth504 LATR teeth 504project project5mm, 5mm, - - - the tips the tips 107 107ofofthe thetipped tipped region region 101 101 - in -the in form the form of aplate of a hex hex -plate have -a have radiusaof radius of 67.5mm 67.5mm from from the the centre centre ofof therotator the rotatorshaft shaft 104a 104atoto which whichthey theyare areattached. attached.

In In the the embodiment shown embodiment shown in Figures in Figures 31,31, 32 32 andand 38, 38, the the housing housing 50015001 has ahas a hexagonal hexagonal outer outer

surface profile surface profile when whenviewed viewed in in cross-section cross-section withwith removable removable panelspanels 5002 on5002 each on each outer outer surface of surface of the the hexagon whichprovide hexagon which providethe theLATR LATR teeth teeth 504504 on on thethe cylindricalsurface cylindrical surface502 502ofofthe the bore 501. bore 501.

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Theremovable The removable panel panel 5002 5002 is shown is shown in more in more detail detail in in Figure Figure 39.39.

Thefeed The feed auger auger 30043004 is rotated is rotated at a speed at a speed of substantially of substantially 5 rpm at 5 rpmupattostart start up to substantially substantially 25 25 rpmwhen rpm whenthe the outlet outlet is its is in in its fullyopen fully open position. position.

Therotor The rotor100 100is is rotated rotated at at a speed a speed of substantially of substantially 857rpm 857rpm to provide to provide a tipof speed a tip speed of substantially6m/s. substantially 6m/s.

In In operation, when operation, when the the FMMAFMMA is started is first first started the restrictor-plate/conical the restrictor-plate/conical projection projection remain inremain its in its their closed their closed position position until untilatatleast leastpartially partiallymolten plastic molten is achieved plastic -see is achieved Figure -see Figure30B. 30B. The The

restrictor-plate/conical projection restrictor-plate/conical projectionisisthen thenmoved to the moved to the fully fully open openposition positionwhen when near near fully fully

flowablefully flowable fullymolten molten plastic plastic is is achieved achieved - see- Figure see Figure 30B. 30B.

In In Figures 41 and Figures 41 and4242the thethermal thermalbreak break arrangement arrangement in place in place between between the feed the feed housing housing and and rotor housing rotor housing is is illustratedininmore illustrated more detail. detail.

Whatisis shown What shownin in thethermal the thermal break break in in thethe form form of of an an annular annular ring ring of of Teflon Teflon 300a 300a interfaced interfaced

betweenthe between thefeed feedhousing housing 3009 3009 andand thethe rotor rotor housing housing 5001 5001 and and the the annular annular ringring of Teflon of Teflon 300300

onthe on therotor rotorininthe theinterface interface between between theplates the hex hex plates and theand the auger. auger.

Figure 42also Figure 42 alsoshows showsthethe flowflow of beads of beads into into the melt the melt mix chamber mix chamber and and their their longitudinsl longitudinsl

directionofoftravel direction travelthere therealong along (i.e.,notnot (i.e., showing showing any radial any radial acceleration, acceleration, solely solely in in the interests the interests

of clarity of clarityand andunderstanding understanding these drawings). these drawings).

D ISCUSSIONOF DISCUSSION OFTHE INVENTIONAND THEINVENTION ANDALTERNATE ALTERNATE WAYS WAYS IT CAN IT CAN BE BE IMPLEMENTED IMPLEMENTED

Rotor Rotor

Therotor, The rotor, rotor rotor teeth teeth and/or and/or parts parts therefor therefor may generallybe may generally bemade made from from any any metal metal or metal or metal

composite composite which which hasrequisite has the the requisite characteristics characteristics to make to it make it suitable suitable for: for:

- - crushing and crushing andcompressing compressing plasticshreds plastic shreds or or beads; beads;

- - having aa specific having specific heat heat capacity capacity which enablesthe which enables therotor rotor to to heat heat up up quickly quickly due due

to the to the frictional frictional forces ofcrushing forces of crushing plastic plastic shreds shreds or beads. or beads.

In In one one preferred preferred embodiment, therotor embodiment, the rotor and andthe the parts parts thereof thereof may be made may be madefrom fromstainless stainlesssteel. steel.

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In In another another preferred preferred embodiment, therotor embodiment, the rotor and andthe theparts parts thereof thereof may bemade may be made from from mild mild steel. steel.

In In some embodiments, some embodiments, thethe RTR, RTR, tipped tipped region region and and discharge discharge region region may may allmade all be be made from the from the

samematerial. same material.

Alternately, one Alternately, one or more of the more of the RTR, RTR,tipped tippedregion regionand and discharge discharge region region may may be made be made from from different materials, different materials,provided provided said said materials materials are are suitable suitable for forcrushing crushing plastic plasticshreds shreds or or beads beads

and melting and meltingsame. same.

Theinventor The inventor has hasfound foundthat thatthe thecrushing crushingand andmelting meltingaction actionofofthe therotor rotor also also imparts a mixing imparts a mixing

actiontotothe action theplastic. plastic.This This is particularly is particularly useful useful when when two or two more or moreofsources sources differentofplastic different plastic beadsoror shreds beads shredsare arebeing beingmelted meltedbybythe thepresent presentinvention. invention. For For example, example,ifif polyethylene beads polyethylene beads

and polypropylene and polypropylenebeads beadsareare being being mixed. mixed.

Therotor The rotorteeth teeth of of the the RTRRTR may may be be angled angled withtorespect with respect to the longitudinal the longitudinal axis of the axis of rotor. the rotor.

In In aa preferred preferred embodiment therotor embodiment the rotor teeth teeth may havetheir may have theirlongitudinal longitudinal axis axis angled angled at at around around 39 39

degrees degrees to to thethe longitudinal longitudinal axisaxis of the of the rotor. rotor.

In In an alternate embodiment, an alternate the embodiment, the rotorteeth rotor teethmay may be be substantially substantially parallel parallel to to thelongitudinal the longitudinal axis of axis of the therotor rotor(i.e., (i.e., not angledwith not angled withrespect respect to said to said axisaxis of rotor). of the the rotor).

Therotor The rotorteeth teeth may may preferably preferably be straight be straight (i.e. curved (i.e. non- non- curved - if viewed - if viewed from above). from directly directly above).

Therotor The rotor teeth teeth preferably preferably have havea asharp sharp(i.e. (i.e. non-curved) non-curved)outer outeredges. edges. Preferably, Preferably, thethe outer outer

edgesofofthethe edges rotor rotor teeth teeth form form a right a right angle. angle.

Housing Housing

Thehousing The housingmay may have have a number a number of different of different outward outward profileshapes profile shapes without without departing departing from from thethe

scopeof scope of the the present present invention. invention.

In In one one embodiment, thehousing embodiment, the housing maymay in the in the form form of of cylinder. cylinder.

In In some otherembodiments some other embodimentsthe the housing housing may may have have a rectangular a rectangular outside outside profile profile shapeshape with awith a

cylindrical bore cylindrical bore(bore) (bore)extending extending through through the middle the middle thereof.thereof.

In In aa preferred preferred embodiment thehousing embodiment the housingmay may have have a hexagonal a hexagonal outside outside profile profile withwith a cylindrical a cylindrical

(bore) extending (bore) throughthe extending through themiddle middlethereof. thereof. Preferably, Preferably,each eachface faceofofthe thehexagon hexagonmaymay havehave

a removable a removablesection sectionwhich which forms forms part part of of thethe cylindricalbore. cylindrical bore.TheThe inventors inventors have have found found this this

feature enables feature enablesrapid rapidaccess accesstotothe themelting meltingchamber chamberfor for maintenance, maintenance, cleaning cleaning or easily or for for easily replacingparts replacing parts- -if ifrequired. required.

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.

In In general, thebore general, the bore maymay have have a substantially a substantially circularcircular or circular-like or circular-like profile profile in whichinthe which rotor the rotor

canrotate. can rotate.

In In embodiments thebore embodiments the boremay may have have an an internal internal profileformed profile formedfrom frompolygonal polygonal shapes shapes with with eight eight

or more or sideseach more sides eachapproximating approximating a circularprofile a circular profile to to aa greater greater or orlesser lesserdegree degree from from octagon octagon

through to through to an anaperigon. aperigon.Thus, Thus, it itshould shouldbebe appreciated appreciated thatthat any any profiles profiles approximating approximating the the shapeofofa a shape circleareare circle within within thethe scope scope ofpresent of the the present invention. invention.

In In some embodiments some embodiments the the surface surface of the of the cylinder cylinder orportion or a a portion thereof thereof maymay be grooved. be grooved. The The groovesmay grooves may have have differentprofiles different profiles without without departing departing from fromthe the scope scopeofofthe the present presentinvention. invention.

In In one one embodiment embodiment thethe grooves grooves maymay havehave a substantially a substantially triangular triangular V-shaped V-shaped profile. profile.

In In another another embodiment embodiment thethe grooves grooves maymay havehave a substantially a substantially U-shaped U-shaped profile. profile.

In In some still further some still furtherembodiments theinternal embodiments the internal surface surfaceof of the the bore boremay may include include upup andand down down

sequentialprofile sequential profilepatterns patterns thereon. thereon.

In In some embodiments some embodiments the the sequential sequential patterns patterns maymay be sinusoidal be sinusoidal patterns. patterns.

In In other other embodiments embodiments thethe sequential sequential patterns patterns maymay be some be some form form of of a corrugated a corrugated patternpattern or or cross corrugated cross corrugatedpattern. pattern.

In In embodiments where embodiments where thethe cylinder cylinder hashas grooves grooves it may it may be formed be formed via roll via roll forming forming a flat a flat plate plate

oncethe once thegrooves grooveshave have been been machined machined in orinotherwise or otherwise formed formed into surface into the the surface of plate of the the plate to to formthe form theinternal internalsurface surface of the of the cylinder. cylinder.

In In one one example, thecylinder example, the cylinder may beformed may be formedbybycomputer computer numerical numerical controlled controlled machining machining fromfrom

two or two or more piecesofofmetal. more pieces metal.

Thetooth The tooth axis axis of of the the LATR teeth may LATR teeth mayininsome someembodiments embodiments be parallel be parallel to the to the longitudinalaxis longitudinal axis of the of bore(bore the bore (bore axis). axis).

In a preferred In a preferred embodiment thetooth embodiment the toothaxis axisofof the the LATR LATRteeth teethmay may have have an an angle angle of of substantially substantially

39 degrees 39 degreestotothe thebore boreaxis. axis.

Housingand Housing andRotor Rotor

In In general, general, at at least least the the housing, cylinder (bore) housing, cylinder (bore) and LATR and LATR teeth teeth maymay all all be be mademade from from the the

samematerial. same material.

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Alternately, one Alternately, one or more of the more of the housing, bore and housing, bore andLATR LATR teeth teeth maymay all all be be made made from from different different

materials, provided materials, said materials provided said materials utilised utilised for forbore bore and LATRteeth and LATR teethare aresuitable suitablefor forcrushing crushing plastic shreds plastic shreds or or beads andmelting beads and meltingsame. same.

As mentioned, As mentioned,the theLATR LATR teeth teeth of of thethe housing housing maymay generally generally be made be made fromsame from the the material same material as the as thebore. bore.

In aa preferred preferred embodiment one embodiment one or or more more of the of the housing, housing, bore, bore, and and LATRLATR teeth teeth may bemay madebe made

fromstainless from stainlesssteel. steel.

Theseries The series of of LATRs LATRsmay may in in some some embodiments embodiments comprise comprise a single a single tooth. tooth.

Alternately, there Alternately, there may bea aplurality may be plurality of of longitudinally longitudinally spaced apartLATR spaced apart LATR teeth teeth in in a series. a series.

Generally, the Generally, the longitudinal longitudinal axis axis of ofeach each tooth tooth in inan an LATR may LATR may be be aligned aligned andand either either parallel, parallel,

or angled, or angled,with withrespect respect to the to the longitudinal longitudinal axis axis ofbore of the the of bore the of the housing. housing.

TheLATR The LATR teeth teeth preferably preferably have have a sharp a sharp (i.e. (i.e. non-curved) non-curved) outer outer edges. edges. Preferably, Preferably, the the outer outer

edgesofof the edges the LATR LATR teethform teeth forma aright rightangle. angle.

Thesurface The surfaceofof the the bore bore may maybebesmooth smooth in in oneone preferred preferred embodiment. embodiment.

Alternately, the Alternately, the surface surface of of the the bore bore may beaaseries may be series of of ridges ridges and andgrooves grooveswhich which extend extend in in a a longitudinal direction. longitudinal direction.InIn such suchembodiments the ridges embodiments the ridges form formthe the LATR LATR teeth. teeth.

Scraper Scraper

Thescraper The scraperelement element may may generally generally be be in in thethe form form of of a a tongue tongue likeprojection. like projection.

In In some embodiments some embodiments thethe scraper scraper element element may may be a be a straight straight elongate elongate projection projection substantially substantially

rectangularininshape rectangular shape which which has ahas flatacross-sectional flat cross-sectional profile.profile.

In In some embodiments some embodiments thethe scraper scraper maymay be abe a straight straight elongate elongate projection projection with with anan arcuate arcuate cross- cross-

sectionalprofile. sectional profile.

Discharge port Discharge port

Thedischarge The dischargeport portmay maybebe located located at at any any downstream downstream location location of the of the housing. housing.

In In some embodiments some embodiments the the discharge discharge port port may may be be substantially substantially aligned aligned withlongitudinal with the the longitudinal axis of axis of the thebore boreand/or and/or rotor. rotor.

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In In aa preferred preferred embodiment thedischarge embodiment the discharge portmay port may be be substantially substantially orthogonal orthogonal with with respect respect to to

the longitudinal the longitudinal axis of the axis of the bore bore and/or and/orrotor, rotor, oror put putanother anotherway, way, radiallypositioned radially positioned with with

respecttotothe respect thecentre centre axis axis of the of the rotor. rotor.

In In such such embodiments, the embodiments, the bore bore may may include include a projection a projection adjacent adjacent thethe downstream downstream innerinner edge edge

of the of the port portrelative relativetotothethe rotational rotational flow flow of the of the molten molten plastic. plastic. The projection, The projection, in use, in use, helps helps direct, molten direct, plasticinto molten plastic intothe thedischarge discharge port port andofout and out theof the bore/housing. bore/housing.

Thedischarge The dischargeportport may may be directly be directly or indirectly or indirectly in fluid in fluid communication communication with with a mould a mould part. part.

Feed Port Feed Port

Thefeed The feedport port may mayhave havea a number number of differentshapes of different shapes dependent dependent on housing on the the housing provided provided it it is sufficiently is sufficiently dimensioned in use dimensioned in use to cover to cover the bore. the bore.

In In one one example thefeed example the feedport portmay maybebe substantiallyrectangular substantially rectangularfor foraa rectangular rectangular housing. housing. Preferably, theport Preferably, the portmaymay be substantially be substantially circular circular in shape. in shape.

In In alternate alternate example the feed example the feed port port may bemade may be made from from steel steel andand thethe port port may may be be liquid liquid

jacketed. jacketed.

In In aa further furtheralternative alternativeexample, example,the thefeed feedport portmay may comprise oneor comprise one or two twolayers: layers:

- aa first - first layer layer adjacent therotor adjacent the rotorwhich which is steel; is steel; and/or and/or

Theplurality The plurality ofofapertures apertures which which are are circumferentially circumferentiallyarranged arranged may havea anumber may have numberof of

different shapes different shapes without without limiting limiting the the scope scope of theofpresent the present invention. invention.

For example,the For example, theapertures aperturesmay may have have anyany oneone of the of the following following shapes: shapes:

- square; - square; - circular; - circular; - rectangular; - rectangular; - oblong. - oblong.

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However, this However, this listshould list should notnot be seen be seen as limiting. as limiting.

Theplurality The plurality ofofapertures apertures which which are are circumferentially circumferentiallyarranged arranged may also have may also haveaanumber numberof of

different layouts different layoutson on the theplate platewhich whichmay also be may also dependentononthe be dependent thenumber number of of apertures. apertures.

In In one one embodiment there embodiment there may may be four be four equidistantly equidistantly spaced spaced apertures apertures which which may be may be

positioned on aa common positioned on common circumference. circumference.

In In another another embodiment there embodiment there may may be eight be eight or or more more apertures apertures which which may may be be positioned positioned on a on a

common common circumference circumference and and thusthus formform a ring-shape. a ring-shape.

It Itwill willbebeappreciated appreciatedthe thecommon circumference common circumference onon which which thethe apertures apertures or or elongate elongate arcarc

profiled apertures profiled apertures (EAPAs) may (EAPAs) may bebe positioned positioned is is largerthan larger thanthe thecircumference circumferenceofofthe theportion portion of the of rotor, which the rotor, whichininuse, use, willbebe will adjacent adjacent the the feed feed port.port. Thus,Thus, enabling enabling plastic plastic beads orbeads or shredstotobebe shreds delivered delivered to the to the outer outer surface surface of theof the rotor. rotor.

In In aa preferred preferred embodiment thefeed embodiment the feedport portmay maybe be in in theform the formofofananannular annularspace space shared shared

betweenthe between thefeed feedhousing housing and and melt melt mixmix chamber. chamber.

Feed Feed Arrangement Arrangement

Thefeed The feedarrangement arrangementmay may come come in a variety in a variety of different of different formsforms without without departing departing from from the the scopeof scope of the the present present invention. invention.

In In one example one example thethe feed feed arrangement arrangement may utilise may utilise a hopper a hopper and an and augeranarrangement auger arrangement to to deliver beads/shreds deliver to the beads/shreds to the melt melt mix mix chamber. chamber.

In In another examplethe another example thefeed feedarrangement arrangement may may utilise utilise a hopper a hopper in direct in direct communication communication with with

the melt the melt mix chamber.Such mix chamber. Suchan an arrangement arrangement having having an orifice an orifice which which canvaried can be be varied near near real-real-

time to time to control control the theamount of shreds/being amount of delivered or shreds/being delivered or not not delivered delivered to to the the melt melt mix mix chamber chamber

via aa gravity via gravityfeed. feed.

FMMA FMMA FMMA Theplastic The plastic frictional frictional melting meltingmixer mixerapparatus apparatus(FMMA) of the (FMMA) of the present present invention invention has hasapplication application to plastic to plastic beads beads or or shreds shreds obtained obtained from recycled from recycled plastic.plastic.

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In In some embodiments some embodiments the the recycled recycled plastic plastic beads beads / shreds / shreds may may be from be from a polyethylene a polyethylene plastic plastic

product. product.

In other embodiments In other embodimentsthe the plastic plastic beads/shreds beads/shreds may bemay be obtained obtained from polyolefin from polyolefin plastic plastic product. product.

The above The aboveexamples examplesshould shouldnot notbebeseen seenasaslimiting limiting as as in in some embodimentsthe some embodiments theplastic plastic beads/shredsmay beads/shreds maybe be from from PVCPVC (polyvinyl (polyvinyl chloride). chloride).

It It is isenvisaged thatwhen envisaged that when moving moving to different to different plastics plastics or mixtures or mixtures of plastics of plastics or different or different sizes sizes of beads/shreds of beads/shredsroutine routineoptimisation optimisationof ofthethe operating operating parameters parameters for achieving for achieving a flowable a flowable

moltenplastic molten plastic may berequired. may be required.

Theplastic The plastic beads/shreds used beads/shreds used by by thethe present present invention invention maymay alsoalso include include different different types types or or a a mixtureofofdifferent mixture differenttypes typesof of plastic. plastic.

In In one one example, shredded example, shredded plastic(shreds) plastic (shreds)may maybe be sourced sourced fromfrom milkmilk bottles. bottles.

Thesource The sourceofofplastic plastic in in the the FMMA may FMMA may in in one one embodiment embodiment be inbe in form the the form of a of a hopper. hopper.

Thehousing The housingmaymay havehave a number a number of different of different external external profiles profiles provided provided it has itanhas an internal internal

cylindrical bore cylindrical borefor forhousing housingthethe rotor. rotor. SaidSaid cylindrical cylindrical bore bore and andbeing rotor rotormade being of amade of suitable a suitable metal as metal as discussed discussedabove. above.

The feed The feedarrangement arrangementmaymay movemove the plastic the plastic beads/shreds beads/shreds to housing to the the housing and and rotor rotor arrangement arrangement in ainhorizontal a horizontal direction direction which which is parallel is parallel to the to the rotor’s rotor's axis ofaxis of rotation. rotation.

Outlet Nozzle Outlet Nozzle

Theoutlet The outletnozzle nozzle maymay have have a variety a variety of different of different configurations configurations without departing without departing from the from the scopeof scope of the the present present invention. invention.

In In one one preferred preferred embodiment the embodiment the outletnozzle outlet nozzlemay may have have a substantially a substantially ring-shaped ring-shaped outer outer

bodywhich body which includes includes a conical a conical throatthroat leading leading to an to an exit exit port. port.

Restrictor Plate Restrictor Plate

Therestrictor The restrictorplate plateisisused, used,in in conjunction conjunction with with a conical a conical projection projection to control to control the rate the output output rate of material of material from from the the chamber (e.g. beads/shreds, chamber (e.g. beads/shreds,ororpartially partially melted melted beads/shreds, or beads/shreds, or

partially molten partially plasticuntil molten plastic untilflowable flowable fullymolten fully molten plastic plastic is achieved, is achieved,

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In one one embodiment there embodiment there may may be two be two restrictor restrictor plateswhich plates which maymay rotationally rotationally move move withwith

respecttotoone respect one another, another, eacheach plate plate including: including:

- aa common - centralaperture common central aperturewhich which can can accommodate accommodate the conical the conical projection; projection;

- aa plurality - plurality of of circumferentially spaced circumferentially spaced apart apart slotsslots (or other (or other aperture aperture shapes)shapes)

surroundingthe surrounding thecentral central aperture aperture positioned positioned in in the the same relative position same relative position on on each each

plate so plate so the the respective respective slots slotson on each each plate plate are are capable capable of of alignment with one alignment with another one another

(to (to each form each form a collective a collective aperture); aperture);

said rotational said rotationalmovement movement increasing increasing or decreasing or decreasing the effective the effective size of thesize of the collective collective apertures and apertures andthus thusamount amountof of materialthat material thatcan canpass passtherethrough, therethrough, oror notpass not pass through, through, ififthe the slots on slots onrespective respective plates plates are are non-aligned. non-aligned.

In In some embodiments some embodiments it may it may be be the the restrictorplate restrictor platewhich whichmoves moves relative relative toto theconical the conical projection. For projection. example,three For example, threeor or more moreequi-spaced equi-spaced apart: apart: cams; cams; or or linearactuators; linear actuators;may maybe be

engaged engaged to to move move the restrictor the restrictor plate plate towards towards or move or move away from away from actuator), (if a liner (if a liner or actuator), allow or allow the restrictor the restrictorplate platetoto move moveaway away from, from, via via the the force forceofofmolten moltenplastic plastic(when (whenthe thecams cams are are no no

engaged), engaged), thethe conical conical projection. projection.

Theinvention The invention may mayalso alsobebesaid saidbroadly broadlytotoconsist consistin in the the parts, parts, elements andfeatures elements and features referredtotoororindicated referred indicatedin in the the specification specification of the of the application, application, individually individually or collectively, or collectively, in in anyororall any all combinations combinations of two of two or more or more ofparts, of said said parts, elements elements or features. or features.

Aspectsofof the Aspects the present present invention invention have havebeen beendescribed described by by wayway of example of example onlyonly and and it should it should

be appreciated be appreciatedthat that modifications modifications and andadditions additionsmay maybebe made made thereto thereto without without departing departing from from

the scope the thereof as scope thereof as defined definedin in the the appended claims. appended claims.

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REFERENCES: REFERENCES:

1. Jambeck, 1. Jambeck,Jenna Jenna R.;Geyer, R.; Geyer,Roland; Roland;Wilcox, Wilcox,Chris; Chris; Siegler, Siegler, Theodore Theodore R.; R.; Perryman, Perryman,

Miriam; Miriam; Andrady, Anthony;Narayan, Andrady, Anthony; Narayan,Ramani; Ramani;Law, Law,Kara Kara Lavender Lavender (13(13 February February

2015). "Plastic 2015). "Plastic waste wasteinputs inputs from from land land into into thethe ocean". ocean". Science. Science. 347 (6223): 347 (6223): 768- 768– 771 771

47

Claims

WHAT WE CLAIM IS: 19 Sep 2025

1. A plastic frictional melting mixer apparatus (FMMA) comprising:

- a housing which has a cylindrical bore; wherein the cylindrical bore includes an internal surface having a series of longitudinal toothed regions (LATRs) comprising a plurality of longitudinally aligned and spaced apart teeth (LATR teeth) projecting inwardly from the internal surface; and 2024326375

- a rotor located in the cylindrical bore, wherein the rotor includes a tipped region comprising plurality of circumferentially and longitudinally spaced apart and offset tips;

- a motor arrangement which can rotate the rotor so the tip speed is 6m/s; and

- a feed arrangement to deliver plastic beads/shreds to the rotor; and

wherein the gap between the rotor tipped region and the cylindrical bore - when the tips are not aligned with the LATRs - is sufficient to allow for radial acceleration, in-use, of beads/shreds of plastic from the rotor into the inner surface of the cylindrical bore, given the 6 m/s tip speed;

wherein said apparatus does not include an additional heating source.

2. A plastic frictional melting mixer apparatus (FMMA) as claimed in claim 1 above wherein the gap between the:

- tips; and

- the LATR teeth;

when both are aligned is significantly less than the gap between the tips and the inner surface of cylindrical bore when the tips are teeth are not aligned.

3. A plastic frictional melting mixer apparatus (FMMA) as claimed in claim 2 wherein during rotation of the rotor, when the tips are aligned with LATR teeth, there is a radial gap of:

• substantially 2.5mm when mixing/melting beads/shreds having at least one width or height dimension greater equal to, or above, 3mm but below 7mm; or

• substantially 1.5mm when mixing/melting beads/shreds having at least one width or 19 Sep 2025

height dimension greater of around 1mm - 2mm.

4. An FMMA as claimed in claim 2 or claim 3 wherein during rotation of the rotor, when the tips are positioned intermediate to (i.e., maximally non-aligned therewith) the LATR teeth the radial gap between the tipped region and the LATR teeth is:

• substantially 11.5mm when mixing/melting beads/shreds having at least one width or height dimension greater equal to or above 3mm but below 7mm; or 2024326375

• substantially 10.5mmwhen mixing/melting beads/shreds having at least one width or height dimension greater of around 1mm - 2mm.

5. An FMMA as claimed in anyone of the preceding claims wherein the tipped region includes a series of longitudinally spaced apart tip-sections, wherein each tip-section of the series has six tips thereon, and wherein each tip-section has spirally offset tips with respect to any adjacent upstream or downstream tip-section(s).

6. An FMMA as claimed in claim 5 wherein each tip-section is in the form of a hex plate mounted to a rotor shaft.

7. An FMMA as claimed in claim 6 wherein during rotation of the rotor, when the tips are aligned with the LATR teeth, the radial gap between:

- flat sections of a hex plate intermediate the tips; and

- the internal surface of the cylindrical bore;

is substantially 16.5mm.

8. A plastic frictional melting mixer apparatus (FMMA) as claimed in claim 1 wherein neither the LATRs nor tipped region, have mutually engaging profiles.

9. A plastic frictional melting mixer apparatus (FMMA) as claimed in claim 1 wherein the rotor has a non-tapered longitudinal diameter.

10. A plastic frictional melting mixer apparatus (FMMA) as claimed in anyone of the preceding claims which further includes:

- a source of plastic beads/shreds (plastic); 19 Sep 2025

- a feed arrangement configured to move the plastic from the source to the housing.

11. A plastic frictional melting mixer apparatus (FMMA) as claimed in claim 1 wherein the FMMA does not include any additional heating elements to melt or assist with melting the plastic beads/shreds. 2024326375

12. A method of melting and mixing plastic shreds or beads and the resultant molten plastic comprising the steps of:

a) introducing the shreds or beads to a rotor with tips/teeth located within a cylinder provided with internally radially projected obstacles on the inner surface thereof; wherein said cylinder and rotor provide sufficient gap to allow, in-use, for radial acceleration of the beads/shreds away from the rotor;

b) rotating the rotor so the tips /teeth have a rotational speed of substantially 6m/s;

c) radially accelerating the shreds or beads from the rotor towards the inner surface of the cylinder;

wherein during travel along the cylinder/rotor beads/shreds and any molten plastic formed will be forced against the obstacles on the inner surface of the cylinder and between the obstacles and tips/teeth of the rotor.

13. A method as claimed in claim 12 wherein the beads/shreds are melted without: - additional heating elements to increase the temperature of the cylinder; nor - sequentially increasing compression during axial travel of the beads/shreds;

being required.

14. A method as claimed in claim 13 wherein the melting is achieved by rotational speed of the rotor.

15. A method as claimed in claim 14 wherein the melting is achieved by a rotational speed of 19 Sep 2025

tips/teeth being substantially 6 m/s.

16. A method as claimed in any one of the preceding claims wherein the resultant plastic creating by the mixing and melting process is substantially free of air pockets visible by the naked eye.

17. A rotor and housing arrangement for a plastic frictional melting mixer apparatus (FMMA) wherein there is provided a working section of a rotor which can, in-use: 2024326375

- radially accelerate shreds or beads towards an internal surface of the cylindrical bore of the housing wherein the internal surface has a series of longitudinal toothed regions (LATRs) comprising a plurality of longitudinally aligned and spaced apart teeth (LATR teeth) projecting inwardly from the internal surface; - drive the shreds or beads forward in a downstream direction and force the plastic shreds or beads through reduced diameter gaps between the tips on the rotor and the LATR teeth which periodically align and move away as a consequence of the rotation of the rotor; - thereby alternating between: ▪ radial acceleration (i.e., when the tips and LATR are not substantially aligned and ▪ forcing the plastic shreds or beads through reduced diameter gaps - between the aligned tips and LATR - during axial travel long the rotor from upstream to downstream; so as to: o mix plastic shreds or beads; and/or o melt plastic shreds or beads;

wherein the working section comprises:

- a tipped region formed by a plurality of adjacent spirally offset hexagonal plates.

Figure Figure 11

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