U.S. patent application number 11/610101 was filed with the patent office on 2007-04-19 for system and method for determining components of a blended plastic material.
This patent application is currently assigned to ADVANCED BLENDING TECHNOLOGIES, LLC. Invention is credited to Alan C. Ernst, Todd C. Ernst.
Application Number | 20070085229 11/610101 |
Document ID | / |
Family ID | 34919904 |
Filed Date | 2007-04-19 |
United States Patent
Application |
20070085229 |
Kind Code |
A1 |
Ernst; Todd C. ; et
al. |
April 19, 2007 |
SYSTEM AND METHOD FOR DETERMINING COMPONENTS OF A BLENDED PLASTIC
MATERIAL
Abstract
Methods and systems are disclosed for determining plastic
components of a blended plastic material. According to a method of
the present invention, a blending computer access supply data
describing characteristics of each of a plurality of plastic
components. The blending computer receives specification data which
identifies at least one desired characteristic of the blended
plastic material. The blending computer processes the supply data
and the specification data to determine combinations of certain of
the plastic components that may produce the blended plastic
material having the at least one desired characteristic. The
blending computer determines, for each combination, a preferred
percentage of each of the plastic components of the combination,
and reports the combinations and preferred percentages.
Inventors: |
Ernst; Todd C.; (Tallmadge,
OH) ; Ernst; Alan C.; (Perrysburg, OH) |
Correspondence
Address: |
CALFEE HALTER & GRISWOLD, LLP
800 SUPERIOR AVENUE
SUITE 1400
CLEVELAND
OH
44114
US
|
Assignee: |
ADVANCED BLENDING TECHNOLOGIES,
LLC
Perrysburg
OH
|
Family ID: |
34919904 |
Appl. No.: |
11/610101 |
Filed: |
December 13, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10796648 |
Mar 9, 2004 |
7158847 |
|
|
11610101 |
Dec 13, 2006 |
|
|
|
Current U.S.
Class: |
264/5 |
Current CPC
Class: |
B29C 2948/9219 20190201;
B29C 48/03 20190201; B29C 2948/92828 20190201; B29C 2948/92266
20190201; B29C 2948/92333 20190201; B29C 2948/92723 20190201; B29C
2948/92228 20190201; B29C 2948/92361 20190201; B29C 2948/92466
20190201; B29C 48/92 20190201 |
Class at
Publication: |
264/005 |
International
Class: |
B29B 9/00 20060101
B29B009/00 |
Claims
1. A method for determining plastic components of a blended plastic
material, the method comprising: accessing supply data describing
characteristics of each of a plurality of plastic components;
receiving specification data identifying at least one desired
characteristic of the blended plastic material; processing the
supply data and the specification data to determine a plurality of
different combinations of plastic components that may produce the
blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; and reporting at least one selected combination and
the corresponding preferred percentages; wherein the supply data
includes a cost associated with each plastic component and the step
of determining a preferred percentage of each of the plastic
components is based on a total cost of the blended plastic material
produced by the combination, the total cost being the sum of the
percentage cost of each plastic component of the combination, the
percentage cost of each plastic component of the combination being
the cost of the plastic component multiplied by the preferred
percentage of the plastic component.
2. The method of claim 1 wherein the steps for processing and
determining are performed on a remote computer.
3. The method of claim 1, wherein the at least one characteristic
of the blended plastic material includes a characteristic
reflecting a physical property of the blended plastic material.
4. The method of claim 3, further comprising: determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; and
processing the supply data and the specification data to determine
at least one combination plastic components that produce a blended
plastic material having a characteristic approximating the at least
one desired characteristic; and; determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
5. The method of claim 4, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
6. The method of claim 5, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
7. The method of claim 4, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
8. The method of claim 1, further comprising: determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; and
processing the supply data and the specification data to determine
at least one combination plastic components that produce a blended
plastic material having a characteristic approximating the at least
one desired characteristic; and; determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
9. The method of claim 1, wherein the at least one characteristic
is a physical property relating to density.
10. The method of claim 9, further comprising: determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; and
processing the supply data and the specification data to determine
at least one combination plastic components that produce a blended
plastic material having a characteristic approximating the at least
one desired characteristic; and; determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
11. The method of claim 10, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
12. The method of claim 11, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
13. The method of claim 10, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
14. The method of claim 1, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
15. The method of claim 1, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
16. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; and reporting at least one selected combination and
the corresponding preferred percentages; wherein the steps for
processing and determining are performed on a remote computer.
17. The method of claim 16, wherein the at least one characteristic
of the blended plastic material includes a characteristic
reflecting a physical property of the blended plastic material.
18. The method of claim 16, further comprising: determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; and
processing the supply data and the specification data to determine
at least one combination plastic components that produce a blended
plastic material having a characteristic approximating the at least
one desired characteristic; and; determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
19. The method of claim 16, wherein the at least one characteristic
is a physical property relating to density.
20. The method of claim 16, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
21. The method of claim 16, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
22. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; and reporting at least one selected combination and
the corresponding preferred percentages; wherein the at least one
characteristic of the blended plastic material includes a
characteristic reflecting a physical property of the blended
plastic material.
23. The method of claim 22, further comprising: determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; and
processing the supply data and the specification data to determine
at least one combination plastic components that produce a blended
plastic material having a characteristic approximating the at least
one desired characteristic; and; determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
24. The method of claim 22, wherein the at least one characteristic
is a physical property relating to density.
25. The method of claim 22, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
26. The method of claim 22, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
27. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; reporting at least one selected combination and the
corresponding preferred percentages; determining that no
combination of the plastic components produces a blended plastic
material having the at least one desired characteristic; processing
the supply data and the specification data to determine at least
one combination plastic components that produce a blended plastic
material having a characteristic approximating the at least one
desired characteristic; and determining, for the at least one
combination, a preferred percentage of each of the plastic
components of the combination.
28. The method of claim 27, wherein the at least one characteristic
is a physical property relating to density.
29. The method of claim 27, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
30. The method of claim 27, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
31. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; and reporting at least one selected combination and
the corresponding preferred percentages; wherein the at least one
characteristic is a physical property relating to density.
32. The method of claim 31, wherein reporting at least one selected
combination and the corresponding preferred percentages includes
sorting and presenting the selected combinations according to a
cost associated with each selected combination.
33. The method of claim 31, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
34. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; and reporting at least one selected combination and
the corresponding preferred percentages; wherein reporting at least
one selected combination and the corresponding preferred
percentages includes sorting and presenting the selected
combinations according to a cost associated with each selected
combination.
35. The method of claim 34, further including: receiving target
blended plastic material data defining the plastic components and
percentages of a target blended plastic material; and wherein the
step of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
36. A method for determining plastic components of a blended
plastic material, the method comprising: accessing supply data
describing characteristics of each of a plurality of plastic
components; receiving specification data identifying at least one
desired characteristic of the blended plastic material; processing
the supply data and the specification data to determine a plurality
of different combinations of plastic components that may produce
the blended plastic material having the at least one desired
characteristic; determining, for at least one combination, a
preferred percentage of each of the plastic components of the
combination; reporting at least one selected combination and the
corresponding preferred percentages; and receiving target blended
plastic material data defining the plastic components and
percentages of a target blended plastic material; wherein the step
of determining includes calculating comparative cost data
associated with each combination and the reporting includes
reporting preferred percentages based at least in part on the
target blended plastic material data.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/796,648, filed Mar. 9, 2004, now U.S. Pat.
No. ______, entitled SYSTEM AND METHOD FOR DETERMINING COMPONENTS
OF A BLENDED PLASTIC MATERIAL the disclosure of which is
incorporated herein by reference in its entirety.
BACKGROUND
[0002] The systems, methods, and computer readable media described
herein relate generally to optimizing and/or determining components
of a blended plastic material.
[0003] The creators of blended plastic materials, known in the
industry as converters, typically purchase single component
incoming material streams directly from resin suppliers, with
little or no testing of the incoming raw materials. Converters
generally assume that the incoming materials meet or exceed the
physical properties of the product and process requirements. In
some cases, the incoming materials will vary in one or more
critical physical properties creating a hardship for the converter.
Such materials may be returned to the supplier or reduced in price
as a concession and blended into a finished product formulation at
low concentrations so as not to materially affect the required
physical properties or processing of the finished product.
[0004] It is also common practice today that many converters use
wide specification, recycled post-industrial, recycled
post-consumer and/or reprocessed resins in the production of
numerous products. Traditionally, the use of post-industrial
recycled resins, and to a greater extent recycled post-consumer
resins, has been limited to non-critical applications or used at
relatively low percentages due to the degradation of blended
material properties or processing of the finished product. Low
percentages of previously used materials included in the finished
compound or reduced quality have been the norm due to a limited
understanding of how to blend two or more materials together to
alter the finished blend to meet the desired physical properties
and not reduce processing efficiencies. The technology embodied in
this invention may permit the converter to use up to 100% recycled
post-consumer, wide specification, recycled and/or reprocessed
resins or any combination aforementioned while achieving the
desired finished product physical properties and processing
characteristics.
[0005] A need presently exists in the industry for a method and
system which optimize the physical properties of finished plastic
products in relation to cost. Typically, the objective of blending
two or more materials together is to achieve the desired properties
of one polymer, for example, combined with the desired properties
of a second polymer and so on. Rather than synthesizing a new
polymer with all the desired properties, two or more polymers may
be identified and mixed together to form a finished new blend that
will have all of the desired properties, at the molecular level.
The objective remains to produce the highest quality product at
desire physical properties and maintain or improve processability,
at the least cost. Current technology does not provide for a method
to determine a relative value of a component in relation to one's
physical properties within a blend or database.
SUMMARY
[0006] The following presents a simplified summary of methods,
systems, and computer readable media associated with optimizing
and/or determining components of a blended plastic material to
facilitate providing a basic understanding of these items. This
summary is not an extensive overview and is not intended to
identify key or critical elements of the methods, systems, and
computer readable media or to delineate the scope of these items.
This summary provides a conceptual introduction in a simplified
form as a prelude to the more detailed description that is
presented later.
[0007] According to a first aspect of the present invention, a
method is disclosed for determining plastic components of a blended
plastic material. The method includes accessing supply data
describing characteristics of each of a plurality of plastic
components. The method also includes receiving specification data
which identifies at least one desired characteristic of the blended
plastic material. The method further includes processing the supply
data and the specification data to determine combinations of
certain of the plastic components that may produce the blended
plastic material having the at least one desired characteristic.
The method still further includes determining, for each
combination, a preferred percentage of each of the plastic
components of the combination, and reporting the combinations and
preferred percentages.
[0008] According to a second aspect of the present invention, a
method is disclosed for determining a plastic component of a
blended plastic material. The method includes accessing supply data
describing characteristics of each of a plurality of plastic
components. The method also includes receiving specification data
which identifies at least one desired characteristic of the blended
plastic material. The method further includes receiving presumed
plastic component data identifying a portion of ingredients of the
blended plastic material.
[0009] According to the method, supply data is processed. The
presumed plastic component data and the specification data is
processed to determine combinations of one or more plastic
components that may be combined with the components identified by
the presumed plastic component data to produce the blended plastic
material having the desired characteristic(s). For each
combination, a preferred percentage of each of the plastic
components of the combination is determined, and the combinations
and preferred percentages are reported.
[0010] An advantage of the present invention is that it enables a
reduction in the cost of blended plastic materials having
particular characteristics.
[0011] Another advantage of the present invention is that it
enables improved physical performance and processability of a
finished product.
[0012] A further advantage of the present invention is that it
enables a value to be placed on an component's contribution of
physical properties in relation to the physical properties of other
blend components and their cost.
[0013] An additional advantage of the present invention is that it
provides a method to facilitate the design of a multi-component
blend solution when at least one component is unknown.
[0014] Yet a further advantage of the present invention is that it
provides a method to routinely secure in line test specimens,
compare the sample to the blend specifications and refine the blend
if needed. This process may be continuous and provides for real
time quality control and cost efficiency.
[0015] These as well as other objects, features and advantages of
the present invention are readily apparent from the following
description of illustrative example methods, systems, and computer
readable media which are described herein in connection with the
following description and the annexed drawings. These examples are
indicative, however, of but a few of the various ways in which the
principles of the methods, systems, computer readable media and so
on may be employed and thus are intended to be inclusive of
equivalents. Other advantages and novel features may become
apparent from the following detailed description when considered in
conjunction with the drawings.
DRAWINGS
[0016] Comprehension of the invention is facilitated by reading the
following detailed description, in conjunction with the associated
drawings, in which:
[0017] FIG. 1A is a block diagram illustrating a first example
operating environment in accordance with the present invention;
[0018] FIG. 1B is a block diagram illustrating a second example
operating environment in accordance with the present invention;
[0019] FIG. 2 is a block diagram illustrating an example blending
computer of FIG. 1A;
[0020] FIG. 3 is a block diagram illustrating one example
methodology for determining components of a blended plastic
material;
[0021] FIGS. 4-7 are example computer windows which may be employed
by the control logic of the blending computer of FIG. 1A;
[0022] FIG. 8 is a block diagram illustrating an alternate example
operating environment in accordance with the present invention;
[0023] FIGS. 9-12 are example computer windows which may be
employed by the control logic of the blending computer to enable
the use of remote supply data; and
[0024] FIGS. 13-17 are example computer windows which may be
employed by the control logic of the blending computer to provide
preferred material valuation.
DESCRIPTION
[0025] Example systems, methods, computer media, and so on are now
described with reference to the drawings, where like reference
numerals are used to refer to like elements throughout. In the
following description for purposes of explanation, numerous
specific details are set forth in order to facilitate thoroughly
understanding the methods, systems and computer readable media. It
may be evident, however, that the methods, systems and computer
readable media can be practiced without these specific details. In
other instances, well-known structures and devices are shown in
block diagram form in order to simplify description.
[0026] Some portions of the detailed descriptions that follow are
presented in terms of algorithms and symbolic representations of
operations on data bits within a computer memory. These algorithmic
descriptions and representations are the means used by those
skilled in the data processing arts to convey the substance of
their work to others skilled in the art. An "algorithm" is here,
and generally, conceived to be a self-consistent sequence leading
to a desired result. The sequence includes actions like those
requiring physical manipulations of physical quantities. Usually,
though not necessarily, these quantities take the form of chemical,
biological, electrical or magnetic signals capable of being stored,
transferred, combined, compared, and otherwise manipulated.
[0027] It has proven convenient at times, principally for reasons
of common usage, to refer to these signals as bits, values,
elements, symbols, characters, terms, numbers, or the like. It
should be borne in mind, however, that these and similar terms are
to be associated with the appropriate physical quantities and are
merely convenient labels applied to these quantities. Unless
specifically stated otherwise as apparent from the following
discussions, it is appreciated that throughout the description,
discussions utilizing terms like processing, computing,
calculating, determining, displaying, or the like, refer to the
action and processes of a computer system, computer component,
logic, or similar electronic computing device, that manipulates and
transforms data represented as physical (electronic) quantities
within the computer system's registers and memories into other data
similarly represented as physical quantities within the computer
system memories or registers or other information storage,
transmission or display devices.
[0028] It will be appreciated that some or all of the processes and
methods of the system involve electronic and/or software
applications that may be dynamic and flexible processes so that
they may be performed in sequences different than those described
herein. It will also be appreciated by one of ordinary skill in the
art that elements embodied as software may be implemented using
various programming approaches such as machine language,
procedural, object oriented, and/or artificial intelligence
techniques.
[0029] The processing, analyses, and/or other functions described
herein may also be implemented by functionally equivalent circuits
like a digital signal processor (DSP), a software controlled
microprocessor, or an ASIC. Components implemented as software are
not limited to any particular programming language. Rather, the
description herein provides the information one skilled in the art
may use to fabricate circuits or to generate computer software
and/or computer components to perform the processing of the system.
It will be appreciated that some or all of the functions and/or
behaviors of the present system and method may be implemented as
logic as defined above.
[0030] Referring to FIG. 1A, there is illustrated a first example
operating environment 100 for systems and methods for determining
components of a blended plastic material in accordance with the
present invention. As illustrated, environment 100 includes resin
testing equipment 110 which receives incoming component resins.
Testing equipment 110 may include capillary, oscillating or
rotational rheometer, density column, melt flow indexer, infrared
spectrophotometer, impact tester, and the like and may be used to
test the incoming resins to determine any of various properties.
The determined resin properties associated with the incoming resin
are supplied to blending computer 200. Generally, such resin
properties may reflect, among other things, mechanical, electrical,
thermal, polymeric, aging, flammability, optical, rheological,
chemical resistance, and color properties of the resin or plastic
component. More specific properties include, for example, melt
index, density, Theological characterization, molecular weight,
molecular weight distribution, impact strength, tear strength,
tensile strength, compression strength, slow crack growth
resistance, rapid crack growth resistance, melt strength,
processibility, die swell, creep resistance, flexural strength,
flexural modulus, elongation, melting point, dielectric strength,
contamination, post-consumer grade characterization, post
industrial grade characterization, virgin grade characterization,
color, and hardness. This list of properties is merely
representative, and other specific properties may be readily
identified by those of ordinary skill in the art. For example,
other specific properties may be identified in "Handbook of Polymer
Testing: Physical Methods" by Roger Brown and published in 1999 by
Marcel Dekker, and "Handbook of Plastics Testing Technology, 2nd
Edition" by Vishu Shah, published in 1998. The entirety of each of
these texts is incorporated herein by reference.
[0031] When used in environment 100, blending computer 200 includes
control logic for determining and/or optimizing components of
blended plastic materials based on specifications provided by a
user and on supply data describing the incoming resins. The
blending computer 200 uses the specification data and supply data
to determines an appropriate list of plastic components which may
be used by a resin blender 120 to create the composite material. In
one embodiment, the identification of the plastic components and
respective percentages are manually entered into resin blender 120.
In another embodiment, blending computer 200 transmits the
identification of the plastic components and respective percentages
directly to resin blender 120. The composite material created by
resin blender 120 may be provided to extruder 130 which forms the
composite material into a finished product or compound.
[0032] Referring to FIG. 1B, there is illustrated a second example
operating environment 150 for systems and methods for determining
components of a blended plastic material in accordance with the
present invention. Like environment 100, environment 150 includes
resin testing equipment 110, resin blender 120 and extruder
130.
[0033] One distinction between operating environments 100 and 150
is that operating environment 150 is configured to determine
blending solutions remotely, with blending computer 200 operating
as a client to blending server 230. Blending computer 200 includes
control logic for collecting blending parameters and reporting
solutions. Blending parameters are collected from a user by
blending computer 200 and transmitted to solution server 230.
Solution server 230 processes the data received from blending
computer 200 and returns solution data to blending computer 200.
The solutions are then provided to the user via blending computer
200.
[0034] Another illustrated distinction between operating
environments 100 and 150 is the addition of optional production
monitors, such as resin samplers 125 and 135. As illustrated, resin
sampler 125 obtains samples of the blended resin prior to extrusion
and provides the resin samples to resin testing equipment 110 or
comparable testing equipment integrated with sampler 125. The resin
properties are then fed back to blending computer 200 to enable
further refinement and/or calibration of the component percentages
so as to produce a blended plastic material within tight tolerances
of the specifications initially provided by the user. Resin sampler
125 may be a Dynisco on-line rheometer CMR III, a Dynisco on-line
viscometer #ViscoSensor, or IMI on-line ultrasonic polymer monitor,
or any other suitable sampling device known to those of skill in
the art.
[0035] In addition to refining the component percentages, resin
sampler 125 may be used to monitor the blended resin to determine
any need for additives, enhancers and/or fillers to be included
with the plastic components. The supply data may describe such
additives, enhancers and/or fillers making selection of such
non-plastic components readily available to the blending computer
when determining the plastic blended material. Examples of
additives include lubricants and other processing aids. Enhancers
include, for example, UV stabilizers, antioxidants and heat
stabilizers. Fillers include mineral fillers, wood fillers and
fiber fillers, for example.
[0036] Environment 150 may also include resin sampler 135
positioned in-line after the extruder 130. Resin sampler 135
samples melted resin properties, and feeds the sampling data back
to the blending computer for further refinement of the component
percentages. Of course, resin sampler 135 may include certain
integrated testing equipment in order to determine specific resin
properties. Although not illustrated in FIG. 1A, it should be
appreciated that environment 100 could be modified to include
either resin sampler 125 or resin sampler 135, or both.
[0037] In one example embodiment of the present invention, blending
computer 200 may be a programmed general purpose computer as
illustrated in FIG. 2. FIG. 2 illustrates computer 200 that
includes a processor 202, a memory 204, a disk 206, input/output
ports 210, and a network interface 212 operably connected by a bus
208. Executable components of the systems described herein may be
located on a computer like computer 200. Similarly, computer
executable methods described herein may be performed on a computer
like computer 200. It is to be appreciated that other computers,
such as solution server 230, for example, may also be employed with
the systems and methods described herein.
[0038] The processor 202 can be a variety of various processors
including dual microprocessor and other multi-processor
architectures. The memory 204 can include volatile memory and/or
non-volatile memory. The non-volatile memory can include, but is
not limited to, read only memory (ROM), programmable read only
memory (PROM), electrically programmable read only memory (EPROM),
electrically erasable programmable read only memory (EEPROM), and
the like. Volatile memory can include, for example, random access
memory (RAM), synchronous RAM (SRAM), dynamic RAM (DRAM),
synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), and
direct RAM bus RAM (DRRAM). The disk 206 can include, but is not
limited to, devices like a magnetic disk drive, a floppy disk
drive, a tape drive, a Zip drive, a flash memory card, and/or a
memory stick. Furthermore, the disk 206 can include optical drives
like, a compact disk ROM (CD-ROM), a CD recordable drive (CD-R
drive), a CD rewriteable drive (CD-RW drive) and/or a digital
versatile ROM drive (DVD ROM). The memory 204 can store processes
214 and/or data 216, for example. The disk 206 and/or memory 204
can store an operating system that controls and allocates resources
of the computer 200.
[0039] The bus 208 can be a single internal bus interconnect
architecture and/or other bus architectures. The bus 208 can be of
a variety of types including, but not limited to, a memory bus or
memory controller, a peripheral bus or external bus, and/or a local
bus. The local bus can be of varieties including, but not limited
to, an industrial standard architecture (ISA) bus, a micro channel
architecture (MSA) bus, an extended ISA (EISA) bus, a peripheral
component interconnect (PCI) bus, a universal serial (USB) bus, and
a small computer systems interface (SCSI) bus.
[0040] The computer 200 interacts with input/output devices 218 via
input/output ports 210. Input/output devices 218 can include, but
are not limited to, a keyboard, a pointing and selection device,
various resin testing equipment 110, resin sampler 125,cameras,
video cards, displays, and the like. The input/output ports 210 can
include but are not limited to, serial ports, parallel ports, and
USB ports.
[0041] The computer 200 can operate in a network environment and
thus is connected to a network 220 by a network interface 212.
Through the network 220, the computer 200 may be logically
connected to a remote computer 222. The network 220 can include,
but is not limited to, local area networks (LAN), wide area
networks (WAN), and other networks. The network interface 212 can
connect to local area network technologies including, but not
limited to, fiber distributed data interface (FDDI), copper
distributed data interface (CDDI), ethernet/IEEE 802.3, token
ring/IEEE 802.5, and the like. Similarly, the network interface 212
can connect to wide area network technologies including, but not
limited to, point to point links, and circuit switching networks
like integrated services digital networks (ISDN), packet switching
networks, and digital subscriber lines (DSL). Since the computer
200 can be connected with other computers, and since the systems
and methods described herein may include distributed communicating
and cooperating computer components, information may be transmitted
between these components.
[0042] The systems, methods, and objects described herein may be
stored, for example, on a computer readable media. Media can
include, but are not limited to, an ASIC, a CD, a DVD, a RAM, a
ROM, a PROM, a disk, a carrier wave, a memory stick, and the
like.
[0043] Referring now to FIG. 3, there is illustrated an example
methodology 300 for determining components of a blended plastic
material. At block 305, plastic component data is accessed. Such
plastic component data may be maintained locally on blending
computer 200 in an operating environment such as operating
environment 100. Alternatively, such plastic component data may be
maintained remotely, for example, on solution server 230 in an
operating environment such as operating environment 150. Of course,
other stores of plastic component supply data may be employed, such
as a on a plastic manufacture or supplier web site or other
purchasing or inventory web site.
[0044] In an embodiment in which the component supply data is
stored locally, the component supply data may be maintained in a
database such as the example database illustrated by the Graphical
User Interface shown in FIG. 4. FIG. 4 shows a plastic component
supply database window 400 having the following fields:
TABLE-US-00001 Field Name Field Description ID Plastic component
identifier MATERIAL TYPE Material code identifying the type of
plastic, such as post-consumer, post- industrial, wide
specification, regrind, reprocessed, virgin, prime, for example.
VENDOR Source of the plastic component. PRODUCT Product identifier
of the material MI Melt Index Flex Flexural Modulus IZOD Izod
impact NCTL Notched constant tensile load R1 Rheology 1 R2 Rheology
2 R3 Rheology 3 PP_PERCENT Percent Contamination of Polypropylene
MIN_PERCENT Minimum Percentage to be used in blended material
MAX_PERCENT Maximum percentage to be used in blended material.
AVAILABLE_LBS Amount of component material available. COST Cost per
pound of component material.
As previously described, the supply data may include descriptions
of certain additives, enhancers and/or fillers which may be
included in the final blended material.
[0045] Referring now to block 310, the methodology includes
receiving specification data for the blended plastic material to be
created. The specification data may include a number of parameters
relating to the blended plastic material, including a specification
of certain physical properties for the blended plastic material.
Such a specification may be provided in a variety of ways, such as
absolute values, a range of absolute values or a range of
percentages, for example. One example of a specification input
window 500 for receiving specification data from a user is
illustrated in FIG. 5. As shown, the user has requested that a
blended plastic material be determined where the melt index of the
blended plastic material is between 0.3 and 0.4, the flexural
modulus is between 191 and 195, the IZOD is between 3 and 5.
Further, the blended plastic material should have an NCTL, value of
at least 24, R1 should be between 20 and 40, R2 should be between
25 and 30 and R3 should be between 250 and 300. Finally, the
blended plastic material may include between 1 and 4 different
component materials, but no component material may be less than 10
percent.
[0046] The blended plastic material specification may be
accomplished using a variety of techniques. Although ranges are
illustrated in the example specification input window 500, specific
target values and offsets may also be used, in addition to various
other techniques known by those of skill in the art.
[0047] Example methodology 300, at block 315, next determines
combinations of plastic components described by the supply data
that meet the specifications of the blended plastic material. At
block 320, the optimum or otherwise preferred percentages of the
plastic components for each combination are determined. In the
example embodiment, these determinations are made according to the
Simplex Method, a method of solving Linear Problems. The described
example embodiment employs open source LP Solve Software. One of
ordinary skill in the art would recognize a number of alternate
algorithms for determining the combinations and percentages of
component materials that would satisfy the specifications for the
blended plastic material based on the available supply of component
materials. One of ordinary skill in the art will recognize various
alternate embodiments of the present invention to accomplish block
320. For example, one alternate embodiment could employ neural
network technology to accomplish the step of determining the
optimum or otherwise preferred percentages of the plastic
components for each combination
[0048] At block 325, the solutions, namely the combinations of
components and percentages of each component, are reported. In one
embodiment, such information is reported to the user via the GUI of
the blending software application executed by blending computer
200. In such an embodiment, the various combinations may be
presented in a first window, such as solution window 600
illustrated in FIG. 6. As illustrated, the projected specifications
of each of the 19 determined combinations are presented, including
a solution identifier, melt index, flexural modulus, density, IZOD,
NCTL, various Theological characterizations cost and weight. Of
course, other projected characteristics of the combinations are
possible.
[0049] Although the solutions of window 600, as illustrated, are
sorted according to cost, the user may select a particular heading
to resort the solutions according to another order. For example, if
the user wanted to maximize the R1 value, the user could select the
"R1" heading to instruct the blending application to re-sort the
solutions in R1 order.
[0050] Detailed information regarding each of the 19 combinations
reported in window 600 may be obtained including, for example the
percentage of each component. In the present example, such detailed
information may be obtained by selecting a link 610 associated with
a particular solution combination.
[0051] Referring now to FIG. 7, solution detail window 700
containing the detailed solution data for solution 1 is
illustrated. Detailed solution data is provided for each component
of the solution, including the percentage for each component
material and various characteristics of each component material.
Other information which may be presented in the solution detail
window 700 includes the cost, available weight, amount used and the
remaining supply of each component material.
[0052] Once the user is presented with a list of solutions 600 and
the detail behind each solution 700, the user may select the
solution that is best suits his/her needs. For example, if
minimizing cost is a paramount concern, the user may elect to
produce the blended plastic material of solution 1 costing 0.2664
per pound. Alternatively, if minimizing the rheological
characteristic R1 is most important to the user, solution 6 may be
selected. Of course, the user may have a variety of objectives
which may be met in whole or in part by other solutions. The
ability for the user to select from among several preferred
solutions is a significant benefit. The present invention
recognizes the advantage of providing more than a single "optimum"
solution for the user to select from.
[0053] Referring now to FIG. 8, there is illustrated an alternate
environment 800 of the present invention in which the supply data
may be stored remotely and/or provided by third parties. In the
illustrated example, blending computer 200 accesses and retrieves
supply data 810 from a third party web server via the internet 805.
In the example embodiment, there is no need to test the incoming
resin, as it is supplied according to specifications listed on the
third party web server. Of course, hybrid environments for the
present invention are also possible, such as an environment in
which supply data is be stored locally as well as remotely. In such
an embodiment, testing equipment such as that described with
reference to FIG. 1A may be utilized with respect to the locally
stored supply data.
[0054] In one embodiment, supply data 810 may be a catalog of
plastic resins provided by a single supplier. In another
embodiment, supply data 810 may be a listing of resins available
from a variety of suppliers. In yet another embodiment, supply data
810 may be a list of resins available through auction.
[0055] Referring now to FIG. 9, an example "Edit Components" window
900 is illustrated. Window 900 provides a facility for maintaining
records of the supply data 810. The supply data records of window
900 contain essentially the same fields as illustrated with respect
to window 400 illustrated in FIG. 4.
[0056] An example "Edit Constraints" window 1000 is illustrated in
FIG. 10. Window 1000 enables a user to define the constraints of
the blended plastic material for which components will be
determined. Fields 1010-1060 are essentially the same as those
illustrated with respect to window 500 in FIG. 5. "Select Database"
field 1065 enables the user to identify a database which contains
the supply data from which plastic components will be selected. The
database identified by field 1065 may be a local database, a remote
supplier database, a remote marketplace database, a remote auction
database or any other type of database that a user may find useful.
"Database Components" field 1070 enables the user to identify the
minimum and maximum number of components which may be selected from
the database identified by field 1065.
[0057] Example "Report" window 1100, illustrated in FIG. 11,
presents a list of solutions which satisfy the constraints defined
using window 1000. Each record in the Report window 1100 represents
a particular blended plastic material solution. The detail of each
solution, including the specific component plastics associated with
the solution, may be viewed by the user by selecting the solution
of interest and displaying the "Report Detail" window 1200
illustrated in FIG. 12.
[0058] The "Report Detail" window 1200 provides detailed solution
data for each component of the selected solution, including the
percentage for each component material and various characteristics
of each component material. Other information which may be
presented in the solution detail window 1200 includes the cost,
available weight, amount used and the remaining supply of each
component material.
[0059] One significant advantage of this and other aspects of the
present invention is the ability to view the impact of a particular
solution on the available inventory of a specific plastic
component. It is intended that the solution software provide an
interface with an inventory management and/or accounting
application in order to provide an integrated solution.
Specifically, upon determination and selection of the plastic
components of a blended plastic material, the blending computer
will transmit inventory data to an inventory management application
to accurately reflect the effect of the selection on any available
inventory. The integrated inventory management application may
reside locally on the blending computer or remotely via a LAN, WAN
or other network configuration.
[0060] According to another aspect of the present invention, the
blending computer software application enables the preferred
valuation of one or more plastic components FIGS. 13-17 illustrate
example windows of a user interface which may be used to embody a
methodology for such plastic component valuation. FIG. 13
illustrates an example "Edit Components" window 1300 which enables
a user to define and maintain the supply data describing the
plastic components that may be used in determining a blended
plastic material. FIG. 14 illustrates an example "Edit Constraints"
window 1400 which enables the user to define the specifications,
including the desired blended cost which must be met by the blended
plastic material. As illustrated at 1410, a target or desired blend
cost may be received from the user. In this example, the desired
blend cost 1410 represents the cost of plastic components which the
user can presently procure to manufacture a blended plastic
material that meets the user's specifications.
[0061] FIG. 15 illustrates an example "Component to Cost" window
1500 which enables the user to define the characteristics of a
component for which the user wishes to determine a preferred cost.
In the instant example, the fields defining the component to cost
are substantially similar to the fields defining the supply data of
window 1300. As illustrated, window 1500 does not include a cost
field, because cost is variable that the instant embodiment of the
material blending software application is expected to determine. Of
course, an actual cost field could be included in window 1500 to
provide a comparison with the preferred cost determined by the
application.
[0062] FIG. 16 illustrates an example "Report" window 1600 which
provides a list of solutions, each of which includes the component
to cost. Upon selecting a solution, the user may view the detail of
the solution, as illustrated by example "Report Detail" window 1700
of FIG. 17. Window 1700 provides the detail regarding each
component in the determined blended plastic material, including the
cost of each plastic component 1710. As illustrated, for plastic
components selected from the supply data, the cost field is
populated based on the cost field maintained in the "Edit
Components" window 1300. Regarding the plastic components defined
in the "Component to Cost" window 1500, the blending application
determines the highest cost at which the plastic component may be
purchased to render a cost effective blended plastic material
meeting the user's specifications that is less than the target or
desired blend cost 1410.
[0063] As described, the present invention provides for the
prediction and/or the optimization of a blended plastic material
made from various component materials. The blended plastic material
is determined based on certain specifications and available supply
of component materials. The component materials, such as those
physically received from or alternatively available from a
supplier, may be classified according to various physical
characteristics and costs. Each plastic component material may be
tested for physical properties using an assortment of test
practices. The desired blend physical properties are entered into a
database accessible by a computing device. The computing device
then calculates the preferred or optimal blend(s) for the desired
blend physical properties from those inventory materials available,
at least cost. The computing device is programmed with linear and
non-linear equations
[0064] The present invention provides significant advantages over
the prior art, in which solutions were derived using manual hand
calculations or through the use of a computing devise that required
an iterative solution (such as an excel spread sheet), but is not
designed to provide an optimal solution
[0065] A second aspect of the present invention is a methodology
which enables a value to be placed on a component based upon its
attribute(s) in relation to other components and then suggests a
corresponding maximum value that should be paid at current
component prices. A third aspect of this invention is a methodology
which determines a multi-component blend solution when one or more
components is unknown. A fourth aspect of the present invention is
a methodology which monitors dry or melt blends properties, compare
same to initial blend specifications and as necessary refines the
blend solution. This activity is done in line and on a real time
basis. Accordingly, a user of the present invention derives the
benefit of consistent quality control at least cost. As described,
the optimized blend calculations could be made on a remote
computer, available via internet access
[0066] Having described the invention in detail, those skilled in
the art will appreciate that, given the present disclosure,
modifications may be made to the invention without departing from
the spirit of the inventive concept herein described. Therefore, it
is not intended that the scope of the invention be limited to the
specific and preferred embodiments illustrations as described.
Rather, it is intended that the scope of the invention be
determined by the appended claims. Furthermore, the preceding
description is not meant to limit the scope of the invention.
Rather, the scope of the invention is to be determined only by the
appended claims and their equivalents.
* * * * *