FIEUD OF INVENTION

[0001] The present disclosure relates to a system and a method of manufacturing of multiple lines of multi-layer extruded products such as, but not limited to, writing or coloring pencil or cosmetic pencil, plastics, rods, rubber cables, foods, chocolates, lipsticks, wires, optical fibers, and the like.

BACKGROUND

[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the present invention, or that any publication specifically or implicitly referenced is prior art.

[0003] While the present disclosure is explained from a perspective of manufacturing of writing or coloring pencil or cosmetic pencil, however, it needs to be appreciated that the present disclosure relates to manufacturing of multi-layer extruded products such as, but not limited to, plastics, rods, rubber cables, foods, chocolates, lipsticks, wires, optical fibers, etc, and the writing or coloring pencil or cosmetic pencil may be considered as one of the embodiments for the multi-layer extruded products.

[0004] A pencil is an implement for writing or drawing, constructed of a narrow, solid pigment core in a protective casing that prevents the core from being broken and/or marking the user's hand. Pencils create marks by physical abrasion, leaving a trail of solid core material that adheres to a sheet of paper or other surfaces. They are distinct from pens, which dispense liquid or gel ink onto the marked surface.

[0005] Most pencil cores are made of graphite powder mixed with a clay binder. Graphite pencils (traditionally known as 'lead pencils') produce grey or black marks that are easily erased, but otherwise resistant to moisture, most chemicals, ultraviolet radiation , and natural aging. Other types of pencil cores, such as those of charcoal, are mainly used for drawing and sketching. Colored pencils are sometimes used by teachers or editors to correct submitted texts, but are typically regarded as art supplies — especially those with waxy core binders that tend to smear when erasers are applied to them. Grease pencils have a softer, crayon-like waxy core that can leave marks on smooth surfaces such as glass or porcelain. The most common pencil casing is thin wood, usually hexagonal in section but sometimes cylindrical or triangular, permanently bonded to the core. Casings may be of other materials, such as plastic or paper. To use the pencil, the casing must be carved or peeled off to expose the working end of the core as a sharp point. Mechanical pencils have more elaborate casings that are not bonded to the core; instead, they support separate, mobile pigment cores that can be extended or retracted through the casing's tip as needed. These casings can be reloaded with new cores (usually graphite) as the previous ones are exhausted. [0006] The conventional pencils are manufactured by depositing graphite or pigmented lead inside a wood casing. The limited selection of suitable woods, the treatments that they have to undergo, and the complexity of the steps of the manufacturing and finishing method are known to be major disadvantages. Moreover, the trees from which the wood comes are an important component of natural balance and excessive elimination of these can but affect such balance.

[0007] Conventionally, the existing process involves one plant producing one polymer pencil extrusion. Normally, the process of producing one polymer pencil extrusion includes, but is not limited, to: a) Material extruded from one extruder as the core of pencil identified as lead (can be of graphite, color core lead, or cosmetic core); b) Material extruded from another extruder which may or may not be used as a coat layer over the lead core; c) Both materials are co-extruded at stage one of the extrusion die, which forms lead core, which is air-cooled and fed manually into the second stage of co-extrusion. d) The Material extruded from one extruder each for sheath (pencil body), for sheath coat (body coat) and design coat, along with lead core from first stage enters into second stage of extrusion die, to give a continuous line of one pencil. e) The pencil formed is sized and cooled and by traction of pencil same is cut in coarse length of desired pencil length.

[0008] In an example, a conventional method for continuously manufacturing a writing or coloring pencil, by simultaneous extrusion of thermoplastic materials constituting successively, on the one hand the lead, and on the other hand the material enveloping the lead, and which is hereinafter called wood material by analogy with the composition of the conventional pencils in which said material is made of wood.

[0009] Extrusion plants for extruding a single line of multi-layer product through a co-extrusion die are widely known and used. Whereas there is certainly nothing wrong with the existing techniques for manufacturing writing or coloring pencil nonetheless, however, it is challenging to design and manufacture extrusion plants which can extrude multiple lines of multi-layer product through multiple co-extrusion dies.

[00010] In addition, the challenges that may be faced by multiple lines of multi-layer product are increased complexity, differences/ inconsistency in the flow rates of the different extrude lines that go into the multiple co-extrusion dies etc., due to the multiple numbers of lines of material required in the extrusion plant. For example, if an extrusion plant is required to be made to extrude 6 lines of pencils simultaneously and each pencil has 5 concentric layers (e.g, lead core, lead (inter-layer) coating, pencil body, pencil body coating and striping design on coating) then 30 (6x5) lines of layer materials has to be initially extmded/created by 30 extruders and then divided between 6 Co-Extrusion Dies, thereby requiring more labor, time, electric consumption, leading to increase in over all cost of installation and operation of such extrusion plants.

[00011] Thus, there still exists a dire need to provide an efficient, effective and reliable system and method for producing two and or more polymer pencils coextruded in two or more colors in tandem. Further, there is also need to provide devices and machinery, involved and designed, in improving the co-extrusion process by innovating of two and or more polymer pencils in tandem.

OBJECTS OF THE PRESENT DISCLOSURE

[00012] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[00013] It is an object of the present invention to reduce the number of extruders and lines and making it easier to ensure a uniform flow rate of the materials.

[00014] It is an object of the present invention to extrude multiple lines of multi-layer product, thereby reducing costs savings in terms of capital, increased production, decease in labor, time and electric consumption, etc

[00015] It is an object of the present invention to provide a system and process for producing multiple lines of multi-layer extruded products using one or more splitters.

[00016] It is an object of the present invention to provide a system and method for producing two and or more polymer pencils coextmded in two or more colors in tandem. [00017] It is an object of the present invention to provide devices and machinery, involved and designed, in improving the co-extrusion process by innovating two and or more polymer pencils in tandem. SUMMARY

[00018] The present disclosure relates to a system and a method of manufacturing of multiple lines of multi-layer extruded products such as, but not limited to, writing or coloring pencil or cosmetic pencil, plastics, rods, rubber cables, foods, chocolates, lipsticks, wires, optical fibers, and the like.

[00019] An aspect of the present disclosure pertains to a system for manufacturing multiple lines of multi-layer extruded products. The system includes at least two extruders, which are configured to receive raw materials corresponding to at least two layers of the multi-layer extruded products, and extrude out at least two lines of corresponding layer materials. The system further includes at least one splitter device, which is configured to receive at least one line of extruded layer material from at least one extruder and to divide the received at least one line of extruded layer material into at least two lines of layer material. The system further includes at least two co-extrusion dies, each of which receives at least two layer materials and extrudes the multi-layer extruded product having at least two layers, where at least one of the layer materials of the multi-layer extruded product may be received from the at least one splitter device.

[00020] In an aspect, the at least two layers in the the multi-layer extruded product may be shaped as any or a combination of concentric shape layers, wedge-shaped layers, overlapping shape layers, and adjoining regular and irregular shape layers.

[00021] In an aspect, each of the at least one splitter device may include an inlet configured to receive at least one line of extruded layer material from at least one of the extruders, and at least two outlets configured to expel at least two lines of the received layer material.

[00022] In an aspect, each of the at least one splitter devices may be configured to ensure uniform flow of the divided at least two lines of layer material.

[00023] In an aspect, the profile of the multilayer extruded product may be shaped as any or a combination of circular, oval, curved, and multisided shapes including triangular, square, rectangular, pentagonal, and polygonal.

[00024] In an aspect, the multilayer extruded product may be any or a combination of pencil, plastic, rod, rubber cable, food, chocolate, lipstick, wires, optical fiber, and any product that has multiple layers.

[00025] In an aspect, at least one of the layer materials of the multi-layer extruded product may be received at each of the least two co-extrusion dies directly from at least one of the extruders. [00026] In an aspect, at least two extruders may be selected from a single screw and multiple screws.

[00027] In an aspect, the system may include one or more cutting means configured to cut the produced multi-layer extruded product into sections of predefined length.

[00028] In an aspect, the system may include one or more traction units configured between at least one first outlet of each of the at least two co-extrusion dies and the one or more cutting means to facilitate controlled movement of the produced multi-layer extruded product towards the one or more cutting means.

[00029] In an aspect, the system may include one or more flow control mechanism configured with each of the at least two extruders, the at least one splitter device, and the at least two co-extrusion dies, to facilitate the controlled flow of any or a combination of the raw materials, at least two lines of corresponding extruded layer materials, the at least one line of layer material, and the multi-layer extruded product.

[00030] In an aspect, the system may include one or more heat control means configured with any or a combination of each of the at least two extruders, the at least one splitter device, and the at least two co-extrusion dies, to control the temperature of any or a combination of the raw materials, at least two lines of corresponding extruded layer materials, the at least one line of layer material, and the multi-layer extruded product, in the system

[00031] Another aspect of the present disclosure pertains to a method for manufacturing multiple lines of multi-layer extruded products. The method comprising steps of receiving, at least at two extruders, raw materials corresponding to at least two layers of the multilayer extruded products; extrude, by the at least two extruders, at least two lines of corresponding layer materials; receiving, at least at one splitter device, at least one line of extruded layer material from the at least two extruders; splitting, by the at least at one splitter device, the received at least one line of extruded layer material into at least two lines of layer material; receiving, at least at two co-extrusion dies, at least one of the layer materials of the multi-layer extruded product from any or a combination of the at least two extruders, and at least one splitter device; and co-extruding, by at least one of the co-extrusion dies, the at least one of the received layer materials of the multi-layer extruded product to produce the multi layer extruded product.

[00032] In an aspect, the method may include the steps of: shaping and sizing, by one or more shaping and sizing means, each of the multi-layer extruded products into predefined shape and sizes; and cutting, by one or more cutting means, each of the shaped and sized multi-layer extruded products into sections of predefined lengths.

BRIEF DESCRIPTION OF DRAWINGS [00033] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein: [00034] FIG. 1 illustrates a block diagram of the proposed system for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure.

[00035] FIG. 2A illustrates a first embodiment of the proposed system being used in an ice-cream industry for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure.

[00036] FIG. 2B illustrates a second embodiment of the proposed system being in a pencil industry for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure

[00037] FIG. 3 illustrates the process flow diagram of the proposed method for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure. [00038] FIG. 4A and 4B illustrate an exemplary top view and front view of the splitter of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[00039] FIG. 5 illustrates exemplary view of a co-extrusion die of the proposed system, in accordance with an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[00040] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details. [00041] The present disclosure relates to a system and a method of manufacturing of multiple lines of multi-layer extruded products such as, but not limited to, writing or coloring pencil or cosmetic pencil, plastics, rods, rubber cables, foods, chocolates, lipsticks, wires, optical fibers, and the like.

[00042] While the present disclosure is explained from a perspective of manufacturing of writing or coloring pencil or cosmetic pencil, however, it needs to be appreciated that the present disclosure relates to manufacturing of multi-layer extruded products such as, but not limited to, plastics, rods, rubber cables, foods, chocolates, lipsticks, wires, optical fibers, etc, and the writing or coloring pencil or cosmetic pencil may be considered as one of the embodiments for the multi-layer extruded products.

[00043] According to an aspect, the present disclosure elaborates upon a system for manufacturing multiple lines of multi-layer extruded products. The system can include at least two extruders, which can be configured to receive raw materials corresponding to at least two layers of the multi-layer extruded products, and extrude out at least two lines of corresponding layer materials. The system can further include at least one splitter device, which can be configured to receive at least one line of extruded layer material from at least one extruder and to divide the received at least one line of extruded layer material into at least two lines of layer material. The system can further include at least two co-extrusion dies, each of which can receive at least two layer materials and extrude the multi-layer extruded product having at least two layers, where at least one of the layer materials of the multi-layer extruded product can be received from the at least one splitter device. In another embodiment, at least one of the layer materials of the multi-layer extruded product can be received at each of the least two co-extrusion dies, directly from at least one of the extruders. [00044] In an embodiment, the at least two layers in the multi-layer extruded product can be shaped as any or a combination of concentric shape layers, wedge-shaped layers, overlapping shape layers, and adjoining regular and irregular shape layers, but not limited to the likes.

[00045] In an embodiment, each of the at least one splitter device can include an inlet configured to receive at least one line of extruded layer material from at least one of the extruders, and at least two outlets configured to expel at least two lines of the received layer material. Each of the at least one splitter devices can be configured to ensure uniform flow of the divided at least two lines of layer material. [00046] In an embodiment, the profile of the multilayer extruded product can be shaped as any or a combination of circular, oval, curved, and multisided shapes including triangular, square, rectangular, pentagonal, and polygonal, but not limited to the likes.

[00047] In an embodiment, the system can include one or more cutting means configured to cut the produced multi-layer extruded product into sections of predefined length.

[00048] In an embodiment, the system can include one or more traction units configured between at least one first outlet of each of the at least two co-extrusion dies and the one or more cutting means to facilitate controlled movement of the produced multi-layer extruded product towards the one or more cutting means.

[00049] In an embodiment, the system can include one or more flow control mechanism configured with each of the at least two extruders, the at least one splitter device, and the at least two co-extrusion dies, to facilitate the controlled flow of any or a combination of the raw materials, at least two lines of corresponding extruded layer materials, the at least one line of layer material, and the multi-layer extruded product.

[00050] In an embodiment, the system can include one or more heat control means configured with any or a combination of each of the at least two extruders, the at least one splitter device, and the at least two co-extrusion dies, to control the temperature of any or a combination of the raw materials, at least two lines of corresponding extruded layer materials, the at least one line of layer material, and the multi-layer extruded product, in the system

[00051] Another embodiment of the present disclosure pertains to a method for manufacturing multiple lines of multi-layer extruded products. The method including a step of receiving, at least at two extruders, raw materials corresponding to at least two layers of the multilayer extruded products, and extruding at least two lines of corresponding layer materials. Further, the method can include a step of receiving, at least at one splitter device, at least one line of extruded layer material from the at least two extruders, and splitting the received at least one line of extruded layer material into at least two lines of layer material; Further, the method can include a step of receiving, at least at two co-extrusion dies, at least one of the layer materials of the multi-layer extruded product from any or a combination of the at least two extruders, and at least one splitter device, and co-extruding the at least one of the received layer materials of the multi-layer extruded product to produce the multi-layer extruded product. [00052] In an embodiment, the method can include the steps of: shaping and sizing, by one or more shaping and sizing means, each of the multi-layer extruded products into predefined shape and sizes, and cutting, by one or more cutting means, each of the shaped and sized multi-layer extruded products into sections of predefined lengths.

[00053] FIG. 1 illustrates a block diagram of the proposed system for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure.

[00054] As illustrated, in an aspect, the proposed system 100 for producing multiple lines of multi-layer extruded product can include at least two extruders which can be configured to receive raw materials corresponding to at least two layers of the multi-layer extruded products, and extrude out at least two lines of corresponding layer materials. The at least two extruders can include a first set of extruders 102-1 to 102-M (also referred to as first extruders 102, herein) configured to receive one or more first raw materials (also referred to as first raw materials, herein), and correspondingly produce a first line of extruded layer materials (also referred to as first extruded materials, herein). The at least two extruders can further include a second set of extruders 104-1 to 104-N (also referred to as second extruders 104, herein) configured to receive one or more second raw materials (also referred to as raw materials, herein), and correspondingly produce a second line of extruded layer materials (also referred to as second extruded materials, herein). Each of the first raw materials and the second raw materials can be associated with at least two layer of the multi-layer extruded product to be manufactured.

[00055] In an embodiment, the system 100 can include at least one splitter 106 (also referred to as splitters 106 or splitter device 106, herein) operatively coupled to the second extruders 104, such that each of the splitters 106 are configured to receive at least one line of the second layer materials from the second extruder 104, and correspondingly provide at least two lines (multiple lines) of the received second extruded materials. The splitters 106 can split a single line of the received second extruded materials into at least one line of second layer materials without requiring or involvement of additional extruders to produce each of these multiple lines of layer materials, thereby reducing the number of extruders and lines required in the proposed system compared to conventional extrusion systems.

[00056] In another exemplary embodiment, the at least one line of second layer material being extruded by the splitter 106 and/or the first line of extruded layer materials being extruded by the first extruders 102 can include any or a combination of semi-solid, plastic material, molten material, viscous material, molten rubber, molten plastic, molten polymer, molten glass, pencil lead, pencil body material, pencil coating material, paint, lipstick material, and food material, but not limited to the likes. These materials may not be a liquid, nor dry particles such as sand, and may be deformable/moldable but not free-flowing. [00057] In an embodiment, the system 100 can include at least one co-extrusion die 108 (also referred to as co-extrusion dies 108 or die 108 or extrusion crossheads 108, herein), where each of the co-extrusion dies 108 can include at least first inlets, each of which can be configured to receive a distinct extruded material from any or a combination of at least one of the multiple lines of second layer materials being produced by the splitters 106, and at least one line of the first extruded layer materials being produced by the first extruders 102.

[00058] In an embodiment, each of the splitter device 106 can include a second inlet configured to receive at least one line of extruded layer material from at least one of the extruders (102, 104), and at least two second outlets configured to expel at least two lines of the received layer material. Each of the splitter device 106 can be configured to ensure uniform flow of the divided at least two lines of layer material.

[00059] In an embodiment, each of the co-extrusion dies 108 can include a cylindrical cone configured at a first outlet of the corresponding co-extrusion die 108, and operable to produce the one or more multi-layer products from the received first extruded materials and the second extruded materials. The produced multi-layer products can include multiple layers of materials comprising the first raw materials and the second raw materials.

[00060] In an embodiment, the system 100 can include cutting and shaping means 110 including one or more shapers or sizers, and one or more cutting means. The shapers and sizers can be configured to mold the produced multi-layer products into the desired shape and size. Further, the cutting means can be configured to cut the produced multi-layer products into sections of predefined lengths to provide finished multi-layer products.

[00061] In an embodiment, the system 100 can include one or more traction units (also referred to as traction unit or extraction unit, herein) configured between the first outlet of each of the co-extrusion dies 108, and the shaping and cutting means 110 to facilitate controlled movement of the produced multi-layer products towards the shaping and cutting means 110.

[00062] In an embodiment, the system 100 can include one or more flow control means configured with each of the first extruders 102, the second extruders 104, the splitters 106, and the co-extrusion dies 108, to facilitate the controlled flow of any or a combination of the first raw materials, one or more second raw materials, the first extruded layer materials, the second extruded layer materials, the multiple lines of second layer materials extruded by the splitters 106, and the multi-layer products, throughout the system 100.

[00063] In an embodiment, the system 100 can include one or more heat control means configured with each of the first extruders 102, the second extruders 104, the splitters 106, and the co-extrusion dies 108, to control temperature and allow continuous and controlled flow of any or a combination of the first extruded layer materials, the second extruded layer materials, the multiple lines of second materials extruded by the splitters 106, and the multi layer products, throughout the system 100. The heat control means can maintain the temperature of the materials within a specified temperature range such that the materials are stiff enough not to break away and plastic enough that it can be deformed [00064] In an exemplary embodiment, the multilayer extruded product can be any or a combination of pencil, plastic, rod, rubber cable, food, chocolate, lipstick, wires, optical fiber, and any product that has multiple layers.

[00065] In an exemplary embodiment, the profile of the multilayer extruded product can be shaped as any or a combination of circular, oval, curved, and multisided shapes including triangular, square, rectangular, pentagonal, and polygonal, but not limited to the likes.

[00066] In an exemplary embodiment, the at least two extruders 102, 104 can be selected from a single screw, and multiple screw.

[00067] FIG. 2A illustrates a first embodiment of the proposed system being used in an ice-cream industry for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure.

[00068] In an embodiment, the proposed system can be used for producing different variants of ice-creams, each having multiple layers of different flavors. The extruded products can be chocolates with 3 different fruit flavors extruded from 3 different Co- extrusion Dies, wherein each of the chocolates can have 3 different layers. A first inner layer can be a fruit layer/material with 3 different flavors including, but not limited to Strawberry, Orange or Cranberry. The second inner layer can be Caramel, but not limited to the likes. The third layer can be an outer Chocolate coating layer.

[00069] As illustrated in FIG. 2A, for the first inner layer, three separate extruders 102- 1 to 102-3 can be used for extruding three different fruit flavors for the three co-extrusion dies 108-1 to 108-3. Since the second inner layer is a single material i.e., Caramel, only one extruder 104-1 is used to extrude the Caramel which is then input to a first splitter device 106-1 which divides the single line of caramel into three lines of Caramel. The three lines of caramel can then be further input into the three co-extrusion dies 108-1 to 108-3. Similarly, since the third outer coating inner layer is a single material - i.e., Chocolate, only one extruder 104-2 is used to extrude the Chocolate which is then input to a second splitter device 106-2 that divides the single line into three lines of Chocolate. The three lines of chocolate can then be further input into the three co-extrusion dies 108-1 to 108-3. Further, the 3-layer materials pass through the three co-extrusion dies, to produce 3 lines (flavors) of 3-layer chocolates produced from the three co-extrusion dies - i.e., multiple lines of multi-layer extruded products. The three layers in the chocolate could be concentric or side by side or any other layer structure.

[00070] As a result, fewer number of extruders (5 instead of 9, in this embodiment) are used in the extrusion system due to the use of the splitter devices. Thus, the use of fewer extruders in the multiple line multi-layer extrusion system, leads to reduction in the cost, size and complexity of the extrusion system. Additionally, the system becomes more reliable and requires less maintenance.

[00071] FIG. 2B illustrates a second embodiment of the proposed system being used in pencil industry for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure

[00072] In an embodiment, the proposed system provides for producing multiple lines of multi-layer extruded products, for example pencils, using one or more splitters.

[00073] In an exemplary embodiment, the polymer pencils as a writing instrument may have a core of graphite, color, or for cosmetic purpose core in tandem.

[00074] As illustrated in FIGs. 1 and 2B, in an exemplary embodiment, the proposed system 200 can include at least one extruder including the first extruders 102, and the second extruders 104. The first lines of extruded layer materials and the second lines extruded layer materials being produced by the first extruders 102, and the second extruder 104, respectively of the system 200 can include one or more lead materials extruded from one or more lead extruder, one or more lead coat materials extruded from one or more lead coat extruder, one or more body coat materials extruded from one or more body coat extruder, and one or more design coat materials extruded from one or more design coat extruder, but not limited to the likes. In an example, all the extruded materials may be received preferably in molten form. [00075] The extruders (102 and 104) can be configured to receive the first raw materials, and the raw materials, and process them to produce the extruded materials comprising the one or more lead materials, the one or more body coat materials, the one or more body coat materials, the one or more design coat materials, but not limited to the likes. [00076] In an exemplary embodiment, a material extruded from the extruders with the splitter 106-1 to 106-6 (collectively referred to as splitters 106, herein) can be used as a protective coat (also referred to as lead coat, herein) between the lead core and the sheath (pencil body). This coating system may or may not be used depending on the end product of the pencil as desired.

[00077] In an exemplary embodiment, a material extruded from one of the extruders with the splitter(s) 106 can be used to create a thickly layered sheath (also referred to as pencil body, herein) over the lead core and lead coat.

[00078] In an exemplary embodiment, a material extruded from the extruders with or without the splitter(s) 106 can be used to create an outer coat (also referred to as color coat, herein) over the pencil body.

[00079] In an exemplary embodiment, a material extruded from the extruders with or without splitter(s) 106 can be used to create a separate add-on color (also referred to as a design coat or as strip/s or thin lines, herein) along the pencil length. This coating system may or may not be used depending on the end product of the pencil as desired.

[00080] All the materials which have been extruded from the above-mentioned levels with different extruders, which may be single or twin-screw extruders, with or without the splitter(s), can enter into its individual co-extrusion die 108 or core crosshead 108, and utilized as a co-extruded multiplayer product of pencil line from each extrusion crosshead, whereupon each of its individual lead core, lead coat, pencil body, color coat, and design coat flows into a thermally controlled crosshead to form a continuous line of the pencil which may have a different color core of lead and a matching color of body coat as may be desired. The number of extrusion crosshead 108 used in the system 200 can be varied in number with that of the number of pencil lines to be extruded in by the proposed system 200.

[00081] In an exemplary embodiment, raw materials (comprising first raw material and the second raw materials) used as a material for lead core may include, but not limited to, a binder plastics such as styrene-acrylonitrile resin (SAN), polystyrene, high impact polystyrene, low density polyethylene and or a mixture of some or all, fillers such as organic color pigments, graphite powder, talcum powder, bentonite clay, titanium dioxide, calcium carbonate, calcium sulphate, lubricants such as montana wax, palm oil, etc. compounding is done in a high-speed mixer, or kneader or with a co-rotating twin-screw Extruder and Pelletized in form of free flowing granules. [00082] In an exemplary embodiment, raw materials used as material for lead coat may include, but is not limited to, a mixture of some materials such as SAN, polystyrene, low- density polyethylene, high impact polystyrene, and alloys.

[00083] In an exemplary embodiment, raw material used as a material for pencil body may include, but is not limited to, a mixture of plastics such as SAN, Polystyrene, High impact Polystyrene, Low-density Polyethylene, fillers such as Talcum Powder, Calcium Carbonate, Titanium dioxide, etc., Lubricants such as stearic acid, calcium stearate, zinc stearate, foaming agents or concentrates, etc. compounding is done in a kneader or a co- rotating twin-screw extruder and pelletized in form of free-flowing granules.

[00084] In an exemplary embodiment, raw material used as a material for color coat may include, but is not limited to, styrene-acrylonitrile resin (SAN), polystyrene, and or color concentrates of desired outer color.

[00085] In an exemplary embodiment, raw material used as a material for stripping, lining, clear, dull or gripping finish may include, but is not limited to, SAN, polystyrene, low- density polyethylene, ethylene-vinyl acetate (EVA), Silicon, TPE, and or color pigments or concentrates of the desired color.

[00086] In an exemplary embodiment, the pencil line/s extruded from each extrusion die(s) 108 passes individually through shaping and sizing means, to provide a desired outer size to the pencil(s) which may or may not go through a vacuum tank, during the process of cooling.

[00087] In an embodiment, the traction unit can be an infinitely variable pencil puller unit which is followed by one or more cutting means, wherein two or more pencils are cut to desired final lengths. This cutting principal may be incorporated with either a fly knife, rotating carbide or high-speed steel cutter and or by shearing action using a plain high-speed cutter. Through the traction units, the pencil(s) can be pulled and with the encoding system, the length of the pencil is cut to size.

[00088] It is to be appreciated by a person skilled in the art that the present invention is not limited to the embodiments described above as non-exhaustive examples. It is possible to use base components for the lead material and the wood material other than a polystyrene methacrylate copolymer. Furthermore, it is possible to give the pencil any other type of shape, without being limited to a hexagonal shape. It can be circular, triangular, octagonal, carpenter without this list being exhaustive. It is also possible for the protective layer to comprise a thermoplastic material which is not only deformable when hot (while the lead is shrinking) but which does not solidify and which remains flexible after the pencil has solidified completely, e.g. based on thermoplastic elastomer

[00089] FIG. 3 illustrates the process flow diagram of the proposed method for producing multiple lines of multi-layer extruded products using one or more splitters and its overall working, in accordance with an exemplary embodiment of the present disclosure. [00090] As illustrated, in an embodiment, the proposed method for producing multiple lines of multi-layer extruded products can include a step 302 of receiving, at least at two extruders, raw materials corresponding to at least two layers of the multilayer extruded products, and correspondingly extrude at least two lines of corresponding layer materials. [00091] In an exemplary embodiment, the step 302 includes receiving, at a first set of extruders, one or more first raw materials, and correspondingly produce a first line of extruded layer materials, and further receiving, at a second set of extruders, one or more second raw materials, and correspondingly produce a second line of extruded layer materials. In an implementation, each of the one or more first raw materials and the one or more second raw materials can be associated with multiple layers of one or more products to be manufactured.

[00092] In an embodiment, the method can include the step 304 of receiving, at least at one splitter, the second line of extruded layer materials from the second set of extruders in the step 302. Each of the splitters can be configured to receive one of the second line of extruded layer materials.

[00093] In an embodiment, the method can include the step 306 of splitting, by the at least one splitters, the second line of extruded layer material received from each of the second set of extruders in the step 304 to provide at least two lines of each of the second line of extruded layer materials. Since the splitters can split the second line of extruded layer materials into multiple lines of second extruded materials without requiring the involvement of additional extruders to produce each of these multiple lines of extruded materials, as a result, the number of extruders and lines required in the proposed system is less compared to conventional extrusion systems.

[00094] In an embodiment, the method can include the step 308 of receiving, at least at two co-extrusion dies, at least one of the layer materials of the multi-layer extruded product being produced by any or a combination of the at least two extruders in the step 302, and at least one splitter device in the step 306. [00095] In an embodiment, the method can include the step 310 of co-extruding, by the at least two co-extrusion dies, the one or more distinct extruded materials being received in the step 308 to produce the one or more multi-layer products.

[00096] In an embodiment, the method can further include a step of shaping and sizing, by one or more shaping and sizing means, each of the one or more multi-layer products into predefined shape and sizes, and another step of cutting, by one or more cutting means, each of the shaped and sized one or more multi-layer products into sections of predefined lengths to provide finished multi-layer products.

[00097] FIG. 4 A and 4B illustrate an exemplary top view and front view of the splitter of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[00098] As illustrated, in an embodiment, the splitters 106 of the proposed system 100 can include an inlet 402 configured to receive controlled supply of the second line of extruded layer materials from the second set of extruders 104; and at least two outlets 404-1 to 404-N (collectively referred to as 404, herein) configured to provide a controlled supply of the at least two lines of the received second line of extruded layer materials.

[00099] In an embodiment, as illustrated in Fig. 4A and 4B, each of the splitters 106 can include a single inlet 402 to receive a controlled supply of one of the second lines of extruded materials from one of the second set of extruders, and N-number of outlets 404-1 to 404-N (collectively referred to as outlets 404, herein) to produce N-number of lines of the received second extruded materials. Since, a single individual splitter 106 can split one of the second lines of extruded layer materials into multiple lines of second extruded layer materials without requiring the involvement of additional extruders to produce each of these multiple lines of extruded materials, as a result, the number of extruders and lines required in the proposed system is less compared to conventional extrusion systems.

[000100] In an embodiment, the splitter 106 can include flow control means 406-1 to 406-N (collectively referred to as flow control 406, herein) configured with each of the outlets 404, to control the inflow of one of the second line of extruded layer materials into the splitter 106, and further control the outflow of the multiple lines of the second extruded layer materials in a controlled manner. In an exemplary embodiment, the flow control means 406 can include any or a combination of a valve, a screw, a flap, and any mechanism that can be used to increase or decrease the flow of the material through any of the outlets by controlling the extent to which the outlets are open. Each of the at least one flow control means 406 can be individually controlled using any or a combination of a lever, a knob, a handle, a piston, a gear, and a control unit, and any other mechanism which helps with control.

[000101] In an embodiment, the splitter 106 can include a thermal control system being configured at any or a combination of the inlet 402, and the outlets 404-1 to 404-N, to maintain the temperature of the extruded materials at a predefined temperature. The thermal control system can include a temperature sensor to monitor the temperature of the material in the housing of splitter 106, and any or a combination of a heating mechanism, heating elements, cooling mechanism, fan, control unit, and any other mechanism that can help control the temperature around the outlets 404, to control the temperature of the material in the splitter 106.

[000102] It is to be appreciated by a person skilled in the art that various embodiments and figures of the present disclosure elaborate upon a total of six outlets 404-1 to 404-N, and six flow control means 406-1 to 406-N, however, various other embodiments comprising a different number of outlets and flow control means in the splitter 106, are also well within the scope of the present invention.

[000103] FIG. 5 illustrates an exemplary view of a co-extrusion die of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[000104] As illustrated, in an embodiment, the co-extrusion dies 108 or die 108 can include one or more inlets 502-1 to 502-N (collectively referred to as inlets 502, herein), each of which can be configured to receive a distinct extruded layer material from any or a combination of at least one of the multiple lines of second extruded layer materials being produced by the splitters 106, and at least one of the first line of extruded layer materials being produced by the first extruders 102.

[000105] In an embodiment, each of the co-extrusion dies 108 can include a cylindrical cone configured at an outlet 504 of the corresponding extrusion die 108, which are operable to produce the one or more multi-layer products from the received first extruded materials and the second extruded materials, where the produced multi-layer products can include multiple layers of materials comprising the first raw materials and the second raw materials. [000106] In an exemplary embodiment, the outlet 504 can be provided at a center of the die 108, along a central axis of the die 108. In another embodiment, the die 108 can be made of AISI 4140 and can be pre -hardened and hard-surface coated.

[000107] In another embodiment, the extruded materials can be fed in the inlets 502 in the order of succession of materials to be coated on or deposited on one another, along the direction of movement of the first extruded material being fed into the die 108. In an exemplary implementation, one of the inlets (say 502-1) carrying pencil body material is first opened to the ceramic cone carrying the lead core, followed by the other inlets (say 502-2 to 502-N) carrying the color coat, the design coat, and other materials.

[000108] In an exemplary implementation, the proposed system can be used to manufacture pencils. The die 108 can be provided with a self-centered ceramic cone at one of the inlets (502-1), through which a lead core of the pencil can be fed. The other inlets 502-2 to 502-N can be adapted to receive different extruded layer material from the splitters 106, and the first extruder 102, each of which forms a different layer of the pencil. The inlets 502 can be adapted to carry the extruded material being fed into them towards the ceramic cone. The extruded materials are then deposited around the lead core to form the different co-axial layers of the pencil, the layers being pencil body, color coat of the pencil body, and design coat of the pencil body.

[000109] In an embodiment, the extruded materials being fed in the die 108 is required to be at predefined temperatures in order to facilitate adequate adhesion of one another. In order to maintain the predefined temperature of the fed materials, the die 108 can be provided with one or more heating elements, which can be controlled through a control unit.

[000110] In an exemplary implementation, while manufacturing the pencil in the proposed system, the lead core in the ceramic cone of the die 108 can required to be at an elevated temperature in order to facilitate adequate adhesion of the other materials with the lead core. In order to maintain the temperature of the lead core, the die 108 can be provided with the heating elements, which can be controlled through the control unit.

[000111] In an embodiment, the die 108 can be designed such that, after deposition of one of the extruded materials, a time gap is given before deposition of the next extruded material. This is done so that the first extruded material deposited has time to solidify, such that the deposition of the next extruded material is on a solidified layer.

[000112] In an embodiment, a driving mechanism (not shown in figure) can be employed at the inlets 502 to push the extruded materials into the die 108. In another embodiment, an extracting mechanism (not shown in figure) can be employed at the outlet 504 to assist in extracting the produced multi-layer product from the die 108. The produced multi-layer products can then be cooled, sized, and cut into a desired length as required. [000113] It is to be appreciated by a person skilled in the art that various embodiments and figures of the present disclosure elaborates upon a total of five inlets 502-1 to 502-N, however, various other embodiments comprising a different number of inlets in the coextrusion die 108, are also well within the scope of the present invention. [000114] Those of skill in the art would further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system.

[000115] As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other or in contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. Within the context of this document terms “coupled to” and “coupled with” are also used euphemistically to mean “communicatively coupled with” over a network, where two or more devices are able to exchange data with each other over the network, possibly via one or more intermediary device.

[000116] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention can be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION

[000117] The proposed invention reduces the number of extruders and lines and making it easier to ensure a uniform flow rate of the materials.

[000118] The proposed invention extrudes multiple lines of multi-layer product, thereby reducing costs savings in terms of capital, increased production, decease in labor, time and electric consumption, etc

[000119] The proposed invention provides a system and process for producing multiple lines of multi-layer extruded products using one or more splitters.

[000120] The proposed invention provides a system and method for producing two and or more polymer pencils coextruded in two or more colors in tandem. [000121] The proposed invention provides devices and machinery, involved and designed, in improving the co-extrusion process by innovating two and or more polymer pencils in tandem.