Method and apparatus for sorting recycled material

Multiple discs for a material separation screen, comprising:

• primary discs on a first shaft having a first outside perimeter;
• secondary discs on the first shaft having a second outside perimeter smaller than the first outside perimeter;
• each one of the primary discs on the first shaft abutted with one of the secondary discs on the first shaft on adjacent lateral sides to form multiple unitary compound discs, the multiple unitary compound discs on a second parallel adjacent shaft aligned with compound discs on the first shaft so that the compound discs on the adjacent shafts overlap to form a non-linear gap;
• and
• wherein adjacent multiple unitary compound discs on each shaft are spaced apart from each other.

A screen for separating material, comprising:

• a frame;
• a first shaft mounted on the frame;
• a second shaft mounted on the frame adjacent to the first shaft in a substantially parallel relationship therewith;
• a first set of compound discs mounted on the first shaft, the first set of compound discs each having a primary disc with a smaller secondary disc abutting with a side of the primary disc, wherein adjacent compound discs of the first set are spaced apart from each other;
• a second set of compound discs mounted on the second shaft, the second set of compound discs each having a primary disc with a smaller secondary disc extending from a side of the primary disc, wherein adjacent compound discs of the second set are spaced apart from each other;
• and
• the first set of compound discs on the first shaft in offset alignment with the second set of compound discs on the second shaft such that each disc in the first set of compound discs overlaps with an adjacent disc in the second set of discs.

A method for separating material on a screen having multiple shafts, comprising:

• providing multiple primary discs and multiple secondary discs abutted together and each having an outside perimeters, wherein the outside perimeters of the primary discs are larger than the outside perimeters of the secondary discs;
• mounting the primary discs and the secondary discs on the shafts in alternating order where at least some of either the primary discs or secondary discs are co-linearly aligned with at least some of the secondary discs from adjacent shafts such that a non-linear gap is formed between the discs of one shaft and the discs of another shaft, and wherein adjacent non-attached discs are spaced apart from each other;
• rotating the shafts in the same direction;
• and
• dropping materials on the screen so that shaft rotation causes the material to be pushed by the discs along the screen while at the same time separating the materials according to size.

A disc for a material separation screen, comprising:

• a primary disc having a first outside perimeter;
• and
• a secondary disc having a second outside perimeter smaller than the first outside perimeter;
• the primary disc and the secondary disc formed from a unitary piece of molded rubber or plastic an abutted together;
• the primary disc located on a first shaft spaced apart from adjacent primary discs and maintaining a substantially constant spacing with a first adjacent disc on a second shaft during rotation;
• and
• the secondary disc shaped to maintain a substantially constant spacing with a second adjacent disc on the second shaft during rotation.

A disc for a material separation screen, comprising:

• a primary disc on a first shaft having a first outside perimeter shaped to maintain a substantially constant spacing with a first adjacent disc on a second shaft during rotation;
• a secondary disc on the first shaft having a second outside perimeter smaller than the first outside perimeter and shaped to maintain a substantially constant spacing with a second adjacent disc on the second shaft during rotation;
• and
• the primary disc and secondary disc in abutting along lateral sides thereof and each disc being made from a plastic or rubber type material that grips certain materials while allowing other materials to fall off the screen.

A compound disc for a material separation screen comprising:

• a primary disc having a first outside perimeter and two lateral sides;
• one and only one secondary disc formed on and extending from each lateral side of the primary disc, said secondary discs each having a second outside perimeter smaller than the first outside perimeter;
• and
• wherein said primary disc and one of said secondary discs are configured to abut with a primary disc and a secondary disc on a second compound disc to form a non-linear gap between them.