US20080267003A1 - Extrusion method and apparatus - Google Patents
Extrusion method and apparatus Download PDFInfo
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- US20080267003A1 US20080267003A1 US11/739,231 US73923107A US2008267003A1 US 20080267003 A1 US20080267003 A1 US 20080267003A1 US 73923107 A US73923107 A US 73923107A US 2008267003 A1 US2008267003 A1 US 2008267003A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
- B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
- B29C48/402—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders the screws having intermeshing parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
- B29B7/38—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary
- B29B7/46—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft
- B29B7/48—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws
- B29B7/482—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws provided with screw parts in addition to other mixing parts, e.g. paddles, gears, discs
- B29B7/483—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws provided with screw parts in addition to other mixing parts, e.g. paddles, gears, discs the other mixing parts being discs perpendicular to the screw axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/58—Component parts, details or accessories; Auxiliary operations
- B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
- B29B7/603—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material in measured doses, e.g. proportioning of several materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/84—Venting or degassing ; Removing liquids, e.g. by evaporating components
- B29B7/845—Venting, degassing or removing evaporated components in devices with rotary stirrers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/86—Component parts, details or accessories; Auxiliary operations for working at sub- or superatmospheric pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/88—Adding charges, i.e. additives
- B29B7/90—Fillers or reinforcements, e.g. fibres
- B29B7/92—Wood chips or wood fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
- B29C48/29—Feeding the extrusion material to the extruder in liquid form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
- B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
- B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
- B29C48/405—Intermeshing co-rotating screws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/505—Screws
- B29C48/52—Screws with an outer diameter varying along the longitudinal axis, e.g. for obtaining different thread clearance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/505—Screws
- B29C48/57—Screws provided with kneading disc-like elements, e.g. with oval-shaped elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/76—Venting, drying means; Degassing means
- B29C48/765—Venting, drying means; Degassing means in the extruder apparatus
- B29C48/766—Venting, drying means; Degassing means in the extruder apparatus in screw extruders
- B29C48/767—Venting, drying means; Degassing means in the extruder apparatus in screw extruders through a degassing opening of a barrel
Definitions
- This invention relates generally to a method and apparatus for forming an extrudate.
- an extrudate using an extruder that includes a housing having a mixing chamber defined by a pair of parallel intersecting housing bores, and a pair of screw shafts supported for rotation about respective generally parallel axes and including respective screw sections positioned for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber.
- a drive mechanism is operably attached to the screw shafts and rotates the screw shafts in the same direction and in the same sense.
- U.S. Pat. No. 6,042,260 issued 28 Mar. 2000 to Heidemeyer et al. discloses an extruder that includes a pair of screw shafts supported for rotation in a housing and including respective screw sections positioned for co-wiping intermeshing rotation within respective housing bores of a mixing chamber in the housing,
- the screw sections each have an outside diameter to inside diameter (OD-ID) ratio of “greater than or equal to” 1.55.
- a drive mechanism rotates screw shafts are rotated in the same direction and in the same sense at rotational speeds of “at least” 800 rpm and at a torque density of “at least” 11 Nm/cm 3 ).
- the screw sections of the screw shafts and the housing bores are sized to leave only a small screw-to-chamber wall clearance, i.e., a small gap between the screw sections of the screw shafts and the respective housing bores of the mixing chamber.
- a small tolerance can result in significant shear heating in the vicinity of the screw sections—especially at shaft rotation speeds in excess of 800 rpm.
- An extrusion apparatus for forming an extrudate.
- the apparatus includes a mixing chamber comprising two parallel intersecting housing bores and two screw shafts supported for rotation about respective generally parallel axes and including respective screw sections positioned for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber.
- the apparatus is configured to support screw shaft rotational speeds greater than approximately 800 rpm.
- the screw shafts also include respective conveying portions rotatably cantilevered for self-journaled support within respective separate conveying chambers arranged generally parallel to one another downstream of the mixing chamber. This self-journaled support arrangement reduces shear heating in the vicinity of the screw sections by allowing for a larger screw-to-chamber wall clearance in the mixing chamber.
- a method for forming an extrudate is provided. According to this method one can form an extrudate by providing a housing including a mixing chamber comprising two parallel intersecting housing bores and including separate conveying chambers arranged generally parallel to one another downstream of the mixing chamber, supporting screw sections of two screw shafts for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber and conveying portions of the screw shafts for rotation within the separate conveying chambers of the housing, feeding material into the mixing chamber, mixing the material within the mixing chamber and conveying the mixture downstream through the mixing chamber and along the respective conveying chambers by rotating the screw shafts in the same sense at a rotational speed in the range of 800 to 1800 rpm.
- FIG. 1 is a top view of a twin-screw extruder constructed according to the invention and with two side feeders and a de-gassing port connected and in communication with a mixing chamber of the extruder;
- FIG. 2 is a partial cross-sectional view of the twin-screw extruder of FIG. 1 ;
- FIG. 3 is a cross-sectional top view of one end of the twin-screw extruder of FIGS. 1 and 2 showing a downstream conveying section and profile die connected to a downstream end of a mixing chamber section of the extruder;
- FIG. 4 is a cross-sectional perspective view of the twin-screw extruder of FIGS. 1 and 2 , again showing the downstream conveying section and profile die connected to the downstream end of the mixing chamber;
- FIG. 5 is a top view of a sinusoidally splined engagement section of one of two screw shafts of the twin-screw extruder of FIGS. 1 and 2 ;
- FIG. 6 is a cross-sectional end view of the engagement section of FIG. 5 ;
- FIG. 7 is a magnified view of a portion of the screw shaft engagement section shown in circle 7 of FIG. 6 .
- the apparatus 10 may include a housing 12 including a mixing chamber 14 comprising two parallel generally cylindrical intersecting housing bores 16 .
- Two screw shafts 18 are supported for rotation about respective generally parallel axes and include respective screw sections 20 positioned for co-wiping intermeshing rotation within the respective housing bores 16 of the mixing chamber 14 .
- a drive mechanism 22 is operably attached to the screw shafts 18 and is actuable to rotate the screw shafts 18 in the same direction and in the same sense at rotational speeds in the range of approximately 100 to 1800 rpm.
- the drive mechanism 22 may be of any suitable model and may be obtained from any one of a number of different manufacturers including Flender Antriebstechnik, Eisenbeiss GmbH, Zambello Riduttori, P.I.V., and Thyssen Henschel Power Transmission.
- the screw shafts 18 include respective conveying portions 24 rotatably cantilevered for self-journaled support within respective separate tubular conveying chambers 26 that are arranged generally parallel to one another downstream of the mixing chamber 14 .
- This cantilevered self-journaled support also minimizes shaft sag and, consequently, internal wear and tear associated with shaft sag.
- the apparatus 10 can support rotation of the screw shafts 18 at rotational speeds in the range of approximately 200 to 1800 rpm.
- the cantilevered self-journaled support of the conveying portions 24 of the screw shafts 18 within their respective separate conveying chambers 26 accommodates this range of mixing chamber screw-to-chamber wall clearances 19 .
- D os /64 has been determined, both through theoretical modeling and practical experience, to be the maximum allowable screw-to-chamber wall clearance that a compounding twin-screw extruder of this type can have at high rpm without encountering an unacceptably high shear rate that would be potentially detrimental to extrudate being produced.
- the screw-to-chamber wall clearance in each of the conveying chambers 26 may be in the range of approximately D oc /128 to D oc /150. Because the conveying section screw-to-chamber wall clearance 27 is less than the mixing chamber screw-to-chamber wall clearance 19 , leakage flow losses between screw crests and chamber walls are reduced.
- the conveying portions 24 of the screw shafts 18 may be configured for pumping and not for melting so as to provide greater flow rate at higher RPM without the significant viscous dissipation effects.
- each screw shaft conveying portion 24 has an outer diameter smaller than an outer diameter of the screw section 20 of each screw shaft 18 .
- the conveying portions 24 of the screw shafts 18 include helical screw flights 28 shaped to convey mixed material axially downstream from the screw shaft screw sections 20 toward a mixing chamber outlet 30 disposed axially downstream from the conveying portions 24 of the screw shafts 18 .
- the screw shaft screw sections 20 have a shaft center distance to screw diameter ratio of 0.775.
- each screw shaft screw section 20 may have an outside diameter to inside diameter (OD-ID) ratio of approximately 1.78.
- OD-ID outside diameter to inside diameter
- each screw shaft screw section 20 may have an OD-ID ratio anywhere in the range of approximately 1.4-1.8.
- the point at which the OD-ID ratio falls within this range depends on the available torque density that a gearbox of the drive mechanism 22 provides as well as the configuration of the screw sections 20 of the screw shafts 18 . Variations in the OD/ID ratio for a given screw configuration alter screw shaft and gearbox power available for mixing.
- a lower ratio e.g., of 1.55, is associated with a larger diameter drive shaft and generally greater available power for mixing, but lower free volume inside the mixing chamber 14 .
- a higher OD/ID ratio is associated with a slimmer drive shaft and less power capability, but higher free volume.
- the conveying portions 24 of the screw shafts 18 may have an OD-ID ratio of 1.3.
- the drive mechanism 22 and the screw shaft screw sections 20 of the present embodiment may operate at a torque density in excess of 11 Nm/cm 3 .
- the screw shaft screw sections 20 may be shaped and the drive mechanism 22 selected and/or set to develop, withstand, and operate at a torque density in the range of approximately 8.7 to 13.6 Nm/cm 3 .
- the torque-carrying capability of the screw shafts 18 may be enhanced by including sinusoidally splined engagement sections 29 at the ends of the screw shafts 18 that engage the drive mechanism 22 .
- the sinusoidally splined engagement sections 29 may include a radially outwardly extending spline array that engages a complementary radially inwardly extending spline array of the drive mechanism 22 .
- the torque delivery capability of the drive mechanism 22 is limited primarily the useful life of gearbox bearings of the drive mechanism 22 . Operating at a torque density of approximately 8.7 Nm/cm 3 the gearbox bearings can be expected to last for approximately 40,000 hours. Operating at approximately 13.6 Nm/cm 3 of operation the bearings can be expected to last approximately 20,000 hours. In other embodiments drive mechanisms 22 and screw shaft screw sections 20 may be provided that develop and operate at any suitable torque density over a desired operating life.
- What constitutes a suitable torque density is related to the OD/ID ratio of the screw shaft screw sections 20 .
- a sufficient torque density will be approximately 11 Nm/cm 3 .
- a sufficient torque density will be approximately 8.7 Nm/cm 3 .
- the torque density will generally be in the range of approximately 8-11 Nm/cm 3 .
- the apparatus 10 includes a first or upstream inlet 32 that receives material into the mixing chamber 14 and may include additional downstream inlets 34 positioned to receive material into the mixing chamber 14 downstream from the upstream inlet 32 from side feeders 35 or, alternatively, to serve as degassing ports 36 .
- Each degassing port 36 may comprise a stuffing device 37 with degassing of the material in the mixing chamber 14 being accomplished by applying a staged incremental vacuum 39 to the stuffing device 37 .
- the apparatus 10 may further comprise a profile die 40 supported downstream from the conveying portions 24 of the screw shafts 18 .
- the profile die 40 may be arranged to receive mixed material discharged from the conveying chambers 26 and to form an extrudate of a desired cross-sectional shape.
- a pelletizer may be positioned downstream from the conveying portions 24 of the screw shafts 18 in place of a profile die 40 .
- the apparatus 10 may further comprise a common discharge cavity 42 disposed downstream from the conveying chambers 26 , in advance of the profile die 40 , and in fluid communication with the conveying chambers 26 .
- Two screw tips 43 may be disposed within the common discharge cavity 42 and supported on respective downstream ends of the screw shafts 18 for coaxial rotation with the respective screw shafts 18 .
- an extrudate may be formed at high screw rpm and without excessive shear heating by first fabricating a twin-screw extruder apparatus 10 that, as described above, includes a housing 12 comprising both a mixing chamber 14 comprising two parallel generally cylindrical intersecting housing bores 16 , and separate conveying chambers 26 arranged generally parallel to one another downstream of the mixing chamber 14 .
- the conveying chambers 26 and the conveying portions 24 of the screw shafts 18 may be formed to leave a conveying section screw-to-chamber wall clearance 27 in the range of approximately D oc /128 to D oc /150 between respective inner walls of the conveying chambers 26 and the conveying portions 24 of the screw shafts 18 .
- the screw sections 20 of the two screw shafts 18 are then supported for co-wiping intermeshing rotation within the respective housing bores 16 of the mixing chamber 14 while the conveying portions 24 of the screw shafts 18 are supported for rotation within the separate conveying chambers 26 of the housing 12 .
- the housing bores 16 and the screw sections 20 of the screw shafts 18 may be formed to leave a mixing chamber screw-to-chamber wall clearance 19 in the range of approximately D oc /64-D oc /128 between the inner wall of the mixing chamber 14 and the screw sections 20 of the screw shafts 18 .
- the screw sections 20 of the screw shafts 18 may be formed to have respective outside diameter to inside diameter (OD-ID) ratios in the range of approximately 1.4-1.8.
- the drive mechanism 22 may then be operably attached to the screw shafts 18 .
- Material to be extruded may then be fed into the mixing chamber 14 and the drive mechanism 22 actuated to mixing or agitating the material by rotating the screw shafts 18 in the same direction and in the same sense at rotational speeds in the range of approximately 200 to 1800 rpm, depending on the composition of the material to be extruded.
- the drive mechanism 22 is actuated to rotate the screw shafts 18 in the same direction and in the same sense at rotational speeds in the range of 600 to 1500 rpm, which has been found to be an acceptable speed range for polymer compounding, while developing a torque density in the range of approximately 8-11 Nm/cm 3 .
- the polymeric material may be heated to a molten state before reaching the downstream inlet 34 and before minor components are mixed into it through the downstream inlet 34 as is described in PCT/US2006/035855, which is incorporated herein by reference.
- Polymeric materials fed into the mixing chamber 14 may include thermoplastic resins such as high-density polyethylene, low-density polyethylene, linear low-density polyethylene, polyvinyl chloride, and/or polypropylene.
- Organic materials fed into the mixing chamber 14 may include wood flour, wood pellets, wood fibers, wastepaper, kenaf, flax, rice hulls, jute, sisal, coconut, and/or hemp.
- Inorganic materials such as glass fibers, carbon fibers, modifiers and fillers such as calcium carbonate, talc, wollastonite, carbon black, and other additives such as antioxidants, UV stabilizers, colorants, impact modifiers, and lubricants, may also be fed into the mixing chamber 14 .
- the material continues to be mixed or agitated within the mixing chamber 14 as it is conveyed further downstream through the mixing chamber 14 and along the respective conveying chambers 26 by the rotation of the screw shafts 18 .
- the material may be degassed or devolatilized through one ore more degassing vents downstream from the downstream inlet 34 .
- the material may then be conveyed and merged into the discharge cavity 42 provided additional mixing and propulsion by the rotation of the screw tips 43 within the discharge cavity 42 .
- the mixture may then be discharged axially from the discharge cavity 42 through one or more dies 40 , such as may be provided as disclosed in U.S. Pat. No. 5,516,472, which is incorporated herein by reference.
- the material or mixture may, alternatively, be axially discharged from the discharge cavity 42 through a pelletizer.
- a twin-screw extruder may thus be constructed in such a way as to reduce shear heating in the vicinity of the screw shaft screw sections 20 by allowing for a larger mixing chamber screw-to-chamber wall clearance 19 in the mixing chamber 14 .
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
Description
- 1. Field of the Invention
- This invention relates generally to a method and apparatus for forming an extrudate.
- 2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
- It is known to form an extrudate using an extruder that includes a housing having a mixing chamber defined by a pair of parallel intersecting housing bores, and a pair of screw shafts supported for rotation about respective generally parallel axes and including respective screw sections positioned for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber. A drive mechanism is operably attached to the screw shafts and rotates the screw shafts in the same direction and in the same sense.
- For example, U.S. Pat. No. 6,042,260 issued 28 Mar. 2000 to Heidemeyer et al., discloses an extruder that includes a pair of screw shafts supported for rotation in a housing and including respective screw sections positioned for co-wiping intermeshing rotation within respective housing bores of a mixing chamber in the housing, The screw sections each have an outside diameter to inside diameter (OD-ID) ratio of “greater than or equal to” 1.55. A drive mechanism rotates screw shafts are rotated in the same direction and in the same sense at rotational speeds of “at least” 800 rpm and at a torque density of “at least” 11 Nm/cm3). To support the screw shaft for rotation, the screw sections of the screw shafts and the housing bores are sized to leave only a small screw-to-chamber wall clearance, i.e., a small gap between the screw sections of the screw shafts and the respective housing bores of the mixing chamber. However, such a small tolerance can result in significant shear heating in the vicinity of the screw sections—especially at shaft rotation speeds in excess of 800 rpm.
- What would be desirable would be an extruder designed to reduce shear heating in the vicinity of the screw sections to acceptable levels, even at shaft rotation speeds in excess of 800 rpm.
- An extrusion apparatus is provided for forming an extrudate. The apparatus includes a mixing chamber comprising two parallel intersecting housing bores and two screw shafts supported for rotation about respective generally parallel axes and including respective screw sections positioned for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber. The apparatus is configured to support screw shaft rotational speeds greater than approximately 800 rpm. The screw shafts also include respective conveying portions rotatably cantilevered for self-journaled support within respective separate conveying chambers arranged generally parallel to one another downstream of the mixing chamber. This self-journaled support arrangement reduces shear heating in the vicinity of the screw sections by allowing for a larger screw-to-chamber wall clearance in the mixing chamber.
- Also, a method is provided for forming an extrudate. According to this method one can form an extrudate by providing a housing including a mixing chamber comprising two parallel intersecting housing bores and including separate conveying chambers arranged generally parallel to one another downstream of the mixing chamber, supporting screw sections of two screw shafts for co-wiping intermeshing rotation within the respective housing bores of the mixing chamber and conveying portions of the screw shafts for rotation within the separate conveying chambers of the housing, feeding material into the mixing chamber, mixing the material within the mixing chamber and conveying the mixture downstream through the mixing chamber and along the respective conveying chambers by rotating the screw shafts in the same sense at a rotational speed in the range of 800 to 1800 rpm.
- These and other features and advantages will become apparent to those skilled in the art in connection with the following detailed description and drawings of one or more embodiments of the invention, in which:
-
FIG. 1 is a top view of a twin-screw extruder constructed according to the invention and with two side feeders and a de-gassing port connected and in communication with a mixing chamber of the extruder; -
FIG. 2 is a partial cross-sectional view of the twin-screw extruder ofFIG. 1 ; -
FIG. 3 is a cross-sectional top view of one end of the twin-screw extruder ofFIGS. 1 and 2 showing a downstream conveying section and profile die connected to a downstream end of a mixing chamber section of the extruder; -
FIG. 4 is a cross-sectional perspective view of the twin-screw extruder ofFIGS. 1 and 2 , again showing the downstream conveying section and profile die connected to the downstream end of the mixing chamber; -
FIG. 5 is a top view of a sinusoidally splined engagement section of one of two screw shafts of the twin-screw extruder ofFIGS. 1 and 2 ; -
FIG. 6 is a cross-sectional end view of the engagement section ofFIG. 5 ; and -
FIG. 7 is a magnified view of a portion of the screw shaft engagement section shown incircle 7 ofFIG. 6 . - An apparatus for forming an extrudate is generally shown at 10 in the drawings. The
apparatus 10 may include ahousing 12 including amixing chamber 14 comprising two parallel generally cylindrical intersectinghousing bores 16. Twoscrew shafts 18 are supported for rotation about respective generally parallel axes and includerespective screw sections 20 positioned for co-wiping intermeshing rotation within therespective housing bores 16 of themixing chamber 14. Adrive mechanism 22 is operably attached to thescrew shafts 18 and is actuable to rotate thescrew shafts 18 in the same direction and in the same sense at rotational speeds in the range of approximately 100 to 1800 rpm. Thedrive mechanism 22 may be of any suitable model and may be obtained from any one of a number of different manufacturers including Flender Antriebstechnik, Eisenbeiss GmbH, Zambello Riduttori, P.I.V., and Thyssen Henschel Power Transmission. - Operating in the high end of this rotational speed range can lead to significant shear heating in the vicinity of the
screw sections 20 to the potential detriment of extrudate that theapparatus 10 is producing. Therefore, to reduce shear heating by allowing for greater clearance between the screwshaft screw sections 20 and thehousing bores 16, while at the same time supporting screw shaft rotational speeds greater than approximately 800 rpm, thescrew shafts 18 include respective conveyingportions 24 rotatably cantilevered for self-journaled support within respective separatetubular conveying chambers 26 that are arranged generally parallel to one another downstream of themixing chamber 14. This cantilevered self-journaled support also minimizes shaft sag and, consequently, internal wear and tear associated with shaft sag. The basic structure of twin screw extruders having downstream conveying chambers and screw shaft conveying portions is disclosed in U.S. Pat. Nos. 3,195,868; 4,752,135; and 5,439,286; and PCT International Patent Application No. PCT/US2006/035855; all of which are incorporated herein by reference in their entirety. - The
apparatus 10 can support rotation of thescrew shafts 18 at rotational speeds in the range of approximately 200 to 1800 rpm. To accomplish this, the housing bores 16 and thescrew sections 20 of thescrew shafts 18 may be sized to have a mixing chamber screw-to-chamber wall clearance 19 in the range of approximately Dos/64 to Dos/128, where Dos=an outside diameter of thescrew sections 20 as best shown inFIG. 3 . The cantilevered self-journaled support of the conveyingportions 24 of thescrew shafts 18 within their respectiveseparate conveying chambers 26 accommodates this range of mixing chamber screw-to-chamber wall clearances 19. Dos/64 has been determined, both through theoretical modeling and practical experience, to be the maximum allowable screw-to-chamber wall clearance that a compounding twin-screw extruder of this type can have at high rpm without encountering an unacceptably high shear rate that would be potentially detrimental to extrudate being produced. - To provide sufficient cantilevered self-journaled support of the
screw shafts 18, theconveying chambers 26 and the conveyingportions 24 of thescrew shafts 18 may be sized to have a conveying section screw-to-chamber wall clearance 27 of less than Doc/128, where Doc=an outside diameter of the conveyingportions 24 of thescrew shafts 18 as shown inFIG. 3 . In other embodiments the screw-to-chamber wall clearance in each of theconveying chambers 26 may be in the range of approximately Doc/128 to Doc/150. Because the conveying section screw-to-chamber wall clearance 27 is less than the mixing chamber screw-to-chamber wall clearance 19, leakage flow losses between screw crests and chamber walls are reduced. The conveyingportions 24 of thescrew shafts 18 may be configured for pumping and not for melting so as to provide greater flow rate at higher RPM without the significant viscous dissipation effects. - To allow for the intermeshing of the
screw sections 20 of thescrew shafts 18 within intersectinghousing bores 16 while, at the same time, allowing for the conveyingportions 24 of thescrew shafts 18 to be received inseparate conveying chambers 26, each screwshaft conveying portion 24 has an outer diameter smaller than an outer diameter of thescrew section 20 of eachscrew shaft 18. The conveyingportions 24 of thescrew shafts 18 includehelical screw flights 28 shaped to convey mixed material axially downstream from the screwshaft screw sections 20 toward amixing chamber outlet 30 disposed axially downstream from the conveyingportions 24 of thescrew shafts 18. - In the present embodiment, the screw
shaft screw sections 20 have a shaft center distance to screw diameter ratio of 0.775. Also, each screwshaft screw section 20 may have an outside diameter to inside diameter (OD-ID) ratio of approximately 1.78. However, in other embodiments, each screwshaft screw section 20 may have an OD-ID ratio anywhere in the range of approximately 1.4-1.8. In other embodiments, the point at which the OD-ID ratio falls within this range depends on the available torque density that a gearbox of thedrive mechanism 22 provides as well as the configuration of thescrew sections 20 of thescrew shafts 18. Variations in the OD/ID ratio for a given screw configuration alter screw shaft and gearbox power available for mixing. In general, a lower ratio, e.g., of 1.55, is associated with a larger diameter drive shaft and generally greater available power for mixing, but lower free volume inside themixing chamber 14. In general, a higher OD/ID ratio is associated with a slimmer drive shaft and less power capability, but higher free volume. In contrast, the conveyingportions 24 of thescrew shafts 18 may have an OD-ID ratio of 1.3. - The
drive mechanism 22 and the screwshaft screw sections 20 of the present embodiment may operate at a torque density in excess of 11 Nm/cm3. Depending on the application, the screwshaft screw sections 20 may be shaped and thedrive mechanism 22 selected and/or set to develop, withstand, and operate at a torque density in the range of approximately 8.7 to 13.6 Nm/cm3. As shown inFIGS. 5 and 6 the torque-carrying capability of thescrew shafts 18 may be enhanced by including sinusoidally splinedengagement sections 29 at the ends of thescrew shafts 18 that engage thedrive mechanism 22. The sinusoidallysplined engagement sections 29 may include a radially outwardly extending spline array that engages a complementary radially inwardly extending spline array of thedrive mechanism 22. - The torque delivery capability of the
drive mechanism 22 is limited primarily the useful life of gearbox bearings of thedrive mechanism 22. Operating at a torque density of approximately 8.7 Nm/cm3 the gearbox bearings can be expected to last for approximately 40,000 hours. Operating at approximately 13.6 Nm/cm3 of operation the bearings can be expected to last approximately 20,000 hours. In other embodiments drivemechanisms 22 and screwshaft screw sections 20 may be provided that develop and operate at any suitable torque density over a desired operating life. - What constitutes a suitable torque density is related to the OD/ID ratio of the screw
shaft screw sections 20. For shallow channel depth, e.g., OD/ID=1.5, a sufficient torque density will be approximately 11 Nm/cm3. For deeper channel depth, e.g., OD/ID=1.8, a sufficient torque density will be approximately 8.7 Nm/cm3. Accordingly, in embodiments having OD/ID ratios in the range of approximately 1.5 to 1.8, the torque density will generally be in the range of approximately 8-11 Nm/cm3. Further information on this subject is available in a paper entitled “Deeper Screw Flights 28 Offer New Opportunities for Co-rotating Twin Screw Extruders” by Klaus Kapfer and Erwin Häring, Published in SPE Conference Proceedings, ANTEC 2002, San Francisco, Calif., and is incorporated herein by reference. - As shown in
FIG. 1 theapparatus 10 includes a first orupstream inlet 32 that receives material into the mixingchamber 14 and may include additionaldownstream inlets 34 positioned to receive material into the mixingchamber 14 downstream from theupstream inlet 32 fromside feeders 35 or, alternatively, to serve as degassing ports 36. Each degassing port 36 may comprise astuffing device 37 with degassing of the material in the mixingchamber 14 being accomplished by applying a stagedincremental vacuum 39 to thestuffing device 37. - The
apparatus 10 may further comprise a profile die 40 supported downstream from the conveyingportions 24 of thescrew shafts 18. The profile die 40 may be arranged to receive mixed material discharged from the conveyingchambers 26 and to form an extrudate of a desired cross-sectional shape. In other embodiments, a pelletizer may be positioned downstream from the conveyingportions 24 of thescrew shafts 18 in place of aprofile die 40. - The
apparatus 10 may further comprise acommon discharge cavity 42 disposed downstream from the conveyingchambers 26, in advance of the profile die 40, and in fluid communication with the conveyingchambers 26. Twoscrew tips 43 may be disposed within thecommon discharge cavity 42 and supported on respective downstream ends of thescrew shafts 18 for coaxial rotation with therespective screw shafts 18. - In practice, an extrudate may be formed at high screw rpm and without excessive shear heating by first fabricating a twin-
screw extruder apparatus 10 that, as described above, includes ahousing 12 comprising both a mixingchamber 14 comprising two parallel generally cylindrical intersecting housing bores 16, and separate conveyingchambers 26 arranged generally parallel to one another downstream of the mixingchamber 14. The conveyingchambers 26 and the conveyingportions 24 of thescrew shafts 18 may be formed to leave a conveying section screw-to-chamber wall clearance 27 in the range of approximately Doc/128 to Doc/150 between respective inner walls of the conveyingchambers 26 and the conveyingportions 24 of thescrew shafts 18. Thescrew sections 20 of the twoscrew shafts 18 are then supported for co-wiping intermeshing rotation within the respective housing bores 16 of the mixingchamber 14 while the conveyingportions 24 of thescrew shafts 18 are supported for rotation within the separate conveyingchambers 26 of thehousing 12. The housing bores 16 and thescrew sections 20 of thescrew shafts 18 may be formed to leave a mixing chamber screw-to-chamber wall clearance 19 in the range of approximately Doc/64-Doc/128 between the inner wall of the mixingchamber 14 and thescrew sections 20 of thescrew shafts 18. Thescrew sections 20 of thescrew shafts 18 may be formed to have respective outside diameter to inside diameter (OD-ID) ratios in the range of approximately 1.4-1.8. Thedrive mechanism 22 may then be operably attached to thescrew shafts 18. - Material to be extruded may then be fed into the mixing
chamber 14 and thedrive mechanism 22 actuated to mixing or agitating the material by rotating thescrew shafts 18 in the same direction and in the same sense at rotational speeds in the range of approximately 200 to 1800 rpm, depending on the composition of the material to be extruded. Where the material includes polymeric material fed into the mixingchamber 14 through anupstream inlet 32 and organic material fed into the mixingchamber 14 through adownstream inlet 34 disposed downstream from theupstream inlet 32, thedrive mechanism 22 is actuated to rotate thescrew shafts 18 in the same direction and in the same sense at rotational speeds in the range of 600 to 1500 rpm, which has been found to be an acceptable speed range for polymer compounding, while developing a torque density in the range of approximately 8-11 Nm/cm3. The polymeric material may be heated to a molten state before reaching thedownstream inlet 34 and before minor components are mixed into it through thedownstream inlet 34 as is described in PCT/US2006/035855, which is incorporated herein by reference. - Polymeric materials fed into the mixing
chamber 14 may include thermoplastic resins such as high-density polyethylene, low-density polyethylene, linear low-density polyethylene, polyvinyl chloride, and/or polypropylene. Organic materials fed into the mixingchamber 14 may include wood flour, wood pellets, wood fibers, wastepaper, kenaf, flax, rice hulls, jute, sisal, coconut, and/or hemp. Inorganic materials such as glass fibers, carbon fibers, modifiers and fillers such as calcium carbonate, talc, wollastonite, carbon black, and other additives such as antioxidants, UV stabilizers, colorants, impact modifiers, and lubricants, may also be fed into the mixingchamber 14. - The material continues to be mixed or agitated within the mixing
chamber 14 as it is conveyed further downstream through the mixingchamber 14 and along the respective conveyingchambers 26 by the rotation of thescrew shafts 18. As it is being conveyed further downstream through the mixingchamber 14 the material may be degassed or devolatilized through one ore more degassing vents downstream from thedownstream inlet 34. The material may then be conveyed and merged into thedischarge cavity 42 provided additional mixing and propulsion by the rotation of thescrew tips 43 within thedischarge cavity 42. The mixture may then be discharged axially from thedischarge cavity 42 through one or more dies 40, such as may be provided as disclosed in U.S. Pat. No. 5,516,472, which is incorporated herein by reference. The material or mixture may, alternatively, be axially discharged from thedischarge cavity 42 through a pelletizer. - Through self-journaled support, a twin-screw extruder may thus be constructed in such a way as to reduce shear heating in the vicinity of the screw
shaft screw sections 20 by allowing for a larger mixing chamber screw-to-chamber wall clearance 19 in the mixingchamber 14. - This description, rather than describing limitations of an invention, only illustrates (an) embodiment(s) of the invention recited in the claims. The language of this description is therefore exclusively descriptive and is non-limiting. Obviously, it's possible to modify this invention from what the description teaches. Within the scope of the claims, one may practice the invention other than as described above.
Claims (24)
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US11/739,231 US20080267003A1 (en) | 2007-04-24 | 2007-04-24 | Extrusion method and apparatus |
US12/403,686 US9090013B2 (en) | 2007-04-24 | 2009-03-13 | Dual screw extrusion apparatus having a mixing chamber and a conveying chamber downstream thereof with the mixing chamber having a wall clearance greater than that of the conveying chamber |
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US20080267003A1 true US20080267003A1 (en) | 2008-10-30 |
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US12/403,686 Active 2030-03-03 US9090013B2 (en) | 2007-04-24 | 2009-03-13 | Dual screw extrusion apparatus having a mixing chamber and a conveying chamber downstream thereof with the mixing chamber having a wall clearance greater than that of the conveying chamber |
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US12/403,686 Active 2030-03-03 US9090013B2 (en) | 2007-04-24 | 2009-03-13 | Dual screw extrusion apparatus having a mixing chamber and a conveying chamber downstream thereof with the mixing chamber having a wall clearance greater than that of the conveying chamber |
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US20160207225A1 (en) * | 2013-05-15 | 2016-07-21 | Toshiba Kikai Kabushiki Kaisha | Twin-screw extruder and kneading method using twin-screw extruder |
WO2017171666A1 (en) * | 2016-03-29 | 2017-10-05 | Ptt Global Chemical Public Company Limited | A method for preparing a blend composition of flour and polyolefin |
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