Abstract: An extrusion-molding machine according to the present invention comprises: a screw having a blade portion for extruding a molding material, the screw disposed in a tightly-closed space; and a die for molding an extruded molding material, wherein the space is maintained in a reduced-pressure atmosphere, and a high-hardness coat layer is formed at least on the blade portion.

Abstract: Methods of extruding polyurethane composite materials are described. One method includes introducing at least one polyol and inorganic filler to a first conveying section of the extruder, transferring the at least one polyol and inorganic filler to a first mixing section of an extruder, mixing the at least one polyol and the inorganic filler in the first mixing section, transferring the mixed at least one polyol and inorganic filler to a second conveying section of the extruder, introducing a di- or poly-isocyanate to the second conveying section, transferring the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate to a second mixing section, mixing the mixed at least one polyol and inorganic filler with the di- or poly-isocyanate in the second mixing section of the extruder to provide a composite mixture, and transferring the composite mixture to an output end of the extruder. Other related methods are also described.

Abstract: A method and apparatus for making pellets of wood meal compound according to the present invention is constructed in such a manner that synthetic resin material and wood meal material are supplied into a hopper (3) in a most upstream position, and kneaded in a long kneading section (6) having no side feeder (2), thereby to obtain pellets from mixed material having more uniform properties than in the prior art.

Abstract: There is disclosed a process for removing volatile components in a polyarylene sulfide resin which is produced by subjecting a sulfur source and a dihalogenated aromatic compound to polymerization reaction in an aprotic organic solvent, comprising using an extruder which is equipped with front vent having an opening length in the range of 4D to 11D (D: screw diameter) and which has a distance between a terminal position of a screw in a kneading portion and the opening portion of the front vent being in the range of 4D to 15D. The process is capable of steadily and economically removing volatile components in the polyarylene sulfide resin without necessitating expensive machinery or equipment such as a dryer without plugging up the opening portion of a vent even in the case of degassing a PAS resin having a low molecular weight and further, thus enabling a long-term continuous stable running.

Abstract: The present invention provides a method for preparing flexible thermoplastic compositions that may be used separately or combined with up to fifty percent thermoplastic scrap. One embodiment of the invention comprises creating a melt-blend of blending composition, up to 50% by weight thermoplastic scrap and up to 15% by weight poly(ethyl-co-vinyl) acetate wherein the blending composition comprises an impact polypropylene, impact modifier and plasticizer. The polypropylene, impact modifier and plasticizer are selected to meet requirements of flexible thermoplastic compositions useful in vehicle interiors. In another embodiment of the invention a random polypropylene is used.

Abstract: Described are methods of making electrodes for electrochemical systems, especially cathodes for lithium polymer batteries, and products prepared from the methods; the methods involve the use of a co-rotating, fully intermeshing twin screw extruder, the extrusion of essentially solvent-free systems, or both.

Abstract: An array of dies having a closed configuration is used in a method and apparatus for making a closed composite article that comprises multilayered materials. In the method and apparatus, at least two extruders are used to extrude at least two material streams through the die array to provide an extrudate comprised of alternate layers of material from the at least two material streams. The compositions in the two material streams can be the same or different.

Abstract: Novel window and patio door frame members are formed by an extrusion process that provide these members with at least one channel and with an outer weather resistant surface and an internal imitation wood surface together with integrated sealing strips formed in the channels for the doors, these components being fully integrated. The process is carried out by extruding a foamed profile with a channel through a first die therein having reduced dimensions where a protective shell is desired, co-extruding a plastic with said foamed profile in a second die to form a protective shell where the reduced dimensions occur, passing the co-extrusion though a calibration die, and then heating the co-extrusion at selected location where weather stripping is desired and then passing the co-extrusion through a final die where plastic weather stripping is extruded therewith and then cooling the integrated member.

Abstract: This invention relates to methods for manufacturing super-micro fibers to produce fibers having dimensions of between 0.003-0.0003 denier per filament. The manufacturing methods include the following steps: blending polyamide-polyester mixtures; passing said polyamide-polyester mixtures through single-path and twin-screw extrusion processes; spinning said polyamide-polyester mixtures; melting and dissolving said polyamide-polyester mixtures; and separating polyester compounds from said polyester-polyamide mixtures to form polyamide compound or super-micro fibers.

Abstract: The invention relates to a method for adjusting an extrusion die in an extruder by recording at least one master flow curve (40, 41) in a first extruder to which the extrusion die is optimized, in which curve the volume flow is entered over the pressure, which master flow curve (40, 41) is obtained in a measuring channel (20) which branches off in the extruder, the extrusion die or in any interposed adapter part from the flow channel (4), and the repeated recording of flow curves (30, 31) in the same or similar measuring channels (20) as in the first extruder after the assembly of the extrusion tool in the extruder to be checked and adjusted, and the purposeful change of process parameters for such a time until the flow curves (30, 31) correspond to the master flow curves (40, 41) within predetermined tolerance ranges.

Abstract: A method is disclosed wherein synthetic materials and elastomers (e.g., PET or rubber) can be carefully processed with throughput amounts which are so high as to improve the quality of the final product and increase the cost-effectiveness of the entire process. Process tasks such as mixing, cooling/heating (heat exchange) and de-gasing (exchange of materials) can be carried out simultaneously and with greater efficiency.

Abstract: A method for removing volatile components from wet, polymer powders using a vacuum vented extruder is described. Polymer powders containing substantial amounts of water, 1-20% by weight, are rapidly converted to polymer compositions containing less than about 0.5% by weight water at high throughput rates while avoiding complications resulting from excessive steam backflow through the extruder feed throat. The method provides a screw design comprising a powder seal section upstream of kneading and melting sections of the extruder. Steam generated as the polymer is heated flows downstream to one or more vacuum vents for removal. The partially devolatilized polymer melt is then subjected to additional melt kneading and vacuum venting. The method converts wet polycarbonate powder containing residual methylene chloride to essentially dry polycarbonate powder containing less than about 1 ppm methylene chloride.

Abstract: A process for producing a component from a sheet molding compound (SMC) material includes raw-material preparation, semi-finished product production and component shaping.

Abstract: A method is disclosed for producing elastomer compounds for use in the production of rubbers. At least one elastomer to be processed for the production of an elastomer mixture can be slowly added to a mixer/extruder and is mixed and plasticized and/or masticated (melted) while it passes through the mixer/extruder. The elastomer, when slowly added to the mixer/extruder, can be present in a fluid medium in an evenly distributed form.

Abstract: Biodegradable starch-based extruded products and methods of manufacturing those products are provided. In particular, extruded starch products processed by compression, stretching or compression and stretching provide excellent flexibility, pliability, dimensional stability, resiliency, abrasion resistance and other properties making them attractive for use as packaging materials.

Abstract: Dry-blended powders of poly(vinyl chloride) can be extruded as much as 30% faster by replacing a poly(vinyl chloride) powder with another poly(vinyl chloride) powder with an Inherent Viscosity of about 3-35% higher. Unexpectedly, the reduction in bulk density of the product made by the replacement formulation is manageably small, less than about 8%. Poly(vinyl chloride) compounds from such replacement formulations so extruded at such higher speeds can save time, energy, and money for the polymer engineer.

Abstract: The present invention provides low cost resins (e.g., advanced epoxy resins), processes for making these resins, and coatings made with theses resins. Specifically, the present invention provides high throughput extrusion processing of advanced epoxy resins using an appropriate amount of an iminium salt catalyst. Preferred iminium salt catalysts are stable at room temperature in the reaction mixture (thereby enabling the pre-mixing of ingredients and the stable storage of the pre-mixed ingredients) and yet are highly efficient at the processing temperatures described herein. An example of one such advance epoxy resin is the reaction product of diglycidyl ether of bisphenol A with bisphenol A in the presence of an iminium salt catalyst. Preferred processes are performed using no solvent or only negligible amounts of solvent. One preferred extrusion process utilizes an intermeshing co-rotating twin-screw extruder, however, other types of extruders may alternatively be employed.

Abstract: An improvement in a process of making honeycomb articles, which process utilizes a co-rotating, intermeshing twin screw extrusion apparatus to mix, screen, and extrude a batch of ceramic materials through a die, the improvement which comprises the steps of separating the mixing and screening phase from the extrusion phase, by passing the batch through a first co-rotating, intermeshing twin screw extruder or a mixer extruder to mix and screen the batch, and then directly passing the mixed and screened batch through a second co-rotating, intermeshing twin screw extruder or a pumping extruder to extrude said batch through a die assembly to produce a honeycomb article.

Abstract: A method for manufacturing a polyethylene terephthalate (PET) packaging web, wherein PET material is extruded using a twin-screw extruder and wherein the extruder interior space is degassed during the extrusion. The molten plastic is outputted in a strip shape from a spinning head located after the twin-screw extruder. The plastic strip is then cooled and stretched.

Abstract: There is disclosed a process for removing volatile components in a polyarylene sulfide resin which is produced by subjecting a sulfur source and a dihalogenated aromatic compound to polymerization reaction in an aprotic organic solvent, comprising using an extruder which is equipped with front vent having an opening length in the range of 4D to 11D (D: screw diameter) and which has a distance between a terminal position of a screw in a kneading portion and the opening portion of the front vent being in the range of 4D to 15D. The process is capable of steadily and economically removing volatile components in the polyarylene sulfide resin without necessitating expensive machinery or equipment such as a dryer without plugging up the opening portion of a vent even in the case of degassing a PAS resin having a low molecular weight and further, thus enabling a long-term continuous stable running.

Abstract: Process for the continuous solvent-free and mastication-free production of self-adhesive compositions based on non-thermoplastic elastomers in a continuously operating apparatus having a filling section and a compounding section, comprising a) feeding the solid components of the self-adhesive composition, such as elastomers and resins, into the filling section of the apparatus, optionally feeding of fillers, colorants and/or crosslinkers, b) transferring the solid components of the self-adhesive composition from the filling section to the compounding section, c) adding the liquid components of the self-adhesive composition, such as plasticizers, crosslinkers and/or further tackifier resins to the compounding section, d) preparing a homogeneous self-adhesive composition in the compounding section, and e) discharging the self-adhesive composition.

Abstract: In a method and apparatus for the continuous production of rubber mixtures, rubber is introduced into a short-screw extruder for subsequent plasticization.

Abstract: A method for producing a plastic scintillator is disclosed. A plurality of nano-sized particles and one or more dopants can be combined with a plastic material for the formation of a plastic scintillator thereof. The nano-sized particles, the dopant and the plastic material can be combined within the dry inert atmosphere of an extruder to produce a reaction that results in the formation of a plastic scintillator thereof and the deposition of energy within the plastic scintillator, such that the plastic scintillator produces light signifying the detection of a radiative element. The nano-sized particles can be treated with an inert gas prior to processing the nano-sized particles, the dopant and the plastic material utilizing the extruder. The plastic scintillator can be a neutron-sensitive scintillator, x-ray sensitive scintillator and/or a scintillator for the detection of minimum ionizing particles.

Abstract: A multi-shaft extruder is disclosed with at least two shafts for compounding and/or molding an elastomer staggered with filler, in particular rubber, with at least one softener and/or additives.

Abstract: An extruder for producing a thermoplastic material having a first and second portion, namely, an axially extending barrel; first and second screw conveyers co-axially disposed within said barrel, said second screw conveyer co-axially disposed within said first screw conveyer with relative rotatable movement between said first and second screw conveyers so as to define a first passage for conveying thermoplastic material from an input to a melt zone and then an output and define a second passage from said melt zone to said output; a connecting passage for communication between said first and second passages whereby a first portion of said thermoplastic melt is conveyed through said first passage to said output and another portion of said thermoplastic melt is conveyed through said connecting passage and through said second passage to said output; means for changing the characteristic of said portion; means for merging said first and second portions together.

Abstract: The present invention relates to a biodegradable composition for the preparation of table-ware, mulching film and package, which comprises: 2-6% by weight of starch; 35-45% by weight of plant powders; 20-30% by weight of calcium carbonate; 2-7% by weight of sorbital; 7-13% by weight of polypropene; 2-5% by weight of polyethylene; 2-6% by weight of coupling agent; 1-2% by weight of defoamer; 2-5% by weight of stearic acid; 2-6% by weight of stearate; 3-6% by weight of glycerine or epoxidized soybean oil; and 60-100 ppm photosensitizer. The present invention also relates to a method for preparing the composition, which comprises: treating a plant wastes with a diluent acid, drying and pulverizing, then mixing it with starch, polypropene, and polyethylene, sorbital, defoamer, coupling agent, stearic acid, stearate, glycerine and photosensitizer homogeneously; blending the mixture obtained in a double-screw extruder at a temperature of 160-180 C to obtain the composition of the present invention.

Abstract: In the process of the present invention, a polyamide A1 and an organized clay B are mixed mainly by dispersive mixing, and after added with a polyamide A2, mixed mainly by distributive mixing in a corotating intermeshing twin-screw extruder so designed as to effect the dispersive mixing and the distributive mixing. The organized clay B is completely and finely dispersed and distributed throughout the resultant polyamide composite material. Shaped articles such as films and sheets made of the polyamide composite material exhibit excellent gas barrier properties and transparency with little malodor mainly attributable to the decomposed products of the organizing agent for preparing the organized clay B.

Abstract: The present invention has for its object to provide a molded article of a thermoplastic composite material which is not only durable with little discoloration or fading even on prolonged outdoor exposure and is very satisfactory in physical properties and appearance qualities inclusive of wood-like texture but also has high productivity and good economics. The present invention is a method of producing a molded article of a thermoplastic composite material comprising extruding the thermoplastic composite material containing a thermoplastic resin and a vegetable filler, said vegetable filler content being 50 to 90 weight % of the total weight of said thermoplastic resin and said vegetable filler, wherein extrusion is carried out by means of an extrusion apparatus comprising at least an extruder, a hot shaping die, and a cooling die, said hot shaping die and cooling die being directly coupled.

Abstract: A deodorant or antiperspirant soft solid composition is filled into dispensing containers by injection moulding, i.e. under pressure, preferably in the vicinity of its normal setting temperature. The deodorant or antiperspirant composition is preferably continuously produced in a screw extruder, especially a twin screw extruder, controlled to deliver the composition in a suitably viscous state under low shear and particularly for formulations in which a particulate antiperspirant is suspended in a fluid carrier. The pressure in the injection head at the point of injection is greater than 120 kPa and in many instances from 800 to 2000 kPa. The combined process offers benefits for controlled fill of dispensing containers, particularly for formulations incorporating sensitive ingredients and offers tolerance in composition temperature at the time of fill.

Abstract: Methods for manufacturing super micro fibers to produce fibers having dimensions of between 0.003-0.003 denier per filament. The manufacturing methods include the following steps: blending polyamide and polyester compounds; passing the polyamide-polyester mixture through twin-screw extrusion; spinning the mixture and; melting, dissolving and removing the polyester compounds with alkaline solvents.

Abstract: A method for processing an impact modifier material having a core and shell molecular structure comprises working the impact modifier material in a mild extruder to a state such that at least a portion of the shells of the impact modifier material fuse together to form an impact modifier material output, and pelletizing the impact modifier output. The output is preferably pellitized, and produces pellets having a narrow size distribution.

Abstract: The present invention is a continuous in-line compounding and extrusion system that does not require pre-dried wood flour or pelletized feed stock of cellulosic/polymer composite materials in order to produce net shapes from cellulosic/polymer composite materials. An exemplary embodiment of the present invention utilizes automated loss-in-weight feeders to dispense wood flour and all of the other cellulosic/polymer composite materials into a compounder. The compounder blends the cellulosic/polymer composite materials into a composite melt. The composite melt is continuously devolitalized as it travels through the compounder, a transition chute, and a finish extruder. The composite melt is then forced through a profile die which is fitted to the finish extruder in order to achieve a net shape.

Abstract: A wear resistant resin composition containing (A) 100 parts by weight of a modified microblend obtained by bonding an organic acid group to a microblend consisting of 1 to 70 wt % of polypropylene and 99 to 30 wt % of a propylene-ethylene random copolymer consisting of 15 to 50 mol % of an ethylene polymer unit and 85 to 50 mol % of a propylene polymer unit, or a mixture of the microblend and the modified microblend, and (B) 1 to 1,000 parts by weight of at least one filler of a fibrous filler or a lamellar filler, the microblend contains 10 to 90 wt % of a component eluting at a temperature of −40 to +30° C. based on the total of all the eluting components fractionated by temperature rise elution fractionation using o-dibromobenzene as a solvent. The composition has a flexural modulus of 2,000 MPa or less.

Abstract: A process for extruding a thin positive electrode sheet having at least 40% /wt of solid content for a lithium polymer battery through a single or twin screw extruder is disclosed as well as a positive electrode sheet produced therefrom. A mixture of active cathodic intercalation material, lithium salt and electronic conductive material is mixed with a polymer of the polyether family in a ratio of at least 40% of total weight into the mixing chamber of an extrusion machine and extruded through a classical sheet die into a thin cathode sheet or film onto a substrate in sheet form.

Abstract: Described are methods of making electrodes for electrochemical systems, especially cathodes for lithium polymer batteries, and products prepared from the methods; the methods involve the use of a co-rotating, fully intermeshing twin screw extruder, the extrusion of essentially solvent-free systems, or both.

Abstract: A positive displacement extruder for a viscous material, such as unvulcanized rubber, includes a feed member arranged in a chamber of a main body and driven for rotation so that the viscous material charged into the chamber is extruded from its outlet. A mouthpiece has an inlet that is spaced in a circumferential direction from the outlet of the main body and, in communication therewith, an extrusion nozzle. At least one cylinder device is rotatable about a center axis of the extruder so that the cylinder is alternately bought into communication with the outlet of the main body and the inlet of the mouthpiece. The viscous material is charged from the chamber of the main body into the cylinder device and discharged from the cylinder device into the mouthpiece, as the cylinder device is rotated about the center axis of the extruder and the piston of the cylinder device is driven by a cam device to reciprocate in the cylinder.

Abstract: Described is a process for producing segmented polyurethanes having improved processing characteristics in the melt state and an efficient spinning process based thereon to form highly elastic, fine linear density elastane yarn and filament having improved mechanical and thermal properties by using hydroxyalkyl-terminated polysiloxanes in combination with specific crosslinking-capable polyisocyanates in the reaction of long-chain high molecular weight polyhydroxy compounds with organic diisocyanates and low molecular weight diols and also optionally further auxiliary and additive substances in the melt.

Abstract: The present invention relates to industrial high relative viscosity (RV) filaments, such as, for use in papermaking machine felts and other staple fiber applications. The invention is further directed to apparatus and processes for solid phase polymerization (SPP) of polyamide flake suitable for use, such as, in remelting and then spinning the industrial high RV filaments. The invention is also directed to processes for melt phase polymerization (MPP) of molten polymer for making the filaments.

Abstract: The invention concerns a micro-composite polymer/polymer material comprising an amorphous polymer (I) forming a dispersed phase localised inside a thermoplastic or elastomeric polymer (II) forming a matrix, the glass transition temperature of polymer (I) forming a dispersed phase being higher by at least 20° C. than the melting or softening point of matrix-forming polymer (II), and the amorphous polymer content (I) forming the dispersed phase being not less than 40 wt. %.

Abstract: A process for making load limiting yarn comprising making block copolymer and then spinning the block copolymer into yarn. The process employs a twin screw extruder and comprises (A) forwarding aromatic polyester melt to an injection position in a twin screw extruder, (B) injecting lactone monomer into the molten aromatic polyester, (C) dispersing the monomer into the aromatic polyester melt so that a uniform mixture forms in less than about thirty seconds, and (D) reacting the uniform mixture resulting from step (C) at a temperature from about 250° C. to from a block copolymer. Steps (A) through (D) occur in less than about four minutes residence time in the twin screw extruder. The process is advantageous because high IV starting aromatic polyester can be used and the short reaction time at high temperature results in block copolymer with minimum transesterification, a high melting point, and a high melt viscosity.

Abstract: Injection-molding materials comprised of polycarbonate can be processed into optically isotropic films in a chill roll extrusion method. The optically isotropic films are used as covering films for protecting data carriers (CD-ROMS) from becoming scratched, or they are used as supporting materials for the information layer.

Abstract: The method for manufacturing a thermoplastic elastomer composition of the present invention comprises continuously feeding a mixture comprising pelletized olefinic resin (A), a pulverized product (B) obtained by pulverizing bulk olefinic rubber, and a crosslinking agent (C) into a continuous kneading machine, and performing a dynamic heat treatment to yield the thermoplastic elastomer composition. An olefinic thermoplastic elastomer composition having excellent tensile characteristics and molded appearance can be manufactured with high productivity by the method of the present invention.

Abstract: A method and apparatus (20) for extruding fibre cement. The extruder comprises a casing (30) with a pair of inter-meshing self-wiping screws (40) rotatably mounted therein. The screws continuously mix and or knead the components of the fibre cement provided through various feed means (61, 62) to form a substantially homogeneous paste and force the paste through a die (50) to form a green cementitious extrudate suitable for curing.

Abstract: A method of making polymeric particulates wherein polymeric scrap material, virgin polymeric material and mixtures thereof are supplied to intermeshing extruder screws which are rotated to transport the polymeric material along their length and subject the polymeric material to solid state shear pulverization and in-situ polymer compatibilization, if two or more incompatible polymers are present. Uniform pulverized particulates are produced without addition of a compatibilizing agent. The pulverized particulates are directly melt processable (as powder feedstock) and surprisingly yield a substantially homogeneous light color product.

Abstract: An extrusion method and an extruder, the material to be extruded being fed with a material feeding device (1) into a radial pump unit included in the equipment. The radial pump unit comprises conical gearwheels (2) which are adjacently positioned and rotate in opposite directions. The radial pump unit transfers the material in an annular flow into the extruder's nozzle (4). Additional material (20) can be supplied into the product through the radial pump unit.

Abstract: Polyethyleneterephthalate extrusion equipment of material in granule form, still humid, coming from both ground recovered products and also virgin material, comprising a chassis (29), containing a co-rotating, oil-thermoregulated extruder with two screws (31, 32), which comprises a first zone (A), equipped with an opening (34) where there is an aspiration hood (35) for a first “open top” degassing, a second zone (C) where there is at least one stack (37, 38) for a further degassing, between the two zones (A, C), there being a tight zone (B), and a carrying and loading zone (E) activated by the screws (31, 32).

Abstract: A method for processing an impact modifier material having a core and shell molecular structure comprises working the impact modifier material in a mild extruder to a state such that at least a portion of the shells of the impact modifier material fuse together to form an impact modifier material output, and pelletizing the impact modifier output. The output is preferably pellitized, and produces pellets having a narrow size distribution.

Abstract: A process for the preparation of a composition useful in telecommunications jacketing comprising: (i) introducing a polyolefin into the first mixing zone of a melt/mixer having first and second mixing zones; (ii) introducing particulate carbon black per se or a premix of said carbon black and polyolefin into the first mixing zone, said carbon black being in an amount of about 2 to about 50 percent based on the weight of the polyolefin introduced into the first mixing zone; (iii) melting the polyolefin in the presence of the carbon black in the first mixing zone; (iv) mixing the carbon black and the molten polyolefin in the first mixing zone to provide a molten mixture; (v) passing the molten mixture from step (iv) into the second mixing zone; (vi) adding sufficient polyolefin to the molten mixture from step (v) to dilute the carbon black to a level of about 2 to about 3 percent by weight based on the weight of the total polyolefin in the melt/mixer; (vii) mixing the added polyolefin with the molten mix

Abstract: An extrusion method and an extruder, the material to be extruded being fed with a material feeding device (1) into a radial pump unit included in the equipment. The radial pump unit comprises conical screws (2) which are adjacently positioned and rotate in the same direction. The radial pump unit transfers an annular flow of the material into the extruder's nozzle (4). Additional material (20) can be supplied into the product through the radial pump unit.

Abstract: A single pass, continuous, automated system for producing a pharmaceutical granulation includes multiple feeders to feed powders and liquids, a twin screw processor to granulate, a radio frequency or microwave based drying apparatus to dry the granulation, and at least one mill to process the dried granulation to desired particle sizes. The system incorporates means for monitoring key process parameters on-line, all of which are controlled by a controller provided with feedback at each component of the system. The granulation produced can be compressed into a tablet or incorporated into a capsule, both having a uniform distribution of the active ingredient. The system produces product having consistent properties even when production is scaled up for manufacture of the tablet in commercial volume.