Abstract: Disclosed are additively manufactured extruder components comprising a lattice structure formed within a structural support frame that defines an impervious surface and an axial aperture. An axial aperture of a screw segment is configured to couple to a drive shaft, and its impervious surface is configured to contact extrudable material. An axial aperture of a barrel segment is configured to contact extrudable material.

Abstract: Disclosed are additively manufactured extruder components including a surface layer configured to contact extrudable material. The surface layer has a first additively manufactured metal composition. A base support for the surface layer has a second additively manufactured metal composition that is different from the first additively manufactured metal composition. A functionally graded material (FGM) is formed from the first and second additively manufactured metal compositions connecting the surface layer to the base support.

Abstract: A multiple screw extruder (50) combines application of vacuum to a vacuum vent (62) positioned between material feed locations (70, 72) of the extruder and use of specially configured extruder screws (58) to extract gases, primarily air, out of the extruder to densify the materials introduced into it and to extract unwanted fluid from material introduced for mixture with molten polymeric material flowing through the extruder. The multiple screw extruder is operationally versatile in that it is capable of carrying out the material densification and fluid extraction processes either separately or simultaneously. Implementation of the disclosed vacuum feed technology provides an increase in rate of extrudate throughput as compared with that achievable by implementation of atmospheric venting (16) in a conventionally configured extruder (10a, 10b).

Abstract: A multiple screw extruder (50) combines application of vacuum to a vacuum vent (62) positioned between material feed locations (70, 72) of the extruder and use of specially configured extruder screws (58) to extract gases, primarily air, out of the extruder to densify the materials introduced into it and to extract unwanted fluid from material introduced for mixture with molten polymeric material flowing through the extruder. The multiple screw extruder is operationally versatile in that it is capable of carrying out the material densification and fluid extraction processes either separately or simultaneously. Implementation of the disclosed vacuum feed technology provides an increase in rate of extrudate throughput as compared with that achievable by implementation of atmospheric venting (16) in a conventionally configured extruder (10a, 10b).

Abstract: A multi-row melt-blown fiber spinneret (8) enables stacking rows (121, 122, 123) of polymer outlet orifices (36) more closely together than is achievable with conventional melt-blown fiber spinnerets. The fiber spinneret configuration also enables dense side-by-side packing of the polymer outlet orifices. The fiber spinneret is configured so that air knife channels (141c, 142c, 143c, 144c) and individual intricate small air knife passage feeds, together with their associated melt flow channels (501, 502, 503), are formed in the same body member. The rows of polymer outlet orifices are supplied with a polymer melt by a single polymer inlet (20), which delivers the polymer melt to the individual polymer melt flow channels. The air knife channels are directed through the body member, in which the polymer melt flow channels are formed by islands and air flow passage feeds. The body member is constructed by operation of a 3D printer for direct metal printing.

Abstract: Puck and collar alignment device embodiments facilitate simultaneous insertion of free end portions of screw shafts into open end portions of complementary drive couplings. The embodiments have alignment keys that correct deviations in alignment and rotation introduced while moving the screw shafts though a barrel of an extruder. Tapered front faces of the alignment keys incrementally adjust coaxial alignment, and tapered side faces of the alignment keys incrementally adjust rotational position cooperatively between the alignment devices and drive couplings. The coaxial and rotational position adjustments cooperate to simultaneously guide multiple alignment keys to fit within corresponding keyway sections while providing alignment of external splines on the screw shafts to interlock in a timed relationship with internal splines on the drive couplings during the simultaneous insertion.

Abstract: Puck and collar alignment device embodiments facilitate simultaneous insertion of free end portions of screw shafts into open end portions of complementary drive couplings. The embodiments have alignment keys that correct deviations in alignment and rotation introduced while moving the screw shafts though a barrel of an extruder. Tapered front faces of the alignment keys incrementally adjust coaxial alignment, and tapered side faces of the alignment keys incrementally adjust rotational position cooperatively between the alignment devices and drive couplings. The coaxial and rotational position adjustments cooperate to simultaneously guide multiple alignment keys to fit within corresponding keyway sections while providing alignment of external splines on the screw shafts to interlock in a timed relationship with internal splines on the drive couplings during the simultaneous insertion.