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. The pulverized particulates also can be more intimately mixed than mixtures which are provided by only melt mixing, and can be melt processed without a significant delay in achieving phase inversion. The pulverized particulates also provide a stable microstructure.

Abstract: The present invention relates to a process for preparing mixture from a large number of components, the concentrations of the components used being capable of continuous variation over prescribed ranges in a very simple manner. For this, the mixtures are continuously prepared in a mixing assembly and continuously converted into a form which can be subjected to further processing. By way of example, the invention may be used for producing substance libraries for high-throughput screening in the plastics industry, in particular of mixtures of polymers with one another and of mixtures of polymers with added materials.

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: Tire rubber material is highly accurately and efficiently extruded by a positive displacement extruding system that includes, as seen from an upstream side of the tire rubber, a screw extruder unit, a gear pump unit and an extrusion head unit with an extrusion nozzle, which are connected in series with each other. While the tire rubber is caused to flow through the extruding system, the temperature of the rubber material is measured and controlled to be within a predetermined temperature range, in accordance with the measured temperature of the rubber material. The rubber material maintained at a controlled temperature is extruded from the extrusion nozzle, thereby improving the positive displacement performance of the extruding system.

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: Uniformly sized granules are formed using the present extruder and granulation process. The extruder contains a spiral worm screw for guiding a granulation material to an apertured plate. The spiral worm screw is rotated within a chamber and is formed from a guiding slant which terminates at a blunt edge near the apertured plate. The blunt edge rubs the granulation material against the apertured plate which softens the material foming a semi-solid material. The semi-solid material is then gently pushed through the apertured plate using just the required pressure. The granules are formed when the semi-solid material hardens after exiting the apertured plate.

Abstract: A method of extruding a mixture made of a granulate, chips, or powder, etc. of a first thermoplastic and a second thermoplastic is described, the melting range of the first thermoplastic differing from the melting range of the second thermoplastic, using an extruder which has a heatable housing and a screw, which has an intake zone, a melting zone, a delivery zone, and a hole, extending from the intake zone up to the delivery zone, into which a temperature control media may be introduced, in which the temperature control medium causes heating of the screw in the intake zone to a temperature below the melting range of the thermoplastic having the lower melting range and temperature control of the screw in the delivery zone to a temperature which lies between the melting range of the first thermoplastic and the second thermoplastic.

Abstract: New wood-synthetic resin composite products and methods of forming these products are provided. The products comprise a cellulosic or fibrous material and polypropylene (preferably reactor flake polypropylene). The products are formed by passing ingredients including the fibrous material and polypropylene through an extruder (preferably a twin screw extruder) at temperatures of from about 150-260° C. The extruded composite products have physical properties very similar to those of natural wood, including high tensile strengths, high compressive strengths, and high densities.

Abstract: A liquid phase continuous reactor comprising a screw within a barrel, the screw and the barrel being relatively rotatable and defining a mixing zone therebetween, the barrel having at least one inlet for introduction of components for mixing into the barrel and an outlet for discharge of product from the barrel, the screw having at least one spiral groove whereby relative rotation of the screw and barrel is adapted to axially transport the components between the screw and the barrel while mixing the components and to extrude the product through the outlet, wherein the land surface area between the spiral groove forms at least 50% of the surface area of the screw in the mixing zone.

Abstract: An extruder apparatus for compounding thermoplastic resin and reinforcing fibers is disclosed. Molten thermoplastic resin is mixed in intimate contact with long reinforcing fibers of at least one and one quarter inches in length under the control of a sophisticated computer system, resulting in charge ready for molding.

Abstract: A method and system (10) of fabricating elastomeric compounds is provided. The method includes the steps of establishing a thermo-kinetically heated high speed mixer (100) and introducing into that high speed mixer (100) in predetermined quantities a comminuted rubber composition (110), a plasticizing agent composition (120), and at least one additive composition (130, 132, 134). The method includes the further step of simultaneously mixing and thermo-kinetically heating the comminuted rubber (110), plasticizing agent (120), and additive compositions (130, 132, 134) in the high speed mixer (100) for a predetermined residence time period to form a first intermediate mixture composition. The first intermediate mixture composition contains a substantially homogenous mixture of the comminuted rubber (110), plasticizing agent (120), and additive compositions (130, 132, 134).

Abstract: The present invention is a non-porous, breathable membrane of at least polyamide-4,6, with an elongation at rupture of about 250 to about 500% in the longitudinal direction and about 200 to about 500% in the transverse direction. The membrane has a higher heat resistance than a non-porous, breathable membrane made from polyether ester and, if it also contains an antioxidant, passes the oven/watertightness test. If the membrane is produced from a mixture of polyamide-4,6 and about 10 to about 30% by weight polyether amide, the membrane exhibits a surprisingly increased water-vapor permeability. The membrane is usable in the manufacture of thermally protective clothing.

Abstract: A method and apparatus for manufacturing a rubber sheet containing short fibers. The method includes the steps of: mixing short fibers in a flowable rubber matrix; forming the flowable rubber matrix with the fibers therein into a cylindrical shape with a circumferential extent; separating a portion of the circumferential extent from the cylindrical shape, and forming the cylindrical shape with the portion separated into a sheet form.

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: 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: In an extrusion method and an extruder, an annular material flow is created by extruding material into an annular extrusion channel (6). The extruder has a tubular filtering unit (7) arranged to the annular extrusion channel (6), whereby the annular material flow flows through the tubular surface of the filtering unit (7).

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 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. The pulverized particulates also can be more intimately mixed than mixtures which are provided by only melt mixing, and can be melt processed without a significant delay in achieving phase inversion. The pulverized particulates also provide a stable microstructure.

Abstract: An mandrel for extrusion of hollow bodies, such as, polyvinyl chloride (PVC) hard, compact, and foamed pipes, includes an inner collar and an outer collar, and webs radially joining the inner collar and outer collar. The webs can be arranged twisted and/or offset in radial direction.

Abstract: The invention relates to a mixing device comprising at least one screw injection moulding machine (S1) and a screw injection moulding machine (S2). (S1) is provided with heating devices at least in the plasticising and homogenising section, and the outlet pertaining to (S2) is connected to the screw cylinder of (S1) in the plasticising or homogenising section pertaining to (S1). It is essential that (S1) and (S2) are connected by means of a connecting device provided with a cooling device which acts up to the inner wall of the screw cylinder of (S1). The invention also relates to methods for producing thermoplastically processable moulding materials, especially additive batches, consisting of at least one thermoplastic component (K1) and at least one component (K2). The melting or decomposition temperature (TSK2) of (K2) is at least ca. 50° C. lower than the temperature (TWK1) which limits the lower end of the thermoforming range of (K1), (K2) only largely being melted after coming into contact with (K1).

Abstract: A resilient article and method of manufacturing the same using recycled materials are described. Predetermined amounts of thermoset material and thermoplastic binder are mixed and extruded into a die, from which the mixture emerges in the form of a sheet having the approximate thickness of the finished article. The mixture then enters a calibrator, which more precisely shapes the sheet to the desired thickness. The sheet is then cooled and cut to the desired dimensions to provide the finished article. The thermoset material used in the mixture is preferably ground vehicle tire rubber with the fabric and metal removed and the thermoplastic binder is preferably waste polyethylene. The apparatus and method according to the present invention is particularly well suited for manufacturing resilient articles for use as expansion joint material.

Abstract: An aromatic polycarbonate extruder which is a twin screw extruder for kneading components into a molten aromatic polycarbonate, the extruder having at least one module consisting of a kneading unit, a material seal unit, a back kneading unit and full-flight unit which are arranged from an upstream side to a downstream side and a method of kneading components into an aromatic polycarbonate by using the above extruder. The present invention also provides a kneading apparatus and method for producing an aromatic polycarbonate which has an extremely small content of foreign matter and is free from residence deterioration such as coloration, crosslinking or gelation when the aromatic polycarbonate is to be kneaded with various components.

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: 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: This invention describes the use of organoclays as additives to plasticizers to provide a plasticizer composition, to allow the mixing of the plasticizers with thermoplastic resins in the same process used to convert the resin formulation to finished product. The use of this invention eliminates the need for a preliminary compounding step to incorporate plasticizers into thermoplastics prior to extrusion or molding.

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: 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: The present invention relates to apparatus for extruding mouldings from cross-linkable polymer material. The apparatus includes a first part to which the polymer material is delivered from a material container, and a second part which forms a moulding tool for moulding and cross-linking said article. The first part of the apparatus includes a feed zone (2) that has an inlet (8), a generally tubular outlet (7) and a rotatable feed screw (10) that functions to compress and feed the polymer material in a unmelted or solid state from said inlet (8) to said outlet (7), wherein the length of the feed screw (10) does not exceed the length of the feed zone (2).

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: The invention relates to an extruder for the preparation of rubber mixtures for elastomeric products and comprises a cylinder, an endless screw rotatably mounted in the cylinder for uptake transport and homogenization of the rubber mixture, and an extrusion tool; wherein the endless screw is configured with zones of multiple treads in dependence of varying helix angle and depth of thread so that the rubber mixture transported through the zones undergoes a temperature increase through heat dissipation to such an extent that the temperature of the extrudate approaches the vulcanization temperature thereof.

Abstract: A method to melt process a thermoplastic, partially-crystalline, olefin polymer in a multi-temperature stage extruder wherein the polymer has a broad melting temperature range comprises setting the temperature profile of the extruder such that a portion of the polymer crystallizes in the extruder and passing the resulting partially-crystallized polymer through an extruder die.

Abstract: In a method of producing a ceramic molding 8 having a desired shape by extruding a ceramic material 80 pressure-fed into a resistance pipe 3 from a mold 4 by using a production apparatus including a screw type extruder 10 and the mold 4 connected to the distal end of the extruder 10 through the resistance pipe 3, the ceramic material 80 pressure-fed from the extruder 10 into the resistance pipe 3 is heated or cooled from round the periphery of the resistance pipe 3 so as to control the shape of the ceramic molding 8 extruded from the mold 4.

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. The pulverized particulates also can be more intimately mixed than mixtures which are provided by only melt mixing, and can be melt processed without a significant delay in achieving phase inversion. The pulverized particulates also provide a stable microstructure.

Abstract: The present invention is a non-porous, breathable membrane of at least polyamide-4,6, with an elongation at rupture of about 250 to about 500% in the longitudinal direction and about 200 to about 500% in the transverse direction. The membrane has a higher heat resistance than a non-porous, breathable membrane made from polyether ester and, if it also contains an antioxidant, passes the oven/watertightness test. If the membrane is produced from a mixture of polyamide-4,6 and about 10 to about 30% by weight polyether amide, the membrane exhibits a surprisingly increased water-vapor permeability. The membrane is usable in the manufacture of thermally protective clothing.

Abstract: The invention relates to a system for delivering elastomeric media, the system consisting of a gear pump (1), a filter (20) and a screw-type extruder (10) which, viewed in the delivery direction (6) of the pumping medium, is arranged in front of the gear pump (1) and which consists of a screw (11) and of a screw casing (12).

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. A preferred 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 process for pelletizing elastomeric anionically polymerized polymers which comprises subjecting the polymer to solid state extrusion in a single screw extruder with a length to diameter ratio of 10:1 or less wherein the barrel of the extruder has longitudinal grooves and transversally extending pins to increase mixing wherein the temperature in the extruder is sufficient to agglomerate or melt the polymer but be lower than the degradation temperature of the polymer and the speed of the extruder screw is from 30 to 100 rpm.

Abstract: The present invention provides a method for producing an ethylene-vinyl alcohol copolymer resin composition, said method comprising: a) introducing into an extruder an ethylene-vinyl alcohol copolymer resin having a water content of at least 0.5 weight % and an additional component; b) kneading the resin and the additional component whereby to form an ethylene-vinyl alcohol copolymer resin composition; and c) discharging said resin composition from the extruder; wherein said method further comprises feeding water in a liquid state to the extruder and/or removing water in a liquid state from the extruder. Thereby, strand-breakage or cutting errors are suppressed and thus, molded products such as pellets can be provided with a stable shape.

Abstract: A process is provided for single screw extrusion of a composition or masterbatch comprising a polymer and an antistatic agent wherein the feed zone temperature is maintained below 385° F. in order to allow processability of the composition.

Abstract: According to the present invention an in-line compounding/extrusion deposition and molding apparatus and method of using the same are provided. The apparatus comprises a single step compounding and extrusion apparatus which includes an extruder screw. The apparatus includes a first zone, a second zone, and a third zone. The first zone is used to melt an inlet material before the screw advances the melted inlet material into the second zone which comprises a preparation and cutting zone. Simultaneously, as the inlet material is melted in the first zone, the screw rotation feeds a reinforcing fiber bundle into the second zone where the reinforcing fiber bundle is prepared for melt impregnation and is sheared to a desired length. While in the second zone, mixing begins between the melted inlet material and the sheared reinforcing fiber bundle.

Abstract: A fiber reinforced thermoplastic resin structure comprising a thermoplastic resin and reinforcing fibers, having a ratio (Lw/Ln) of the number average fiber length (Ln) to the weight average fiber length (Lw) of the uniformly dispersed reinforcing fibers of 1.1 to 5, and having a weight average fiber length of 1.0 mm to 200 mm as well as a process and extruder for the production thereof.

Abstract: High levels of treated fumed silica, processing fluid and high molecular weight silicone polymer are continuously compounded into a homogeneous silica filled heat-vulcanizable silicone composition by forming a premix in a continuous annular layer mixer and continuously discharging the premix into a compounding apparatus for compounding to form the filled heat-vulcanizable silicone composition.

Abstract: A method and apparatus for making filter elements in which a mixture of activated carbon granules and fibers are processed with meltable polymer fibers to form a porous element. The density of the porous structure increases in a direction from the periphery thereof to its center. Also, the article formed by the method using the apparatus.

Abstract: New wood-synthetic resin composite products and methods of forming these products are provided. The products comprise a cellulosic or fibrous material and polypropylene (preferably reactor flake polypropylene). The products are formed by passing ingredients including the fibrous material and polypropylene through an extruder (preferably a twin screw extruder) at temperatures of from about 150-260° C. The extruded composite products have physical properties very similar to those of natural wood, including high tensile strengths, high compressive strengths, and high densities.

Abstract: In a method for molding a raw material including a plastic material or a mixture of plastic and non-plastic materials fed into a cylinder, the said raw material is subjected to a melt-kneading performed under oxygen-free conditions, and at the same time the molten material is sent from the tip of an extrusion screw towards the head section of the cylinder in straight flow conditions. In the method satisfactory molding can be made for plastics of poor fluidity or thermal stability or for plastic materials mixed with more than 10 to 30% by weight of wood flour, paper powders, stone powders, metal powders, fiber reinforcements and the like, without causing molding defects such as burn or cavitation; and also for raw materials mixed with more than several per cent by weight of metal powders or stone powders without causing excessive wear at the extrusion screw.

Abstract: The invention relates to a method and an apparatus for manufacturing an extruded plastic product, the apparatus comprising at least one rotor (1) and at least one stator (2, 3) 4 with a feed gap (4) provided between them, a groove (7) being situated on the other side of the feed gap (4), the groove pressing the material to be extruded out of the apparatus when the rotor (1) is rotated. The cross section of the groove (7) remains substantially unchanged. At the opposite side of the feed gap (4) there is positioned a countergroove (8) in such a way that a processing cavity consisting of the grooves (7), the countergrooves (8) and the clearance between 6 them decreases at least partially continuously along 5 the axis of the extruder. The deformation energy of the material can thus be kept as small as possible due to the unchanging cross section of the groove (7), and the material stays in the groove (7) due to the placement of the flights (7a, 8a).

Abstract: A process for preparing a starch-based thermoplastic hydroxy-functionalized polyetheramine comprising continuously feeding from about 40 to about 98 weight percent starch and from about 2 to about 60 weight percent of a thermoplastic hydroxy-functionalized polyetheramine into a mixing screw extruder at a temperature of from about 30° C. to about 120° C. while maintaining a water content in the extruder of from about 7 to about 50 percent, continuously removing the compounded mixture from the extruder in the form of strands at a rate of from 13.5 to 2725 kg/hour, and forming the strands of compounded mixture into pellets.

Abstract: This invention relates, in general, to methods of making blend compositions of an unmodified polyvinyl alcohol and a metallocene polyolefin or grafted metallocene polyolefin and thermoplastic film and fiber structures comprising these blend compositions. More specifically, this invention relates to methods of making substantially water-free films and fibers comprising unmodified polyvinyl alcohol and a metallocene polyolefin or grafted metallocene polyolefin.

Abstract: A process for the continuous preparation of melt processable polyurethane elastomers having improved softening behavior is disclosed. The process entails reacting a polyisocyanate, a polyol and a chain extender, which have a temperature of at least 170° C., in a static mixer, wherein the reaction mixture is prepared. The reaction mixture is then metered into an extruder into which optional auxiliaries and/or further components are fed.