The disclosure relates to an extruder system. More particularly the disclosure relates to an improved feed regulator for an extruder.

BACKGROUND

Extruders are well known machines that are extensively used for mixing materials including kneading, dispensing, homogenizing and distributing a material with or without increase in temperature or heat input in a continuous and controlled manner.

Extruders are widely used in the creation of plastics from polymers. Material is typically input to the extruder by a hopper at the inlet. The compounding of polymers in the manufacture of plastics is highly technical where most ingredients are used in a solid or powder form resulting in a dusty environment. The use of solids or powders in the manufacture of plastics also creates a problem of agglomeration at the extruder inlet which may disrupt continuous feed to the extruder. Furthermore, as the manufacture of plastic products generally requires a clean environment, plastic manufacturing and production of plastic products is usually done at separate locations.

There is therefore a need for an improved extruder system, which is capable of overcoming the aforementioned limitations.

SUMMAR

The invention relates to a feed regulator for an extruder capable of feeding high viscosity raw material continuously to the extruder wherein the feed regulator is a single or twin screw extruder.

DESCRIPTION OF ACCOMPANYING DRAWINGS

The accompanying drawings illustrate the preferred embodiments of the invention and together with the following detailed description, serve to explain the principles of the invention.

Figure 1 illustrates an extruder system with a feed regulator in accordance with an embodiment of the present invention.

Figure 2 illustrates a feed regulator in accordance with an embodiment of the present invention.

Figure 3 illustrates an extruder system including a feed regulator attached to an extruder outlet in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

A method of extruder operation including feeding high viscosity raw material to an extruder is disclosed. The method includes the use of feed regulator configured to feed the high viscosity raw material to the extruder. The raw material is preferably as thick as possible to reduce the amount of solvent added to the raw material that will have to be eventually removed from the processed product.

An integrated method of production of plastic and plastic components is also disclosed. The method involves feeding high viscosity raw material to the extruder. A feed regulator configured to feed the high viscosity raw material to the extruder is used. The plastic produced by the extruder is passed to a plastic component manufacturing system such as an injection molding system.

Referring to Figure 1, an extruder system with a feed regulator 2 in accordance with an embodiment is disclosed. The feed regulator 2 is configured to feed high viscosity liquids to the extruder 3 in a continuous manner. In accordance with an embodiment, the feed regulator 2 may be a single or twin screw extruder.

Referring to Figure 2, the feed regulator 2 is illustrated as a small scale twin screw counter rotating extruder and comprises of a barrel 12 having two cylindrical bores (not shown), each housing bore having an axis A-A disposed parallel to the other axis B-B and two shafts (13,14) disposed in the first and second housing bores. The shafts (13, 14) are provided with intermeshing lobes forming a screw profile. The lobes may be in the form of external elements, such as extruder elements, or may be integrally formed on the shafts (13, 14). A small clearance is provided between the lobes and the barrel 12.

The lobes on the counter rotating shafts (13, 14) engage each other in a manner such that the material in the elements is moved forward along the shaft length. The feed regulator 2 includes an inlet 15 to receive the high viscosity raw material and a discharge 16 to feed the high viscosity raw material to the extruder 3. The high viscosity raw material may be stored in a pressurized container 1 configured to be attached to the feed regulator inlet 15.

The lobes on the shafts (13, 14) may be any extruder element. Specifically, extruder conveying elements may be used on the counter rotating shafts (13, 14) to transport the high viscosity raw material from the feed regulator inlet 15 to the extruder inlet in a continuous non pulsating manner.

A motor 10 and gear box 11 may be connected to one shaft 13 of the feed regulator. This shaft 13 is provided with a driving gear, which is in mesh with a driven gear provided on the other counter rotating shaft 14.

In accordance with an alternate embodiment, the feed regulator 2 may be a small scale single screw extruder and comprises of a barrel having a single cylindrical bore with a shaft disposed in the bore. The shaft is provided with lobes forming a screw profile and a small clearance is provided between the lobes and the barrel.

The feed regulator 2 may include a heating element to heat the high viscosity raw material to the extruder 3.

In accordance with an embodiment, the high viscosity raw material is stored in an elastic container 1 with an outlet configured to engage the inlet 15 of the feed regulator 2. The outlet of the elastic container 1 includes a no return valve.

In accordance with an alternate embodiment, the extruder system includes a feed regulator 5 attached to the extruder outlet as illustrated in Figure 3. This feed regulator 5 may be identical to the feed regulator 2 connected to the extruder inlet.

In accordance with a further embodiment the feed regulator 5 at the extruder outlet may be connected to an injection molding device 7. An accumulator 6 may be provided between the feed regulator 5 and the injection molding device 7.

The length of the feed regulator 2 may be configured to enable a good mixing of the high viscosity liquid material prior to entering the extruder. The length of the feed regulator 2 may also depend on the desired throughput of the high viscosity raw material. The length of the feed regulator 2 may also be dependent on the presence of heating elements.

SPECIFIC EMBODIMENTS ARE DESCRIBED BELOW

A feed regulator for an extruder capable of feeding high viscosity raw material continuously to the extruder wherein the feed regulator is a single or twin screw extruder. Such a feed regulator(s), wherein the single or twin screw extruder is small scale. Such a feed regulators), wherein the twin screw extruder as a feed regulator is counter rotating.
Such a feed regulator(s) comprising a heating element.

Such a feed regulator(s) capable of variable feed rates by varying the speed of operation of the single or twin screw extruder.

INDUSTRIAL APPLICABILITY

The extruder system as disclosed provides for the use of high viscosity liquids as a material input that creates a clean environment for the manufacture of plastics. By creating a clean environment in plastic manufacture, the manufacture of plastic and the manufacture of plastic products can now be integrated.

The extruder system with the feed regulator 2 disclosed allows for high viscosity liquids to be fed to an extruder 3 in a continuous manner. The use of high viscosity liquids minimizes chances of cavitations in the extruder 3 and also reduces the need to remove the liquid solvent from the plastic produced.

The extruder system provides for a variable feed rate of high viscosity liquid material to the extruder 3. Moreover, the extruder system provides for a continuous non pulsating feed of high viscosity liquid material at the desired feed rate.

WE CLAIM:

1. A feed regulator for an extruder capable of feeding high viscosity raw material continuously to the extruder wherein the feed regulator is a single or twin screw extruder.

2. A feed regulator as claimed in claim 1 wherein the single or twin screw extruder is small scale.

3. A feed regulator as claimed in claim 1 wherein the twin screw extruder as a feed regulator is counter rotating.

4. A feed regulator as claimed in claim 1 comprising a heating element.

5. A feed regulator as claimed in claim 1 capable of variable feed rates by varying the speed of operation of the single or twin screw extruder.

6. A feed regulator substantially as herein described with reference to and as illustrated by the accompanying drawings.