Extruded cellulose-polymer composition and system for making same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-017/10
B29C-047/00
B29D-007/00
출원번호
US-0856431
(2007-09-17)
등록번호
US-8382464
(2013-02-26)
발명자
/ 주소
Keller, Brian D.
Dostal, David F.
Laver, Terry C.
England, Alfred B.
출원인 / 주소
Strandex Corporation
인용정보
피인용 횟수 :
3인용 특허 :
18
초록▼
The present invention is directed to a device for the production of a cellular wood plastic composite material comprised of an orifice that conducts the composite material from the adapter of the extruder to the transition die plate in such a manner that a uniform flow of material reaches the transi
The present invention is directed to a device for the production of a cellular wood plastic composite material comprised of an orifice that conducts the composite material from the adapter of the extruder to the transition die plate in such a manner that a uniform flow of material reaches the transition die plate; a transition die plate that further directs the flow of material to a flow restriction die plate in a manner ensuring that equal amounts of material are delivered to all areas of the flow restriction die plate; a flow restriction die plate that provides sufficient resistance to material flow to increase the melt pressure of the portion of the material that is upstream in relation to the flow restriction die plate and controls the temperature increase caused by this restriction by dividing the flow into numerous suitably sized and shaped streams; a compression die plate that fuses the separate streams issuing from the flow restriction die plate into a single stream of material and maintains the melt pressure at a level which will prevent premature development of cells in the material; a shaping die plate that is designed to shape the material in such a way that the fully expanded material will approximate the shape of the desired profile and to control the rate of cell development and expansion so that large numbers of uniform cells are produced.
대표청구항▼
1. A die system for extruding a cellular, foamed extrudate from an extruder, the extruder including an exit opening, and forming a molded extrudate product having a substantially uniform cell structure from a cellulosic fibrous-polymer composite material, comprising: a. an adapter die plate, removab
1. A die system for extruding a cellular, foamed extrudate from an extruder, the extruder including an exit opening, and forming a molded extrudate product having a substantially uniform cell structure from a cellulosic fibrous-polymer composite material, comprising: a. an adapter die plate, removably connected to the extruder for receiving the extrudate from the exit opening of the extruder, the adapter die plate including a front opening, a rear opening and a flow channel connecting the front opening to the rear opening, wherein the flow channel of the adapter die plate decreases in cross-sectional area from the front opening to an intermediate portion of the flow channel between the front opening and the rear opening, and increases in cross-sectional area from the intermediate portion to the rear opening;b. at least one transition die plate adjacent the adapter die plate, the transition die plate including a front opening, a rear opening and a flow channel connecting the front opening to the rear opening;c. a flow restriction die plate adjacent the transition die plate, the flow restriction die plate having a front opening, a rear opening and a flow channel connecting the front opening to the rear opening, wherein the flow channel includes a plurality of stranding channels to divide the flow of extrudate, wherein the stranding channels have a diameter and length to provide sufficient resistance pressure to the extrudate flow such that resistance pressure of the extrudate entering the adapter die plate is increased, wherein the increase in resistance pressure alters extrudate entering the adapter die plate such that the extrudate entering the adapter die plate is characterized by increased uniform cell structure and lower density, wherein the flow channel of the transition die plate is shaped such that equal amounts of extrudate are delivered to the stranding channels;d. a compression die plate adjacent the flow restriction die plate and comprising a front opening, a rear opening and a flow channel, wherein the compression die plate front opening is adjacent the flow restriction die plate rear opening, wherein the compression die plate flow channel is shaped to reform the extrudate into a single stream of extrudate and wherein further the compression die plate flow channel is shaped to maintain melt pressure at a level which will prevent premature development of cells in the material;e. a shaping die plate adjacent the compression die plate and comprising a front opening, a rear opening and a flow channel, wherein the shaping die plate front opening is adjacent the compression die plate rear opening and wherein the shaping die plate flow channel is shaped to approximate the shape of the desired profile of a final extruded product and to control rate of cell development and expansion so that large numbers of uniform cells are produced, and wherein a ratio of a volume of the flow channel of the at least one transition die plate to a volume of the flow channel of the shaping die plate ranges from 1.05:1 to 3.45:1. 2. The die system of claim 1 wherein the cellulosic fibrous-polymer composite material has a ratio of cellulosic fibers to the thermoplastic material between approximately 4:1 and 1:0. 3. The die system of claim 1 wherein the composite material entering the adapter die plate has a density from 0.50 gm/cc to 0.90 gm/cc. 4. The die system of claim 1, wherein the ratio of the volume of the flow channel of the at least one transition die plate to the volume of the flow channel of the shaping die plate is about 2:1. 5. The die system of claim 1, wherein the flow channel of the compression die plate tapers at a rate between 15% and 30% per unit length. 6. A process for forming a cellular, foamed extrudate having a substantially uniform cell structure from a cellulosic fibrous-polymer composite material, comprising: a. mixing the composite material in a hopper;b. forwarding the mixed composite material to an extruder to form an extrudate;c. passing the extrudate through an adapter die plate removably connected to the extruder for receiving the extrudate from the exit opening of the extruder, the adapter die plate including a front opening, a rear opening and a flow channel connecting the front opening to the rear opening, wherein the flow channel of the adapter die plate decreases in cross-sectional area from the front opening to an intermediate portion of the flow channel between the front opening and the rear opening, and increases in cross-sectional area from the intermediate portion to the rear opening;d. passing the extrudate through at least one transition die plate adjacent the adapter die plate, the at least one transition die plate including a front opening, a rear opening and a flow channel connecting the front opening to the rear opening wherein the transition die plate flow channel has a shape designed to transform the extruded material discharged from the flow channel of the adapter die plate to a shape more generally approaching that of a finished extruded product;e. passing the extruded material through a flow restriction die plate adjacent the transition die plate, the flow restriction die plate having a front opening, a rear opening and a flow channel connecting the front opening to the rear opening, wherein the flow channel includes a plurality of stranding channels to divide the flow of extrudate, wherein the stranding channels have a diameter and length to provide sufficient resistance pressure to the extrudate flow such that resistance pressure of the extrudate entering the adapter die plate is increased, wherein the increase in resistance pressure alters extrudate entering the adapter die plate such that the extrudate entering the adapter die plate is characterized by increased uniform cell structure and lower density, wherein the flow channel of the transition die plate is shaped such that equal amounts of extrudate are delivered to the stranding channels;f. passing the extruded material through a compression die plate adjacent the flow restriction die plate, the compression die plate comprising a front opening, a rear opening and a flow channel, wherein the compression die plate front opening is adjacent the flow restriction die plate rear opening, wherein the compression die plate flow channel is shaped to reform the extrudate into a single stream of extrudate and wherein further the compression die plate flow channel is shaped to maintain melt pressure at a level which will prevent premature development of cells in the material;g. passing the extruded material to a shaping die plate, the shaping die plate adjacent the compression die plate and comprising a front opening, a rear opening and a flow channel, wherein the shaping die plate front opening is adjacent the compression die plate rear opening and wherein the shaping die plate flow channel is shaped to approximate the shape of the desired profile of a final extruded product and to control rate of cell development and expansion so that large numbers of uniform cells are produced, and wherein a ratio of a volume of the flow channel of the at least one transition die plate to a volume of the flow channel of the shaping die plate ranges from 1.05:1 to 3.45:1; andh. cooling the extruded product material. 7. The process of claim 6 wherein the composite entering the adapter die plate has a density from 0.50 gm/cc to 0.90 gm/cc. 8. The process of claim 6 wherein the extruder operates at a temperature between 150°-200° F. and a flow rate between about 100 and 2500 pounds per hour. 9. The process of claim 6 wherein the adapter die plate flow channel has a diameter between 50 mm and 300 mm. 10. The process of claim 6 wherein the at least one restriction die plate comprises at least three transition die plates to transform the composite to the finished shape and equalize the flow rate at the outer edges of the extruded material with the flow rate at the center of the extruded material. 11. The process of claim 6 wherein the number and size of the stranding channels in the flow restriction die plate are designed to produce an optimal pressure increase for a specific range of volume flow rates. 12. The process of claim 6 wherein the stranding channels are in the form of cylinders or slots. 13. The process of claim 6 wherein the ratio of the volume of the flow channel of the at least one transition die plate to the volume of the flow channel of the shaping die plate is about 2:1. 14. The process of claim 6 wherein the flow channel of compression die plate tapers at a rate between 15% and 30% per unit length. 15. The die system of claim 1 wherein the at least one transition die plate comprises at least three transition die plates.
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이 특허에 인용된 특허 (18)
Muller, John J.; Wittenberg, Roger A.; Yarmoska, Bruce S., Apparatus for making a wood-plastic profile.
Soda Shigenari (Nagaokakyo JA) Hayashi Motoshige (Ikoma JA) Tanaka Shigetoshi (Nara JA), Method of forming a foamed article having a simulated wood grained surface.
Goforth Billy D. (Fayetteville AR) Goforth Charles L. (Lowell AR) Brooks Joe G. (Junction TX), System and process for making synthetic wood products from recycled materials.
Swanson, William J.; Johnson, Kevin C.; Hjelsand, Timothy A.; Batchelder, J. Samuel, Liquefier assembly for use in extrusion-based additive manufacturing systems.
Avery, James Frederick; Boyko, Ronald Alan; Corbett, Daniel Wayne; Malarkey, Christopher John; Sariego, Kenneth Charles; Treacy, Jr., David Robertson, Methods of extruding a honeycomb body.
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