CA1111225A

CA1111225A - Method and apparatus for processing polymeric material

Info

Publication number: CA1111225A
Application number: CA282,341A
Authority: CA
Inventors: Zehev Tadmor
Original assignee: Individual
Current assignee: Individual
Priority date: 1977-05-11
Filing date: 1977-07-08
Publication date: 1981-10-27
Also published as: SE429519B; GB1592261A; AU517417B2; FR2390259B1; NL7712481A; NL189284B; SE7708283L; SU1011039A3; NL189284C; DE2732173A1; JPS6147684B2; DE2732173C2; JPS53139688A; FR2390259A1; BE860142A; DE2759878C2; AU2742277A

Abstract

Abstract of the Disclosure Method and apparatus for processing solid and viscous plastic materialor polymeric material and the like in which plastic or polymeric material is fed through an inlet into an enclosed passage of which opposed side walls are moving simultaneously toward an outlet and the material is processed and dragged forward by the moving side walls against a channel block and with progressive build up of pressure along said passage for discharging the processed material through the outlet form the enclosed passage. Rotary apparatus for practicing the method includes one or more annular channels having opposed side walls and carried by a driven rotor member for movement relative to a housing of which an annular surface coaxial with the rotor cooper-ates with the walls of the channel or channels to form an enclosed annular passage or enclosed annular passages. An inlet for feeding the plastic or polymeric material into each annular passage extends through the housing and an outlet for discharge of material from each passage is disposed circumfer-entially a major portion of a complete revolution from the inlet. A channel block supported by the housing projects into each channel to hold the plastic or polymeric material for relative movement with respect to the channel side walls and to wipe or scrape the side walls moving past it, and is located between the outlet and the inlet to each annular passage.

Description

This invention relates -to machines and methods for processing solid and viscous plastic and polymeric materials.
The most important machine at the present time for processing plastic and polymeric materials is the single screw extruder. The term processing refers to one or more of the following operations: handling and conveying and pressurizing of particulate solids; melting or plasticating of solid materials;
conveying, pressurizing or pumping of liquid or molten materials; mixing blendingJ dispersing and homogenizing the materials and various liquid or solid additives; devolatilizing the materials; bringing about any microscopicor macroscopic structural change in the materials by chemical reactions such as polymerization, cross-linking and foaming or by other means to modify, alter or improve some property. It is well recognized in the field, that the ordinary screw extruder for processing plastic and polymeric materials is generally modelled as a shallow stationary channel defined by the root of the screw and the flights and a fourth wall defined by the inner surface of the barrel which moves relative to the stationary channel, (see for example Z. Tadmor and I. Klein, "Engineering Principles of Plasticating E~xtrusion", von Mastrand Reinhold Book Co., New York, 1970) .
The relative rotational movement of the barrel and the extruder screw drags material both in particulate solids and viscous liquid form toward the discharge end of the barrel and toward a screw flight bringing about conveying, pressurization and pumping actions of solids and viscous liquids, and mixing dispersion and homogenization of the viscous liquids. Heat -energy from the barrel together with frictional heat generation and viscous heat generation create a relatively thin film of melt on the barrel surface, " . . ' ~ '.'. . ' ~

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which i~3 dragged by the said relative motion toward a screw ilight where it is scraped off bringin&~ about an e~-~icient melting and plasticating action.
Material on the root of the screw and flights of the screw cannot be scraped off, neither do these walls, which are stationary r~lative to the processed material, bring about any dragging action toward the discharge end of the barrel to facilitate conveying, pressurization or pumping of the solids and viscous material, nor do they facilitate in the mixing, dispersing and homogenization process. In the screw extruder, therefore, the single surface, that of the barrel, is the sole agent for processing material.
It i8 an object of the present invention to provide a method and machine - -for processing plastic and polymeric materials in which the material is processed by two simultaneously moving opposed surfaces operating to drag and process material ~rom an inlet to an outlet for discharge and in which removal of material from the moving surfaces is readily and efficiently achieved.
To this end and in accordance with the feature of the present invention I have provided a method and machine in which plastic or polymeric material is fed to an enclosed passageway which may be an annular channel mounted for rotation in close engagement with a housing which forms with the channel an enclosed passage, and in which a channel block is disposed in the channel to hold material in the channel ~or movement relative to the channel surface -for processing which may be conveying of solids ~ melting or plasticating, conveying, pumping or pressurizing the molten material, mixing, blending, dispersing and homogenizing the material, devolatilizing and/or bringing about molecular microscopic or macroscopic structural changes by chemical reactions such as polymerization, cross linking and foaming or by other ;`
means, to modify, alter or improve some property o~ the material.

s In accordance with the present invention, there is provided a machine ~or processing solid and viscous plastic and polymeric materials comprising:
A. a rotatable element carrying an annular channel providing a polymer processing surface area which includes opposed side walls;
B. a stationary element providing a coaxial surface forming with said channel an enclosed annular processing passage, C. means including an inlet opening to feed polymeric or plastic material to said passage to form a body of material substantially filling said passage;
D. means for causing relative rotation between said channel and said surface about their common a~is to move said side walls in a circumferential dir-ection from the inlet opening of said passage;
E. an outlet opening from said passage circumferen-tially disposed a major portion of a complete :
revolution from said inlet opening in the direc-tion of rotation of said channel, and F. a blocking member comprising a material collect- -ing end wall and sc.raper portions disposed in said passage between said outlet opening and said inlet opening in the direction of rotation of said channel, said end wall being constructed to hold said body o~ material in said channel so that there is relative movement between said polymer -processing surface area and said body of material in the channel whereby said polymer processing surface area drags forward material in contact with said polymer processing surface area to said :

` ~ - 3a -material collecting end wall surface fo:r process-ing and discharge.
In accordance with another feature of the present invention, the method of processing of plastic and polymeric materials which are, or become in the course of processing, viscous liquids including the steps of dragging the material by one wall relative to another for processing and discharge, is improved by introducing the material at a feed point into a channel between opposed walls moving simultaneously toward a discharge point, retaining the material in the channel b~ a surface, blocking the channel adjacent the discharge point to restrain the main body of the material from movement with the walls to create relative movement between the main body of the material and the walls, dragging forward viscous liquid portions of the material in contact with the walls and collect- ;~
ing the viscous liquid portions as a pool of viscous liquid :
against the blocking for processing and discharge, and coord-inating the rate of discharge of material from the channel with the surface area and the rate of movement of the opposed :~
walls relative to the main body of material and with the properties of the material to develop pressure in the pool and to effect the desired processing. ;~

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The subject invention will be described in connection with the attached drawings which show two forms of the machine of the present invention.
In the clrawing:
Figure 1 is a schematic perspective view of the processing machine which is exploded to show the various parts;
Figure 2 is a perspective view partially in section of the processing machine OI Figure l;
Figure 3 is a flattened sectional view of a channel taken along a selected radius and illustrating the movement of material within a channel;

Figure 4 is a sectional elevational view of a second form of the processing machine taken on the line of IV-IV of Figure 5 parallel to and along the axis of .rotation of the rotor of the processing machine;
Figure 5 is a sectional end elevational view of the processing machine of Figure 4 taken along the line V-V of ~igure 4 perpendicular to the axis of rotation of the rotor; and Figure 6 i9 a graph on which are plotted the relationship of channel width and channel diameter for given operating conditions.
The method and apparatus of the present invention give the unique `
advantage that plastic or polymeric material is processed by feeding a body ~ ; ;

of the material through an inlet to the space between two opposed surfaces and simultaneously moving both surfaces relative to the material in a direction to drag the material from the inlet toward an outlet to process the material and discharge it through the outlet.
Apparatus effective to provide this action (see Figs. 1 & 2) may comprise a rotor lO shown as a number of spaced disc-like elements 12 mounted on a drive shaft 14 for rotation within a housing 16, with the shaft 14 journalled in end plates 18 of the housin~ 16. The rotor lO is constructed with annular, suitably cylindrical, surIace portions 20 and with at least one annular channel 22 formed with spaced opposed side walls 24 disposed with an annular surface portion 20 on each side of the channel. The housing 16 provides an annular, suitably cylindrical surface 26 coaxial with and in close relation to the annular surface portions 20 of the rotor to form with the channel (s) 22 enclosed annular passage (s) .
An inlet opening 28 through the housing lB is provided for introduction of plastic or polymeric material for processing from a suitable feeder, shown as a hopper 30, into the annular channel (s) 22. It will be understood tha-t suitable plastic or polymer feeding devices will be used which may be a simple gravity feed hopper as shown or may be a screw feeder, a ram feeder, a disc-type pre-heater feed and so on depending on the character of the plastic or polymeric material and the difficulty of controlling its supply to the channel(s) 22.
Channel blocks 32 mounted on the housing~ 16 e~tend into each channel 22 at a circumferential position at least a major portion of a complete revolution of the rotor 10 from the inlet 28 to provide an end wall 34 to the annular channel 22 and scraper portions in close relation to the walls 24 of the channel.
The channel block 32 has a shape complementary to and fitting closely within the channel 22 into which it extends and the end wall facing the annular channel 22 may be radially disposed or at another suitable angle depending upon the material and treatment desired. Adjacent to the channel block 22, upstream from it, i. e. counter to the direction of movement of the channel, an outlet opening 36 through the housing 13 is provided.
In operation of the processor, plastic or polymeric material in solid or liquid state is fed by the feeding device which distributes the material into each channel 22 through the inlet 28. As the rotor 10 turns, the main `

body o~ material is held b~ the end wall 34 of the channel block 32 so that ~he channel side walls 2fls move relative to the body of material and the material adjacent the opposed side walls 2~ of the channel 22 is dragged forward by the side walls toward the end wall 34 of the channel block 32 with a gradual buildup of pressure reaching a maximum value at channel block 32 where it is discharged. The melting mechanism is schematically shown in Figure

3 where the material is a granular solid. As shown, the granules are compacted into a solid bed as a result of the relative motion between the rotating side walls 24 of the channel 22 and the solids within the channel. Optionally, the channel walls 2~ may be preheated, but in any case, the relative movement lQ ~ ~ -generates frictional heat and forms a film of molten plastic or polymeric material ;
on the side walls 24 of the channel. The molten :Eilm thus formed, moves with the walls 24 and i8 vigorously sheared by motion relative to the main body oE plastic or polymeric material in the channel to generate further heat by viscous dissipation. The action of the side walls 24 of the channel 22 in dragging forward material on its surface bui]ds up pressure progressively along the length of travel of the side walls reaching a maximum value at the channel block 32. The channel block 32 scrapes o~f and collects vi9cous li~uid material carried forward by the side walls of the channel and this material accumulates as a pool against the end wall o~ the channel block and may be discharged from the channel by the built up pressure.
As shown schematically in Figure 3, cGntinued supply of material dragged forward by the channel walls produces a strong circulatory motion in the pool of molten material and this circulatory motion gives a vigorous mixing action, Similar vigorous mixing action can be achieved with liquid fed material by appropriate selection oE operational controls.
In the treatment of polymeric and plastic materials having slrnilar :

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characteristics, such as material normally processed in screw type extruders and which are, or become in the course of processing, high viscosity liquids, coordination of physical design factors and operational controls in the present machine and method enables processing, that is conveying and pressurization of solid~; melting or plasticating of solids materials; conveying, pressurizing or pumping of liquid or molten material; mixing, blending, dispersing and homogeniging the material, devolatili~ation and combination of these process treatments, in relation to solid material feed and viscous material feed or combinations of both. The method and machine can feed various shaping dies such as sheeting and profile dies, cross head dies, cable and wire coating dies, pelletizers, and many other sequentially arranged processing apparatus.
As shown in Figs. 1 and 2, such a die 38 may be disposed directly in the outlet opening 36 of the machine.
Further, the method and machine can be used to bring about microscopic or macroscopic structural changes in the material to modify, alter or improve some property of the material, by chemical reaction such as polyrnerization of prepolymers and monomers leading to viscous polymeric liquid~, cross-linking, chain break down, foaming and the like.
Machine design factor variables include the geometry of the annular channel (s), the nature of the feeding device, the dimensions and location of the inlet opening (s), the shape of the channel block (s), and the dimension (s) and location (s) of the outlet opening (s) .
The geometry of the channel 22 must achieve a balance of the various purposes which the channel serves. The cross section of the channel must be of appropriate shape and the space between opposed side walls 24 must be sufficiently wide to enable material fed to it to reach the root of the channel and fill the channel directly; but a balancing factor is that the pumping or 2~

pressurizing ability of the channel 22 be maintained close to the optimum and not be made too wide to decrease the pressurizing ability. naelting, mixing and pumping or pressurizing action increases as the rate of passage of channel walls area past the material increases; but the ratio oE channel wall area to channel volume must be balanced so that where solid material is fed to the channel it will fill a portion of the channel for melting at a desired rate by the action of the channel walls and that the molten material will fill a portion of the channel sufficient to produce desired mixing and pumping -or pressurizing of the material for discharge. The linear speed of portions of the channel walls at a given rate of rotation increases directly as the radial distance of each wall portion from the axis of rotation and it has been found that the variation in processing action due to difference in radial distance from the axis may be compensated by increasing the space, H, between channel walls in proportion to the distance, R, from the axis so that H/R is a constant.A simple arrangement would involve forming the channel walls as spaced truncated cones of which the vertices would substantially coincide at the axis of rotation.
Channels such as formed by opposed faces 24 of discs 12 mounted ~ ~ -adjustably in spaced relation on a drive shaft 14 as in Fig. l will operate to process polymer materials, and this construction has advantages for experi-20mental analysis of processing of various viscous and solid materials.
That is, the space between opposed faces of the discs is readily altered by use of different spacers and the depths of the channels defined by the opposed faces can be altered by use of annular spacers having different diameters. The number of channels may be altered by removing or adding discs to enable operation with different material, different energy inputJ ~ :
different processing rates and so on through selection of dimension for ' ` ~

on-line operation. B~r reason of the straightforward relations in the present machine and method, data derived from machines constructed with rectangular cross section channels formed by discs may be transferred to more sophisticated machines with a good measure of confidence. Also, the discs may be of any shape or cross sections and need not necessarily be flat. Wedge shaped or fin shaped discs may be useful for certain functions. Alternatively, the channels may be annular grooves or passageways formed in a driven rotor.
The feeder for introduction of plastic or polymeric material or the li~e to the processing channel is designed for s~peration with the particular material and state of the material to be processed. Where the plastic or polymèric material to be processed is granular, the feeder will be designed to insure filling the channels from bottom to top for effective use of the processing surfaces of the channel. A simple hopper leading through the inlet opening may be useful with some granular materials while with others it may be important to have mec:hanical feed suoh as a screw or ram type feed. Where the material to be processed is a viscous li~uid, the feeder may be a conduit t~lrough which the liquid flows to the channel or may be a pump such as a screw type or gear type device for supplying material at a desired rate and pressure.

The outlet opening 36 through the housing 16 is disposed at least a major portion of a complete revolution of the rotor 10 from the inlet opening 28 in a position to receive and discharge processed material reaching the channel block 32. Control of the rate at which processed material is allowed .
to discharge îrom the channel i9 an important factor in determining the extent to which the material is processed and the outlet 36 is constructed and arranged to provide this discharge control. Control may be effected by the size of the opening or by a throttling valve or other device in the discharge outlet. The discharge rate may also be controlled by connecting the outlet opening ~o a further processing stage such as an e~trusion nozzle or die 38 or the like which may provide desired flow resistance controlling the rate of discharge from the outlet and the extent oE processing of material in the channel, In a modification, in a processing device according to the present invention having more than one channel, the outlet from one channel may be lead through a conduit to the inlet of a further channel for further processing. This arrangement is particularly valuable since the series pressure-producing and pumping action of successive processing channels is cumulative so that high outlet pressure is readily secured.
It will be understood that succeasive channels may each have different geometry from other channels for best processing of material supplied to it. Also, material processed in and discharged from one channel or a given number of channels operating in paral].el may be fed to one channel or to any suitable number of channels operating in parallel.
Separate feeders and inlet openings may be provided to feed each chanrlel or any combination of channels with polymeric or plastic material which may be the same as or different from the material fed to any other channel or combination of channels. Different materials processed by separate channels or combinations of channels may be discharged through separate outlet openings and may be supplied to separate extrusion nozzles or, may be fed to a nozzle for co-extrusion, for example with one material as a core and another material as a coating.
Effective processing of plastic or polymeric material by the method of the present invention is achieved by coordinating the rate of feed and discharge of material to the processing channel (s), temperature control and speed of the channel walls ~,vith respect to the properties of the material and the geometry of the channel.
Materials ~rhich may be processed by the method and machine of the present invention include all plastic materials and polymeric materialR
normally liquid or reducible by heat or mechanical energy, or diluent to viscous liquid or deformable state, processing and which have sufficient stability to avoid serious degradation under treatment conditions. Such materials include but are not limited to thermoplastic, thermosetting and elastomeric polymeric materials such as for example, polyolefins (e. g.
polyethylenes, polypropylenes) J vinylchloride polymers ~e. g. poiyvinylchlor-ide), fluorine containing polymersJ polyvinylacetate based polymers, acrylic based polymers, styrene based polymers (e. g. polystyrene), polyamides (e. g. nylons), polyacetals, polycarbonates, cellulose based plastics, polyestersJ polyurethanes, phenolic and amino plastics, epoxy based resins, silicone and inorganic polymers, polysulphone based polymers, various elatural based polymers and the like together with copolymers and blends of those materials with each other or with solvents or diluents or with diferent solid and liquid additives. Also, it is contemplated that chemically reactive materials such as materials or mixtures of materials which may form polymers which are viscous liquids at some stage of their formation, -and at the temperatures maintained in the channel (s) may be fed to the machine for reaction and processing in the channel (s) .
Temperature of the material as supplied and during the course of processing in the machine will be controlled so that the viscosities and flow characteristics of the material being processed are determinable.
The inter-relationship of rate of feed and discharge of liquid viscous plastic and polymeric materials, to an annular rectangular -- 11 -- ~
!

-processing channel and the speed of the channel walls with respect to the properties of the selected material and temperature and to the geornetry of the channel, assuming: isothermal, laminar, steady, fully developed flow of an incompressible power law model non-Newtonian fluid, neglecting gravitational and inertial (centrifugal) forces is e}~pressed by the following equation:

Q = 7TNHR 2 (l - d.2) _ ( Hs ~2 Rl-S ( a~ l-s _l))(dP s) d 2S (s-l) (2+s)mS d ~3 In the above equation:
Q = volumetric flow rate (in3/sec.) N = frequency of channel rotation (r.p.s. ) Rd = outside radius of annular channel (in.) Rs = inside radius of annular channel (in.) = R /R
s d H = width of annular channel P = pressure (pBi) ~3 = angle (radians) dP = Pout-Pin = angular pressure gradient (psi/rad.) d~3 2lr 0 Pout = exit presure (psi) Pin = inlet pressure (psi) = fraction of circumference from inlet to outlet.

S = 1/n empirical parameter of the 'powerlaw' model fluid:
n-1 71 = m non-Newtonian viscosity (lbf.-sec. lin m = empirical parameter (lbf.-sec.n/in2) n = empirical parameter = shear rate, (l/sec,) In the above equation the first term on the right-hand side is the 'drag flow' and the second term is the 'pressure' flow. This equation also applies for Newtonian fluids in which s=n= 1 and m-~ is the Newtonian viscosity.
As illustration to the use of the above equation a mel$ pump for polsrmeric material will be designed . It is required to pump 1, 000 lbs . /hr . melt and generate a 1500 psi. pressure at the discharge. The power-law parameters of this melt at the processing temperature are m = 1 lb . f secQ 5/in2 and n = 0. 5 . Assuming Pin = and ~ = O . 75, the required gradient is dP = _ 1500 = 318 . 3 psi/rad d~3 (2) (~f ) (0 . 75) Further assuming that the density of this melt at the processing temperature and the average pres9ure is 50 lb . /ft. 3, the volumetric ilow rate is ( 3 6 0 0 ) ( 5 0 ) Substitution of the available date into the design equation with G( = O. 5 gives 9.6=2.356N(rp.s.)H(in)Rd(in2) _ 3166~ c )H (in ?

The above equation provides the required relationship between 20 Rd, H and N. Next by selecting a reasonable N value e. g. 30 RPM, the relationship between Rd and H is obtained as shown in Fig. 6. Thus, a disc radius of 6 . 3 " is the optimum with a channel width of 0 . 24" .
Therefore, an annular rectangular channel of outside diameter of 12.6", inside diameter of 6.3" and width of 0.24" rotating at 30 r.p.m. pumps 1,000 lb./hr. melt and generates 1,500 psi, pressure.
It is observed that the annular channel is narrow and deep and this may pose difficulties in effectivel~r feeding material to be treated 3~) .

in a n~anner to reach the bottom oi the channel. In practice, this problem can be solved either by providing sufficient undercut in the housing as shown in Fig. 5 undercut 70 is provided in housing 41 or using a plurality of channels with the first stage somewhat wider than the optimum.
By way of illustration, where the material to be fed is particulate solid material, it is preferred to have a first channel as narrow as possible, but suitably wide for gravitational feeding. For common polymeric materials in particulate form, this is of the order of about 0 . 25" to about 2 . 5" .
For practical considerations, the speed of the rotor and channel will generally not exceed 500 RPM and desirably will not exceed about 250 RPM. Lower limits of rotor and channel speed may be as low as about 10 RP~
A further embodiment of the invention is shown in Figures 4 and ` `
5 in which is provided an improved structure in which two proces9ing channels are connected in series. In this machine, a rotor 40 is mounted for rotation in housing 41 on a drive shaft 42 journalled in end wfllls 44 of the housing 41. Annular channels 46 and 47 are provided with the opposed side walls 48 in fixed relation to each other providing a wedge shaped channel cross section and with relatively wide cylindrical surface portions 50 at each side of the channels 46 and 47. These c~lindrical surface portions 50 are in close sliding fit with the coaxial cylindrical inner surPacs 51 of the housing 41 so that the inner sur~ace 51 and the channels 46 and 47 form enclosed annular passages.
Chambers 52, 54 and 56 are provided on the outside of each of the walls 48 of the channels for introduction of a temperature control ~luid for heat transfer through the walls of the channel. Eleat transfer fluid is supplied to these chambers throug~h an axial passage 58 constructed irl the xhaft 42 through which te~nperature control fluid flows to a first chamber 56 thlough the tube 60 from the .I`irst chamber 56 through a channel 62 to the seconcl chamber 5~, then through a channel 64 to the third chamber 52 and through a tube 66 to a fu:rther passageway 68 in the shaft 42. :
~9 sho~,vn more clearly in Figure 5, the interior surface 51 of ~he housing 41 is cylindrical over most of its extent but iS provided with an undercut 70 acljacent the material inlet opening 71 to channel 46. This undercut 70 is of a width such that its walls 72 e~tend out over the cylindricalportions 50 of the rotor 40 to form an intake chamber 74 so that when viscous liquid material is supplied through the inleL opening 71, the viscous liquid material is dragged by the cylindrical surface 50 of the rotor to the nip where the surface of the walls 7~ of the undercut 70 approaches the cylindrical surface 50 of the rotor. This acl:ion fflcilitates squeeæing of the viscous material into the channel 46. ~ -Channel block 76 mounted on the housing 41 has a shape complementary :
to and fitting closely within the channel 46 to hold the main body of plastic or polymeric material for motion relative to the walls 46 of channel 46 and to scrape off viscous liquid material carried forward by the walls 48 for discharge as processed material through outlet 78. .A passageway 80 is provided to conduct processed material from outlet 78 to the inlet 82 into annular channel 47 .for filrther processing. Channel bloc3~ 84 mounted on the housing 41 has a shape complementary to and fitting closely within `~
channel '17 to hold the main body of plastic or polymeric rnaterial in that channel for motion relative ~o the walls 48 and to scrape off viscous liquid material carried forward by the walls 48 for discharge as processed material through outlet 86.
Referring to Figure 5, the provision of an optional further mi~ing .f~

st:ructure 88 is shown. l'his structure 88 will extend part way into the channels and by its action on the material in the channels 46 and 47 increases the shear on the material being processed and improves the mixing action of the machine. The mi~ing structure ~/can be constructed in a variety of uses and shapes, for example pegs, wedge~ or blocks oE a shape and size to provide clearances with the walls of the channel, screens, static mixing devices and so on. By moving in and out a wedge shaped mi~ing block to vary the clearance to the channel walls and an adjustable extent of mixing is obtained. In the form shown, the structure is a dam wbich will create a void of material on its forward face ~P the forward and rear ;
face being defined relative to the direction of travel of the rotor channel 46. This void may be used to vent the channel 46 by inserting a port 92 in the housing 41 at the forward face of the dam 88 to allow any material volatilized to escape. The port 92 may also be used as an inlet for processing additives .
Alternatively, the channel block itself can serve as a mixlng block by allowing a certain clearance, which can be varied by moving the channel block in and out, and consequently recycling some or all of the material. ~ ~
If all material is recycled, batch operation is obtained. If part of the material ~-is recycled, continuous operation is obtained.

13y use of these options a variety of procedures may be carried out.
Thus, the channel block may be set for recycling some or all of the material to bring material in the channel to a selected condition, further material may then be added either through inlet opening 71 or through port 92 or both for mixing or combination with the material which has been brought to the selected condition in the channel.
The following Example is given as of assistance in understanding the invention and it i9 to be understood that the invention is not re~tricted to the particular procedures, proportions, materials, temperatures or other details of the process.
EXAMPLE
processor as shown in Fig. 1 was set up with a rotor having a channel gap width of 0.25" and an outside diameter of 7.5" and inside diameter of 4.5". The inlet to the housing of the processor was connected by a conduit to receive molten low density polyethylene from a screw extruder, and the outlet from the housing was connected to a restricted orifice. -~

The following results were obtained~
Rotor Speed Material Flow Pressure Rise Channel Material Temp.
(r.p.m.) (lb./hr.) over Processor wall temp. in (F.) out (Pout-Pin) (Psi) (F.) (~F ) _..
21 183.5 490 400 410 as24 21 141.0 870 300 420 396 19 64.2 1275 300 420 396 55.5 279 1510 300 420 423 73. 5 275 1705 300 418 423 A further example comprises the sam~? processor with a channel width of 0.75" gravitationalLy fed by solid :Low density polyethylene pellets:

Rotor Speed Channel wall Rate of Discharge Temp. .
(r.p.m.) temp. ~F.) Plasticating (F.) ~, lb . /hr.

26.6 400 23. 3 348 75,5 400 46.2 368 `~ 153.6 400 79.2 408 ` ' ~ Having thus described my invention, what I claim as new and desire ~
... . to secure by Latters Patent of the United States is:

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:` :

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Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. A machine for processing solid and viscous plastic and polymeric materials comprising:
A. a rotatable element carrying an annular channel providing a polymer processing surface area which includes opposed side walls;
B. a stationary element providing a coaxial surface forming with said channel an enclosed annular processing passage;
C. means including an inlet opening to feed poly-meric or plastic material to said passage to form a body of material substantially filling said passage;
D. means for causing relative rotation between said channel and said surface about their common axis to move said side walls in a circumferential dir-ection from the inlet opening of said passage;
E. an outlet opening from said passage circumferen-tially disposed a major portion of a complete revolution from said inlet opening in the direc-tion of rotation of said channel; and F. a blocking member comprising a material collecting end wall and scraper portions disposed in said passage between said outlet opening and said inlet opening in the direction of rotation of said channel, said end wall being constructed to hold said body of material in said channel so that there is relative movement between said polymer processing surface area and said body of material in the channel whereby said polymer processing surface area drags forward material in contact with said polymer processing surface area to said material collecting end wall surface for process-ing and discharge,

2. A machine for processing plastic and polymeric mat-erials as defined in claim 1 in which a means are provided to control discharge of processed material from said outlet open-ing to secure the desired extent of processing or plastic material.

3. A machine for processing plastic and polymeric mat-erials as defined in claim 2 in which substantially cylindrical surface members are provided at the outer edges of said annular channel for rotation with the channel and in which said inlet opening leads to an intake chamber having a surface sloping toward said cylindrical members to form a nip for improved feeding of material to said annular channel.

4. A machine for processing plastic and polymeric materials as defined in claim 2 in which said machine further includes one or more mixing structures carried by said coaxial surface and extending partially into said annular channel at a location intermediate said inlet opening and said outlet open-ing to increase the mixing action of the machine.

5. A machine for processing plastic and polymeric mat-erials as defined in claim 4 in which said mixing structure includes a dam carried by said coaxial surface and extending partially into said annular channel to improve the processing action of the machine, said dam having forward and rear faces relative to the direction of rotation of said annular channel.

6. A machine for processing plastic and polymeric mat-erials as defined in claim 5 in which a venting port is con-structed in said coaxial surface at the forward face of the mixing dam to allow for the venting of volatilized material.

7. A machine for processing plastic and polymeric materials as defined in claim 4 in which said mixing structure is mounted for movement into and out of said channel to adjust its clearance from the channel walls to control the mixing action.

8. A machine for processing plastic and polymeric mat-erials as defined in claim 2 in which said blocking member is constructed to provide a limited clearance between said scraper portions and said side walls to allow passage of a limited quantity of material for a further passage through and process-ing in said annular channel.

9. A machine for processing plastic and polymeric mat-erials as defined in claim 2 in which said blocking member is mounted for movement into and out of said channel to adjust its clearance from the channel walls to control the mixing action.

10. A machine for processing plastic and polymeric mat-erials as defined in claim 8 in which means are provided to cut off discharge of material from said outlet for batch processing of a charge of material in said channel and for discharging material from said channel when processing of said charge is achieved.

11. A machine for processing plastic and polymeric mat-erials as defined in claim 2 in which the outlet opening from an annular channel is connected for discharge of processed material to a further annular channel for further processing.

12. A machine for processing plastic and polymeric mat-erials as defined in claim 2 in which said annular channel is formed by spaced disc shaped elements mounted on a drive shaft with adjacent faces of disc elements constituting said opposed side walls.

13. A machine for processing plastic and polymeric mat-erials as defined in claim 12 in which said disc shaped elements are adjustably mounted on the shaft in order to allow the space between said disc shaped elements to be varied.

14. A machine for processing plastic and polymeric materials as defined in claim 1 which comprises a plurality of annular channels, separate material feeders and separate inlet openings to separate channels or combinations of channels and separate discharge openings from the separate channels or combinations of channels associated with said material feeders and inlet openings.

15. A machine for processing plastic and polymeric materials as defined in claim 1 where the processing surface area is provided by a channel having opposing side walls ex-tending inwardly from a cylindrical surface of the rotatable element which is adapted for rotation in the stationary ele-ment having the coaxial surface for forming with the channel the enclosed processing passage.

16. A machine for processing plastic and polymeric mat-erials as defined in claim 1 where the depth of the channel walls is at least as great as the width of the channel.

17. A machine for processing plastic and polymeric mat-erials as defined in claim 1 where the depth of the channel walls is greater than the width of the channel.

18. A machine for processing plastic and polymeric mat-erial as defined in claim 1 where the outlet is disposed from the inlet so that the outlet and inlet are positioned closely adjacent each other and said blocking member is positioned between said closely adjacent positioned outlet and inlet separating said outlet and inlet.

19. In the method of processing of plastic and polymeric materials which are, or become in the course of processing, viscous liquids including the steps of dragging the material by one wall relative to another for processing and discharge, the improvement which comprises introducing said material at a feed point into a channel between opposed walls moving simul-taneously toward a discharge point, retaining said material in said channel by a surface, blocking said channel adjacent said discharge point to restrain the main body of said mat-erial from movement with said walls to create relative move-ment between the main body of said material and said walls, dragging forward viscous liquid portions of said material in contact with said walls and collecting said viscous liquid portions as a pool of viscous liquid against said blocking for processing and discharge, and coordinating the rate of dis-charge of material from said channel with the surface area and the rate of movement of said opposed walls relative to said main body of material and with the properties of said material to develop pressure in said pool and to effect the desired processing.

20. The method of processing plastic and polymeric materials as defined in claim 19 in which said channel and said material retaining surface are annular and coaxial.

21. The method of processing plastic and polymeric materials as defined in claim 20 in which the rate of move-ment of said walls relative to said main body of material is within the range giving laminar flow to liquid material in said channel.

22. The method of processing plastic and polymeric materials as defined in claim 21 in which a mixing structure is disposed in said channel at a location intermediate said feed point and said discharge point to give additional mixing action.

23. The method of processing plastic and polymeric materials as defined in claim 22 in which said mixing struc-ture is a dam projecting across a portion of the cross section of said channel and in which gases and vapors are removed or agents added to material in said channel closely forward of said dam.

24. The method of processing plastic and polymeric materials as defined in claim 21 in which said blocking allows passage of a portion of the material on said walls for further passage through and processing in said annular channel.

25. The method of processing plastic and polymeric materials as defined in claim 24 in which discharge of mat-erial from said outlet is cut off for batch processing a charge of material in said channel and discharge is resumed when processing of said charge is achieved.

26. The method of processing plastic and polymeric materials as defined in claim 21 in which material from the discharge of one processing channel is conducted to the feed point of a further processing channel for further processing and discharge from said further processing channel.

27. The method of processing plastic and polymeric materials as defined in claim 21 in which said material is in the form of solid particles and is supplied in a manner substantially to fill said annular channel and in which the temperature at which said material is supplied and the tempera-ture of said opposed side walls is controlled to effect melt-ing of portions of said material contacting said side walls.

28. The method of processing plastic and polymeric materials as defined in claim 21 in which said material is supplied as a viscous liquid and is fed through said inlet under conditions substantially to fill said annular passage.

29. The method of processing plastic and polymeric materials as defined in claim 28 in which said material is fed through said inlet to an intake chamber including a sur-face sloping toward a cylindrical surface at an outer edge of and rotating with said annular channel and is dragged by said cylindrical surface into the nip between said sloping surface and said cylindrical surface for improved feeding of said material into said annular channel.

30. The method of processing plastic and polymeric material as defined in claim 20 in which said annular channel rotates at a frequency of rotation from about 10 to about 500 r.p.m.

31. The method of processing plastic and polymeric materials as defined in claim 20 in which a material or mix-ture of materials reactive to form a viscous liquid plastic or polymeric material is introduced into said channel and the temperature, pressure, rate of discharge of material from said channel, rate of movement, and surface area of said opposed walls are coordinated to effect processing.

32. The method of processing plastic and polymeric material as defined in claim 31 in which a component of a mixture of materials reactive to form a viscous liquid plastic or polymeric material is introduced into said channel inter-mediate said feed point and said discharge point for mixing and interaction with materials in said channel.

33. The method of processing plastic and polymeric materials as defined in claim 23 in which a material or mix-ture of materials reactive to form a viscous liquid plastic or polymeric material is fed through said inlet into said channel and the temperature, pressure, rate of discharge of material from said channel, rate of movement, and surface area of said opposed walls are coordinated to effect processing.

34. The method of processing plastic and polymeric mat-erial as defined in claim 33 in which a component of a mixture of materials reactive to form a viscous liquid plastic or polymeric material is introduced into said channel intermediate said feed point and said discharge point for mixing and inter-action with materials in said channel.