Methods for extruding elastomeric compositions
AssigneeCabot Corporation
InventorsMartin C. Green, Carlos Andres Echavarria Yepes, Dhaval A. Doshi, Kento Uemura, Hiroomi Katano, Quentin Hartley, David P. Cacciola
Life of this patent
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Abstract
Disclosed herein are methods for processing a composition comprising an elastomer and filler. The method comprises processing the composition through a single screw or twin-screw extruder having a die with at least one non-circular slot extending through the die body in which the non-circular slot has an inner surface that is tapered. Also disclosed are extrudates resulting from the processing.
Claims48
A method for processing a composition, the method comprising:
- feeding the composition to a screw extruder, wherein the composition comprises at least one elastomer and at least one filler;
- flowing the composition through the extruder by applying a shearing force on the composition;
- and
- extruding the composition through a stationary die provided at an exit end of the extruder, wherein the extruding comprises:
- forcing the composition through at least one non-circular slot extending through a die body of the stationary die from a first face of the die body to an opposing face of the die body that opposes the first face forming a passageway such that the composition is forced across an inner surface of the at least one non-circular slot, wherein the inner surface is tapered such that a first opening at one of the first face or the opposing face is smaller than a second opening at the other of the first face or the opposing face.
A method for processing a composition, the method comprising:
- feeding the composition to a screw extruder, wherein the composition comprises at least one elastomer and at least one filler;
- flowing the composition through the extruder by applying a shearing force on the composition;
- and
- extruding the composition through a stationary die provided at an exit end of the extruder, wherein the extruding comprises:
- forcing the composition through at least one slot extending through a die body of the stationary die from a first face of the die body to an opposing face of the die body that opposes the first face forming a passageway such that the composition is forced across an inner surface of the at least one slot, wherein the inner surface is tapered such that a first opening at one of the first face or the opposing face is smaller than a second opening at the other of the first face or the opposing face, and wherein the first and second openings are non-concentric.
A method for processing a composition, the method comprising:
- feeding the composition to a screw extruder, wherein the composition comprises at least one elastomer and at least one filler having a filler loading of at least 20 phr, wherein the composition is substantially free of rubber chemicals;
- flowing the composition through the extruder by applying a shearing force on the composition;
- extruding the composition through a die provided at an exit end of the extruder, wherein the die comprises a die body having a first face and an opposing face, wherein the extruding includes traversing the composition through at least one slot extending through the die body from the first face to the opposing face that forms a passageway;
- and
- cutting the extruded composition with an associated blade of the die, wherein one or more of the die or the associated blade is rotatable.
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15-16. (canceled)
23-25. (canceled)
29-32. (canceled)
34-38. (canceled)
A method of processing a composite in an integrated manufacturing operation, comprising:
- feeding the composite to a screw extruder;
- flowing the composite through the extruder by applying a shearing force on the composition;
- and
- extruding the composite through a die provided at an exit end of the extruder such that the extruded composite has an irregular shape.
(canceled)
A method for processing a composition, the method comprising:
- feeding the composition to screw extruder, wherein the composition comprises at least one elastomer and at least one filler;
- flowing the composition through the extruder by applying a shearing force on the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second exit end, and (ii) a screw flight provided on the shaft along the longitudinal axis from the first end to the second exit end for applying the shearing force on the composition;
- and
- extruding the composition through a die provided at the second exit end of each screw or screws of the extruder, wherein the second exit end has an end portion with a flat face formed by the shaft and the screw flight, and wherein the flat face has a surface area ranging from 20% to 70% of an area defined by an outer diameter of the screw flight.
44-48. (canceled)
A method for processing a composition, the method comprising:
- feeding the composition to a screw extruder, wherein the composition comprises at least one elastomer and at least one filler;
- flowing the composition through the extruder by applying a shearing force on the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second exit end, and (ii) screw flight provided on the shaft along the longitudinal axis from the first end to the second exit end for applying the shearing force on the composition;
- and
- extruding the composition through a die provided at the second exit end of the screw or screws, wherein the second exit end has an end portion with a flat face formed by the shaft and the screw flight, and wherein at least a portion of the flat face is configured to have a surface area ranging from 0.9 to 3 times an area of a slot of a die of the extruder.
50-57. (canceled)
An elastomeric extrudate comprising at least one elastomer and at least one filler in an amount of at least 20 phr, wherein the extrudate has:
- a length no more than 500 mm;
- and
- an angle of curvature in at least one dimension ranging from 50° to 160°.
64-85. (canceled)
A plurality of elastomeric extrudes each having an irregular shape and comprising at least one elastomer and at least one filler in an amount of at least 20 phr, wherein:
- at least 75% of the plurality of extrudates has a length no more than 500 mm;
- and
- at least 75% of the plurality of elastomeric extrudates has an angle of curvature in at least one dimension ranging from 50° to 160°.
87-89. (canceled)
A method for extruding a material, the method comprising:
- feeding the material to a screw extruder;
- flowing the material through the extruder by applying a shearing force on the material;
- extruding the material through a die plate provided at an exit end of the extruder,
- wherein the elastomeric extrudate has an irregular shape, wherein the extrudate has an angle of curvature in at least one dimension ranging from 50° to 160°, and
- wherein a length of the extrudate is no more than 500 mm.
(canceled)
Dependencies are inferred from the claim text.