Method and apparatus for material flow characterization

A method of quantifying the characteristics of a flowing thermoplastic material to determine its behavior in a plasticating injection unit comprising:

• (1) connecting a tool comprising a plurality of flowing material characterization channels on an adjustable and removable cartridge, each having a predetermined cross-sectional geometry, to the plasticating injection unit;
• (2) melting the material into a fluid state with the plasticating injection unit;
• (3) flowing the material through a single flowing material characterization channel at multiple set flow rates;
• (4) measuring the material characteristics through the single flowing material characterization channel at the multiple set flow rates;
• (5) repeating steps (1) through (4) for a different flowing material characterization channel from the plurality of flowing material characterization channels, by adjusting and/or removing said cartridge.

A material characterization system for quantifying the characteristics of a developing frozen layer occurring in a laminar flowing thermoplastic material, the developing frozen layer developing in the outer laminates between the laminar flowing material and a relatively lower temperature flowing material characterization channel, the laminar flowing thermoplastic material melted into a fluid state by a plasticating injection unit, the system comprising:

• a tool comprising a first tool half, a second tool half, a plurality of flowing material characterization channels on an adjustable and removable cartridge, and a feed runner having a flow path to said plasticating injection unit;
• said tool is at a temperature that causes phase changes from fluid to solid to occur in at least the outer laminates of the material being characterized and that enables solidification of the material in said flowing material characterization channel;
• each of said plurality of flowing material characterization channels having a first end, a second end, and a predefined channel cross-section geometry;
• said feed runner connectable to a single said flowing material characterization channel in succession at said first end, extending the material flow path from said plasticating injection unit to said material flow characterization channel;
• said tool is adjustable to disconnect said feed runner from said flowing material characterization channel and connect said feed runner to a different flowing characterization channel;
• and
• a sensor for quantifying the characteristics of the developing frozen layer of the material under different flow conditions.

A method of quantifying the characteristics of a developing frozen layer occurring in a laminar flowing thermoplastic material, the developing frozen layer developing in the outer laminates between the laminar flowing material and a relatively lower temperature flowing material characterization channel, to determine the thermoplastic material's behavior in a plasticating injection unit comprising:

• (1) connecting a tool comprising a plurality of flowing material characterization channels on an adjustable and removable cartridge, each having a predetermined cross-sectional geometry, to the plasticating injection unit;
• (2) melting the material into a fluid state with the plasticating injection unit;
• (3) flowing the material through a single flowing material characterization channel at multiple set flow rates;
• (4) measuring the material characteristics of a developing frozen layer occurring in the material through the single flowing material characterization channel at the multiple set flow rates;
• and
• (5) repeating steps (1) through (4) for a different flowing material characterization channel from the plurality of flowing material characterization channels, by adjusting and/or removing said cartridge.