On-line monitoring of the residence time distribution along a kneading block of a twin-screw extruder

An on-line Residence Time Distribution (RTD) measuring set-up that enables the characterisation of twin screw extruders at short axial increments is presented. It uses the light emission of a fluorescent tracer (perylene) to generate concentration versus time curves, which are then used to determine the usual RTD parameters, delay time, mean residence time and variance. The system is initially mounted on a rectangular die coupled to a single screw extruder, on-line and off-line measurements being directly contrasted. Then, the optical probe is positioned at several points along the axis of a modular co-rotating twin screw extruder, on-line and off-line data being again compared. Having gained confidence in the measuring technique, an experimental unit utilizing a transparent barrel is used to characterize the evolution of RTD along a kneading block of a twin screw extruder.     

Preparation and evaluation of solid dispersion for nitrendipine-carbopol and nitrendipine-HPMCP systems using a twin screw extruder

In the present study, we prepared solid dispersions of the poorly water-soluble drug nitrendipine (NIT) using the twin screw extruder method with high-molecular-weight substances, hydroxypropylmethylcellulosephthalate (HPMCP) and Carbopol (CAR), as carriers. Powder X-ray diffraction (PXRD) and differential scanning calorimetry (DSC) evaluation showed that solid dispersions can be formed when NIT-HPMCP and NIT-CAR mixtures are treated with the twin screw extruder method. Fourier Transformation IR Spectroscopy (FT-IR) obtained with NIT-HPMCP and NIT-CAR solid dispersions indicated the presence of hydrogen bonding between the drug and the carriers. NIT-CAR solid dispersions were found to give somewhat higher dissolution than crystalline NIT and physical mixtures, while the dissolution of NIT-HPMCP solid dispersions was markedly decreased compared with the crystalline NIT and physical mixtures. These findings indicated that CAR has a greater ability to improve the dissolution of NIT than HPMCP when a twin screw extruder was employed to prepare the solid dispersions. The twin screw extruder method can be used as a simple and effective method for the preparation of solid dispersions to improve the dissolution properties of poorly water-soluble drugs when choosing proper polymers as carriers.     

Screw extrusion of thermoplastics: I. General model of the screw extrusion

New approach to a simulation of single and twin screw extruders for thermoplastics processing was suggested. The approach takes into account real boundary geometric conditions and conditions on velocity (a screw is rotated, cylinder is fixed), and also that there exist phase transformations of the processed material and its heat exchange with surfaces of the screw and cylinder limiting the working channel of the extruder.     

同向啮合双螺杆挤出机挤出过程的计算机模拟

计算机模拟研究了聚苯乙烯在TSE-35A型同向啮合双螺杆挤出机的挤出过程.计算得到不同喂料速率与不同转速下的停留时间分布,并与在线荧光法测量值对比,二者基本相符.确定了停留时间与螺杆转速及喂料速率之间的函数关系式.模拟结果还预测了喂料速率、螺杆转速等工艺参数对双螺杆内流场变量,如温度、填充率、压力及粘度等的影响.模拟计算有助于了解双螺杆挤出机内部聚合物材料流动状态及停留时间长短,从而指导实际聚合物生产.     

Rheological and mechanical properties of nylon 6 nanocomposites submitted to reprocessing with single and twin screw extruders

The effect of multiple extrusions on nanostructure and properties of nylon 6 nanocomposites was investigated. Nanocomposites at different silicate loadings were produced by melt compounding and submitted to further reprocessing by using single and twin screw extruders. Rheological, morphological and mechanical analyses were carried out on as-produced and reprocessed samples in order to explore the influence of the number and the type of extrusion cycles on silicate nanodispersion.Rheological measurements, correlated to TEM analyses, were used to probe the nanoscale arrangement developed with the reprocessing as well as the thermo-mechanical degradation involving both the neat matrix and the organoclay. The results have shown that the reprocessing by single screw extruder can modify the initial morphology since the re-agglomeration of the silicate layers can occur. On the other hand, a better nanodispersion was observed in the hybrids reprocessed by twin screw extruder. This was attributed to the additional mechanical stresses able to realizing a dispersive mixing that contributes to avoid re-agglomeration phenomena. The high shear stresses produced with twin screw geometry determined also a significant degradation of neat matrix, principally based on chain scission mechanism.A strong correlation between the rheological behaviour and mechanical properties was observed and all as-produced and reprocessed hybrids showed a substantial enhancement in tensile modulus with the adding of silicate. However, the entity of performance enhancements displayed by the reprocessed hybrids was found to be highly dependent on the degradation of both organoclay and polymer matrix as well as the silicate amount, the number and the type reprocessing.     

Effect of Organoclay Mixture on the Rheological Properties of ABS-Clay Nanocomposites

Summary: In this work, poly(acrylonitrile-butadiene-styrene) (ABS) and different organically modified montmorillonite clay nanocomposites were prepared by melt intercalation in a co-rotating twin screw extruder. The influence of the screw torque during processing and of the mixture of the modified organoclays in the intercalation/exfoliation of the clay in the polymeric matrix was evaluated through low angle X-ray diffraction range and capillary and parallel plate-plate rheometry.     

Modeling of particle‐dispersed melting mechanism and its application in corotating twin‐screw extrusion

Particle‐dispersed melting is a complex but important melting mechanism in the corotating twin‐screw extruder. In this study, the complex multi‐particle‐dispersed system was simplified into a single‐particle melting model. The finite‐difference method was introduced to solve this problem. The simulation results show that the melting of a particle may involve two steps: the heating stage and melting stage. The heating time and melting time depend on solid concentration, initial melt and solid temperature, and shear rate. Calculations indicate that high solid concentration and solid temperature, low melt temperature and shear rate will result in a more uniform temperature distribution after polymer melting. The model offers valuable information for designing the melting zone in a corotating twin‐screw extruder, especially at high screw speed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part B: Polym Phys 39: 2461–2468, 2001     

Peroxide‐controlled degradation of poly(propylene): rheological behaviour and process modelling

The control of the molecular weight distribution of poly(propylene) resins by peroxide degradation is widely used in polymer industry. It allows to adjust the viscosity of these resins to the level required for processing applications. The purpose of this work was to characterise the influence of peroxide degradation on the rheological behaviour of an homopolymer PP and a block copolymer PP/PE, and to use these results to obtain a predictive model of the degradation in a twin‐screw extruder. By coupling a thermomechanical model of the twin‐screw extrusion process, a kinetic model of the considered reactions and the rheological behaviour, it was possible to calculate the changes in molecular weight along the extruder, during the peroxide‐controlled degradation.     

The effect of filler surface modification and processing conditions on distribution behaviour of silica nanofillers in polyesters

Dispersion and distribution of nanosized precipitated amorphous silica particles in poly(ethylene terephthalate) PET and poly(butylene terephthalate) PBT matrices have been studied. The effect of silane coupling agent as well as processing conditions has been analysed on the basis of microscopic analysis of sample morphology. N-2-(aminoethyl)-3-aminopropyltrimethoxysilane (A-1120) has been used as a silica surface modifier. The effect of the extrusion process performance with a single and a twin screw extruder has been tested. It has been found that the processing conditions are more important factors determining fine dispersion and homogenous distributions of filler particles in the matrix than the filler surface modification. The results obtained have revealed that single screw extrusion is preferred only for processing the composites comprising the silica modified with aminosilane, while the application of twin screw extrusion leads to homogenous dispersion and fully deagglomeration of filler particles without silane treatment. It has been established that when the concentration of silica filler increased from 3 up to 7% by weight, the secondary process of particle aggregation occurs.     

自由基聚合反应挤出过程的化学流变分析

进行了甲基丙烯酸正丁酯在异向旋转双螺杆挤出机内的自由基聚合反应过程数值模拟,描述了单体转化率、重均分子量、流体粘度等物理量的变化特点,分析了其影响因素,获得了材料体系的化学流变规律.模拟结果与实验结果基本吻合.     

Polystyrene prepared by reactive extrusion: kinetics and effect of processing parameters

The conversion and residence time were investigated during the bulk polymerization of styrene in a twin screw extruder. It was found that polymerization mainly occurred in the zone between 400 and 1000 mm along the screw axis in the extruder, corresponding to the residence time of the reactants ranging from 1 to 4 min in the extruder. Furthermore, the processing conditions (feed rate, screw rotation rate) and average molecular weight of the polymer have a great effect on the residence time. Based on dimensionless analysis, a model of the residence time has been built‐up, which has been confirmed by the results of realistic measurements. A kinetic model of the polymerization has also been established under the assumption that the screw extruder can be regarded as an ideal plug flow reactor. Copyright © 2004 John Wiley & Sons, Ltd.     

Morphology of PC/SAN blends: effect of reactive compatibilization,SAN concentration,processing, and viscosity ratio

This article examines the effects of dispersed phase concentration, processing apparatus, viscosity ratio, and interfacial compatibilization using an SAN–amine compatibilizer on the morphology of blends of bisphenol A–polycarbonate (PC) with styrene–acrylonitrile (SAN) copolymers. For uncompatibilized blends, the dispersed phase particle size increased significantly with SAN concentration, and was found to exhibit a minimum at a viscosity ratio of approximately 0.35 for a fixed concentration of 30% SAN in the blend. Although the morphology of uncompatibilized PC/SAN blends mixed in a Brabender mixer, single‐ and twin‐screw extruders were quite similar, the twin‐screw extruder produced significantly finer morphologies in blends containing SAN–amine. The average particle size for blends compatibilized with the SAN–amine polymer was approximately half that of uncompatibilized blends and was relatively independent of viscosity ratio and dispersed phase composition. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 71–82, 1999     

Blend uniformity evaluation during continuous mixing in a twin screw granulator by in-line NIR using a moving F-test

This study focuses on the twin screw granulator of a continuous from-powder-to-tablet production line. Whereas powder dosing into the granulation unit is possible from a container of preblended material, a truly continuous process uses several feeders (each one dosing an individual ingredient) and relies on a continuous blending step prior to granulation.     

酞侧基聚芳醚砜和聚芳醚酮的相容性

本文报道注射级酞侧基聚芳醚砜(PES-C)和聚芳醚酮(PEK-C)共混试样的玻璃化转变行为和部分力学性能的研究结果。并讨论共混工艺对相容性的影响。 PES-C和PEK-C树脂均由中国科学院长春应用化学研究所徐州工程塑料厂合成,在三氯甲烷中的比浓粘度ηsp/c(20℃)分别为0.45和0.47。将粉状树脂在GH-100Q高速搅拌器内按配方混合,并在烘箱内干燥后,用SHJ-30双螺杆挤出机在320～350℃(物料温度)挤出造粒。     

Study on In-Situ Compatibilization of the PP/PA6 Blends in Twin Screw Extruders

The in-situ compatibilization of PP/PA6 blend was studied in a twin screw extruder. The maleic anhydride (MA) content, peroxide concentration, shear rate and feeding order were among the variables investigated. Degree of grafting of samples collected prior to feeding of PA6 into the extruder was measured using titration combined with FTIR technique. From the SEM results it was found that the increasing of initial MA concentration led to larger PA particle size which could be related to secondary reactions between excess MA and PA. The melt linear viscoelastic measurements performed on the blend samples and the obtained relaxation time spectra showed shorter form relaxation time and interfacial relaxation time for one-step compatibilized sample compared to the sample prepared by the two-step method with the same degree of grafting. This was attributed to the stronger interfacial interaction of the one-step compatibilized blend samples which could be resulted from greater efficiency of grafting and/or compatibilization. These results were supported by SEM results which showed smaller particle size for the one-step compatibilized samples. It was demonstrated that melt linear viscoelastic measurement could provide a great insight into understanding the compatibilization process in twin screw extruder.     

An experimental technique for characterizing dispersion in compounds of particulates in thermoplastics using small-angle light scattering

An experimental technique based on small-angle light scattering for characterizing dispersion of particles and presence of agglomerates in compounds of minerals in thermoplastics is described. The technique is critically discussed in terms of the Mie and Rayleigh-Gans theories of scattering. An experimental study of dispersion in compounds of polypropylene and polystyrene with calcium carbonate by mixing variously on two roll mills, an internal mixer, and a modular intermeshing co-rotating twin screw extruder.     

Detection of co-continuous structures in SAN/PA6 blends by different methods

This paper describes the 70/30 wt% composition of SAN/PA6 blends having different types of morphology, namely PA6 dispersed in SAN, a co-continuous structures of PA6 and SAN, and a “mixed structure” which exhibits PA6 particles in SAN which themselves form the matrix for smaller SAN particles. These morphologies were achieved by using different processing conditions during extrusion blending in a twin screw extruder, especially variation in the screw speed and by injection molding. Morphological analysis using SEM and TEM, solubility experiments, DMA, and oscillatory rheometry are presented. These methods were shown to be able to distinguish between the different types of morphology. In addition, DSC was used to detect the PA6 crystallization behavior.     

Pseudomerohedral twinning,pseudosymmetry and complex hydrogen‐bonded sheets in 2‐methoxy‐4‐(pyrrolo[1,2‐a]quinoxalin‐4‐yl)phenol

The title compound, C₁₈H₁₄N₂O₂, crystallizes as a nonmerohedral twin, but the structure can be satisfactorily refined as a merohedral twin, in which a monoclinic unit cell with a cell angle β close to 90° emulates a metrically orthorhombic cell. The two molecules in the asymmetric unit are very similar in structure and they are related by an approximate pseudo‐screw axis. The molecules are linked into complex sheets by a combination of two O—H...N hydrogen bonds and four C—H...O hydrogen bonds.     

Morphologies and properties of plasticized starch/polyamide compatibilized blends

A new sodium carboxymethylcellulose (CMC) compatibilized glycerol-plasticized starch/polyamide PA11 blend having improved mechanical properties was realized in a one step extrusion process. Blends were prepared in internal mixer and twin screw extruder. Mechanical properties (stress and strain at break) are improved by adding 1 wt% of CMC. Rheological characterization and scanning electron microscopy show that a co-continuous morphology is observed on a wide range of TPS amount.     

Compatibilized PP/EPDM/PA6 ternary blends: extended morphological studies

Polypropylene (PP)/polyamide6 (PA6)/ethylene propylene diene monomer (EPDM) (70/15/15) ternary polymer blends compatibilized with maleic‐anhydride‐grafted EPDM (EPDM‐g‐MA) were prepared by melt blending using a twin‐screw extruder (TSE) in different processing conditions (barrel temperature profile, screw speed, and mixing sequence). The microstructures of prepared ternary blends were studied and compared to the predictions of spreading coefficient, minimum relative interfacial energy (RIE), and dynamic interfacial energy phenomenological models. The observed morphologies were somehow different from the model predictions. Copyright © 2011 John Wiley & Sons, Ltd.