A DYNAMIC MIXING SYSTEM AND METHOD FOR PRODUCING THERMOPLASTIC MATERIALS

Abstract: A mixing apparatus for mixing thermoplastic melt with ingredients contained therein, which comprises: barrel means having an inner cylindrical surface; spindle means having a cylindrical surface configuration and being rotatably disposed within said barrel means to define a mixing space for receiving said thermoplastic melt between the said surfaces of said barrel means and spindle means; a plurality of mixing balls disposed in said mixing space in a plurality of circumferential rows disposed around the said surface of said spindle; said balls being responsive to the rotation of said spindle to rotate about said spindle to impart a mixing action to said thermoplastic melt.

Description: A DYNAMIC MIXING SYSTEM AND METHOD FOR PRODUCING THERMOPLASTIC MATERIALS FIELD OF THE INVENTION This invention relates to a dynamic mixing apparatus and system and to a method for the production of thermoplastic materials in the form of extrudates. More particularly, the invention relates to an apparatus employing mixing balls to intensively mix a thermoplastic melt with other materials and to a method for intensively mixing such materials to form foamed thermoplastic extrudates. In addition, the invention embraces a new thermoplastic foam. BACKGROUND OF THE INVENTION The predominant blowing agents for the generation of thermoplastic foam extrudates on a commercial basis have been fluorocarbons, for example, trichlorofluoromethane and dichlorodifluoro ethane. As a result of ecological studies, these fluorocarbons have been determined to be an undesirable pollutant for the atmosphere. In particular, they have been identified as having particularly deleterious effects on the earth's protective ozone layer. Accordingly, ways are being sought to eliminate or materially reduce the utilization of fluorocarbons for all purposes wherever possible. A significant area in which to eliminate fluorocarbons from manufacturing processes is in the generation of thermoplastic foam extrudates such as thermoplastic foam sheeting and the like. In the process of eliminating fluorocarbons, it becomes apparent that if conventional chemical blowing agents also can be successfully eliminated and only harmless ingredients utilized as the blowing agents, then the manufacturing processes for foamed thermoplastics extrudates would become more ecologically sound. Natural gases such as air, nitrogen or carbon dioxide, all of which have predictable and acceptable effects on the ecology, would be the most desirable types of blowing agents. Water is also a prime candidate for an ecologically sound blowing agent. Quite apart from the ecological problems associated with the manufacture of these foamed thermoplastic extrudates there are clear cost benefits to be achieved if gases such as C0 2 , air or nitrogen can be used as the blowing agent for the production of thermoplastic foams. Traditional fluorocarbon blowing agents are a significant cost factor in the total cost of production of such foams. Further, as gases such as air, nitrogen and C0 2 are substantially insoluble in thermoplastic materials such as polystyrene the use of these gases can enable the manufacture of stronger and more durable foam extrudate as is more fully explained hereafter. In the past, there have been difficulties associated with the manufacture of foams due to inadequate mixing of thermoplastic and blowing agent during the mixing process prior to extrusion. As gases such as C0 2 , nitrogen and air are largely insoluble in thermoplastic materials, it is desirable for the manufacture of such foams that the thermoplastic/gas mixture be thoroughly and intensively mixed immediately prior to extrusion so that there is not separation of the materials into separate phases. Of course to extrude a plastics sheet it is also necessary that the thermoplastic/gas mixture be cooled whilst at the same time being mixed. For this reason, it has been recognized that it is desirable for the continued and low maintenance operation of such a mixing device that it have minimal or no dead regions where solidification or channelling might occur. Stagnation also reduces the heat loss efficiency. Thus, there has been as desire to provide a means and method for agitating a thermoplastic melt in such a manner to achieve better mixing and to reduce stagnation and dead regions during the mixing process. It is thus an object of the present invention to provide an improved mixing apparatus which enables the thorough mixing of thermoplastic extruded material with a gas or gases not being fluorocarbons for the formation of foamed sheet. This and other objects of the present invention will become more fully apparent with reference to the description and drawings which relate to several different embodiments of the invention. SUMMARY OF THE INVENTION According to the present invention, there is provided a dynamic mixing apparatus for intensively mixing thermoplastic melt with ingredients contained therein, which comprises: source means providing a flowing mass of thermoplastic melt; and dynamic mixing means for receiving and mixing said thermoplastic melt from said source means, comprising: inlet means for receiving said thermoplastic melt; barrel means having an inner cylindrical surface; spindle means having a cylindrical surface configuration and being rotatably disposed within said barrel means to define a mixing space for receiving said thermoplastic melt between the said surfaces of said barrel means and spindle means; a plurality of mixing balls disposed in said mixing space in a plurality of circumferential rows disposed around the said surface of said spindle; said balls being responsive to the rotation of said spindle to rotate about said spindle to impart a mixing action to said thermoplastics melt; the mixing balls in respectively adjoining rows being staggered with respect to immediately adjacent balls located in said adjoining rows to provide a labyrinth of dynamic flow paths for said thermoplastic melt; and outlet means for receiving mixed thermoplastic melt from said mixing space downstream of said inelt means. The use of such apparatus enables the entrainment of desired additives but importantly enables gases such as C0 2 , nitrogen or air in an extruded thermoplastic melt due to the intense agitation and mixing caused by forcing the mixture through the labyrinth of dynamic flow paths created by the movement and configuration of the mixing balls as described above. It is through this labyrinth which the thermoplastic melt and gas (and/or other material) are agitated and mixed to enable the extrusion of an homogeneous foamed sheet. The mixing balls are preferably disposed in a plurality of circumferential rows so as to provide for clearance between adjacent balls within each circumferential row and point contact between the staggered balls from adjoining circumferential rows. The surface of the spindle may either be smooth or it may include a plurality of circumferential grooves which accommodate the circumferential rows of mixing balls so as to allow the arrangement of mixing balls to have greater downstream stress capability, which can reach high levels at ball contact points in the last several rows, when a large number of rows are used without grooves supporting each row of balls independently. Although reference to "point contact" is made, in practice a thin film of plastic acts as a separating lubricant preventing wear at these points. The preferred arrangement of mixing balls as hereinbefore described leads to reduced wear between adjacent mixing balls. In the preferred embodiment, the adjacent mixing balls in the same circumferential row are separated due to overlapping contact with adjacent balls in adjoining rows. As there is no contact between adjacent balls in the same circumferential row there is consequently no wear occasioned between the balls. If the balls were in contact there would be significant wear as the balls are moving in the same direction and hence at the point of contact the surface of the respective balls would be moving in exactly opposite directions (i.e. if two adjacent balls are both moving in a clockwise direction, the ball surface on the left would be moving down at the point of contact and the ball surface on the right would be moving up at the point of contact) . Furthermore, the velocity of those portions of the balls are the highest being on the "equators" of both respective balls and thus wear is potentially greatest at these points. The contact which occurs between the staggered adjacent balls of adjoining rows causes less wear than would occur if adjacent balls in the same row were permitted to contact. This is because the contact occurs on the respective surfaces of the balls closer to the axis of rotation. This means that the velocities of the surfaces of the respective balls at the point of contact are slower than at the "equator" and whilst the respective balls still move in opposite directions at the point of contact they do so at slower rotational speed hence causing reduced wear. Preferably the barrel means, the spindle or both further include heat exchange means for cooling or controlling the temperature of the thermoplastic melt between the inlet and outlet means. The heat exchange means may be of any type known in the art. A suitable arrangement is to include cavities within the barrel means or spindle means which permit the circulation of heat exchange fluids such as cool water or oil. According to another aspect of the present invention, there is provided a method of incorporating and mixing materials in an homogeneous manner in a flowing mass of thermoplastic melt, comprising: providing a mixing space of substantially tubular configuration having an inlet and an outlet; providing a labyrinth of dynamic flow paths in said mixing space; and delivering a flowing mass of thermoplastic melt containing entrained material to be mixed therewith into said inlet and constraining said melt to flow through said labyrinth of dynamic flow paths to said outlet while rotating said labyrinth within said tubular mixing space. A preferred embodiment of the method of the present invention includes the steps of forming an extruded flowing mass of thermoplastic melt and subjecting the flow to a mixing action by causing the melt to flow into the dynamic mixing system of the present invention which includes mixing balls in a particular configuration within a tubular mixing chamber. The mixing balls in this arrangement impart multiple divisions in the flow of melt from row to row by geometric progression, so as to create a significantly large number of flow divisions thereby enhancing the mixing action. Thus, there is provided a labyrinth of dynamic paths which increase in number by geometric progression from the inlet to the outlet of the dynamic mixer of the present invention. The passage of thermoplastic melt with a suitable gas through this labyrinth makes possible the production of commercially acceptable foamed thermoplastic products while obviating the need for blowing agents containing fluorocarbons. This mixing system is excellent for dispersing colour, pigments, fillers, lubricants and other ingredients which can be quite difficult to mix in existing extrusion systems. The methods of the present invention also include the controlled injection of gases such as air, nitrogen and carbon dioxide and/or water, with or without nucleating agents such as talc, into an extrusion system upstream of the extruding die. Some embodiments also include the addition of chemical blowing agents, which further illustrate the versatility of the methods of the present invention. Generally, the extrusion systems contemplated by the present invention are of either a single extruder or a tandem extruder configuration with various access points at which controlled amounts of thermoplastic, nucleating agents, gas, water and/or chemical blowing agents can be added to the molten thermoplastic mass being produced by the extrusion system upstream of the extruding die. Examples of single and tandem extrusion systems are described in U.S. Patent No. 4,436,679 issued March 13, 1984 to Winstead and entitled "Method and Apparatus for Generating Foamed Thermoplastic Materials" which is herein incorporated by reference. In a preferred single extruder embodiment of the present invention, resin, granulate and a nucleating agent are introduced into the upstream end of an extruder and a controlled volume of water is optionally introduced mid-way between the upstream end and the gate of the extruder valve. The extruder barrel includes a gas injection port as well as the dynamic mixing system of the present invention disposed near the downstream or output end thereof. After gas injection and mixing action, the extrudate output of the extruder passes through a screen changer and a gear pump. The final foam produced emanates from the extrusion die. A transducer may be provided to control the speed of the extruder and thus maintain constant pressure at the gas injection point in the system. This constant pressure ensures a substantially uniform flow of compressible gas into the molten extrudate upstream of the mixer and cooler system of this invention to ensure a homogeneous product. The water optionally injected into the extruder barrel is introduced by the use of a metering pump or the like. In an alternative preferred single extruder embodiment, the dynamic mixing system of this invention is located downstream of the screen changer and gear pump so as to deliver thoroughly mixed and cooled extrudate with entrained blowing agent, as desired, to the extrusion die from which it is emitted in the form of foam sheeting. Typical examples of flow rates of molten polystyrene extrudate would be on the order of one hundred and fifty to three hundred pounds per hour; if water is introduced into the extruder barrel, its pressures may range form 750-4000 PSIG. Gas is introduced into the injector at a delivery pressure from 250-4000 PSIG; and the extrudate is fed to the extrusion die at a temperature of approximately 300°F. All of these parameters are approximate but represent desired orders of magnitude in the process of the present invention to produce, for example, polystyrene foams of the densities desired. The apparatus and methods of the present invention thus enable the production of thermoplastic foam sheet in which the blowing agent is an inert gas which is substantially insoluble in the thermoplastic material. The use of such gases as blowing agents has been found to have a further advantage in that the pressure inside each of the respective foam cell walls can be increased to pressures significantly greater than when partially soluble blowing agents such as fluorocarbons are used. This is accomplished by adding more gas which remains in the gaseous phase throughout the process (during mixing, cooling and expansion at the die lip) and thus providing cell pressures proportional to the amount of gas added. The higher pressures within the individual foam cells (at the appropriate temperature) results in a higher degree of orientation of each cell wall as expansion occurs. To achieve maximum cell wall orientation expansion of the foam as it exits the die lip should preferably be carried out at the optimum orientation temperature for the thermoplastic involved. This temperature is above the glass transition temperature and below the crystal melting point of the particular thermoplastic. In the case of polystyrene, this temperature is between about 270°F to 310°F. Orientation of the cell walls is instrumental in providing increased strength in thermoplastic products and extruded foam made in accordance with the present invention has been found to have significantly better physical properties, including brittleness and tensile strength when compared to similar density foams made using fluorocarbons. The extent or degree of molecular orientation can be determined by known techniques. X-Ray diffraction is one such method. In non crystalline polymers shrinkage on subsequent reheating above the glass transition temperature of thermoplastic can more readily be employed to guage the degree of molecular orientation. The change in area or volume is proportional to the degree of cell wall orientation. Thus in accordance with a further aspect of this invention there is provided a thermoplastic foam sheet or foamed product in which the cell walls of the foam have a high degree of orientation. The degree of orientation can be conveniently measured by comparative testing with known foams made from fluorocarbon blowing agents. To be useful in assessing the improvement in orientation in the foam cell walls it is important that in such comparative testing that the "control" foam be made under identical processing methods and conditions as used in the manufacture of the foam of the invention (other than the nature of the blowing agent) . Preferably the thermoplastic foam sheet or foamed product of this invention has cell walls in which the degree of orientation is between 10%-50% higher than in a corresponding foam made from the same thermoplastic under identical processing methods and conditions and having the same density wherein the blowing agent used was 100% chlorodifluoromethane. Most preferably this degree of orientation is between 25%-50% higher than in the corresponding chlorodifluoromethane foam. Any suitable thermoplastic may be used as is known in the art. Preferably polystyrene foam is used. BRIEF DESCRIPTION OF THE DRAWINGS The objects and many of the attendant advantages of the present invention will be readily appreciated as the same become better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which there are illustrated certain preferred embodiments of the invention. These embodiments do not purport to characterise only the essential features of the invention and it should be appreciated that various modifications to these examples can be made whilst still capturing the concept of the present invention. In these drawings: Figure 1 is a partially cut away perspective view of a first embodiment of the dynamic mixing system of the present invention; Figure 2 is a perspective view of a second embodiment of the dynamic mixing system of the present invention showing circumferential grooves; Figure 3 is a perspective view of a third embodiment of the dynamic mixing system of the present invention showing canted circumferential grooves; Figure 4 is a side view of a preferred embodiment of a single extruder extrusion system of the present invention with the mixing and cooling located within the extruder; Figure 5 is a side view of an alternative preferred embodiment of a single extruder extrusion system of the present invention with downstream mixing and cooling; and Figure 6 is a cross-sectional schematic illustration of a dynamic mixer/cooler of the present invention. DETAILED DESCRIPTION OF THE DRAWINGS Referring in detail to the drawings with particular reference to Figure 1, a perspective view of one preferred embodiment of a dynamic mixing system M in accordance with the present invention is illustrated as including a number of mixing balls 20 disposed about the surface of a spindle 2 having an end cap 1 and being connected to the downstream end of an extruder screw 30 having screw flights 32. The mixing balls 20 are arranged in a plurality of circumferential rows 20(1), 20(2), 20(3), 20(4) 20(Z) (where Z is a selected whole number) perpendicular to the axis of the cylindrically shaped spindle 2. The circumferential rows 20(1) 20(Z) of balls 20 are disposed so that adjacent balls in adjoining rows are staggered so as to be intermeshed or overlapping thereby providing for separation between adjoining balls within each circumferential row 20(1) 20(Z) and point contact between adjacent balls from adjacent circumferential rows 20(l)-20(2), 20a-20b, 20b-20c, 20c-20d, etc., as shown in Figure 1. Point contact is nominal. In operation, the melt actually separates balls sufficiently for lubrication. A barrel B encases the mixing balls and spindle. Referring further to Figure 1, the dynamic mixing system M of the present invention is shown to include a spindle 2 rotatably disposed within a barrel B. The spindle 2 is rotatably disposed within the barrel B so as to include a clearance X sufficient to accommodate the mixing balls 20. For example, the clearance X may be in the range of about 1/4" to 1" in order to accommodate balls of equal diameter plus a few thousandths of an inch clearance. The spindle 2 in this embodiment is integrally connected at the downstream end of an extruder screw 30 having screw flights 32. The spindle 2 has a length L which is sufficient to accommodate many rows of the mixing balls. For example, the length of the spindle may be in the range of 10" to 50". The spindle 2 also includes an end cap 1 similar to that of the downstream end portion of a conventional extruder screw, but undercut so as to retain the last row of balls. The spindle 2 is integral with an enlarged transition portion 3 so as to provide for a clearance Y which is similar to that of the end cap 1 and confines the balls 20 upstream. Another transition portion R is disposed adjacent to transition portion 3 and has a clearance Z which is smaller than that of clearance Y. Blowing agent may be injected through the barrel somewhere along the transition portion 3 and the adjacent transition portion R is configured to restrict gas escapement upstream. In the embodiment illustrated in Figure 1, the spindle 2 is attached to the end of an extruder screw 30 in accordance with the configuration of the extrusion system illustrated in Figure 4. In such a configuration, a flow of thermoplastic melt is constrained into a tubular configuration by the screw extruder 30 before the flow of melt is forced through the barrel past the adjacent transition portions 3 and R, and into the dynamic mixing system M of the present invention including the spindle 2 and the mixing balls 20. However, the orientation of the dynamic mixing system is not limited to this configuration. The dynamic mixing system may be located downstream of the extruder E, screen changer S and pump P as shown in Figure 5, or it may be between the screen changer S and the pump P. It can be oriented in a vertical, horizontal or tilted manner, along the projected axis of the extruder screw or perpendicular to it, as long as the flow of melt enters the dynamic mixing system at one or several ports and is subjected to the action of the rotating balls 20 before passing from the exit port to the die. The volume of the dynamic mixing system is preferably in the range of from about 20 to 100 cubic inches. This of course depends upon the total throughput desired from the extrusion system. The rotation rate of the spindle is sufficient to cause the desired mixing action and is prefereably in the range of from about 2 to 60 rpm. Most preferably between 5 to 10 rpm. Each of the circumferential rows 20(1) 20(Z) typically includes from about 18 to 40 mixing balls 20. The number of circumferential rows typically ranges from about 20 to 100 so as to provide for adequate mixing action. As previously stated, the diameter of the mixing balls 20 may range from about 1/4" to 1". The labyrinth arrangement of planetary mixing balls in the dynamic mixing systems M of the present invention further advantageously enhances mixing action based not only on mixing ball rotation, but further because of the generation of multiple divisions or dynamic flow paths created in the thermoplastic melt as it flows from row to row of mixing balls in a geometrically progressive manner. For example, eighteen planetary mixing balls 20 per circumferential row in ten circumferential rows 20(1)-20(10) will produce thousands of dynamic flow paths or flow divisions resulting in enhanced mixing action. The dynamic mixing system of the present invention further advantageously enhances mixing action since the annular flow configuration between the spindle 2 and the barrel B combines with the rotation of the labyrinth of mixing balls 20 to reduce if not eliminate stagnation and dead regions during the mixing action. The rotation of the mixing balls 20 in the dynamic mixing system of the present invention subjects a high number of molecules in the thermoplastic flow of melt to random movement resulting in an advantageously high amount of complex surface motion. This mixing action generated by the dynamic mixing system causes a high amount of agitation in the flow of melt as the melt is caused to pass between the surfaces of the rotating mixing balls, rotating spindle and barrel. In a typical foam extruder wherein gas is injected into the extruder, the dynamic mixing system of the present invention provides excellent mixing of high viscosity thermoplastic melt with the gas blowing agent. Gases such as C0 2 , air, nitrogen, etc., are generally insoluble in thermoplastic melts and thus, the two phases are invariably extremely difficult to mix together. By providing for improved mixing of these materials, the dynamic mixing systems of the present invention provides for a better quality extruded foam which requires less blowing agent and advantageously shorter heat history, i.e. the time period during which the thermoplastic melt is subjected to elevated temperatures. In this regard, the volume of melt in the tubular mixing space between the barrel B and the spindle 2 is reduced by approximately 70% when filled with balls as described. This is particularly significant in reducing heat history of the melt which avoids degradation by oxygen when air is used as the blowing agent. Referring next to Figure 2, wherein like components to Figure 1 bear like designations, a perspective view of a second embodiment of the dynamic mixing system of the present invention is illustrated wherein the spindle 2 includes a plurality of circumferential grooves 25(1) 25(Z) disposed about a cross-section perpendicular to the axis of rotation of the spindle 2, so as to retain a plurality of circumferential rows 20(1) 20(Z) of mixing balls 20, such as those designated 20(6)-20(8). As compared to the previous embodiment, illustrated in Figure 1, the alternative embodiment of Figure 2 allows for an increase in the total length of spindle 2 and, thus, the total number of circumferential rows of planetary mixing balls for more intensive mixing action. By employing the circumferential grooves 25(1) 25(Z), this embodiment provides for higher stress capability so as to accommodate a larger total pressure drop of the thermoplastic melt flow from the upstream to the downstream circumferential rows of mixing balls increases with the increasing length of the spindle 2. The circumferential grooves 25(1) 25(Z) are dimensioned such that the spacing between adjacent ones of the circumferential rows 20(1) 20(Z) of mixing balls 20 maintains the balls 20 in adjacent ones of said circumferential rows in the staggered arrangement described above with regard to the embodiment in Figure 1. Referring to Figure 3, wherein like components to Figures 1 and 2 bear like designations, a perspective view of a third embodiment of the dynamic mixing system of the present invention is shown wherein a spindle 2 includes a plurality of circumferential grooves 35(1) 35(Z) which are canted with respect to the rotational axis of the spindle and which accommodate respective rows 20(1) 20(Z) of planetary mixing balls 20 therein. The canted circumferential grooves 35(1) 35(Z) correspond to slightly elliptical cross-sections of the spindle 2 as compared to the circumferential grooves 25(1) 25(Z) in the second embodiment described above which correspond to circular cross-sections of the spindle. The canted circumferential grooves 35 allow the mixing balls 20 to move axially to a certain extent with respect to the spindle 2 so as to "wipe" the interior surface of the barrel B, thereby further eliminating stagnation in the mixing action. The canted circumferential grooves 35 may be slanted to approximately half of their spacing so as to assure total contact between the mixing balls 20 and the surface of the barrel B at least once per revolution of the mixing balls. Preferably, the plane of the circumferential grooves 35 are canted at an angle so at to displace one end at a distance equal to approximately 86% of ball diameter. In all of the foregoing embodiments the spindle 2 and barrel B may be cooled to whatever degree is required for establishing optimum stock temperature, as is typical in extruder and other mixer-cooling devices in commercial use. The spindle 2 and barrel B may each be provided with channels for circulating coolant (water, oil, etc.) therein for accurately controlling the temperature in the dynamic mixing system and stock therein. In Figure 4, a preferred embodiment of a single extruder extrusion system for producing foamed thermoplastic resin is illustrated as including an extruder E having an elongated barrel B with an input hopper H positioned at the upstream end of the barrel B to receive resin Rl, granulate R2 and, if used, nucleating material N. The extrusion system is operated by controls (not shown) in the control cabinet C. The downstream portion of the barrel B includes the dynamic mixing system M of the present invention. The downstream end of the dynamic mixing system M exhausts through a screen changer S to an extrusion die D from which controllable quantities of extrudate are emitted, for example, in the form of foam sheeting F. An optional water injection point (not shown) which receives water from a controlled volume water pump may be incorporated into the extrusion system in accordance with the description outlined in U.S. Patent No. 4,436,679 to Winstead which is herein incorporated by reference. Gas G is directly introduced into a gas intake GI located in the barrel B upstream of the dynamic mixing system M as schematically shown. In Figure 5, an alternative preferred embodiment of the single extruder extrusion system in accordance with the present invention is illustrated, wherein like components to Figure 4 bear like designations. In this embodiment, it can be seen that the dynamic mixing system M is now located downstream of a screen changer S and a controlled gear pump P. In this configuration, the dynamic mixing system M serves to both thoroughly mix and cool the extrudate, which may include entrained blowing agent, and delivers the extrudate to the outlet die D from which it is emitted in the form of foam sheeting F or the like. The controlled volume pump P is preferably a gear pump having a variable speed drive PD which is set at a level to establish overall output at the desired number of pounds per hour. Another advantage of the mixing balls 20 employed in the present invention is that the mixing balls also act as a bearing support for the downstream end of the screw, thus significantly reducing screw wear. When the mixer is a separate device in Figure 5, no sleeve or other end bearings are required to support the shaft (spindle), which is a necessary evil in other mixers and coolers described in existing art. The balls not only provide the mixing action but also act as bearings in this design. Only simple seals are required at the open ends of the apparatus in this design. Referring to Figure 6, an independent dynamic mixer/cooler DMC, such as that suitable for use as the dynamic mixer M in the embodiment of Figure 5 will now be described. Plastic melt or other viscous material to be mixed and cooled is received at two inlet pipes 50A and 5OB which deliver melt to inlet ports 52A and 52B, respectively, on opposite ends of a mixer/cooler barrel housing 54. Immediately within the inlet ports 52A and 52B are inlet chambers 56A and 56B, which surround the upstream ends of rotary spindle portions 58A and 58B, respectively of rotary spindle 58. Rotary shaft end seals 60A and 6OB are respectively provided on the spindle portions 58A and 58B to seal the ends of the mixer/cooler barrel housing 54 while permitting the spindle portions 58A and 58B to protrude therefrom whereby suitable driving means (not shown) can be provided to rotate the spindle 58 in any desired direction of rotation. The rotational arrow at the outer end of the spindle portions 58A, 58B is for illustrative purposes only. The direction of rotation is not critical to the operation of the dynamic mixer/cooler DMC. It should be noted that because of the ball bearing mixing structures of the present invention, no shaft end bearings are needed for the spindle 58A, 58B as will be more fully described hereinafter. The spindle portions 58A and 58B extend to a median position or waistline 58C within the barrel housing 54 so as to define an annular exhaust or outlet chamber 62 which is in turn connected to an exhaust or outlet port 64. The cooled and mixed melt or other viscous material is emitted from the outlet part 64 and directed to an extrusion die or the like as, for example, the die D of Figure 5. Melt entering the inlets 52A, 52B is at a first temperature which is to be changed, such as by cooling, to a desired controlled temperature at the outlet part 64. This is accomplished by heat exchange between the melt, the internal surfaces of the barrel housing 54 and the external surfaces of the rotary spindle portions 58A, 58B. The rotary spindle portions 58A, 58B carry sets of mixing balls 66A and 66B, respectively, maintained in respective sets of canted circumferential grooves 68A and 68B in the manner described previously in connection with Figure 3. The mixing balls 66A and 66B thus provide a scrubbing action to preclude the stagnation of melt on the interior surface of the barrel housing 54 and thereby enhance heat exchange between the melt and the barrel housing 54. Temperature control of the barrel housing 54 is provided with oil jackets 72A and 72B, having respective inlets 74A and 74B and outlets 76A and 76B. The oil jackets 70A and 7OB are positioned substantially coextensively with those lengths of the rotary spindle portions 58A and 58B carrying the mixing ball sets 66A and 66B. Further temperature control via the rotary spindle portions 58A and 58B is provided by making these spindle portions hollow and inserting therein the heat exchange tube assemblies, such as 78B shown in the right-hand spindle portion 58B, having spiral fluid flow paths defined by a spiral vane structure 80B constraining fluid flowing into the tube 7OB to exit the right-hand spindle portion 58B via a spiral path in heat exchange relationship with the interior of the said spindle portion 58B. This flow is indicated by the arrows within the right-hand spindle portion 58B. A similar structure (not shown) is provided within the left-hand spindle portion 58A. Thus, the temperature of both the barrel housing 54 and the spindle portions 58A and 58B are regulated, such that the incoming melt is mixed by the planetary action of the mixing ball sets 66A and 66B and constrained by the pressure applied by the upstream gear pump, extruder or the like and the said planetary action of the mixing ball sets 66A and 66B to exchange heat with the barrel housing 54 and spindle portions 58A, 58B such that the temperature of the melt, at the outlet 64, is controlled to the optimum desired temperature for the downstream process to be undertaken with that melt. In the context of the present example, that process would be the extrusion of the melt. As previously noted, the orientation of the dynamic mixing apparatus of the present invention can be in¬ line, perpendicular or askew of the longitudinal axis of the extruder. So long as the flow of melt enters the dynamic mixing system and is constrained to flow through the labyrinth of mixing balls 20 before exiting the apparatus, the dynamic function (and temperature control function) of the system will be accomplished. By way of further example, whereas Figure 6 shows the entry path ports 52A, 52B at the ends of the barrel housing 54 with the exit port 64 in the middle, the structure can also be connected in an in-line configuration in which the melt could flow into one entry port 52A and exit from the other entry port 52B, depending upon the connected configuration of the import pipes 50A and 50B and the closing of the outlet port 64. Thus, the apparatus of Figure 6 could be used in the in¬ line configuration of the dynamic mixer M generally illustrated in Figure 5. The foam produced in accordance with this invention has a higher degree of orientation than in corresponding foams made using traditional blowing agents such as Freon 22. It thus has better physical characteristics notably physical strength. As previously discussed the apparatus and method hereinbefore described enables one to add more gas to the thermoplastic melt and thus proportionally increase the pressure within the cells. This is achieved through more intense mixing (which can be achieved with the apparatus of the present invention) which entrains even inert gases such as C0 2 , nitrogen or air evenly throughout the melt. Typically (assuming identical densities) a 100% C0 2 blown styrene foam of the present invention exhibits 10% to 50% better cell wall orientation than conventional foams. The following examples demonstrate the improved orientation in the cell walls of such C0 2 blown foams when compared with standard foams by using standard heat shrinkage methodology. Example 1 Two different foam sheets were produced. Both were made from the same polystyrene thermoplastic under identical production conditions using the apparatus of the present invention. The sheets produced were substantially identical in density. The only difference in production was the blowing agent. In the first case 100% "Freon" 22 was used. "Freon 22" is a trade mark of the Du Pont Company and is used in relation to chlorodifluoromethane. In the case of the second foam 100% C0 2 gas was used as the blowing agent. The cooled foams were then cut into identically shaped and sized test samples and simultaneously placed in a heated liquid bath for a period of approximately 30 seconds. The results were as follows: CO., blown foam: Area Size prior to heating: 1 5/8" X 2 7/16" Size after heating at 300°F for approxi¬ mately 30 seconds: 5/8" X 11/16" 0.43in 2 Freon 22 blown foam: Size prior to heating: 1 5/8" X 2 7/16' Size after heating at 300°F for approxi- mately 30 seconds: 3/4" X 13/16" 0.61in 2 This example demonstrates that the C0 2 blown foam had a significantly higher degree of cell wall orientation. The change in area upon heat shrinkage is proportional to the degree of cell wall orientation and in the above example it can be seen that the C0 2 blown foam shrank about 29% more than the Freon 22 foam of the same density. Thus the degree of orientation in the cell walls in the C0 2 blown foam was approximately 29% higher than in the Freon 22 blown foam. Example 2 Samples of the two foams referred to in Example 1 were subjected to further shrinkage tests at 220°F as follows: C0 blown foam: Area Size prior to heating: 1 5/8" X 2 5/8" Size after heating at 220°F for approxi- mately 30 seconds: 1 9/16" X 1 1/2" 2.34in 2 Freon 22 blown foam: Size prior to heating: 1 5/8" X 2 5/8" Size after heating at 220°F for approxi¬ mately 30 seconds: 1 3/4" X 1 7/8" 3.28in 2 The example demonstrates the consistant comparative value of heat shrinkage to ascertain the difference in the orientation of the cell walls in the respective foams. In these tests the C0 2 blown foam demonstrated 28% greater shrinkage than the corresponding Freon 22 blown foam indicating a higher degree of orientation of this order in the cell walls of the 100% C0 2 blown foam. The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims: The claims defining the invention are as follows: 1. A dynamic mixing apparatus for intensively mixing thermoplastic melt with ingredients contained therein, which comprises: source means for providing a flowing mass of thermoplastic melt; and dynamic mixing means for receiving and mixing said thermoplastic melt from said source means, comprising: inlet means receiving said thermoplastic melt; barrel means having an inner cylindrical surface; spindle means having a cylindrical surface configuration and being rotatably disposed within said barrel means to define a mixing space for receiving said thermoplastic melt between the said surfaces of said barrel means and spindle means; a plurality of mixing balls disposed in said mixing space in a plurality of circumferential rows disposed around the said surface of said spindle; said balls being responsive to the rotation of said spindle to rotate about said spindle to impart a mixing action to said thermoplastic melt; the mixing balls in respectively adjoining rows being staggered with respect to immediately adjacent balls located in said adjoining rows to provide a labyrinth of dynamic flow paths for said thermoplastic melt; and outlet means for receiving mixed thermoplastic melt from said mixing space downstream of said inelt means. 2. The dynamic mixing apparatus of claim 1, wherein said mixing balls in said plurality of circumferential rows are intermeshed such that there is a separation between adjacent balls within each circumferential row and point contact between adjacent balls in adjoining circumferential rows. 3. The dynamic mixing apparatus according to either one of claims 1 or 2, further comprising a plurality of circumferential grooves formed in the surface of said spindle means for retaining said circumferential rows of mixing balls. 4. The dynamic mixing apparatus as claimed in claim 3 wherein said circumferential grooves are canted and are formed in the surface of said spindle means for retaining said circumferential rows of mixing balls. 5. The dynamic mixing apparatus of any one of the previous claims wherein said barrel means and said spindle means of said dynamic mixing means further include heat exchange means for controlling the temperature of said mixed thermoplastic melt between said inlet means and said outlet means of said dynamic mixing means. 6. A dynamic mixing apparatus for intensively mixing thermoplastic melt with ingredients contained therein, said thermoplastic melt being in a flowing pressurized mass, comprising: housing means having an inner cylindrical surface; spindle means having a cylindrical surface configuration and being rotatably disposed within said housing means to define a mixing space for receiving said thermoplastic melt between the said surfaces of said barrel means and said spindle means; said mixing space having upstream and downstream locations relative to the flow of thermoplastic melt therethrough; inlet means and outlet means at respective upstream and downstream locations in said mixing space for receiving and discharging respectively said thermoplastic melt; and mixing means defining a labyrinth of dynamic flow paths between said inlet and outlet means within said mixing space comprising: a plurality of mixing balls disposed in circumferential rows about the said surface of said spindle; said balls being responsive to the rotation of said spindle within said housing to rotate about said spindle in said thermoplastic melt to constrain said melt to follow a geometrically increasing labyrinth of flow paths between said inlet means and said outlet means to thereby intensively mix said thermoplastic melt within said mixing space. 7. The dynamic mixing apparatus of claim 6 wherein said mixing balls in respectively adjoining rows are in staggered relationship with one another to provide said labyrinth of dynamic flow paths. 8. The dynamic mixing apparatus of either one of claims 6 or 7 wherein said planetary mixing balls provide bearing support for said spindle within said housing. 9. The dynamic mixing apparatus of any one of claims 6 to 8 wherein said mixing balls in said plurality of circumferential rows are intermeshed such that there is separation between adjacent balls within each circumferential row and point contact between adjacent balls in adjoining circumferential rows. 10. The dynamic mixing apparatus of any one of claims 6 to 9, further comprising a plurality of circumferential grooves formed in the surface of said spindle means for retaining said circumferential rows of mixing ball means. 11. The dynamic mixing apparatus of any of claims 6 to 10, which further include heat exchange means for controlling the temperature of said mixed thermoplastic melt in said mixing space. 12. A method of incorporating blowing agents in a flowing mass of thermoplastic melt which obviates the need for fluorocarbon blowing agents in the production of foamed thermoplastics, comprising: providing a mixing space of substantially tubular configuration having an inlet and an outlet; providing a labyrinth of dynamic flow paths in said mixing space which increase in number in geometric progression from said inlet to said outlet; delivering a flowing mass of thermoplastic melt containing entrained blowing agent into said inlet and constraining said melt to flow through said labyrinth of flow paths to said outlet while orbiting said labyrinth in planetary fashion within said tubular mixing space. 13. The method of claim 12, which further includes: defining said mixing space with concentric inner and outer cylindrical surfaces; defining said labyrinth of dynamic flow paths in said mixing space by a plurality of mixing balls arranged in adjoining concentric circumferential rows on said inner cylindrical surface from said inlet to said outlet, with adjacent mixing balls in respectively adjoining rows being staggered with one another; and imparting relative rotation to said inner surface and said outer surface to constrain said mixing balls to orbit said inner surface within said mixing space. 14. The method of either one of claims 12 or 13 wherein said blowing agent is devoid of fluorocarbons. 15. The method of claim 14 which further includes: defining said mixing space with concentric inner and outer cylindrical surfaces; defining said labyrinth of dynamic flow paths in said mixing space by a plurality of mixing balls arranged in adjoining concentric circumferential rows on said inner cylindrical surface from said inlet to said outlet, with adjacent mixing balls in respectively adjoining rows being staggered with one another; and imparting relative rotation to said inner surface and said outer surface to constrain said planetary mixing balls to orbit said inner surface withing said mixing space. 16. The method of any one of claims 12 to 15 wherein said blowing agent is selected from the group consisting of water, air, nitrogen, carbon dioxide, and other gases devoid of fluorocarbons. 17. A method of incorporating and mixing materials in a homogenous manner in a flowing mass of thermoplastic melt, comprising: providing a mixing space of substantially tubular configuration having an inlet and an outlet; providing a labyrinth of dynamic flow paths in said mixing space; and delivering a flowing mass of thermoplastic melt containing entrained material to be mixed therewith into said inlet and constraining said melt to flow through said labyrinth of dynamic flow paths to said outlet while rotating said labyrinth within said tubular mixing space. 18. The method of claim 17 which further includes: defining said mixing space with concentric inner and outer cylindrical surfaces; defining said labyrinth of dynamic flow paths in said mixing space by a plurality of mixing balls arranged in adjoining concentric circumferential rows on said inner cylindrical surface from said inlet to said outlet, with adjacent mixing balls in respectively adjoining rows being staggered with one another; and imparting relative rotation to said inner surface and said outer surface to constrain said mixing balls to orbit about said inner surface within said mixing space. 19. The method of claim 18 wherein said entrained material to be mixed is selected from the group consisting of nucleating agents, pigments, fillers, chemical blowing agents devoid of fluorocarbons and lubricants. 20. A thermoplastic foam sheet or foamed product in which the cell wall of the foam have a high degree of biaxial orientation. 21. A thermoplastic foam sheet or foamed product as claimed in claim 20 wherein the degree of orientation of the cell walls is between 10% to 50% higher than in a corresponding foam made from the same thermoplastic under identical processing methods and conditions and having the same density wherein the blowing agent used was 100% Freon 22. 22. A thermoplastic foam sheet or foamed product as claimed in claim 21 wherein the degree of orientation is between 25% to 50% higher than in the corresponding Freon 22 foam. 23. A thermoplastic foam sheet or foamed product as claimed in any one of claims 20 to 22 wherein the thermoplastic material is a polystyrene. 24. A thermoplastic foam sheet or foamed product as claimed in any one of claims 20 to 23 wherein the blowing agent used to make the foam is substantially entirely C0 2 , nitrogen, air or admixtures of these gases. 25. A thermoplastic foam sheet or foamed productt when made in accordance with the method of any one of claims 12 to 19 or claim 28. 26. The dynamic mixing apparatus of any one of claims 1 to 19 wherein said mixing balls occupy on the order of 70% of the mixing space containing said labyrinth. 27. A dynamic mixing apparatus substantially as hereinbefore described with reference to what is shown in any one of the drawings. 28. A method of incorporating and mixing materials in a homogenous manner in a flowing mass of thermoplastic melt substantially as hereinbefore described. 29. A thermoplastic foam sheet or foamed product substantially as hereinbefore described with reference to the examples.

Inventors: WINSTEAD THOMAS W, WINSTEAD, THOMAS, W.
Applicants: WINSTEAD THOMAS W, WINSTEAD, THOMAS, W.
Application year: 1991
Main classification: B29C47
IPC codes: B01F5, B01F7, B29B7, B29C47, B29K25, B29K105, C08J9