Abstract:
A method and apparatus to process a diverted molten polymer waste stream directs the polymer stream to one of at least two passages, separates it into individual segments while containing and discharging it from a containment exit, cools each segment with a quench fluid to form a solid or semi-solid polymer, and transports the solidified segments away from the exit and into a container using the quench fluid. The apparatus includes a cross-section transition connector, a moveable block with two passages, a block oscillator, a cut-off plate, and open space above an inclined transporting device, a quench fluid jet, and a quench fluid transporting trough.

Description:
This application is a 371 of PCT/US00/21158, filed Aug. 3, 2000. This application claims benefit under 35 U.S.C. 119(e) of Provisional Application 60/147,455, filed Aug. 5, 1999 and Provisional Application 60/149,043, filed Aug. 16, 1999 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the field of polymer treatment apparatuses and methods for processing polymer waste wherein the waste is processed in a form suitable for recycling. 
     2. Description of the Prior Art 
     According to known procedures continuous polymerization lines are operated to produce polymer products. One such product is pellets of polymer for further use, such as remelting to produce melt-spun thermoplastic filaments, for example, of nylon or polyester. During routine maintenance of such pelletizing equipment or during system failures the stream of molten polymer from the continuous polymerization line cannot be stopped and must be diverted to waste Normal procedure for machines with a capacity of only one thousand to three thousand pounds per hour is to extrude the polymer directly onto the floor next to the pelletizer or into a buggy during the limited time the pelletizer is not operational. The waste, or “plop”, collected in this manner is manually handled to prepare it for recycle as a second quality polymer. 
     An alternative to placing plop on the floor or into a buggy is disclosed in U.S. Pat. No. 5,496,508 (Hettinga et al). In this patent the purged polymer is directed into a hopper and between two rollers, which cool and compress the purge to a continuous strip thickness suitable for subsequent processing. The strip is collected in a hollow steel container. The strip may be corrugated on one side or split into a plurality of strips. Other alternatives are disclosed by Japanese Patents JO 72 27874 and JO 81 55957 where in both separate cases the waste polymer is separated into discrete volumes and placed into individual containers that are part of a conveying system. In the former patent the polymer stream is never interrupted and is only temporarily diverted as the containers are switched. In the latter patent the polymer is collected between a fixed plate and a moveable plate that opens and closes periodically to discharge a discrete volume of polymer and cut it into a block that falls into a conveyed bucket containing a quench fluid. There is no indication that these alternatives can handle more than one thousand to three thousand pounds per hour of molten polymer. 
     When the capacity of the continuous polymerization pelletizing line is greater than three thousand pounds (1360 Kg) per hour (up to twelve thousand pounds (5440 Kg) per hour) it becomes unwieldy, labor intensive, and dangerous to handle the large volume of hot polymer which approaches two hundred pounds(1.5 Kg) per minute or 3.3 pounds per second. Such large quantities of molten polymer collected in one mass also present a significant fire hazard in the area. For nylon polymer with a specific gravity of 1.2, this is about 2.7 cubic feet (0.08 cubic meters) per minute of polymer at about three hundred (300° C.) degrees Centigrade. If this quantity of nylon polymer is exiting out of a three-inch (7.62 cm) diameter pipe, the velocity of polymer to be handled approaches eleven inches (27.9 cm) per second. There is a need for a system to safely and economically handle large flow rates of molten polymer waste in a way that makes it easy to recycle. 
     SUMMARY OF THE INVENTION 
     The invention is a method and apparatus to process a diverted molten polymer waste stream by directing the polymer stream to one of at least two passages, separating the molten polymer into individual pieces or segments while containing the polymer and discharging the polymer from a containment exit, cooling each segment with a quench fluid to form a solid or semi-solid polymer, and transporting the solidified segments away from the containment exit and into a container using the quench fluid. One preferred apparatus comprises a cross-section transition connector, a moveable block with two passages, a block oscillator, a cut-off plate, an open space above an inclined transporting device, a quench fluid jet, and a quench fluid transporting trough. The transporting trough is designed to provide adequate time and cooling for solidification of polymer segments and to transport the segments to a desired location laterally spaced from the containment exit. The cross-section transition connector changes the polymer cross-section from cylindrical to a flattened cylinder, which reduces the distance required to traverse and cut the polymer stream. Directing the polymer stream to one or the other or both of at least two passages provides a continuous path for the polymer stream so pressure does not build up in the polymer that may damage elements in the system, and so gravity draining is provided when the system shuts down. Other apparatuses show other means of accomplishing the directing of polymer using a conically shaped bloc that is rotatably moved. Movement of the block in some apparatuses may occur in either reciprocating rectilinear directions or in a rotational direction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be more fully understood from the following detailed description thereof, taken in connection with the accompanying drawings, which form a part of this application and in which: 
     FIG. 1 is a side section view of a polymer extrusion line with a diverter valve and polymer segmenting device; 
     FIG. 2A is a side section view of a transporting device for quenching and moving polymer segments away from the segmenting device, and FIG. 2B is a plan view of the upper end of the transporting device; 
     FIG. 3 is a perspective view of a polymer segmenting device; 
     FIG. 4 is a bottom view of the polymer segmenting device of FIG. 3; 
     FIGS. 5A,  5 B, and  5 C are a top view, side section view and bottom view, respectively of a transition connector; 
     FIGS. 6A,  6 B, and  6 C are section views through the polymer segmenting device of FIG. 3 showing the sequence of positions of a moveable block in the operation of the device; 
     FIG. 7 is a perspective view of a portion of a segmenting device showing the passages and cut-off openings in hidden view; 
     FIG. 8 is an alternate embodiment of the segmenting device where the cut-off occurs between the moveable block and the transition connector; 
     FIG. 9 is an end view of the segmenting device of FIG. 7; 
     FIG. 10A is a side section view of an alternate embodiment of FIG. 2A; 
     FIG. 10B is a plan view of the upper end of the embodiment of FIG. 10A; 
     FIG. 10C is a plan view of the upper end of an alternate embodiment of FIG. 2A; and 
     FIGS. 11A and 11B are section views illustrating another embodiment of a segmenting device. 
     FIGS. 12A and 12B are a cross-section view and a bottom view, respectively, illustrating another embodiment of a segmenting device. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Throughout the following detailed description similar reference numerals refer to similar elements in all figures of the drawings. 
     FIG. 1 shows a polymer extrusion line for making polymer pellets. Molten polymer enters through conduit  10  and in normal operation passes through a diverter valve  12 , a polymer stream conduit  14 , and a pellet forming device  16 . The diverter valve is shifted during an unscheduled outage or scheduled maintenance to divert the flow of polymer to a segmenting device  24 . The valve  12  is shifted from the forward position shown to a back position by an actuator  26  that moves the valve  12  and the segmenting device  24  attached thereto back and forth in the direction of double ended arrow  25 . In the back position the polymer flows in the direction of arrow  27  to the segmenting device. The segmenting device contains the polymer until it passes through a containment exit at position  21 . With the exception of the segmenting device  24 , the extrusion line with diverter valve just described is of conventional design known in the art. 
     Beneath the containment exit of the segmenting device is an open space  17  above a transporting device  28 . The transporting device  28  includes an inclined trough  29  which is open on the top to receive falling segments of molten polymer, such as segments  30  from two polymer exit openings in the segmenting device  24 . The open space is sufficient so the polymer passing through the containment exit can be formed into a discrete segment of polymer, preferably before the polymer contacts the transporting device. A fluid conduit  32  attached to the transporting device  28  supplies fluid to the trough at the upper end  34  to lubricate the surface of the trough and to quench and transport the segments  30  along the transporting device  28  away from the segmenting device  24  in the lateral direction indicated by the arrow  36 . 
     FIGS. 2A and 2B show additional details of the transporting device  28 . In one embodiment the inclined trough  29  includes a first trough  29   a  that has an end wall  38  with a slot opening  40  in fluid communication with the conduit  32 . The segmenting device in FIGS. 2A and 2B is rotated ninety degrees from the view in FIG. 1 so the segments are arranged one beside the other in the trough as seen looking at phantom segments  30   a  and  30   b  in FIG. 2B. A separator panel  23 , in the center of the trough, keeps the segments from contacting one another in the portion of the trough where the segments first contact the trough. The panel also keeps each segment in a confined space to limit folding and spreading of the segment when it hits the trough. Fluid, such as water, exiting the opening  40  covers the bottom of the trough with water which acts to lubricate the bottom surface. Another conduit  31  is in fluid communication with a plurality of fluid jet openings, such as jets  33  and  35 , that form forceful streams  42  and  43  that are directed against a segment, such as segment  30   a , to accelerate the segment down the trough  29   a  in the direction of arrow  36 . It is important that a first segment is accelerated to move quickly along the trough so that a second segment following the first will not contact the first when the second contacts the trough. If the two segments contact each other while still molten they may become permanently joined which is undesirable. The segments may fold on themselves and twist and flop over to their flat side when contacting the trough and get quenched in an irregular shape. The quenched shape of the segments is not so important as long as the segments can be transported along the trough and remain separate individual polymer segments that do not join other segments while molten. Along the length of the trough  29   a  are spray nozzles  37  that cover the segments with water to quench the segments as they travel along the trough. The fluid and the angle  44  of the trough act to accelerate the segments and separate them in the trough and continuously propel them along the trough. 
     The first trough  29   a  may join a second trough  29   b . The inclination angle  46  of the trough  29   b  is less than angle  44  of the trough  29   a . Additional fluid is introduced in the trough  29   b  by conduit  48  through opening  50 . At the lesser angle  46  the fluid level  52  builds up to thoroughly quench the segments and carry them along toward the open end  54  of the trough  29   b . The lesser angle  46  preferably results in a pitch to the trough that is the same as a common sewer line pitch of about ¼-inch (0.64 cm)per foot. The cross-section of the troughs is preferably one that has a flat bottom and angled sides diverging from the bottom. This is the same as a common log flume cross-section, which works well to self-clear if one segment (log) hangs up in the trough. As the water level rises behind a hung segment, the width of the water increases to aid clearing. 
     Below the end  54  is a container  56  to collect the segments  30  for further processing, such as recycling. Near the open end  54 , the fluid can be drained off through drain opening  58  and drain conduit  60  or the fluid can flow out of the end  54  and into container  56  where a container opening  62  is attached to a conduit  64 . The fluid collected in conduits  60  and/or  62  can be disposed of, or the fluid can be filtered and returned to the upper end  34  of the trough  29   a  via conduit  32  and be reused. In some cases trough  29   b  may not be needed when the distances to the container are short. In this case, trough  29   a  would terminate at the container  56 . 
     Trough  29   a  is shown with an optional feature where the upper end  34  is moveable to allow it to be displaced from beneath the segmenting device when it is desired to deposit the polymer segments in a buggy or the like, or at an unscheduled start when water flow in the trough has not been established. An actuator  39 , such as a fluid cylinder, has an actuator rod  41  attached to upper end  34  which is part of a moveable portion  45   a  of trough  29   a  which slides within a fixed portion  45   b  of trough  29   a . When the cylinder rod is moved in the direction of arrow  47  the moveable portion  45   a  of the trough slides in the fixed portion  45   b  and moves from beneath the segmenting device  24 . A fluid trough with such a feature can be obtained from Conair, Corp., Pittsburgh, Pa. 
     Transporting the polymer via fluid flow in a trough combines quenching and material handling thereby reducing equipment complexity. The polymer segments are solid enough when reaching the accumulating container so that no cleanup of molten polymer is required and the segments remain discrete and do not weld to each other. Immediate water quenching of the material reduces direct air contact with the molten polymer thereby reducing degradation and increasing the value of the recycle product. 
     FIGS. 3 and 4 show greater detail of the segmenting device  24 . In a preferred embodiment the segmenting device  24  comprises a cross-section transition connector  66 , a block housing  68 , a dual channel moveable block  70  and a block oscillator  72 . The connector  66  attaches to the diverter valve  12  (FIG. 1) with four attachment bolts, such as bolts  74 . The block housing  68  is attached to the bottom of the connector  66  and cop rises side plates  78  and  80  attached to a cut-off plate  82 , end plate  84  and actuator bracket  86 . The cut-off plate  82  has a first cut-off opening  83  and a second cut-off opening  85  passing therethrough. Each opening  83 ,  85  has a flattened shape  87  with a width  89  less than its length  91 . The cut-off openings  83 ,  85  represent containment exits for the segmenting device  24 . The side plates  78  and  80  are covered with thermal insulation plates  88  and  90 , respectively. The block oscillator  72  comprises an actuator  92 , attached to the bracket  86 , and link  94  that attaches the moveable end  96  of the actuator to the block  70 . The end plate  84  is attached to the side plates  78  and  80  and includes an adjustable stop  98 , which is adjusted to contact the block  70  at one movement position when the actuator moves the block toward the end plate. 
     The connector  66  is heated by heaters  100  and  102 . The block housing  68  is heated by heaters  104  and  106  in side plate  78 , and heaters  108 ,  110  (not visible) in side plate  80 . Thermocouple  112  in connector  66  is used to control the heaters  100  and  102 . Thermocouple  114  in side plate  78  is used to control the heaters  104  and  106 . Thermocouple  116  in side plate  80  is used to control the heaters  108  and  110 . The heaters keep the polymer molten in the segmenting device  24 . The heaters can reheat the polymer in the segmenting device so if it is shut down and allowed to cool, it can be restarted without having to clean out the solidified polymer. For instance, if nylon is the polymer being processed, a reheat temperature of about two hundred fifty (250° C.) degrees Centigrade will melt the polymer so the segmenting device can be operated. During operation a temperature of about two hundred eighty five degrees. Centigrade (285° C.) is set for continuous running. 
     The cross-section transition connector  66  is shown in more detail in FIGS. 5A,  5 B, and  5 C. The connector has a first passage  118  for shaping the polymer stream and, in a preferred embodiment, providing a transition from a circular shape  120  at an entrance end  122  to a flattened shape  124  at an exit end  126 . The flattened shape  124  at exit end  126  is surrounded by a flat surface  127  which is arranged to abut the moveable block  70  (FIG.  3 ). The flattened shape  124  has a width  128  that is less than length  130 . In a preferred embodiment the width is about twenty five to thirty percent (25-30%) of the length. In other embodiments the passage  118  may be cylindrical throughout or may have a flattened shape throughout, where the connector cross-section does not change, or may have some other shape suiting a particular need. 
     FIGS. 6A,  6 B, and  6 C show important relationships between the passages in the connector  66  and moveable block  70 , and the cut-off openings  83  and  85  in the cut-off plate  82 . The first passage  118  in connector  66  has its exit end  126  abutting the moveable block  70  held in place by block housing  68  (FIG.  3 ). The moveable block  70  has a second passage  132  and a third passage  134  which each have a cross section with a flattened shape throughout their length similar to the flattened shape  124  at exit end  126 . FIG. 7 shows a perspective view with hidden lines that shows the relationship of the passages when block  70  is in the first position of FIG.  6 A. In FIG. 7 the block oscillator  72 , bracket  86 , end plate  84 , and insulator plates  88  and  90  are omitted for clarity. In a first position of block  70  shown in FIG. 6A an entrance end  136  of second passage  132  is aligned with the exit end  126  of the first passage  118 , thereby permitting the flow of polymer  137  therebetween. At the same first position an exit end  138  of second passage  132  is aligned with the first cut-off opening  83  in plate  82 , thereby permitting the flow of polymer therebetween. At the same first position, an entrance end  140  of third passage  134  is blocked by surface  127  thereby interrupting the alignment of the third passage  134  with the first passage  118  and preventing the flow of polymer therebetween. At the same first position, an exit end  142  of third passage  134  is blocked by a surface  144  of plate  82  thereby interrupting the alignment of the third passage  134  with the second cut-off opening  85  and preventing the flow of polymer therebetween. 
     When it is desired to cut off a segment of polymer  137  that is flowing through passages  118  and  132  and first cut-off opening  83 , the actuator  92  of block oscillator  72  (FIGS. 3 and 4) is energized to move block  70  in the direction of arrow  146  as seen in FIG.  6 B. FIG. 6B shows an intermediate position of block  70  between the first position shown in FIG.  6 A and the second position shown in FIG.  6 C. This begins to cut off flow of polymer between passage  118  and passage  132  and between passage  132  and first cut-off opening  83 . At the same time, this permits flow of polymer between passage  118  and passage  134  and between passage  134  and second cut-off opening  85 . From a previous shifting of the block there is already polymer in the passage  134 , which remains molten due to heaters  104 ,  106 ,  108 , and  110  in block housing  68  (FIGS.  3  and  4 ). It is important that the continuous flow of polymer starts through contained passage  134  and containment exit  85  before the flow is stopped through contained passage  132  and containment exit  83 . 
     After further motion in direction of arrow  146 , as seen in FIG. 6C, block  70  has reached the second position. In the second position, flow of polymer between passage  118  and passage  132  has been stopped as the alignment between an entrance end  136  of passage  132  has been interrupted by surface  127  of connector  66 . The flow of polymer between passage  132  and first cut-off opening  83  has also stopped as alignment between exit end  138  and opening  83  has been interrupted by surface  144 . This forms a polymer segment  30 . At the same time full flow of polymer is established between passage  118  and passage  134  and between passage  134  and second cut-off opening  85 . 
     In this way continuous flow of polymer is maintained through one or both or the other of containment exit  83  and  85  to avoid stopping or “dead-heading” the polymer flow during the segmenting process that might create undesired polymer pressure increases. The use of a contained flow with at least two containment exits permits interrupting flow to one exit to form a discrete segment at that exit while continuing flow to another containment exit without “dead-heading” as might be the case with a single containment exit where the polymer flow is interrupted for segmenting. It is desirable when providing one polymer passage going to two or more passages that the flow of polymer always has a path to one, both or another of the passages so in case of a machine failure with the moveable block, there is always a path for the polymer to exit either under pressure or by gravity drain. 
     When it is desired to cut off polymer flow through passages  118  and  134  and second cut-off opening  85 , the actuator  92  of block oscillator  72  (FIGS. 3 and 4) is energized to move block  70  in the direction opposite arrow  146  (FIGS. 6C and 6B) to reverse the process and move block  70  from the second position of FIG. 6C to the first position of FIG.  6 A. Another segment  30  will be formed, this time at containment exit  85 , as the polymer flow is stopped through passage  134  and second cut-off opening  85 , and the polymer flow is restored to passage  132  and first cut-off opening  83 . 
     Keeping the polymer contained in passages  132  and  134  is important to keep pressure on the polymer before cutting so the segments are forcefully moved toward the inclined surface of the trough and away from the containment exit at cut-off openings  83  and  85 , versus relying solely on gravity to move the segments away from the segmenting device and toward the trough (as in the Japanese Patent JO 81 55957). It is important, however, that the passages are designed to drain under the influence of gravity so polymer does not remain in the device and can be easily removed when polymer flow is stopped during a process shutdown. 
     It is important that the passages  132  and  134  are close together at their entrance ends  136  and  140 , respectively. The entrance ends are separated by only a narrow flat surface  148 , best seen in FIG. 7, when the space  150  between passage centerlines is slightly more than one apparent passage width  152 . The apparent passage width is the width measured across an angled entrance end, such as angled entrance end  140 . The actual cross-section width of passages  132  and  134  would be slightly less than the apparent passage width. Preferably, the apparent passage width for passages  132  and  134  is equivalent to the passage width  128  of passage  118 . The space  150  determines the distance the block  70  must shift from aligning passage  132  with passage  118  to aligning passage  134  with passage  118 . This shift distance, equal to space  150 , is equal to one apparent passage width  152  plus the width of flat surface  148 . During high flow rates of polymer rapid oscillation of block  70  is required to form short segments of polymer. The shorter the shift distance, the more rapid the oscillation can be. 
     It is also important that the passages  132  and  134  are spaced apart at their exit ends  138  and  142 , respectively; they are separated by a centerline to centerline distance  154  of several passage widths, as best seen in FIG.  7 . This distance is important to keep the polymer segments spaced far enough apart so they do not rejoin when two segments are falling from the segmenting device as seen in FIG.  6 B. It also provides some spacing to separately handle the segments in the trough. A spacing distance  154  between the exit ends of passages  132  and  134  equal to two or more passage widths is a preferred minimum, and a spacing of about four or more passage widths is more preferred. A very large spacing would require a thicker block  70  or a larger diverging angle  155  (FIG. 6A) between passages, which would be less preferred. A diverging angle of thirty to seventy degrees (30° to 70°) is preferred; at a large angle, the apparent width of the passages increases, which increases the shift distance. The first and second cut-off openings  83  and  85 , respectively, are placed at a spacing of one to two width dimensions less than the second spacing  154  of the second and third passages  132  and  134 , respectively, where the passages abut the cut-off plate. This serves to space the polymer stream passing from the first cut-off opening apart from the polymer stream passing from the second cut-off opening by a distance of at least two width dimensions. 
     Although a flattened shape is illustrated and preferred for the cross-sectional shape of passages  132  and  134 , and the exit end of passage  118 , a cylindrical or oval shape, suggested by dashed lines  156  in connector  66  of FIG. 6A could also be used. Keeping the passage width the same would decrease the cross-section area of the passages compared to the flattened shape, which would decrease the polymer flow rate at the same polymer driving pressure. Alternatively, this may increase the shift distance compared to the flattened shape if the cross-section area of the cylindrical or oval passages remains the same as the flattened shape and the width of the shape increases, thereby increasing the shift distance. In this case the flow rate of the polymer may need to be decreased if the shift time has increased. Also, a cylindrical or oval shaped polymer segment may have slightly less surface area than a flattened one and would require slightly longer quench times which may require longer trough lengths. Other means of compensating for different shaped passages is possible. For the best shift time, polymer flow rate, and quench time, however, a flattened cross-section is preferred. Shaping the polymer into a flattened shape and separating the polymer into discrete segments exposes more surface area per segment to speed up solidification, and results in a finished material size that is easy to accumulate and cut up for recycle. 
     FIG. 8 shows an alternate embodiment  24   a  of the polymer segmenting device  24  with the block  70  shown in the first position with passage  132  aligned with passage  118 . In this embodiment the polymer cut-off is accomplished at the exit end  126  of connector  66  at surface  127 . The first opening  83   a  and second opening  85   a  in plate  82  no longer function to cut off polymer and are enlarged to avoid contact with the polymer at both the first and second positions of block  70 . After cut-off, and beginning of full flow of polymer  137  through passage  132  as shown, the polymer in block  70  has completely flowed out of passage  134 . An air bleed passage, such as passage  158 , permits air to flow into passage  134  as the polymer is flowing out to permit free flow of polymer out of passage  134  and avoid suction forces on the polymer. If desired a heated pressurized gas may be applied to the bleed passage to speed up the clearing of polymer from passage  134 . Alternatively, the polymer flow rate through passage  118  can be decreased to allow time to clear passage  134 . In this embodiment the exit ends  138  and  142  of passages  132  and  134 , respectively, represent the containment exits for segmenting device  24   a.    
     In referring to FIGS. 3 and 4, the block housing  68  is assembled so the cut-off plate  82  is rigidly attached to the side plates  78  and  80 . The block housing is then attached to the connector  66  to contain the moveable block  70  between the cut-off plate  82  and connector  66 . This containment is tight enough to prevent excessive polymer leakage along surfaces  127  and  144  (FIG.  6 A). An alternate arrangement is shown in FIGS. 7 and 9 where the cut-off plate  82  is resiliently attached to side plates  79  and  80  using spring elements  160 ,  162 ,  164 , and  166  (not seen in far corner of FIG.  7 ). The spring elements may be spring washers that are compressed by the heads of bolts  168 ,  170 ,  172  and  174  (not seen in far corner), respectively. Clearance  176  is provided between cut-off plate  82  and side plate  78 , and clearance  178  is provided between cut-off plate  82  and side plate  80 . This clearance arrangement allows the spring elements to force the surface  144  of cut-off plate  82  against the block  70  thereby forcing block  70  against surface  127  of connector  66 . This results in very low leakage of polymer along surfaces  127  and  144  that are tightly urged against block  70 . Cut-off plate  82  is also provided with shoulders  180  and  182  that bear against mating shoulders  184  and  186 , respectively, on block  70  to align block  70  between side plates  78  and  80  without contacting side plates  78  and  80 . This improves the ease of assembly and reduces the friction compared to a controlled tight fit of block  70  between the side plates  78  and  80 . 
     FIGS. 10A and 10B illustrate another arrangement of troughs to catch and transport the segments away from the segmenting device  24 . In this embodiment the segments  30   c  and  30   d  are oriented one behind the other relative to the direction of travel  36  along the trough. To avoid all possibility of contact of segment  30   c  with segment  30   d , each segment is dropped into a separate inclined trough, such as trough  188  for segment  30   a  and trough  190  for segment  30   b . Each of the troughs  188  and  190  are similar to trough  29   a  in FIGS. 2A and 2B and may include the moveable portion  45   a  as in FIG. 2A, but would exclude the separating panel  23 . In trough  188 , an end wall  192  is extended above the trough to form a wall that is tapered to be thicker at the bottom than the top, to thereby contain the slot and stream openings and associated fluid connections at the bottom. The wall also serves to separate the polymer segments soon after they leave segmenting device  24 . Trough  188  has two or more forceful streams, such as streams  194  and  196 , that act against the broad side of the segment  30   c  as it hits the trough. Trough  190  also has two or more forceful streams, such as streams  198  and  200 , that act against the broad side of the segment  30   d  as it hits the trough. Troughs  188  and  190  both empty into trough  202 , which is essentially the same as trough  29   b  in FIG.  2 A. The embodiment of FIGS. 10A and 10B may be preferred over the embodiment of FIGS. 2A and 2B for exceptionally high throughputs where the possibility of molten segments contacting each other is great. The multiple forceful streams that hit the broad side of the segments may provide better acceleration of the segments along the troughs so contact between two successive segments in a trough is avoided. 
     FIG. 10C illustrates another arrangement where segments  30   c  and  30   d  are oriented one behind the other relative to the direction of travel  36  along the trough. It is proposed that both segments are dropped in the same trough which could be identical to the troughs  29   a  and  29   b  in FIGS. 2A and 2B with the exception that the separating panel  23  is omitted. In this case the polymer throughput would have to be low enough that segment  30   d  would be accelerated out of the way before segment  30   c  landed in the trough. For certain applications, this would provide a simpler system than that of FIGS. 2A and 10A. 
     FIGS. 11A and 11B illustrate another embodiment of a segmenting device  24   b  which has four containment exits. Segmenting device  24   b  comprises a connector  66   a , a block housing  68   a , a moveable block  70   a  and a block rotater  72   a . In this embodiment, the walls of the housing  68   a  have four containment exits  188 ,  190 ,  192 , and  194  which act as cut-off openings (similar to the action of the cut-off openings  83 ,  85  in the plate  82 , e.g., FIGS.  6 A- 6 C). The moveable block  70   a  is rotated continuously in direction  196  by rotater  72   a  that comprises a motor  198  acting through a right angle gear box  200  to rotate block shaft  202 . The speed of the motor can be varied to provide means of controlling the segment size. Connector  66   a  has a first passage  216  with an exit end  217 . Block  70   a  has a vertical passage  204  having an inlet end  205  aligned with exit end  217 . Passage  204  intersects a downwardly inclined horizontal passage  206  having an outlet end  207  which is arranged to momentarily align with each of the containment exits  188 - 194  as it rotates in the direction  196 . Vertical passage  204  has an axis  209  that passes through the center of the inlet end  205  of passage  204 . Horizontal passage  206  has an axis  211  that passes through the center of the outlet end  207  of passage  206 . Axis  211  is angled away from axis  209  by an angle  213  of 45 degrees or less to direct the polymer laterally toward the containment exits, but still in the downward direction of vertical passage  206 . 
     Horizontal passage  206  at outlet end  207  has width  208  that is wide enough to span two adjacent containment exits during a portion of the rotation of the block  70   a . For instance, in FIG. 11B, the dotted and dashed lines  210  represents the horizontal passage  206  at a position intermediate containment exit  188  and  190 . In this position, width  208   a  spans width  215  between exit  188  and  190  so the polymer flowing through passage  206  is passing through exit  190  before it is blocked from passing through exit  188  as lock  70   a  rotates in direction  196 . In this way polymer is always passing through one, both, or another of containment exits  188 - 194  so the continuous flow of polymer is never “dead-headed”. Block  70   a  is shown with a conical shape  212  that mates in a conical recess  214  in housing  68   a . This ensures a tight fit that controls polymer leakage and avoids excessive friction that may otherwise bind up the rotation of block  70   a  in housing  68   a . The passage  216  in connector  66   a  and passages  204 ,  206  and containment exits  188 - 194  are all illustrated as generally cylindrical in shape, but other shapes could also be used. 
     A Housing  68   a  is provided with safety deflectors  218 ,  220 ,  222 , and  224  positioned adjacent containment exits  188 ,  190 ,  192 , and  194  respectively. The deflectors  218 - 224  are spaced from the containment exits  188 - 194  to permit free flow of polymer from the exits in the direction of the axis  211  of the passage  206 , but are provided to direct the polymer downward in the direction of the axis  209  of the passage  204  after it exits the housing  68   a  and toward a transporting device  28  as in FIG.  1 . The safety deflectors may not be needed for all but very high polymer flow rates. Although the segmenting device  24   b  is illustrated where the block  70   a  rotates continuously in direction  196  to segment the polymer, it is contemplated that block  70   a  could oscillate back and forth (i.e., rotatably reciprocate) between any two adjacent containment exits, such as exit  188  and  190 , and polymer segmentation would occur. In this case the other containment exits  192  and  194  would not be necessary and could be omitted from housing  68   a . It is also contemplated that the number of containment exits could be varied to include only three exits or more than the four exits shown. At least two exits would be required to avoid “dead-heading” the polymer stream during segmenting. The passages in device  24   b  are arranged to permit gravity draining of polymer from the device during process shutdown. 
     FIGS. 12A and 12B illustrate another embodiment of a segmenting device which has four containment exits. Segmenting device  24   c  comprises a connector  66   b , a block housing  68   b  comprising continuous vertical side plate  78   a  and cut-off plate  82   a , a moveable block  70   b  and a block mover  72   b . In this embodiment, the cut-off plate  82   a  of housing  68   b  has four containment exits  188   a ,  190   a ,  192   a , and  194   a  which also act as cut-off openings. The moveable block  70   b  is rotated continuously in direction  196   a  by mover  72   a  that comprises a motor  198   a  acting through a right angle gear box  200   a  to rotate block shaft  202   a . The speed of the motor can be varied to provide means of controlling the segment size. Connector  66   b  has a first passage  216   a  with an exit end  217   a . Block  70   b  has a vertical passage  204   a  that intersects a downwardly inclined horizontal passage  206   a  which is arranged to momentarily align with each of the containment exits  188   a - 194   a  as it rotates in the direction  196   a . Vertical passage  204   a  has an axis  209   a  that passes through the center of the inlet end  205   a  of passage  204   a . Horizontal passage  206   a  has an axis  211   a  that passes through the center of the outlet end  207   a  of passage  206   a . Axis  211   a  is angled away from axis  209   a  by an angle  213   a  of 45 degrees or less to direct the polymer laterally toward the containment exits, but still in the downward direction of vertical passage  206   a.    
     Horizontal passage  206   a  at outlet end  207   a  has a width  208   b  that is wide enough to span between two adjacent containment exits during rotation. For instance, in FIG. 11B, the horizontal passage  206   a  is shown at a position intermediate containment exit  188   a  and  190   a . In this position, width  208   b  spans width  215   a  between exit  188   a  and  190   a  so the polymer flowing through passage  206   a  is passing through exit  190   a  before it is blocked from passing through exit  188   a  as block  70   b  rotates in direction  196   a . In this way, polymer is always passing through one, both, or another of containment exits  188   a - 194   a  so the continuous flow of polymer is never “dead-headed”. Block  70   b  is shown with a conical shape  212   a  that mates in a conical recess  214   a  in housing  68   b . Block  70   b  is pressed into conical recess  214   a  by spring washers arranged around the cut-off plate  82   a , such as washers  226  and  228  held in place by bolt heads  230  and  232 , respectively. The cut-off plate  82   a  is urged by spring washers  226  and  228  toward the end of side plate  78   a  within the limits of space  234 . This ensures a tight fit that controls polymer leakage and avoids excessive friction that may otherwise bind up the rotation of block  70   b  in housing  68   b . The passage  216   a  in connector  66   b  and passage  204   a  are generally cylindrical in shape, and passage  206   a  and containment exits  188   a - 194   a  are flattened cylindrical shapes that are bent, but other shapes would work as well. 
     Although the segmenting device  24   c  is illustrated where the block  70   b  rotates continuously in direction  196   a  to segment the polymer, it is contemplated that block  70   b  could oscillate back and forth between any two adjacent containment exits, such as exit  188   a  and  190   a , and polymer segmentation would occur. In this case the other containment exits  192   a  and  194   a  would not be necessary and could be omitted from housing  68   b . It is also contemplated that the number of containment exits could be varied to include only three exits or more than the four exits shown. At least two exits would be required to avoid “dead-heading” the polymer stream during segmenting. The passages in device  24   c  are arranged to permit gravity draining of polymer from the device during process shutdown. 
     It should be understood that other features (e.g., heaters, insulators, thermocouples, seals, fasteners) common in the mechanical art or shown in the embodiments of FIGS. 3 and 4 have been omitted from FIGS. 11A,  11 B,  12 A and  12 B for clarity of illustration. 
     Test Results 
     Several tests were run using the device illustrated in FIGS. 3 and 4 processing nylon polymer. The flattened shape was about one inch (1″) (2.54 cm) thick and 3.5″ (8.9 cm) wide. Different polymer flow rates were tested and the segment sizes and oscillation times recorded. Polymer rates of from about twenty four hundred pounds per hour (2400 lbs./hr) (1090 Kg/hr) to twenty two thousand three hundred pounds per hour (22,300 lbs./hr) (10,100 Kg/hr) (estimated) were successfully run. Oscillation times were varied between 0.3 to 0.5 seconds by using a timer controlling a valve connected to an air cylinder actuator for the oscillator. Segment sizes varied from 0.34 lbs. (0.15 kg) to about 1.86 lbs. (0.84 kg). At low rates, segments were well defined, and at high rates segments sometimes balled up or were drawn out with stringy tails. At higher rates, some segments stuck together in the receiver, but were easily separated by hand after cooling.