Patent GB-679177-A (GB)
Title: Improvements in or relating to the extrusion of filament-forming materials
Inventor: UPTON EDWARD JAMES
IPC: B29C48/475
Filed: 1948-10-01
Abstract: In a melt-spinning process, powdered or granular fusible filament-forming material is fed into a zone laterally bounded at least part-way round by moving surfaces which lie parallel to their direction of motion, and the material is compacted in the zone at a temperature below its melting point so as to form it into a coherent rod and to force it into frictional engagement with the surfaces, whereby the rod is advanced with the surfaces, the rod as it leaves the surfaces being received into a laterally confined space leading to an extrusion orifice, and the end of the rod being melted in the confined space so that the molten material is extruded through the orifice by the pressure of the advancing rod.  Alternatively a compacted rod resistant to longitudinal crushing and consisting of cohering granules of the material may be forced into a laterally confined space, melted therein, and the molten material extruded therefrom by longitudinal pressure transmitted through a laterally unsupported part of the rod.  An apparatus for carrying out the process may comprise two endless flexible members arranged to travel through a zone in which they present to each other opposed continuous surfaces each parallel with a common centre-line, means for rigidly supporting the members behind the parallel surfaces, means for feeding the material to be extruded into the space between the members and for compacting it into a rod between the parallel surfaces, means for driving the members so as to forward the compacted rod and a heated extrusion head to receive the compacted rod.  As shown, 11 and 12 (Figs. 1 and 2) are a pair of endless triple roller chains each driven by sprockets 13, 14, each pair being on a common shaft 15, 16 carried in bearings 17 on two parallel square vertical frame plates 18, 19.  The shaft 15 is driven by the gear 20 (Fig. 2), and the shafts 15, 16 synchronized by a train of gears of which one is 21.  The chains 11, 12 <PICT:0679177/IV (a)/1> <PICT:0679177/IV (a)/2> <PICT:0679177/IV (a)/3> <PICT:0679177/IV (a)/4> (Fig. 1), run downwards and converge slightly over the upper half 22 of their operative runs and are parallel with one another over the lower half 23.  Each chain is guided in its operative run by the edge 25 of a guide plate 26.  Along the working edge 25 of the guide plate 26, as shown in Figs. 3 and 4, extends a deep groove 28, wide enough to accommodate the middle line rollers of the chain and the adjoining flat links 30, and on each side of the groove 28 the edges of the guide plates at 31 are engaged by the rollers 32 of the two outer lines of the chain.  The working edges 25 are also cut away or chamfered at 33 where they adjoin the faces of the frame plates 18, 19 to accommodate the outer lines of links 34 of the chain. Carried by the middle line of rollers 29 of each chain 11, 12 is a series of pairs of blocks 40, 41, each of a width approximately equal to the length of the rollers 29. The blocks 40 on the outer side of the chain are rectangular in the section perpendicular to the rollers 29, except where they are cut away at 42 to fit to the surfaces of the pairs of rollers 29 between the two members of which they are carried.  The lengths of the blocks 40 are exactly equal to the pitch of the chain.  The inner blocks 41 are of less length and are, moreover, tapered towards their bases 43; these blocks are also shaped at 44 to fit to the surfaces of the rollers 29.  The tapering of the inner blocks 41 permits the chains 11, 12 to flex round the sprockets 13, 14.  Each outer block 40 is fastened to the corresponding inner block 41 by means of a screw 45 by means of which the blocks are nipped lightly against the rollers 29.  The bases 43 of the inner blocks bear against a phosphor bronze strip 46 in the bottom of the groove 28 formed in the edge 25 of the guide plate 26, so that the chains 11, 12 are supported by joint action of this strip and of the edge portions 31 of the guide plate 26 which support the outer rollers 32 of the chain.  Each chain 11, 12 is lightly tensioned by a pair of jockey rollers 47 (Fig. 1), carried between the frame plates 18 and 19, engaging the rollers 32 and urged upwards by springs 48.  On one side of each outer block 40 (Fig. 4), is secured a rectangular strip 49 of sheet steel of the same length as the block and projecting beyond its face such a distance that the outer edges 50 of the strips attached to the blocks on the two chains 11, 12 come into contact with one another when the chains are nearest to one another, and parallel, in the course of their operative run. Completely encircling each chain 11, 12 is a continuous steel band 51 covering the faces of the outer blocks 40 over the whole of the operative run of the chain, and held in contact therewith by jockey pulleys 52 (Fig. 1), carried between frame plates 18, 19 and urged upwards by springs 53.  The bands 51 are punched to form small protrusions 54 on the faces of the bands.  One edge 55 (Fig. 3), of each band makes contact with the faces of the successive strips of steel 49 secured to the outer blocks 40.  Secured to each frame plate 18, 19 by screws 56 (Fig. 2), and extending down the middle line thereof is a polished steel cheek plate 57, 58 (Figs. 2 and 3), the cheek plate 57 on the frame plate 18 bearing against the back of the strips 49 secured to the outer blocks 40, while the other cheek plate 58 bears against the blocks 40 themselves on the other side, both plates 57, 58 being of such profile as to clear the links of the chains 11, 12.  The second cheek plate 58 forms the fourth and stationary side of the passage 59 of rectangular section, of which the opposite side is constituted by the strips 49 secured to the other sides of the outer blocks 40, while the adjoining sides are constituted by the continuous bands 51 covering the faces of the blocks 40.  The second cheek plate 58 is formed with an oblique channel 60 entering the rectangular section passage 59 just below the point where the continuous bands 51 enter their parallel run, the channel extending through the adjoining frame plate 19 and communicating with a hopper 61 for the supply of powdered or granular material.  The strips 49 may be omitted, the cheek plate 57 then, like the cheek plate 58, forming a stationary wall of the passage 59. Secured to the top of the frame plates 18, 19 is a pneumatic vibrator 64 (Figs. 1 and 2), e.g. of the kind used for the agitation of mould boxes in foundry work, supplied with compressed air by a pipe 65. Depending from the vibrator is a vertical rod 66 of a rectangular section substantially equal to that of the passage 59, the end 67 of which rod enters the passage 59 between the parallel portions 23 of the bands 51.  At the middle of its vertical stroke the end of the rod is just above the middle of the mouth 68 (Fig. 2) of the channel 60 for the supply of material.  The end 67 of the rod 66 is cut at an angle of about 10 degrees to the horizontal, the lowest portion being adjacent to the cheek plate 57.  Secured to the lower edges of the frame plates 18, 19 is a guide member 69 presenting a passage 70 (Fig. 1), of rectangular cross-section substantially equal to that of the passage 59 between the bands 51.  The guide member 69 is shaped at 71 to accommodate the bands 61 as they pass round the quadrants 36 of the guide plates 26, 27, so that the mouth of the passage 70 can be brought quite close to the point where the continuous bands 51 begin to diverge, though leaving a clearance which is bridged by the laterally unsupported rod of material formed in the passage 59.  To the bottom of the guide member is fixed an extrusion head 74 comprising a cylindrical boiler 75 having electrical windings 76 round its lower part and side walls lagged at 77.  The boiler contains a stable high boiling liquid 78 (such as diphenyl, diphenyl oxide, or an azeotropic mixture of these) and its vapour 79.  Through the axis of the boiler extends a rectangular passage 80 forming a continuation of the rectangular passage 70 in the guide member 69. Within the boiler, however, one of the sides 81 of the lower part of the passage 80 slopes towards the opposite side so that the section of the passage diminishes towards the end.  The converging portion of the passage 80 constitutes a melt chamber, communicating with a filter 82 and a spinning jet 83 of conventional type located in a recess in the bottom of the boiler.  An illustrated embodiment of the parts 82 and 83 and associated parts is described in detail.  The boiler 75 is fitted with a pressure gauge 99 and a thermometer well 100. Associated with the pressure gauge 99 are conventional control means (not shown) for controlling the current supply to the heater 76 and thereby keeping substantially constant the pressure and temperature in the boiler.  In the operation of the apparatus the powdered or granular material is fed to the hopper 61 and is tamped into a compacted rod of rectangular cross-section in the passage 59 between the endless bands 51.  The compacted rod is carried downwards by the bands 51 and forced into the mouth of the rectangular passage 70 in the guide member 69, the friction between the rod and the bands 51 (augmented by the protrusions 54) being sufficient to force the rod into the melt chamber, where it is fused as it comes into contact with the converging wall of the latter.  The pressure of the incoming rod forces the fused material through the filter 82 and the spinning jet 83 in the form of filaments.  The method of starting up the apparatus is described.  Instead of feeding the powdered material to the hopper 61, it may be fed directly into the converging space at 22 between the bands 51, the bands themselves, together with the cheek plates 57, 58 constituting a feeding hopper.  With this method of feeding the apparatus the tip of the tamping rod 66 is shortened so that, at the top of