Patent Publication Number: US-2020282599-A1

Title: Screw designs for use when molding products that include sheer sensitive materials

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 62/813,338, filed Mar. 4, 2019, the entirety of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure pertains to devices and methods for manufacturing products. More particularly, the present disclosure pertains to screw designs for use when molding products that include sheer sensitive materials. 
     BACKGROUND 
     A wide variety of devices for molding products, as well as methods for molding products, have been developed. Of the known devices and methods, each has certain advantages and disadvantages. There is an ongoing need to provide alternative devices as well as alternative methods for molding products. 
     BRIEF SUMMARY 
     This disclosure provides design, material, manufacturing method, and use alternatives for devices for molding products. A system for molding products that include long fiber thermoplastic materials is disclosed. The system comprises: a barrel; a hopper in communication with the barrel; a screw disposed within the barrel, the screw being designed to rotate and reciprocate within the barrel; wherein the screw includes a metering section; and a plurality of dome members coupled to the screw and disposed along the metering section. 
     Alternatively or additionally to any of the embodiments above, the screw includes a root and a helical thread disposed about the root. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed between adjacent windings of the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed symmetrically relative to the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are positioned midway between adjacent windings of the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed asymmetrically relative to the helical thread. 
     Alternatively or additionally to any of the embodiments above, the helical thread includes a first winding and a second winding adjacent to the first winding, wherein the first winding includes a first edge facing downstream, wherein the second winding includes a second edge facing upstream, and wherein at least some of the plurality of dome members are disposed closer to the first edge than to the second edge. 
     Alternatively or additionally to any of the embodiments above, the root has a first root diameter at the metering section and a second root diameter at a feed region, the second root diameter being different than the first root diameter. 
     Alternatively or additionally to any of the embodiments above, the helical thread projects a first distance radially outward from the root, wherein at least some of the plurality of dome members project a second distance radially outward from the root, and wherein the first distance is greater than the second distance. 
     Alternatively or additionally to any of the embodiments above, the screw is free of helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a broken helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a discontinuous helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a broken thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a discontinuous thread. 
     Alternatively or additionally to any of the embodiments above, the screw is designed to translate within the barrel. 
     Alternatively or additionally to any of the embodiments above, the screw includes a feed section and a transition section. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed section. 
     Alternatively or additionally to any of the embodiments above, the feed section is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the transition section. 
     Alternatively or additionally to any of the embodiments above, the transition section is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed section and one or more additional dome members disposed along the transition section. 
     Alternatively or additionally to any of the embodiments above, the feed section is free of dome members and the transition section is free of dome members. 
     A system for molding products that include long fiber thermoplastic materials is disclosed. The system comprises: a barrel; a hopper in communication with the barrel; a screw disposed within the barrel, the screw being designed to rotate and translate within the barrel; wherein the screw includes a metering section; and a plurality of dome members coupled to the screw and disposed along the metering section. 
     Alternatively or additionally to any of the embodiments above, the screw includes a root and a helical thread disposed about the root. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed between adjacent windings of the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed symmetrically relative to the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are positioned midway between adjacent windings of the helical thread. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed asymmetrically relative to the helical thread. 
     Alternatively or additionally to any of the embodiments above, the helical thread includes a first winding and a second winding adjacent to the first winding, wherein the first winding includes a first edge facing downstream, wherein the second winding includes a second edge facing upstream, and wherein at least some of the plurality of dome members are disposed closer to the first edge than to the second edge. 
     Alternatively or additionally to any of the embodiments above, the root has a first root diameter at the metering section and a second root diameter at a feed region, the second root diameter being different than the first root diameter. 
     Alternatively or additionally to any of the embodiments above, the helical thread projects a first distance radially outward from the root, wherein at least some of the plurality of dome members project a second distance radially outward from the root, and wherein the first distance is greater than the second distance. 
     Alternatively or additionally to any of the embodiments above, the screw is free of helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a broken helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a discontinuous helical thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a broken thread. 
     Alternatively or additionally to any of the embodiments above, the screw includes a discontinuous thread. 
     Alternatively or additionally to any of the embodiments above, the screw is designed to reciprocate within the barrel. 
     Alternatively or additionally to any of the embodiments above, the screw includes a feed section and a transition section. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed section. 
     Alternatively or additionally to any of the embodiments above, the feed section is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the transition section. 
     Alternatively or additionally to any of the embodiments above, the transition section is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed section and one or more additional dome members disposed along the transition section. 
     Alternatively or additionally to any of the embodiments above, the feed section is free of dome members and the transition section is free of dome members. 
     A system for molding products that include long fiber thermoplastic materials is disclosed. The system comprises: a barrel; a hopper in communication with the barrel; a screw disposed within the barrel, the screw being designed to rotate and translate/reciprocate within the barrel; wherein the screw includes a metering section; and a plurality of dome members coupled to the screw and disposed along the metering section. 
     A system for molding products that include long fiber thermoplastic materials is disclosed. The system comprises: a barrel; a hopper in communication with the barrel; a screw disposed within the barrel, the screw including a screw root and a helical flight disposed about the screw root; wherein the screw is designed to rotate and reciprocate within the barrel; wherein the screw includes a feed zone, a transition zone, and a metering zone; and a plurality of dome members coupled to the screw and disposed along the metering zone. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are disposed between adjacent windings of the helical flight. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of dome members are positioned midway between adjacent windings of the helical flight. 
     Alternatively or additionally to any of the embodiments above, the helical flight includes a first winding and a second winding adjacent to the first winding, wherein the first winding includes a first edge facing downstream, wherein the second winding includes a second edge facing upstream, and wherein at least some of the plurality of dome members are disposed closer to the first edge than to the second edge. 
     Alternatively or additionally to any of the embodiments above, the screw root has a first root diameter at the metering zone and a second root diameter at the feed zone, the second root diameter being different than the first root diameter. 
     Alternatively or additionally to any of the embodiments above, the helical flight projects a first distance radially outward from the screw root, wherein at least some of the plurality of dome members project a second distance radially outward from the screw root, and wherein the first distance is greater than the second distance. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed zone. 
     Alternatively or additionally to any of the embodiments above, the feed zone is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the transition zone. 
     Alternatively or additionally to any of the embodiments above, the transition zone is free of dome members. 
     Alternatively or additionally to any of the embodiments above, further comprising one or more additional dome members disposed along the feed zone and one or more additional dome members disposed along the transition zone. 
     Alternatively or additionally to any of the embodiments above, the feed zone is free of dome members and the transition zone is free of dome members. 
     A system for molding products is disclosed. The system comprises: a barrel containing a resin and a plurality of fibers; wherein the resin includes a thermoplastic resin; wherein at least some of the plurality of fibers include fibers having a length of at least 6 millimeters; a screw disposed within the barrel, the screw including a screw root and a helical flight disposed about the screw root; wherein the screw is designed to rotate and reciprocate within the barrel; wherein the screw includes a feed zone, a transition zone, and a metering zone; and a plurality of dome members coupled to the screw and disposed along the metering zone. 
     Alternatively or additionally to any of the embodiments above, further comprising a die coupled to the barrel. 
     Alternatively or additionally to any of the embodiments above, further comprising a molding apparatus coupled to the die. 
     Alternatively or additionally to any of the embodiments above, wherein at least some of the plurality of fibers include fibers having a length of at least 7 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of at least 8 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of at least 9 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of at least 10 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of at least 11 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of at least 12 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of about 6-12 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of about 8-12 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of about 10-12 millimeters. 
     Alternatively or additionally to any of the embodiments above, at least some of the plurality of fibers include fibers having a length of about 8-10 millimeters. 
     Alternatively or additionally to any of the embodiments above, a molded product formed by any of the systems above is disclosed. 
     A molded product is disclosed. The molded product comprises: a thermoplastic resin; and a plurality of fibers having a length of at least 6 millimeters. 
     A molded product is disclosed. The molded product comprises: a thermoplastic resin; and a plurality of fibers having a length of at least 8 millimeters. 
     A molded product is disclosed. The molded product comprises: a thermoplastic resin; and a plurality of fibers having a length of at least 10 millimeters. 
     A molded product is disclosed. The molded product comprises: a thermoplastic resin; and a plurality of fibers having a length of at least 12 millimeters. 
     A system for molding products that include sheer sensitive materials is disclosed. The system comprises: a barrel; a hopper in communication with the barrel; a screw disposed within the barrel, the screw being designed to rotate and reciprocate within the barrel; wherein the screw includes a metering section; and a plurality of dome members coupled to the screw and disposed along the metering section. 
     The above summary of some embodiments is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The Figures, and Detailed Description, which follow, more particularly exemplify these embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure may be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, in which: 
         FIG. 1  is schematic overview of an example compression molding system. 
         FIG. 2  is schematic overview of an example injection molding system. 
         FIG. 3  is a schematic representation of a portion of an example system and depicts an example screw that can be used with a molding system. 
         FIG. 4  is a side view of a portion of an example screw and depicting dome members. 
         FIG. 5  is a side view of a portion an example screw with example dome members. 
         FIG. 6  is a side view of a portion an example screw with example dome members. 
         FIG. 7  is a side view of a portion an example screw with example dome members. 
         FIG. 8  depicts a single example dome member. 
     
    
    
     While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure. 
     DETAILED DESCRIPTION 
     For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in this specification. 
     All numeric values are herein assumed to be modified by the term “about”, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (e.g., having the same function or result). In many instances, the terms “about” may include numbers that are rounded to the nearest significant figure. 
     The recitation of numerical ranges by endpoints includes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). 
     As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     It is noted that references in the specification to “an embodiment”, “some embodiments”, “other embodiments”, etc., indicate that the embodiment described may include one or more particular features, structures, and/or characteristics. However, such recitations do not necessarily mean that all embodiments include the particular features, structures, and/or characteristics. Additionally, when particular features, structures, and/or characteristics are described in connection with one embodiment, it should be understood that such features, structures, and/or characteristics may also be used connection with other embodiments whether or not explicitly described unless clearly stated to the contrary. 
     The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the invention. 
       FIG. 1  schematically depicts a system  10  (e.g., a compression molding system) for forming products. The system  10  may include a melting and mixing apparatus  12 . The melting and mixing apparatus  12  may include a hopper  14 , a barrel  16 , and a blade  18 . In this example, a pre-form part  20  may be produced by the melting and mixing apparatus  12  and the pre-form part  20  may be further molded using a compression molding apparatus  22 . When doing so, the pre-form part  20  may be disposed within a mold cavity  24  of the compression molding apparatus  22  in order to form the finished part  26 . 
       FIG. 2  schematically depicts a system  10 ′ (e.g., an injection molding system) for forming products. The system  10 ′ may include a melting and mixing apparatus  12 . The melting and mixing apparatus  12  may include a hopper  14 , a barrel  16 , and a nozzle and/or die  19 . In this example, material passing through the melting and mixing apparatus  12  may pass through or otherwise be injected into an injection molding apparatus  23  (e.g., a molding cavity  24  of the injection molding apparatus  23 ) in order to form the finished part  26 . 
     In some instances, it may be desirable to provide a finished part, such as the finished part  26  formed by the systems  10 / 10 ′, with a structural reinforcement. For example, it may be desirable to reinforce molded parts with glass fibers and/or fiber reinforcements. In general, glass fibers having a longer fiber length provide greater structural reinforcement. Thus, when molding parts with fiber reinforcements, it may be desirable for the fibers to have a relatively long fiber length. In addition, fiber reinforcements and other materials may be described as being sheer sensitive. For the purposes of this disclosure, sheer sensitive materials may be understood to be materials that can break, sever, and/or otherwise be disrupted when exposed to sheer forces such as those sheer forces commonly present in a melting and mixing apparatus. It may be desirable to provide a finished part that includes sheer sensitive materials and, for example, to provide the finished part in which the sheer sensitive materials are less and/or minimally disrupted. 
     Molding parts with fibers reinforcements, along with suitable resin material(s), may include adding the fibers to the hopper  14  and/or barrel  16  of the melting and mixing apparatus  12 . When undergoing the melting and mixing process, sheer forces within the barrel  16  can break, sever, or otherwise reduce the fiber length of the fiber reinforcement. Disclosed herein are systems that are designed to all products to be formed/molded with fiber reinforcements with a relatively long fiber length. For example, the systems disclosed herein may be suitable for forming/molding products with fiber reinforcements in which the fibers have a length of at least 6 millimeters, have a length of at least 7 millimeters, have a length of at least 8 millimeters, have a length of at least 9 millimeters, have a length of at least 10 millimeters, have a length of at least 11 millimeters, have a length of at least 12 millimeters, have a length of 6-12 millimeters, have a length of 6-50 millimeters, have a length of 8-12 millimeters, have a length of 10-12 millimeters, have a length of 8-10 millimeters, or the like. In addition, the systems disclosed herein may be suitable for forming/molding products that include sheer sensitive materials (e.g., fiber material, glass fibers, long fiber thermoplastic materials, sheer sensitive resins, polyvinyl chloride, acetals, sheer sensitive additives, and/or the like) in a manner such that the sheer sensitive materials are less and/or minimally disrupted. 
     A portion of an example system  110  for forming/molding products with long fiber reinforcements (e.g., long fiber thermoplastic materials) and/or sheer sensitive materials is depicted in  FIG. 3 . The system  110  may be part of and/or otherwise take the form of an extrusion system, a molding system, a compression molding system (e.g., similar to the compression molding system  10 ), an injection molding system (e.g., similar to the compression molding system  10 ′), and/or the like. For example, the system  110  may include a hopper  114  and a barrel  116 . A screw  128  may be disposed within the barrel  116 . The screw  128  is generally designed to rotate within the barrel  116 . In addition, the screw  128  may also be designed to translate and/or reciprocate within the barrel  116 . The screw  128  may include a screw root  130  and a helical thread or flight  132 . The screw  128  may include a first region or zone A, a second region or zone B, and a third region or zone C. The first zone A may be understood to be a feed zone A, the second zone B may be understood to be a transition zone B, and the third zone C may be understood to be a metering zone C. These are just examples. 
     In some instances, the screw root  130  may have or define a root diameter. The root diameter may be constant along the length of the screw root  130 . In other instances, the root diameter may vary in diameter. For example, the screw root  130  may have a first root diameter along the feed zone A. The root diameter may increase in diameter along the transition zone B. The screw root  130  may have a second root diameter along the metering zone C. The second root diameter may be greater than the first root diameter. 
     The helical thread or flight  132  may also vary in form. In some instances, the thread  132  may extend helically about the screw root  130  in a regular manner and with a constant pitch. In other instances, the pitch may vary. In still other instances, the thread  132  need not be arranged as a helix and may include sections or regions that extend radially and/or axially, rather than helically. In some instances, the thread  132  may be continuous. In other words, the thread  132  may be a singular structure that extends continuously along the screw root  130 . In other instances, the thread  132  may be broken, interrupted, and/or otherwise discontinuous. In other words, the thread  132  may include a plurality of discrete sections or segments that are spaced apart from one another. 
     As shown in  FIG. 3  and in  FIG. 4 , a plurality of dome members  134  may be disposed along the screw  128 . In general, material (e.g., resin material) disposed in the barrel  116  and/or adjacent to the screw  128  can be melted and form a thoroughly mixed homogenous melt. As the material reaches the metering zone C, the melted resin materials may be mixed with sheer sensitive materials that are present in the barrel  116  along with the resin material. It may be desirable to mix the resin material with sheer sensitive materials (e.g., fiber material, glass fibers, long fiber thermoplastic materials, sheer sensitive resins, polyvinyl chloride, acetals, sheer sensitive additives, and/or the like) in a manner that helps to reduce/minimize disruption, breaking, severing, and/or the like of the sheer sensitive materials. The dome members  134  may be designed to help reduce sheer forces on the sheer sensitive materials and, thus, reduce/minimize disruption, breaking, severing, and/or the like of the sheer sensitive materials. For example, the dome members  134  may be useful when forming products with long fiber thermoplastic materials. When mixing the melted resin with long fiber thermoplastic materials, the dome members may help to gently stir and/or mix the melted resin with the long fiber thermoplastic materials so that the fiber length can be kept relatively long. Some examples of suitable long fiber thermoplastic materials may include those disclosed in U.S. Pat. Nos. 10,016,953, 10,195,818, and 10,086,571, then entire disclosures of which are herein incorporated by reference. Other sheer sensitive materials are contemplated including sheer sensitive resins, polyvinyl chloride, acetals, sheer sensitive additives, and/or the like. It may also be desirable to gently stir and/or mix the melted resin with these and other materials (e.g., additives, fire retardants, colorants, and/or the like). The dome members  134  may be suitable for gently stirring and/or mixing such materials. 
     The dome members  134  may take the form of rounded projections that extend radially from the screw root  130 . In at least some instances, the dome members  134  may have a rounded profile and/or resemble a rounded dome that could be described as being hemispherical. However, the dome members  134  need not have such a shape. For example, the dome members  134  may have a generally rounded or tapering shape. Alternatively, the dome members  134  may have an oval shape, a polygonal shape, or any other suitable shape. 
     The dome members  134  may be arranged in variety of manners. For example, in some instances, the dome members  134  may be disposed midway between adjacent windings of the helical thread  132 . In some instances, the dome members  134  maybe arranged closer to one winding of the helical thread  132  as shown in  FIG. 5 . For example, the helical thread  132  may include a first winding  132   a  having a downstream facing surface  136  and a second winding  132   b  having an upstream facing surface  138 . A line L passing through the center of the dome members  134  may be spaced a distance X 1  from the downstream facing surface  136 . The line L passing through the center of the dome members  134  may be spaced a distance X 2  from the upstream facing surface  138 . In some instances, distance X 1  is smaller than distance X 2 . This, however, is not intended to be limiting. For example,  FIG. 6  illustrates dome members  134 ′ that are equally spaced between the downstream facing surface  136  and the upstream facing surface  138 . In this example, distance X 1  is equal to distance X 2 . Furthermore,  FIG. 7  illustrates dome members  134 ″ that are arranged closer to the upstream facing surface  138  than the downstream facing surface  136 . In this example, distance X 1  is larger than distance X 2 . 
     In some instances, the thread  132  may project radially outward from the screw root  130  a first distance and the dome members  134  may project radially outward from the screw root  130  a second distances. In some instances, the first distance may equal the second distance. In other instances, first distance is greater than the second distance. In some instances, the thread  132  projects radially outward so that the thread is disposed adjacent to or contacts the inner surface of the barrel  116  and the dome members  134  may be spaced from the inner surface of the barrel  116 . Furthermore, systems are contemplated that include dome members  134  that project out differing distances. 
     In some instances, the dome members  134  are disposed along only the metering zone C. However, this is not intended to be limiting. In some instances, the dome members  134  may be disposed along the feed zone A, the transition zone, B, the metering zone C, and/or any combination thereof. For example,  FIG. 3  depicts an example dome member  134   a  in phantom line to illustrate that the feed zone A may include one or more dome members  134 / 134   a .  FIG. 3  also depicts an example dome member  134   b  in phantom line to illustrate that the transition zone B may include one or more dome members  134 / 134   b . In addition, any of the feed zone A, the transition zone, B, and/or the metering zone C may be free of dome members  134 . 
       FIG. 8  illustrates that the dome member  134  may be partially embedded within the screw root  130 . For example, a domed portion  134   a  of the dome member  134  may project radially outward from the screw root  130  and a base portion  134   b  of the dome member  134  may be embedded within the screw root  130 . A weld  140  may be disposed at the interface of the dome member  134  and the screw root  130 . 
     It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the disclosure. This may include, to the extent that it is appropriate, the use of any of the features of one example embodiment being used in other embodiments. The invention&#39;s scope is, of course, defined in the language in which the appended claims are expressed.