1. Field of the Invention
The subject invention generally relates to a method of controlling a flow of molten thermoplastic using strand guide assemblies for guiding a plurality of strands of molten thermoplastic.
2. Description of the Related Art
Strand guides are known for guiding strands during various manufacturing processes. For example, one type of strand guide includes a rod defining grooves cut through a portion of the rod for guiding the strands through the grooves. Typically, the rod is formed of a material such as steel or nylon which wears away rapidly as the strands move through the grooves. The rod is formed of a unitary configuration such that the entire strand guide must be replaced when the wear becomes too great. Further, the grooves of the rod only accommodate strands defining a certain diameter. If the strands define a diameter larger than the grooves, the entire strand guide must be replaced with another strand guide capable of accommodating the strands defining the larger diameter.
Therefore, there remains an opportunity to develop an improved strand guide assembly.
The present invention provides for a method of controlling a flow of molten thermoplastic to form at least a first strand and a second strand moving from an extruder having a die plate to a finishing apparatus. A plurality of guide segments are formed of a ceramic material and abut each other on a support. Each of the guide segments have a first end, a second end, and a shaped step defined between the first and second ends. The guide segments are configured on the support to define a single-step configuration presenting one of the shaped steps and a dual-step configuration presenting an abutting pair of the shaped steps. The method comprises the steps of extruding the molten thermoplastic through the die plate to form the strands, routing the strands from the extruder to the finishing apparatus, and cooling the strands. The method further comprises the step of guiding the first strand across the one of the shaped steps when the guide segments are in the single-step configuration or guiding the first strand across the abutting pair of the shaped steps when the guide segments are in the dual-step configuration to separate the first strand from the second strand. The method also comprises the step of guiding the second strand across another one of the shaped steps when the guide segments are in the single-step configuration or guiding the second strand across another abutting pair of the shaped steps when the guide segments are in the dual-step configuration to separate the second strand from the first strand.
The present invention also provides for a strand guide assembly and a guiding system for guiding at least one of the strands extruded from the extruder to the finishing apparatus. The system includes the support and the guide segments abutting each other. Each of the guide segments are formed of the ceramic material and have the first end, the second end, and the shaped step defined between the first and second ends. The shaped step of each of the guide segments receives one of the strands for separating the strands.
The strand guide assembly of the present invention therefore provides for a more durable and more accommodating strand guide assembly as compared to the known strand guides as discussed in the background of the invention section. For example, the guide segments of the present invention are formed of the ceramic material which increases durability of the guide segments thus increasing the life of the strand guide assembly. As another example, the guide segments allow for easy replacement of any damaged guide segment without having to replace the entire strand guide assembly. As yet another example, the guide segments are reversible to define the single-step configuration presenting one of the shaped steps and the dual-step configuration presenting the abutting pair of the shaped steps thus accommodating different diameters of strands which provides for a more versatile strand guide assembly.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a guiding system 10 and a strand guide assembly 12 are generally shown. The strand guide assembly 12 is utilized in the guiding system 10. Therefore, the structure and function of the strand guide assembly 12 will be discussed before the guiding system 10.
Referring to
Also referring to
The first and second guide segments 22, 24 each have a first end 26 and a second end 28 spaced from each other along the longitudinal axis L. In addition, the first and second guide segments 22, 24 each have a step 30 defined between the first and second ends 26, 28 of each of the first and second guide segments 22, 24 for guiding the strand 14, 15. In certain embodiments, the step 30 of each of the first and second guide segments 22, 24 are further defined as an L-shaped step 30 defined between the first and second ends 26, 28 for guiding the strand 14, 15 across the L-shaped step 30. In other words, the strand 14, 15 is disposed in the L-shaped step 30.
Typically, the L-shaped step 30 of each of the first and second guide segments 22, 24 include a vertical portion 32 and a horizontal portion 34 abutting each other. The vertical portion 32 is disposed transverse to the longitudinal axis L and the horizontal portion 34 is disposed substantially parallel to the longitudinal axis L between the vertical portion 32 and the first end 26. As best shown in
Also referring to
The first and second ends 26, 28 of each of the first and second guide segments 22, 24 define a flat configuration. The flat configuration of one of the first and second ends 26, 28 of the first guide segment 22 abuts the flat configuration of the second end 28 of the second guide segment 24 such that each of the first and second guide segments 22, 24 define only a singular step 30 for guiding the strand 14, 15 of one of the first and second diameters D1, D2. In other words, the first guide segment 22 defines only one-single L-shaped step 30 and the second guide segment 24 defines only one-single L-shaped step 30.
In addition, the first and second guide segments 22, 24 each typically define an aperture 36 along the longitudinal axis L for mounting the first and second guide segments 22, 24 on the support 20. As best shown in
The first and second guide segments 22, 24 are separate individual parts which are identical in configuration to each other. Having individual guide segments 22, 24 allows for easy replaceability of damaged guide segments 22, 24 without having to replace the entire strand guide assembly 12. The damaged guide segments 22, 24 are simply replaced with new guide segments 22, 24 thus extending the life of the strand guide assembly 12.
Further, having individual first and second guide segments 22, 24 allows the strand guide assembly 12 to accommodate different diameter strands 14, 15 by reversing at least one of the first and second guide segments 22, 24. In other words, the first and second guide segments 22, 24 are reversible between a single-step configuration and a dual-step configuration as shown in
In one embodiment, as shown in
As briefly mentioned above, the present invention also discloses the guiding system 10 utilizing the strand guide assembly 12 as discussed above. The strand guide assembly 12 is further defined as a plurality of strand guide assemblies 12 for guiding the strands 14, 15 routed from the extruder 16 to the finishing apparatus 18 as discussed further below. The number of strand guide assemblies 12 utilized for guiding the strands 14, 15 routed from the extruder 16 to the finishing apparatus 18 can vary according to the manufacturing process. The strand guide assemblies 12 discussed below all have the same structure as the strand guide assembly 12 discussed above. The locations of the strand guide assemblies 12 within the guiding system 10 will be focused on below. In addition, the number of guide segments 22, 24 utilized for the strand guide assemblies 12 can vary depending on the number of strands 14, 15 being extruded from the extruder 16.
Referring to
Typically, the molten thermoplastic is formed into strands 14, 15 as either a filled product or an unfilled product. Strands 14, 15 formed as the filled product are more abrasive than strands 14, 15 formed as the unfilled product. The filled product includes a reinforcing material added to the molten thermoplastic for forming strands 14, 15 which are strengthened. The unfilled product lacks the reinforcing material and form strands 14, 15 which are un-strengthened. The guide segments 22, 24 are formed of the ceramic material which resists wear better than other materials as discussed above, thus reducing hang up of the strands 14, 15 on the guide segments 22, 24 as the strands 14, 15 are guided across the strand guide assemblies 12 in either the filled or unfilled product form. The reinforcing material is typically selected from the group of glass, minerals, and combinations thereof. In certain embodiments, the minerals can be further defined as amorphous silica, aluminum silicate, magnesium carbonate, kaolin, calcium carbonate, powdered quartz, mica, feldspar, clay, and combinations thereof. Typically, the mineral is further defined as calcium carbonate for strengthening the strands 14, 15. Additionally, the molten thermoplastic is typically further defined as molten nylon.
The raw material utilized to create the molten thermoplastic can be mixed prior to adding the raw materials into the extruder 16 and/or the raw materials can be added and mixed during any stage of the extrusion process. In addition, the reinforcing materials can be mixed prior to adding the reinforcing materials into the extruder 16 and/or the reinforcing materials can be added or mixed during any stage of the extrusion process. The molten thermoplastic within the extruder 16 has any suitable melt temperature. In certain embodiments, the molten thermoplastic within the extruder 16 typically has a melt temperature ranging between about 240 ° C. to about 290 ° C.
As shown in
Also referring to
As shown in
Referring back to
The supports 20 each define the longitudinal axis L and are coupled to the strand tree 52 with the guide segments 22, 24 disposed on the supports 20. The guide segments 22, 24 abut each other on the supports 20 along the longitudinal axis L to define a plurality of strand guide assemblies 12 for cooling the strands 14, 15. The strand guide assemblies 12 coupled to the strand tree 52 will be referred to as a plurality of second strand guide assemblies 54. Each of the guide segments 22, 24 of the second strand guide assemblies 54 are formed of the ceramic material and have the first end 26, the second end 28, and the shaped step 30 defined between the first and second ends 26, 28 as discussed above. The shaped step 30 of each of the guide segments 22, 24 of the second strand guide assemblies 54 are configured for receiving one of the strands 14, 15 to separate the strands 14, 15. Typically, the shaped step 30 of each of the guide segments 22, 24 of the second strand guide assemblies 54 are further defined as the L- shaped step 30 defined between the first and second ends 26, 28 for guiding the strands 14, 15 across the L-shaped step 30. The L-shaped step 30 ensures separation of the strands 14, 15 as well as proper cooling of the strands 14, 15.
As best shown in
Referring to
Referring to
Referring back to
Each of the guide segments 22, 24 of each of the first, second, and third strand guide assemblies 50, 54, 64 are identical in configuration as discussed above. Each of the guide segments 22, 24 of each of the first, second, and third strand guide assemblies 50, 54, 64 are reversible on respective supports 20 to define the single-step configuration presenting one of the shaped steps 30 for receiving the strands 14, 15 of the first diameter D1 or the dual-step configuration presenting the abutting pair of the shaped steps 30 for receiving the strands 14, 15 of the second diameter D2. More typically, the single-step configuration presents one of the L-shaped steps 30 for receiving the strands 14, 15 of the first diameter D1 and the dual-shaped configuration presents one of the L-shaped steps 30 abutting another one of the L-shaped steps 30 for receiving the strands 14, 15 of the second diameter D2. In other words, each of the guide segments 22, 24 of each of the first, second, and third strand guide assemblies 50, 54, 64 are reversible between the single-step configuration and the dual-step configuration to correspond with the strands 14, 15 of the first and second diameters D1, D2.
For example, if all of the strands 14, 15 extruded from the extruder 16 are of the first diameter D1, then all of the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64 will be in the single-step configuration. Therefore, when in the single-step configuration, there will be one strand 14, 15 per each L-shaped step 30 of the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64. As another example, if all of the strands 14, 15 extruded from the extruder 16 are of the second diameter D2, then all of the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64 will be in the dual- step configuration. Therefore, when in the dual-step configuration, there will be one strand 14, 15 per cooperating pair of L-shaped steps 30 of the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64. As yet another example, if the strands 14, 15 extruded from the extruder 16 have both the first and second diameters D1, D2, then the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64 will be in both the single-step and dual-step configurations to correspond with the first and second diameters D1, D2 of the strands 14, 15.
Referring to
When extruding the first batch of molten thermoplastic, the strands 14, 15 are routed from the extruder 16 to the finishing apparatus 18 by hand. As shown in
Once the three strands 14, 15 are routed into the finishing apparatus 18, the first strand guide assemblies 50 are secured to the container 48 and are at least partially submerged in the water with each of the strands 14, 15 disposed in the respective L-shaped step 30 of the guide segments 22, 24 for separating the strands 14, 15. The upper portion 62 of the blower 58 remains open while the rest of the strands 14, 15 are routed or guided under the first strand guide assemblies 50, through the water of the container 48, over the third strand guide assembly 64, through the blower 58, over the second strand guide assemblies 54 of the strand tree 52, and into the finishing apparatus 18. When all of the strands 14, 15 are routed to the finishing apparatus 18, the upper portion 62 of the blower 58 is rotated toward the lower portion 60 to close the blower 58. Once the strands 14, 15 are routed to the finishing apparatus 18, the finishing apparatus 18 will continuously pull the strands 14, 15 from the extruder 16 toward the finishing apparatus 18.
The present invention also discloses a method of controlling a flow of molten thermoplastic to form at least the first strand 14 and the second strand 15 moving from the extruder 16 having the die plate 46 to the finishing apparatus 18. Typically, the finishing apparatus 18 includes the pelletizer 66 and further comprising the step of cutting the strands 14, 15 with the pelletizer 66.
The method comprises the steps of extruding the molten thermoplastic through the die plate 46 to form the strands 14, 15 and routing the strands 14, 15 from the extruder 16 to the finishing apparatus 18. The method further comprises the step of guiding the first strand 14 across the one of the shaped steps 30 when the guide segments 22, 24 are in the single-step configuration or guiding the first strand 14 across the abutting pair of the shaped steps 30 when the guide segments 22, 24 are in the dual-step configuration to separate the first strand 14 from the second strand 15. The method also comprises the step of guiding the second strand 15 across another one of the shaped steps 30 when the guide segments 22, 24 are in the single-step configuration or guiding the second strand 15 across another abutting pair of the shaped steps 30 when the guide segments 22, 24 are in the dual-step configuration to separate the second strand 15 from the first strand 14.
In certain embodiments, the method further comprises the step of adding the reinforcing material to the molten thermoplastic, wherein the reinforcing material is selected from the group of glass, minerals, and combinations thereof. In addition, in certain embodiments, the molten thermoplastic is further defined as molten nylon and the step of extruding the molten thermoplastic is further defined as the step of extruding the molten nylon through the die plate 46 to form the strands 14, 15. Additionally, in certain embodiments, the method comprises the step of adding the reinforcing material to the molten nylon, wherein the reinforcing material is selected from the group of glass, minerals, and combinations thereof.
The method also comprises the step of cooling the strands 14, 15. Typically, the step of cooling the strands 14, 15 is further defined as the step of cooling the strands 14, 15 in water and the step of cooling the strands 14, 15 in air. More typically, the step of cooling the strands 14, 15 in air occurs before and after the step of cooling the strands 14, 15 in water.
In certain embodiments, the step of cooling the strands 14, 15 is further defined as the step of cooling the strands 14, 15 in the water of the container 48. In other words, the method further comprises the step of submerging the first strand guide assembly 50 at least partially in the water of the container 48 such that the strands 14, 15 are guided across the shaped step 30 of the guide segments 22, 24 under the first strand guide assembly 50 and through the water. Typically, the first strand guide assembly 50 is further defined as the plurality of first strand guide assemblies 50 spaced from each other and further comprising the step of submerging the first strand guide assemblies 50 at least partially in the water of the container 48 such that the strands 14, 15 are guided across the shaped step 30 of the guide segments 22, 24 under the first strand guide assemblies 50 and through the water. In one embodiment, the method further comprises the step of submerging one of the first strand guide assemblies 50 deeper in the water than another one of the first strand guide assemblies 50.
In one embodiment, the blower 58 is adjacent the container 48 to circulate air and the step of cooling the strands 14, 15 in the water of the container 48 occurs before the step of cooling the strands 14, 15 with the air of the blower 58. Typically, the method further comprises the steps of routing the strands 14, 15 through the blower 58 and circulating air about the strands 14, 15 as the strands 14, 15 move through the blower 58. In addition, the method further comprises the step of guiding the strands 14, 15 over the third strand guide assembly 64 before the step of routing the strands 14, 15 through the blower 58.
In certain embodiments, the step of cooling the strands 14, 15 is further defined as the step of cooling the strands 14, 15 guided through the strand tree 52 with air. The strand tree 52 is adjacent the blower 58 and the steps of cooling the strands 14, 15 in the water of the container 48 and cooling the strands 14, 15 in the air of the blower 58 occurs before the step of cooling the strands 14, 15 in the strand tree 52 with air. The second strand guide assemblies 54 are substantially parallel to each other in the row and the method further comprises the step of guiding the strands 14, 15 over the second strand guide assemblies 54 of the strand tree 52.
The method optionally further comprises the step of arranging the guide segments 22, 24 on the support 20 in the single-step configuration to correspond with the first diameter D1 of the strands 14, 15. The method also optionally further comprises the step of arranging the guide segments 22, 24 on the support 20 in the dual-step configuration to correspond with the second diameter D2 of the strands 14, 15. In other words, it has been contemplated that the method can further comprise the step of arranging the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64 to correspond with at least one of the first and second diameters D1, D2 of the strands 14, 15. In addition, the method optionally comprises the step of replacing at least one of the guide segments 22, 24 on the support 20, when damaged. In other words, it has been contemplated that the method can further comprise the step of replacing at least one of the guide segments 22, 24 of the first, second, and third strand guide assemblies 50, 54, 64 when damaged.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The foregoing invention has been described in accordance with the relevant legal standards; thus, the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment can become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.
This application claims the benefit of U.S. Provisional Patent Application Serial No. 61/295,831, filed on Jan. 18, 2010, the disclosure of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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61295831 | Jan 2010 | US |