رسالة دكتوراة بعنوان Characterization of a Co-Rotating Twin-Screw Compounding Extruder

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رسالة دكتوراة بعنوان

Characterization of Dispersive and Distributive Mixing In a Co-Rotating Twin-Screw Compounding Extruder
By John William Ess

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CHAPTER 1 INTRODUCTION 1
CHAPTER 2 LITERATURE REVIEW 6
2.1 TWIN-SCREW EXTRUSION, 6
2.1.1 Background, 6
2.1.1.1 Single-screw extrusion, 6
2.1.1.2 Twin-screw extrusion, 8
2.1.2 Different Formats, 10
2.1.3 Operating Characteristics, 11
2.1.3.1 Counter-rotating machines, 11
2.1.3.2 Co-rotating machines, 12
2.2 MIXING THEORY, 14
2.2.1 Single-Screw Machines, 14
2.2.2 Twin-Screw Machines, 16
2.2.2.1 Counter-rotating, 16
2.2.2.2 Co-rotating, 17
2.3 COMPOUNDING, 18
2.3.1 Definitions, 18
2.3.2 Equipment, 19
2.3.3 Applications, 21
2.3.4 Materials, 22
2.4 CHARACTERIZATION OF MIXING, 25
2.4.1 Representative Parameters, 25
2.4.1.1 Indirect
measurement, 25
2.4.1.2 Direct measurement, 25
2.4.2 Manual Methods, 26
2.4.3 Automated Methods, 27
CHAPTER 3 EXPERIMENTAL 28
3.1 TS40 TWIN-SCREW COMPOUNDING EXTRUDER, 28
3.1.1 Background, 28
3.1.2 Design, 29
3.1.3 Development, 30
3.2 DEVELOPMENT OF CHARACTERIZATION TECHNIQUES, 34
3.2.1 Sample Preparation, 36
3.2.1.1 Isolation
of the filler, 36
3.2.1.2 Thin film formation, 38
3.2.1.3 Polished solid surfaces, 41
3.2.2 Sample Examination, 42
3.2.2.1 Light microscopy, 42
3.2.2.2 Scanning electron microscopy, 42
3.2.2.3 Contact microradiography, 43
3.2.2.4 Acoustic microscopy, 44
3.2.3 Image Analysis, 45
3.2.3.1 Introduction, 45
3.2.3.2 Assumptions, 46
3.2.3.3 Data acquisition, 47
3.2.3.4 Data assimilation, 49
3.2.3.5 Statistical analysis, 50
3.2.3.6 Estimation of errors, 57
3.3 DISPERSIVE AND DISTRIBUTIVE MIXING, 60
3.3.1 Dispersive Mixing, 60
3.3.1.1 Characterization procedure, 60
3.3.1.2 Premixing conditions, 61
3.3.1.3 Material variables, 61
3.3.1.4 Processing variables, 67
3.3.2 Distributive Mixing, 65
3.3.2.1 Characterization procedure, 65
3.3.2.2 Pigment loading, 67
3.3.2.3 Processing variables, 67
3.4 MODEL EXPERIMENTS WITH PRECONDITIONED FILLER, 70
3.4.1 Preconditioning Pressure, 70
3.4.2 Calcium Carbonate Moisture Content, 70
3.4.3 Calcium Carbonate Characteristics, 71
3.4.4 Preconditioning Temperature, 71
CHAPTER 4 DISCUSSION 72
4.1 CHARACTERIZATION OF MIXING, 72
4.2 AGGLOMERATION, 84
4.2.1 Agglomerate Formation and Strength, 84
4.2.2 Influence
of Premixing on Filler
Agglomeration, 87
4.2.3 Effect of Solid 'Dry' Processing, 88
4.2.4 Filler Preconditioning Parameters, 89
4.3 MELTING AND WETTING, 92
4.4 DISPERSION, 96
4.4.1 Material and Processing Variables, 97
4.4.2 Preconditioning of Filler, 101
4.5 DISTRIBUTION, 103
4.5.1 Processing Variables, 104
4.5.2 Distributive Mixing Contribution of Discs, 106
4.5.3 Reorientation within the Twin-Screw
Extruder, 107
CHAPTER 5 CONCLUSIONS 108
SUGGESTIONS FOR FURTHER WORK
REFERENCES
APPENDIX A IMAGE ANALYZER COMPUTER PROGRAMS FOR
DISPERSIVE MIXING 123
A. 1 MEASUREMENT PROGRAM
A. 2 STATISTICS PROGRAM
APPENDIX B IMAGE ANALYZER COMPUTER PROGRAM FOR
DISTRIBUTIVE MIXING 131
APPENDIX C NOMENCLATURE 134

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