阅读说明：本技术 造团粒气体引导件 (Pellet-producing gas guide ) 是由 C·谢弗 T·奥斯瓦尔德 于 2018-06-25 设计创作，主要内容包括：如可与本文的一个或多个实施例一致地实施的,使用下游气体导管内的层流气流形成聚合物团粒。气体通道将气体引导到聚合物挤出心轴的出口,聚合物熔体经由该出口被挤出。下游气体导管远离聚合物挤出心轴的出口延伸,并且沿着从挤出心轴延伸的聚合物熔体并在下游气体导管内提供层流气流。使用这种方法,可以沿聚合物熔体的初始部分保持层流,并用于控制随后从其形成的团粒。(As may be practiced consistent with one or more embodiments herein, polymer pellets are formed using a laminar gas flow within a downstream gas conduit. The gas channel directs the gas to an outlet of the polymer extrusion mandrel through which the polymer melt is extruded. A downstream gas conduit extends away from the outlet of the polymer extrusion mandrel and provides a laminar gas flow along the polymer melt extending from the extrusion mandrel and within the downstream gas conduit. Using this method, laminar flow can be maintained along an initial portion of the polymer melt and used to control pellets subsequently formed therefrom.)

1. An apparatus, comprising:

a polymer extruder constructed and arranged to extrude a polymer material through an extrusion nozzle; and

a gas nozzle coupled to the polymer extruder and having a gas passage, a downstream gas conduit, and a gas outlet offset from the extrusion nozzle, the downstream gas conduit extending from an outlet of the extrusion nozzle to the gas outlet,

wherein the gas nozzle is constructed and arranged to provide laminar flow with the polymer extruder within the downstream gas conduit along the polymer melt extending from the extrusion nozzle.

2. The apparatus of claim 1, wherein the gas nozzle comprises a sidewall extending along the downstream gas conduit in a direction parallel to a direction through which the polymer material is extruded by the polymer extruder, the sidewall being constructed and arranged to direct gas from the gas channel in a direction parallel to a flow direction of the polymer melt extending from the extrusion nozzle.

3. The apparatus of claim 2, wherein the gas nozzle is constructed and arranged with the polymer extruder and with the length of the sidewall to impart a drag force to the polymer melt by using laminar flow within the downstream gas conduit to induce a non-uniform thickness along the polymer melt extending away from the extrusion nozzle and within the downstream gas conduit.

4. The apparatus of claim 3, wherein the downstream gas conduit extends from an outlet of the extrusion nozzle to the gas outlet and is constructed and arranged to mitigate formation of an open jet of the polymer melt within the downstream gas conduit and before the polymer melt exits the gas outlet.

5. The apparatus of claim 4, wherein the gas nozzle is constructed and arranged to rupture the polymer melt along the relatively thin portion of the non-uniform thickness by promoting turbulent gas flow along a portion of the polymer melt extending out of the downstream gas conduit and away from the gas outlet, with the polymer extruder.

6. The apparatus of claim 1, wherein the downstream gas conduit is constructed and arranged to have a length extending from the outlet of the extrusion nozzle sufficient to maintain laminar flow along the polymer melt extending within the downstream gas conduit and to cause periodic necking along the polymer melt within the downstream gas conduit.

7. The apparatus of claim 1, wherein the gas nozzle is constructed and arranged with the polymer extruder to form discrete droplets from the polymer melt by:

necking the polymer melt within the downstream gas conduit by applying a drag force to the polymer melt using a laminar flow along the polymer melt, and

the polymer melt is fractured along the portion thereof that has been extruded beyond the necking of the gas nozzle outlet.

8. The apparatus of claim 7, wherein the downstream gas conduit is constructed and arranged to have a length extending from the outlet of the extrusion nozzle to the gas outlet sufficient to cause periodic necking along the polymer melt within the downstream gas conduit by introducing a Rayleigh disturbance along the polymer melt extending within the downstream gas conduit.

9. The apparatus of claim 7, wherein breaking the polymer melt comprises breaking the polymer melt to form the discrete droplets having a volume that is at least half of a volume of the polymer melt extending from the nozzle when the polymer melt breaks.

10. The apparatus of claim 1, wherein the downstream gas conduit extends in a direction parallel to a direction through which the polymer melt is extruded and has a diameter relative to the polymer melt and relative to a gas flow provided through the gas channel that applies a pressure to the polymer melt sufficient to produce rayleigh interference in the polymer melt.

11. An apparatus, comprising:

a gas passage and an outlet arranged to direct gas to a polymer extrusion mandrel; and

a downstream gas conduit extending away from the outlet of the polymer extrusion mandrel and constructed and arranged to provide a laminar gas flow along a polymer melt extending from the extrusion mandrel and within the downstream gas conduit.

12. The apparatus of claim 11, wherein the downstream gas conduit has a sidewall extending in a direction parallel to a direction through which the polymer melt is extruded from the polymer extrusion mandrel, the sidewall being constructed and arranged to direct laminar gas from the gas channel in a direction parallel to a flow direction of the polymer extending from the extrusion mandrel.

13. A method, comprising:

providing an extrusion nozzle; and is

Coupling a gas nozzle having a gas channel, a downstream gas conduit, and a gas outlet to the extrusion nozzle, the gas outlet offset from the extrusion nozzle, the downstream gas conduit extending away from the outlet of the extrusion nozzle to a gas outlet;

extruding a polymer melt through the extrusion nozzle; and is

While extruding the polymer melt, using the gas channel and the downstream gas conduit to provide a laminar gas flow within the downstream gas conduit and along the polymer melt extending from the extrusion nozzle.

14. The method of claim 13, wherein the gas nozzle includes a sidewall extending along the downstream gas conduit in a direction parallel to a direction through which the polymer melt is extruded by the polymer extruder, further comprising directing a laminar gas flow from the gas channel using the sidewall in a direction parallel to a flow direction of the polymer melt extending from the extrusion nozzle.

15. The method of claim 14, wherein using the sidewall to direct the laminar flow comprises: the laminar flow gas is used to create a non-uniform thickness in the polymer melt extending away from the extrusion nozzle and within the downstream gas conduit by applying a drag force to the polymer melt within the downstream gas conduit.

16. The method of claim 14, wherein using the sidewall to direct the laminar flow gas comprises mitigating formation of an open jet along the polymer melt within the downstream gas conduit.

17. The method of claim 13, further comprising:

using the laminar flow to produce a non-uniform thickness in the polymer melt within the downstream gas conduit, an

Rupturing the polymer melt along a relatively thin portion extending beyond the non-uniform thickness of the downstream gas conduit.

18. The method of claim 13, wherein coupling the gas nozzle comprises controlling a size and an aspect ratio of pellets formed from the polymer melt by providing the downstream gas conduit with a conduit width and a length extending away from the outlet of the extrusion nozzle sufficient to maintain laminar flow along the polymer melt extending within the downstream gas conduit and to cause periodic necking along the polymer melt within the downstream gas conduit.

19. The method of claim 13, further comprising forming discrete droplets from the polymer melt by:

necking the polymer melt within the downstream gas conduit by applying a drag force to the polymer melt using a laminar flow along the polymer melt, and

the polymer melt is caused to rupture along the portion thereof that has been extruded beyond the constriction of the gas outlet.

20. The method of claim 13, wherein extruding the polymer melt through the extrusion nozzle comprises: extruding the polymer melt at a rate that is an order of magnitude less than a threshold rate at which the polymer melt will exhibit melt fracture caused by the extrusion.

Technical Field

Aspects of the present disclosure generally relate to pelletizing, and more particularly to producing polymer pellets using gas conduits.

Background

The polymer-based particles can be used in a variety of applications. In particular, in the field of polymer processing, there is an increasing demand for powders and micro-aggregates (e.g., having a cross-section of less than 2mm, 50 microns, or less). For example, polymer micro-granules or powders having controlled size, geometry, size distribution and morphology can be used for the manufacture and performance of parts using micro-injection molding processes, sintering processes and other processes.

Despite the ever-increasing demand for various micro-aggregates, controlling the properties of the micro-aggregates in terms of their size and shape at a desirable cost has been challenging. The previous methods are costly to implement and the resulting products are not sufficient to meet certain requirements. These and other problems are challenging to manufacture and implement for various types of micro-granules.

Disclosure of Invention

Various aspects of the present disclosure relate to forming polymer-based pellets.

In accordance with one or more embodiments, an apparatus and/or method involves a gas channel that directs a gas to an outlet of a polymer extrusion mandrel, and a downstream gas conduit extending away from the outlet of the polymer extrusion mandrel. The downstream gas conduit provides a laminar gas flow along the polymer melt extending from the extrusion nozzle and within the downstream gas conduit. In various embodiments, the downstream gas conduit has a sidewall that extends in a direction parallel to a direction through which the polymer melt is extruded from the polymer extrusion mandrel. The side wall directs laminar gas from the gas channel in a direction parallel to the flow of polymer melt extending from the extrusion nozzle.

According to another embodiment, an apparatus includes a polymer extruder to extrude a polymer material through an extrusion nozzle and a gas nozzle coupled to the polymer extruder. The gas nozzle has a gas passage, a downstream gas conduit, and a gas outlet offset from the extrusion nozzle. A downstream gas conduit extends from an outlet of the extrusion nozzle to a gas outlet, the gas nozzle providing laminar flow within the downstream gas conduit along the polymer melt extending from the extrusion nozzle.

One or more embodiments based on the method are directed to the following. A gas nozzle having a gas passage, a downstream gas conduit, and a gas outlet is coupled to the extrusion nozzle, the gas outlet being offset from the extrusion nozzle, and the downstream gas conduit extending away from the outlet of the extrusion nozzle to the gas outlet. The polymer melt is extruded through the extrusion nozzle while using the gas channel and the downstream gas conduit to provide a laminar gas flow within the downstream gas conduit and along the polymer melt extending from the extrusion nozzle.

The above summary is not intended to describe each embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify various embodiments.

Drawings

Aspects of the present disclosure may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:

FIG. 1 shows a cross-sectional view of an apparatus including an extruder nozzle and a gas nozzle in accordance with one or more embodiments;

FIG. 2 illustrates a cross-sectional view of another apparatus including an extruder nozzle and a gas nozzle in accordance with one or more embodiments;

FIG. 3 illustrates a cross-sectional view of another apparatus including an extruder nozzle and a gas nozzle in accordance with one or more embodiments;

FIG. 4 illustrates a micro-pellet creating device as can be implemented in accordance with one or more embodiments;

FIG. 5 illustrates a cumulative granularity profile as may be implemented in accordance with one or more embodiments;

FIG. 6 illustrates a diagram of aspect ratio as may be implemented in accordance with one or more embodiments;

FIG. 7 illustrates a graph of granularity as may be implemented in accordance with one or more embodiments;

FIG. 8 illustrates a graph of particle aspect ratio as can be implemented in accordance with one or more embodiments;

FIG. 9 shows cumulative particle size distributions for three different downstream gas conduit configurations and lengths; and

fig. 10 shows the cumulative aspect ratio of three different downstream gas conduit configurations and lengths.

While various embodiments of the present disclosure are amenable to modification 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 disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure, including aspects defined by the claims.

Detailed Description

Various aspects of the present disclosure relate to methods and apparatus for forming polymer-based pellets using downstream gas conduits. While the present disclosure is not necessarily so limited, various aspects may be appreciated through a discussion of examples using this context.

In connection with various exemplary embodiments, the nozzle-type component is configured for implementation with an extruder to provide a downstream gas conduit for an extruded polymer melt. A downstream gas conduit extends from the extruder providing a region where gas can flow along a portion of the extruded polymer melt. In connection with one or more aspects herein, it has been recognized/discovered that the size of the gas conduit can be configured/controlled to facilitate the application of a gas flow to the polymer melt to suit a particular application, such as by providing laminar flow and pressure that assist in the formation of pellets of a particular morphology. Thus, by varying the size of the downstream gas conduit, the particle size and shape can be controlled.

In connection with one or more embodiments, it has further been discovered that by utilizing a downstream gas conduit extending a sufficient distance from an extruder nozzle, laminar flow can be maintained along the polymer melt to such a distance and used to create non-uniform thickness in the polymer melt. This uneven thickness leads to surface instabilities/undulations on the extruded polymer melt, which may also be referred to as Rayleigh disturbances (Rayleigh disturbances). In this way, the onset of turbulent/open jet conditions can be delayed relative to the point at which the polymer melt exits the extruder nozzle. Delaying the onset of turbulent flow/open jet using a downstream gas conduit may promote the development of rayleigh interference, which is beneficial for controlling pellet formation and fragmentation of extruded polymer strands (strand). The size of the nozzle can be used to adjust the pressure applied to the polymer melt, and the length can also be used to set the layer flow rate along the polymer melt. The size and shape of the pellets can be controlled in this respect. For general information on polymer extrusion, and for specific information on the manner in which rayleigh interference can be formed and used, reference may be made to U.S. patent publication No. 2013/0234350 entitled "Method and Apparatus for micro-agglomeration", the entire disclosure of which is incorporated herein by reference.

In various contexts, a sufficient distance/length of a downstream gas conduit is a length that causes laminar flow to occur along the polymer melt such that the aforementioned non-uniform thickness is created within the conduit prior to exposure of the polymer melt to turbulent gas flow. An insufficient distance/length of the downstream gas conduit is a length at which a non-uniform thickness cannot form as the polymer melt exits the conduit before the polymer melt is exposed to turbulent air.

In a more specific embodiment, the micro-pellet die with the extrusion nozzle has a zero setback (setback) configuration with an additional 3mm long downstream gas conduit at the exit of the extrusion nozzle, and the exit of the gas nozzle extending through the downstream gas conduit. The downstream air conduit directs the air flow parallel to the extruded polymer strands extending from the extrusion nozzle, promoting laminar flow in the region where the polymer and air meet, and delaying the formation of an open jet. This promotes pressure oscillations on the surface of the polymer strands, which serve to generate rayleigh interference, which causes the polymer strands to narrow at periodic locations. The use of downstream gas conduits helps control the micro-agglomeration process; by adjusting their length and size, the pellet size and aspect ratio can be controlled. For example, particle size and particle aspect ratio may be reduced by increasing the length of the downstream gas conduit.

Various methods are used to control the location of melt fracture and corresponding droplet size to suit various embodiments. For example, one or more of the gas conduit diameter, length, gas velocity, gas temperature, polymer melt temperature (or the associated temperature of the die through which the polymer melt is extruded), and polymer melt extrusion rate may be controlled to set the size and shape of the pellets and to control the location of melt fracture. For example, melt strength and viscosity may be used to determine the size of the particles after fracture, and the molecular structure of the polymer material may be used to influence the occurrence of fracture. By increasing the viscosity of the melt, the diameter of the resulting pellets can be increased. The downstream gas conduit may be used to flow a gas that applies a drag force to the polymer melt and induces a bias stress and/or strain hardening therein at the portion of reduced thickness that is ultimately achieved by the melt fracture.

Various types of polymer-based materials are used to suit the various embodiments. For example, various embodiments relate to extruding a polymer resin comprising a blend of different polymers. Further, as described herein, the type of polymer and its properties relative to extrusion, such as brittleness and surface tension, may be selected to promote melt fracture. For a general discussion of polymer prills, and for specific methods and experimental types that may be used according to one or more embodiments described herein, reference may be made to Aquite et al, "micro-prill notes on polymer resins", ANTEC (2012), and references cited therein, the entire contents of which are incorporated herein by reference.

More specific embodiments relate to methods and/or apparatuses for forming polymer pellets as follows. According to another embodiment, an apparatus includes and/or is used with a polymer extruder that extrudes a polymer material through an extrusion nozzle. The apparatus includes a gas nozzle coupleable to a polymer extruder and includes a gas channel and a downstream gas conduit extending away from the extrusion nozzle. The gas channel and the downstream gas conduit provide a laminar gas flow within the downstream gas conduit and along the polymer melt extending from the extrusion nozzle. In various embodiments, the gas nozzle has a sidewall extending along the downstream gas conduit parallel to the direction through which the polymer extruder extrudes the polymeric material. The side wall serves to direct gas from the gas channel in a direction parallel to the polymer melt stream extending from the extrusion nozzle. Thus, this laminar flow can be used to mitigate the occurrence of open jets around the extruded polymer melt, promote rayleigh interference (via drag forces), and control necking of the extruded polymer melt therein, thereby promoting production of discrete pellets having controlled morphology and other characteristics.

In connection with this method, it has been recognized/discovered that positioning the downstream gas conduit relative to the extrusion nozzle can achieve these aspects with respect to laminar flow, delayed opening spray characteristics, and pellet formation. Once the necked polymer melt exits the downstream gas conduit, the pellets can be separated at their necked portions using turbulent flow (e.g., via fracturing). Thus, the length of the downstream gas conduit can be set to a sufficient value that maintains laminar flow (and, for example, the generation of the desired pressure/rayleigh interference) along the polymer melt extending within the downstream gas conduit and causes periodic necking along the polymer melt within the downstream gas conduit.

One or more method-based embodiments may be implemented using the described components and/or other components in accordance with the above discussion. A gas nozzle having a gas passage and a downstream gas conduit is used to direct laminar gas flow within the downstream gas conduit and along the polymer melt extruded therefrom. The sidewall of the downstream gas conduit can be used to direct a laminar flow of gas that can be used to mitigate the formation of open jets via sufficient length and offset of the sidewall, and, for example, to impart rayleigh interference to the polymer melt that causes periodic necking therein. Discrete droplets may be formed from the polymer melt by breaking the polymer melt along the necked portion that has been extruded beyond the downstream gas conduit. By using laminar flow, the extrusion rate can be performed at a rate that is an order of magnitude less than the threshold rate at which the polymer melt will exhibit melt fracture caused by extrusion.

Turning now to the drawings, fig. 1 is a cross-sectional view of an apparatus 100 including an extruder nozzle 101 and a gas nozzle 110 according to an exemplary embodiment. An extruder nozzle 101 (e.g., a mandrel) extrudes a polymer melt 102 through an opening at 103. A gas nozzle 110 extends around the extruder and provides a flow of gas along a passageway 112 around the extruder nozzle. The gas nozzle 110 includes a downstream gas conduit 111 extending from the opening 103 to an outlet by a length "L" as shown, with a sidewall 113 of the conduit extending in a direction parallel to the extruded polymer melt. The extruder nozzle 101 is recessed within the gas nozzle 110 and the polymer melt exits the extruder at a location offset from the sidewall 113. As shown, the gas nozzle diameter "D" can be set to accommodate the characteristics of the pellets formed from the polymer melt. The downstream gas conduit 111 promotes laminar flow along the polymer melt extending from the extruder nozzle 101 and causes periodic narrowing of the melt therein to form pellets.

Fig. 2 and 3 illustrate similar apparatus, as may be implemented in accordance with various embodiments, where the location of the extruder nozzle relative to the gas nozzle is different, and similar components are similarly labeled. Thus, fig. 2 shows a cross-sectional view of an apparatus 200 comprising an extruder nozzle 201 and a gas nozzle 210, wherein a polymer melt 202 is extruded through an opening at 203. The gas flows along the channel 212 and the downstream gas conduit 211, which extends from the opening 203 by a length "L" in this embodiment, the extruder nozzle opening 203 is aligned without offset relative to the start of the sidewall 213. The downstream gas conduit 211 promotes laminar flow along the polymer melt extending from the extruder nozzle 201 and along the sidewall 213, causing periodic narrowing of the melt to form pellets after the polymer melt exits the gas nozzle opening.

Fig. 3 shows a cross-sectional view of an apparatus 300, the apparatus 300 comprising an extruder nozzle 301 and a gas nozzle 310, the opening 303 extending into a downstream gas conduit at 311. Polymer melt 302 is extruded through an extruder nozzle opening at 303. Gas enters the downstream gas conduit along channel 312 and flows along side wall 313, the downstream gas conduit extending from opening 303 by a length "L". The downstream gas conduit 311 also promotes laminar flow along the polymer melt extending from the extruder nozzle 301 and along the sidewall 313, causing periodic narrowing of the melt to form pellets after the polymer melt exits the gas nozzle opening.

The downstream gas conduits used in fig. 1, 2 and 3 delay the formation of open jets in the region where the extruded polymer melt and the atmosphere meet and promote pressure oscillations on the surface of the polymer melt (strands) therein. These pressure oscillations generate rayleigh interference. The effect of the downstream gas conduit on micro-pellet production can be adjusted by setting the offset at a length "L" as shown, and setting the diameter "D" of the conduit inner sidewall (e.g., 113 of 111). These length and diameter parameters, as well as gas properties (e.g., velocity, type, temperature) can be controlled to provide aspects such as improved heat balance and independent control of melt and air temperatures. To accommodate various embodiments, adjustable or interchangeable mandrels with different capillary sizes may be used. In addition, adjustable or interchangeable attachments may be used for different retraction configurations of the extruder nozzle relative to (and away from) the downstream gas conduit to set pellet properties. In addition, the angle at which the gas encounters the polymer melt can be controlled to facilitate a desired interaction therewith.

The extruder and gas nozzle components may be implemented in a variety of different types of extrusion processes and in a variety of different types of extruders. For example, various embodiments are directed to a gas nozzle apparatus that can be implemented with one or more extruder types to achieve pellet-making control as characterized herein. Other embodiments are directed to extruder nozzles that can be coupled to one or more of a variety of different extruders, and include gas nozzles having a downstream gas conduit as characterized herein.

Thus, fig. 4 illustrates a micro-pellet creating device 400 as can be implemented in accordance with one or more embodiments. The apparatus 400 includes an extruder 410 and a nozzle apparatus 405 having a heating belt 41, a thermal sensor 412, a mandrel 413, and a gas nozzle 420. The gas nozzle 420 includes a downstream gas conduit 422, which may be implemented in a manner consistent with one or more embodiments characterized herein.

The hot torches 430 and 432, respectively, heat compressed air provided along the air passageway for heating the mandrel 413 and for providing a flow of air along the polymer melt as it is extruded from the mandrel 413. The separate pieces or zones provide independently controllable temperature zones. The gas flow used to heat the mandrel 413 is responsible for controlling the temperature of the mandrel and is therefore directly linked to the polymer melt temperature. As shown, it is heated by the hot torch 430 and flows between the mandrel and the separating member/zone and exits the nozzle through the air outlet. As shown, the gas flow provided through the channel 424 and heated via the hot torch 432 is responsible for causing surface disturbances on the extruded polymer strands and is directed through the gap. The channel 424 is smoothly curved to allow the gas flow to meet the melt strands at the exit of the nozzle while maintaining laminar flow. As can be implemented in accordance with one or more embodiments, general information regarding the micro-pellet molds and detailed calculations regarding flow and heat transfer behavior may be referenced to J · plentes (Puentes): "Building an optimized micro-clustered mold" (Master academic thesis, Colombia trade Bogota, university of Combia, 2011), the entire contents of which is incorporated herein by reference.

Various materials may be used to form micro-pellets with associated downstream gas conduit dimensions and positioned relative to the extruder nozzle (or mandrel) to achieve production of pellets having a desired morphology and/or other characteristics. The following discussion characterizes various methods as may be practiced in connection with one or more embodiments.

Fig. 5 shows the cumulative particle size distribution plot and fig. 6 shows the aspect ratio plot for the micro-pellets produced with 0.5mm capillary and 1mm capillary polymer extrusion mandrels, respectively. Specifically, curves 510 and 610 show the particle size distribution and aspect ratio for a 0.5mm capillary nozzle, while curves 520 and 620 show the particle size distribution and aspect ratio for a 1mm capillary nozzle.

The relative position or setback of the extruder nozzle and the downstream gas conduit can be adjusted to set the properties of the resulting pellets formed from the polymer melt. For example, micro-aggregates having a spherical shape may be formed using positive and zero indentation configurations, and negative indentation may be used to form an elongated aggregate shape. With negative setback, the surrounding air stream encounters the extruded polymer strands after exiting the air gap. Thus, the polymer strands encounter the gas stream at atmospheric conditions and are no longer directed by the air gap. This, along with the reduced gas flow velocity as it encounters the polymer strands, can reduce pressure oscillations on the surface of the extruded polymer strands, forming elongated pellet shapes. It has been recognized/discovered that: at low airflow rates, particles produced with negative setback may exhibit similar shape and fragmentation behavior as those produced with positive setback. In this way, a higher air flow rate can be used with negative setback to achieve full fragmentation. Further recognition/discovery: zero and positive setback may be used to provide the desired particle size and particle size distribution, with positive setback being used to provide relatively smaller particle sizes, aspect ratios, and size distributions than those provided with zero setback. Such a method may be implemented, for example, with the apparatus shown in fig. 1 (positive indentation) and fig. 2 (zero indentation).

Fig. 7 and 8 show graphs of particle size and particle aspect ratio, respectively, as can be implemented in accordance with one or more embodiments. Consistent with the recognition/findings noted herein, curves 710 and 810 show particle size and particle aspect ratio for positive setback, while curves 720 and 820 show particle size and particle aspect ratio for zero setback.

Fig. 9 and 10 illustrate cumulative particle size distributions and cumulative particle aspect ratios for three different downstream gas conduit configurations and lengths (e.g., length "L" in fig. 2) as may be implemented in connection with one or more embodiments. Starting with fig. 9, curve 910 shows the particle size distribution for a 3mm downstream air duct, curve 920 shows the particle size distribution for a downstream air duct having 8mm, and curve 930 shows the particle size distribution without a downstream air duct. In fig. 10, curves 1010 and 1020 show particle aspect ratios with 3mm and 8mm downstream air ducts, respectively, while curve 1030 shows particle aspect ratios without a downstream air duct. Thus, the use of a downstream air duct has a major effect on the aspect ratio of the produced micro-granules, while having a smaller effect on particle size. Thus, it has been recognized/discovered that by using a downstream air duct, the aspect ratio moves to smaller values and produces more spherical pellets. Thus, rather than promoting rayleigh interference (useful for providing uniform, controlled agglomeration), the downstream air duct can be implemented to mitigate the enhanced rotational motion and associated centrifugal forces that may cause polymer strand breakage.

The crushing mechanism is influenced by various parameters such as process conditions and material properties. Aspects relating to the diameter of the capillary through which the polymer melt is extruded, the length and offset of the downstream gas conduit, gas flow, temperature and exit size may be set to tune the particle properties. For example, breaking up of the polymer melt into particles can be achieved via rayleigh interference and controlled conditions that mitigate open jet and/or other flows that may fracture the polymer melt. For example, larger capillaries (e.g., 1mm versus 0.5mm) may be used to promote rayleigh interference and break up the particles by stretching the extruded strands before surface instability causes them to break up into particles. After breaking, the polymer micro-aggregates subsequently solidify. Since the micro-aggregates tend to optimize their volume to surface area ratio, the micro-aggregates produced during cooling will shrink further, supporting the formation of spherical particles.

The particle size can be set by the processing temperature. For higher processing temperatures, a more uniform particle size distribution with smaller particles can be obtained, but collection of micro-aggregates can become more challenging due to the adherence of aggregates and the occurrence of particle agglomeration. Various collection methods may be implemented to facilitate the use of higher temperatures while maintaining collection yields. For example, cooling air may be used to maintain a cooler surface within the collection member, which may mitigate the adherence of pellets. Further, a large amount of air/gas may be drawn into the collection member (e.g., tube) relative to the amount of air/gas exiting the air nozzle as described herein to direct the particles for collection, and this may also facilitate particle cooling. In addition, various other particle cooling techniques may be used, such as by introducing the particles into a liquid.

The extrusion rate can also be adjusted to affect particle size and particle aspect ratio. Higher extrusion rates can provide greater shear rates and result in higher storage of energy per unit time, which can cause the extrudate to swell. Thus, larger particles can be produced at higher extrusion rates, while smaller particles can be produced at lower extrusion rates.

As described above, the capillary diameter may be set to affect the production of the micro-pellets. The aspect ratio of the micro-granules produced with smaller (e.g., 0.5mm) capillaries is greater compared to particles produced with larger (e.g., 1.0mm) capillaries. Due to the larger L/D ratio of the capillaries, particles produced with smaller capillaries can be provided with higher molecular orientation. In addition, a larger L/D ratio provides more time for the polymer fluid to release the stored elastic energy, resulting in less mold expansion. Thus, the polymer strands may solidify faster and break more easily. During this process, the surface tension of the particles decreases and the viscous forces increase (high capillary number). This force balance inhibits the shrinkage of the particles and results in a more elongated particle shape. Thus, particles produced with a 0.5mm capillary may exhibit predominantly a particle size within the range of the capillary diameter itself. In addition, micro-aggregates produced with 0.5mm capillaries can be made with a narrower particle size distribution. These aspects can be achieved with a smaller capillary diameter that results in higher shear forces (e.g., a wall shear rate of a 0.5mm capillary is six times greater than the shear rate of a 1mm capillary). Higher shear rates may result in lower viscosities due to shear-thinning behavior of the processed material.

Although various embodiments characterized herein relate to the formation of micro-aggregates, other shapes can be formed, such as by forming fibers and wires of different sizes and shapes. Various shapes can be obtained under a wide range of process conditions for different polymer resins. For example, ProfaxTM6523 polypropylene from LyondellBasell (Pyrethol, the Netherlands) and EastapakTM 9921 polyethylene terephthalate (PET) from Eastman (Eastman) (Kingsport, Tennessee) can be used to form filaments and pellets of elongated shape.

The various embodiments described above and shown in the figures can be implemented together and/or in other ways. As is useful in accordance with a particular application, one or more items depicted in the figures/figures herein can be implemented in a more separated or integrated manner, or removed and/or rendered as inoperable in certain cases. For example, certain embodiments are directed to nozzles that may be implemented with one or more extruders. Other embodiments involve sizing the downstream gas conduit using one or more different nozzle/extruder combinations. In view of this and the description herein, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present disclosure.