Melting Behavior of Heterogeneous Polymer Bulk Solids Related to Flood Fed Single Screw Extruders

Melting models for flood fed single screw extruders, like the Tadmor model, describe the melting of pure thermoplastic polymers. However, the melting behavior of heterogenous polymer systems is of great interest for recycling issues, for example. In this work, the melting of polymer mixtures and that of pure bulk polymers by the drag induced melt removal principle is examined both theoretically and experimentally. The applied model experiments represent the melting of the solid bed at the barrel in single screw extruders. As polymer pellet mixtures, polypropylene-homopolymer mixed with polypropylene-block-copolymer, high density polyethylene, polyamide 6, and polymethylmethacrylate were studied using different mixing ratios. The melting rate and the shear stress in the melt film were evaluated dependent on the mixing ratio. The results show that when processing unfavorable material combinations, both shear stress and melting rate can be far below that of pure materials, which was also confirmed by screw extrusion and screw pull-out experiments. Furthermore, approaches predicting the achievable melting rate and the achievable shear stress of polymer mixtures based on the corresponding values of the pure materials are presented.