Directional flow bar extruder

Claim 2

An extrusion nozzle for aligning fibers in an extrudable fiber-containing composition comprising: a. a housing having an inlet channel and an outlet channel, said inlet and outlet channels being defined by substantially parallel top and bottom portions; a first intermediate portion connecting the top of the inlet channel to the top of the outlet channel at an upper leading and trailing apex; a second intermediate portion connecting the bottom of the inlet channel to the bottom of the outlet channel at a lower leading and trailing apex; the first and second intermediate portions converging toward the outlet channel such that the height of the outlet channel is less than the height of the inlet channel; b. at least one fiber-aligning flow bar having an essentially diamond-shaped cross-section having an upper and lower leading face converging to an acute angle leading edge and an upper and lower trailing face converging to an acute trailing edge, the leading and trailing edges defining a length of the flow bar and wherein said flow bar is operatively disposed transversely between and spaced from the converging first and second intermediate portions and the inlet channel of said housing to effect fiber alignment of a substantial amount of fiber in the extrudable composition.

Claim 3

The extrusion nozzle of claim 1 wherein the length of the first and second intermediate portions are substantially equal.

Claim 4

The extrusion nozzle of claim 1 wherein the length of the first and second intermediate portions are substantially equal to the length of the upper and lower trailing edges of the fiber-aligning flow bar.

Claim 5

The extrusion nozzle of claim 1 wherein the leading edge of the flow bar is substantially rounded.

Claim 6

The extrusion nozzle of claim 3 wherein the difference between the height of the outlet channel and the height of the inlet channel is substantially equal to the height of the flow bar.

Claim 7

The extrusion nozzle of claim 1 wherein the flow bar further includes a central axis and said flow bar is mounted in the housing with said central axis located in a plane essentially defined by the upper and lower leading apexes.

Claim 8

The extrusion nozzle of claim 6 wherein the flow bar is axially rotatable to effect a predetermined amount of fiber alignment and includes an axially disposed mounting rod.

Claim 9

The extrusion nozzle of claim 7 wherein the flow bar and mounting rod is selectively rotatable within the housing to selectively vary the extent of fiber alignment during extrusion.

Claim 10

The extrusion nozzle of claim 8 including means to adjustably rotate the flow bar and mounting rod and means to adjustably fix the flow bar in a predetermined position in the housing.

Claim 11

The extrusion nozzle of claim 1 wherein the angle defined by the upper and lower trailing faces of the flow bar is substantially equal to the angle defined by the converging first and second intermediate portions.

Claim 12

The extrusion nozzle of claim 10 wherein the flow bar is disposed whereby the first intermediate portion is substantially parallel to the upper trailing face of the flow bar and the second intermediate portion is substantially parallel to the lower trailing face of the flow bar.

Claim 13

The extrusion nozzle of claim 1 wherein the housing includes a discharge nozzle having a top and bottom defining an exit orifice and wherein the top and bottom converge longitudinally and transversely toward the center of the discharge nozzle.

Claim 14

An extrusion apparatus for aligning fibers in an extrudable fiber-containing composition comprising: a. a housing having an inlet and an outlet, said inlet being defined by substantially parallel rectilinear first top and bottom members; said outlet being defined by substantially parallel rectilinear second top and bottom members; a first rectilinear intermediate member extending from the first top member to the second top member to form an upper leading apex and an upper trailing apex; a second rectilinear intermediate member connected to the first bottom member at a lower leading apex and to the second bottom member at a lower trailing apex, said first and second intermediate members converging toward the outlet; b. a fiber-aligning flow bar adjustably mounted in said housing wherein said flow bar has an essentially diamond shape cross-section defined by upper and lower leading faces converging to an acute angle leading edge and upper and lower trailing faces converging to an acute angle trailing edge, the flow bar being mounted in the housing whereby its longitudinal axis is disposed at a midpoint in a plane defined by the upper and lower leading apexes, and wherein the upper and lower leading faces of the flow bar cooperate with the first top and bottom members and said upper and lower trailing faces cooperate with the first and second intermediate members of the housing to effect fiber alignment of a substantial portion of fiber in the extrudable composition.

Claim 15

An extrusion apparatus for aligning fibers in an extrudable fiber-containing composition comprising: a. a housing having an inlet and an outlet, said inlet being defined by substantially parallel rectilinear first top and bottom members; said outlet being defined by substantially parallel rectilinear second top and bottom members; a first rectilinear intermediate member extending from the first top member to the second top member to form an upper leading apex and an upper trailing apex; a second rectilinear intermediate member connected to the first bottom member at a lower leading apex and to the second bottom member at a lower trailing apex, said first and second intermediate members converging toward the outlet; b. a fiber-aligning flow bar adjustably mounted in said housing wherein said flow bar has an essentially diamond shape cross-section defined by upper and lower leading faces converging to an acute angle leading edge and upper and lower trailing faces converging to an acute angle trailing edge, the flow bar being mounted in the housing whereby its longitudinal axis is disposed at a midpoint in a plane defined by the upper and lower leading apexes, and wherein the upper and lower leading faces of the flow bar cooperate with the first top and bottom members and said upper and lower trailing faces cooperate with the first and second intermediate members of the housing to effect fiber alignment of a substantial portion of fiber in the extrudable composition.

Claim 16

The extrusion apparatus of claim 13 wherein the length of the first and second intermediate members is substantially equal to the length of the upper and lower trailing faces of the flow bar.

Claim 17

The extrusion apparatus of claim 13 wherein the leading edge of the flow bar is rounded.

Claim 18

The extrusion apparatus of claim 13 wherein the height of the outlet is equal to the difference between the height of the inlet and the height of the flow bar.

Claim 19

The extrusion apparatus of claim 13 wherein the flow bar is rotatable and includes an axially disposed mounting rod.

Claim 20

The extrusion apparatus of claim 17 including means to adjustably rotate the flow bar and fix the flow bar in a preselected position.

Claim 21

The extrusion apparatus of claim 13 wherein the angle defined by the upper and lower trailing faces is substantially equal to the angle defined by the converging first and second intermediate members.

Claim 22

The extrusion apparatus of claim 13 wherein the flow bar is disposed whereby the first intermediate member is substantially parallel to the upper trailing face and the second intermediate portion is substantially parallel to the lower trailing face of the flow bar whereby the trailing edge is disposed in a plane substantially defined by the upper and lower trailing apexes.

Claim 23

The extrusion apparatus of claim 13 further comprising a discharge nozzle having a top and bottom defining an exit orifice and wherein the top and bottom converge longitudinally and transversely toward the center of the discharge orifice.

Claim 24

An extrusion apparatus for aligning fiber in an extrudable fiber-containing composition comprising: a. a housing having an inlet and an outlet; said inlet being defined by substantially parallel rectilinear first top and bottom members; said outlet being defined by substantially parallel rectilinear second top and bottom members; a first rectilinear intermediate member extending from the first top member to the second top member to form an upper leading apex and an upper trailing apex; a second rectilinear intermediate member extending from the first bottom member to the second bottom member to form a lower leading apex and a lower trailing apex, the first and second intermediate members converging toward the outlet; b. a cooperating fiber-aligning flow bar having an essentially diamond shape cross-section defined by upper and lower leading faces converging to an acute angle leading edge and upper and lower trailing faces converging to an acute angle trailing edge, said flow bar being mounted in the housing whereby its longitudinal axis is in a plane defined by the upper and lower leading apexes and the upper and lower trailing faces are spaced from and oppose the first and second intermediate members and the upper and lower leading faces oppose the first top and bottom members a distance to effect alignment of a substantial portion of fibers generally parallel to the axis of flow; and c. a discharge nozzle at said outlet comprising a top and bottom to define an exit orifice and wherein the top and bottom converge longitudinally and transversely toward the center of the exit orifice.

Claim 25

An extrusion apparatus for aligning fiber in an extrudable fiber-containing composition comprising: a. a housing having an inlet and an outlet; said inlet being defined by substantially parallel rectilinear first top and bottom members; said outlet being defined by substantially parallel rectilinear second top and bottom members; a first rectilinear intermediate member extending from the first top member to the second top member to form an upper leading apex and an upper trailing apex; a second rectilinear intermediate member extending from the first bottom member to the second bottom member to form a lower leading apex and a lower trailing apex, the first and second intermediate members converging toward the outlet; b. a cooperating fiber-aligning flow bar having an essentially diamond shape cross-section defined by upper and lower leading faces converging to an acute angle leading edge and upper and lower trailing faces converging to an acute angle trailing edge, said flow bar being mounted in the housing whereby its longitudinal axis is in a plane defined by the upper and lower leading apexes and the upper and lower trailing faces are spaced from and oppose the first and second intermediate members and the upper and lower leading faces oppose the first top and bottom members a distance to effect alignment of a substantial portion of fibers generally parallel to the axis of flow; and c. a discharge nozzle at said outlet comprising a top and bottom to define an exit orifice and wherein the top and bottom converge longitudinally and transversely toward the center of the exit orifice.

Claim 26

The extrusion apparatus of claim 22 wherein the flow bar includes an axially disposed mounting rod rotatably received in side walls of the housing.

Claim 27

The extrusion apparatus of claim 22 wherein the longitudinal axis of the flow bar is disposed essentially at a midpoint between the upper and lower leading apexes.

Claim 28

The extrusion apparatus of claim 22 wherein the length of the first and second intermediate members is substantially equal to the length of the upper and lower trailing faces of the flow bar.

Claim 29

The extrusion apparatus of claim 22 wherein the leading edge of the flow bar is rounded.

Claim 30

The extrusion apparatus of claim 22 wherein the height of the outlet is equal to the difference between the height of the inlet and the height of the flow bar.

Claim 31

The extrusion apparatus of claim 23 including means to rotate the flow bar and means to selectively fix the axial position of the flow bar and mounting rod.

Claim 32

The extrusion apparatus of claim 22 wherein the angle defined by the upper and lower trailing faces of the flow bar is substantially equal to the angle defined by the converging first and second intermediate members.

Claim 33

The extrusion apparatus of claim 22 wherein the flow bar is disposed in the housing whereby the first intermediate member is substantially parallel to the upper trailing face and the second intermediate member is substantially parallel to the lower trailing face whereby said trailing edge is in a plane defined by the upper and lower trailing apexes of the housing.