Resin melting and shearing method, resin molding processing method and resin products

Abstract

The invention provides a method of obtaining a compatible resin blend from at least two incompatible resins which are not conventionally blended with each other. The blend of an incompatible resins is dissolved at a molecular level by being melted and sheared under a high shearing rate by rotating a screw without adding a compatibilizer or the like.

1 . A melting and shearing apparatus comprising:
 a cylinder;   a heater provided to the cylinder;   a screw rotatably provided in the cylinder and configured to generate a flow by rotation of the screw in the cylinder, the screw having a screw structure at an outer surface thereof and an inner hole extending from a front end side to a rear end side of the screw;   a sealing surface provided at a front end side of the cylinder and facing the front end side of the inner feedback screw so as to form a gap between the sealing surface and the front end side;   a polymer supplier to supply polymers to the outer surface of the screw at a rear end side of the cylinder; and   an outlet to take out the polymer blend which has been melted and sheared;   the melting and shearing apparatus being configured to circulate the polymers in the cylinder by:   melting and shearing the polymers by rotation of the screw, while forwarding the polymers to the front end side of the inner feedback screw;   further rotating the inner feedback screw, thereby filling the polymers into the gap formed between the front end side of the screw and the sealing surface provided at the front end side of the cylinder; and   further rotating the inner feedback screw, thereby returning the polymers toward the rear end side of the screw through the inner hole of the screw.   
     
     
         2 . The apparatus according to  claim 1 , wherein a size of the gap and a size of an inner diameter of the inner hole of the inner feedback screw are determined depending on a viscosity of the polymers. 
     
     
         3 . The apparatus according to  claim 1 , further comprising:
 an adjuster to adjust said gap and/or an inner diameter of the inner hole of the inner feedback screw to adjust intensity of the flow of the polymers and/or degree of shearing, while shearing and melting the polymers.   
     
     
         4 . The apparatus according to  claim 1 , wherein the screw is configured to be rotated at a speed from 600 rpm to 3000 rpm. 
     
     
         5 . A melting and shearing apparatus comprising:
 a cylinder;   a heater provided to the cylinder;   a screw rotatably provided in the cylinder and having an inner hole extending from a front end side to a rear end side of the inner feedback screw, wherein a size of an inner diameter of the inner hole of an inner feedback screw is determined depending on a viscosity of the polymers; and   a polymer supplier to supply polymers to an outer surface of the screw at a rear end side of the cylinder;   wherein by the rotation of the screw, the polymer supplied at the rear end side of the cylinder is fed toward a front end side of the cylinder by passing through between the outer surface of the screw and an inner wall of the cylinder, and then, the polymer is fed to the rear end side of the cylinder by passing through the inner hole of the screw.