Injection moulders have so far used the conventional screw design. However, recent developments have increased the length of screw, thus giving improved homogenization. Typical L/D ration of screw for injection moulding started as low as 16:1. Slowly it has been increased to 32:1 over the years.
Xaloy, a company well known in the field of screw design for polymers, has recently developed an interesting screw design which is called fusion screw for injection molding as well as extrusion. Fusion Screw is a n ew-generation barrier screw that boosts productivity, lowers melt temperature and improves color/additive dispersion in injection molding, extrusion and blow molding.
A fusion screw has undulating profile in the metering section of a screw. The undulating provides intensive and chaotic mixing.
The undulating generally moves in waves of 2 consisting of crest and trough. In addition to the new design, the screw is provided with longer transitions and melting lengths compared to the conventional screw designs.
This new fusion screw design is now commercially used for LDPE, LLDPE, HDPE, PP, PET, ABS and even for biodegradable PLA polymers. The fusion screw always needs a longer screw. The minimum L/D ratio of 22:1 is essential.
The fusion screw has major advantages in Injection Molding of
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