Reservoir reducing screw tip

1. An extruder for extruding extrudate, comprising:

a generally cylindrical barrel portion having a longitudinal axis and an end face;

a screw conveyor rotatably arranged coaxially within the barrel portion, the screw conveyor having a downstream end, the screw conveyor having helical flights that define a first flow path within the barrel for the extrudate;

an adapter arranged on the end face of the barrel portion, said adapter having an opening with varying diameters that defines a second flow path for the extrudate where a downstream end of the opening defines an exit portion of the extruder, the opening of the adapter having a first diameter that tapers toward the longitudinal axis to a narrower second diameter, and a third diameter that tapers from a downstream end of the narrower second diameter outwardly from the longitudinal axis, and the cross-sectional flow of extrudate between an upper edge of the first diameter opening and a side of the screw tip is approximately equal to the cross-sectional flow of extrudate between the third diameter opening and a lower edge of the screw tip; and

a screw tip secured to the downstream end of the screw conveyor and extending into the adapter where the screw tip reduces dead space in a cross-sectional flow area of the second flow path so that the cross-sectional flow of extrudate in the first and second flow paths remain approximately constant whereby the volume of extrudate flowing through the first flow path is relatively constant with the volume of extrudate exiting the extruder.

2. The extruder of claim 1 , wherein the second diameter opening has an approximate constant diameter for a length.

3. The extruder of claim 1 , wherein the screw conveyor terminates within the barrel portion.

4. The extruder of claim 3 , wherein the screw conveyor has lands between the helical flights and a diameter of the screw conveyor is measured between the lands and the screw tip has a base that is secured to the downstream end of the screw conveyor and has a diameter approximately equal to the diameter of the screw conveyor.

5. The extruder of claim 4 , wherein the base of the screw tip extends approximately to the end face of the barrel portion, and the screw tip has a rounded tip, a first portion that tapers at an angle from the base toward the longitudinal axis and a second portion that tapers at a slight angle from a downstream edge of the first portion to the rounded tip.

6. The extruder of claim 5 , wherein the rounded tip extends approximately to the exit portion.

7. The extruder of claim 5 , wherein the tapering angle of the first portion is significantly greater than the slight angle of the second portion.

8. An extruder screw tip to be used in combination with a screw conveyor of an extruder for increasing the output of the extruder, said screw tip comprising:

a base including means for connection with a downstream end of an extruder conveyor screw, the base having a longitudinal axis and a diameter approximately equal to that of the extruder conveyor screw to which the screw tip is to be connected;

a rounded point disposed on an end of the screw tip opposite the base;

a first portion that tapers at an angle from the base toward the longitudinal axis; and

a second portion that tapers at a slight angle from the first portion to the rounded point where the second portion is longer in length than the first portion and the tapering angle of the first portion is significantly greater than the slight angle of the second portion wherein transitions between the base and the first portion, and the first portion and the second portion are angular.

9. An extruder for extruding polymer, comprising:

a generally cylindrical barrel portion having a longitudinal axis and an end face;

a screw conveyor rotatably arranged coaxially within the barrel portion, the screw conveyor having a downstream end, the screw conveyor having helical flights that define a first flow path within the barrel for the polymer;

an adapter arranged on the end face of the barrel portion, said adapter having an opening with varying diameters that defines a second flow path for the polymer where a downstream end of the opening defines an exit portion of the extruder, the opening of the adapter having a first diameter that tapers toward the longitudinal axis to a narrower second diameter, and a third diameter that tapers from a downstream end of the narrower second diameter outwardly from the longitudinal axis, and the cross-sectional flow of polymer between an upper edge of the first diameter opening and a side of the screw tip is approximately equal to the cross-sectional flow of polymer between the third diameter opening and a lower edge of the screw tip; and

a screw tip secured to the downstream end of the screw conveyor and extending into the adapter where the screw tip reduces dead space in a cross-sectional flow area of the second flow path so that the cross-sectional flow of extrudate in the first and second flow paths remain approximately constant whereby the volume of extrudate flowing through the first flow path is relatively constant with the volume of extrudate exiting the extruder.

10. The extruder screw tip of claim 9 , wherein transitions of the screw tip between the base and the first portion, and the first portion and the second portion are curved.

11. The extruder screw tip of claim 9 , wherein transitions between the base and the first portion, and the first portion and the second portion are angular.