Method and device for extrusion of hollow pellets

1. An extrusion process for producing hollow pellets, the process comprising:

extruding molten material through an extrusion die comprising a die orifice and an insert disposed in the die orifice, wherein the insert comprises a mandrel and three or more distinct fins extending a length of the insert, the fins maintaining the position of the insert in the die orifice, and wherein at least one of the three or more distinct fins of the insert is tapered;

cutting the extruded molten material at a die face of the extrusion die using an underwater pelletizer; and

cooling the cut extruded molten material effective to produce a pellet having a hollow cavity.

2. The process of claim 1 , wherein the hollow cavity penetrates a first surface of the pellet and continuously extends through a second surface of the pellet.

3. The process of claim 1 , wherein the hollow cavity is completely encapsulated within the pellet.

4. The process of claim 1 , wherein the hollow cavity penetrates a first surface of the pellet and extends inwardly to an interior portion of a body of the pellet.

5. The process of claim 1 , wherein the extruding comprises pressure extruding.

6. The process of claim 1 , wherein the molten material comprises a polyolefin, a cross-linkable polyolefin, vinyl polymer, substituted vinyl polymer, polyester, polyamide, polyether, polythioether, polyurethane, polyimide, polycarbonate, polysulfide, polysulfone, wax, a copolymer thereof, or a formulation comprising at least two of the foregoing.

7. The process of claim 1 , wherein the extrusion die is a single-body extrusion die or a removable extrusion die assembly.

8. The process of claim 1 , wherein each of the three or more distinct fins is disposed about 180° or less apart from an adjacent fin about the mandrel.

9. The process of claim 1 , wherein the three or more distinct fins are at least partially on the mandrel.

10. An extrusion process for producing hollow pellets, the process comprising:

feeding a molten material into a pelletizer; and

extruding the molten material through an extrusion die of the pelletizer;

wherein during extrusion the molten material flows through a hollow can of an insert, flows through at least one hole of the insert, and flows around fins disposed on a mandrel of the insert, said fins extending from an outer surface of the mandrel to engagement with an inner surface of a die orifice in the extrusion die in which the insert is placed.

11. The process of claim 10 , wherein after the molten material flows around the fins disposed on the mandrel of the insert the molten material flows around a portion of the insert that does not have fins.

12. The process of claim 10 , further comprising cooling the extruded molten material effective to produce a pellet having a hollow cavity, wherein the hollow cavity penetrates a first surface of the pellet and continuously extends through a second surface of the pellet, is completely encapsulated within the pellet, or penetrates the first surface of the pellet and extends inwardly to an interior portion of a body of the pellet.

13. The process of claim 10 , wherein the insert comprises a taper between a back edge of the insert and the hollow can, and the molten material flows through the taper.

14. The process of claim 10 , wherein the pelletizer is an under fluid pelletizer.

15. A pelletizer for producing hollow pellets, comprising:

an inlet for receiving a molten material;

a die hole, downstream of the inlet, for extruding the molten material; and

an insert disposed in the die hole, the insert comprising a rear section and a forward section, the rear section comprising a hollow can and the forward section comprising a mandrel, the mandrel comprising a plurality of fins, said fins extending from an outer surface of the mandrel to engagement with an inner surface of a die orifice in the extrusion die in which the insert is placed; and the insert further comprising at least one hole configured to enable the molten material to flow from the hollow can to the mandrel,

wherein the pelletizer is an under fluid pelletizer.

16. The pelletizer of claim 15 , the plurality of fins comprising protrusions to maintain the position of the mandrel in the die hole.

17. The pelletizer of claim 15 , wherein the mandrel comprises a region furthest from the rear section of the insert, and wherein the region does not comprise fins.

18. The pelletizer of claim 15 , wherein the hollow can is threaded.

19. The pelletizer of claim 15 , wherein the mandrel is a removable mandrel.

20. The pelletizer of claim 15 , wherein the mandrel may be threadedly attached to the can.