A plunger machine for molding reinforced polymer compositions is provided. The
plunger machine has particular application in molding polymer that is reinforced
with particles having an aspect ratio that is greater than 1:1. The plunger machine
includes a barrel housing with a smooth walled barrel with longitudinal fins projecting
inwardly towards the center of the bore that defines a main melt chamber. A plunger
housing, having a plunger bore, defines an initial melt chamber and is in communication
with the main melt chamber. A plunger resides in the plunger bore and is reciprocatable
therein. The barrel bore is continuously inwardly tapered and cooperates with the
longitudinal fins to provide a shortened melt period and a smooth transition and
alignment of reinforcing members within the polymer mixture during the melt process.
The smooth bore and cooperating fins ensure substantial alignment of the reinforcement
members with the longitudinal axis of the bore in the direction of the composition
flow to avoid excessive breakage of the reinforcing particles and prepare the polymer
mixture for extrusion into a mold assembly.