Extrusion die with thermally isolated motor-driven lip profile actuator and related method - Patents.com

Abstract

A system and method for adjusting the thickness of an extrusion die system is disclosed. The lip adjustment assembly includes an engagement member operably coupled to a movable lip of the extrusion die and movable in a first direction and a second direction opposite the first direction, an actuator configured to selectively move the engagement member in the first direction and the second direction, a coupler operably coupled to both the engagement member and the actuator and disposed between the engagement member and the actuator, and an insulator on the coupler configured to prevent heat transfer from the engagement member to the actuator. When the engagement member is moved in the first direction, the movable lip is brought closer to the second lip of the extrusion die, and when the engagement member is moved in the second direction, the movable lip is moved away from the second lip.

Description

[Technical field]

[0001] The present disclosure relates generally to an extrusion die with a lip adjustment assembly, and more particularly to an extrusion die with a lip adjustment assembly for varying a parameter of an extrusion material. The present disclosure also relates generally to a method of adjusting the thickness of an extrusion material, and more particularly to a method of using an extrusion die with a lip adjustment assembly for varying a parameter of an extrusion material.

[0002] [Citation to Related Applications] This application is a claim of U.S. Provisional Patent Application No. 63 / 237,580, filed August 27, 2021, which is incorporated by reference in its entirety and incorporated herein by reference for all purposes. [Background technology]

[0003] Extrusion dies can be used to form polymeric films, laminates, and / or the like. A pumping device, e.g., an extruder or gear pump, forces molten material, e.g., polymeric material, into an extrusion die with an exit orifice having a gap defined by spaced lips to form an extruded film, typically referred to as an extrudate. The extrudate cools as it exits the gap. The size of the gap, among other factors, can define the thickness, gauge, and / or other dimensions of the extrudate. A lip adjustment assembly can be used to help control cross-sectional variations in extrusion thickness. The lip adjustment assembly typically includes a translator and a rod coupled to the translator. In existing systems, the translator may be configured to expand and contract in response to temperature changes. Such expansion and contraction typically causes movement of the rod, which in turn causes movement of the lip, which in turn adjusts the gap size as needed. The movement of the translator may be controlled by a control system during processing in response to a thickness measurement located at or downstream from the gap. The translator may also be manually adjusted as needed to adjust the gap size.

[0004] Adjusting the lip often takes a significant amount of time and may result in either too much or too little adjustment. The process is time consuming and often requires continuous monitoring to ensure the desired results are achieved. The adjustment process may also adversely affect the flow of material through the extrusion die, which may result in an undesirable end product. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, there is a need for an improved lip adjustment assembly that increases the accuracy of the lip adjustment, decreases the time to perform the adjustment, and / or otherwise without adversely affecting the extrusion. [Means for solving the problem]

[0006] The above-mentioned needs are met by various aspects of the disclosed extrusion die system, extrusion die, and lip adjustment assembly. According to one aspect of the invention, a lip adjustment assembly for adjusting a thickness of an extrusion molded product includes an engagement member operably coupled to a movable lip of an extrusion die, the engagement member being movable in a first direction and a second direction opposite the first direction, the lip adjustment assembly further includes an actuator configured to selectively move the engagement member in the first direction and the second direction, and a coupler operably coupled to both the engagement member and the actuator, the coupler being adapted to be disposed between the engagement member and the actuator. When the engagement member is moved in the first direction, the movable lip is moved toward the second lip of the extrusion die, and when the engagement member is moved in the second direction, the movable lip is moved away from the second lip.

[0007] Optionally, the actuator may include a stepper motor having a rotational component and a linear component, where movement of the rotational component in a first rotational direction results in movement of the linear component in a first linear direction and movement of the rotational component in a second rotational direction opposite to the first rotational direction results in movement of the linear component in a second linear direction opposite to the first linear direction.

[0008] Optionally, the linear component may be arranged to be moved a predetermined linear distance proportional to a predetermined rotational distance of the rotational component.

[0009] Optionally, the lip adjustment assembly may further include an insulator disposed on the coupler, the insulator configured to inhibit conduction of heat from the engagement member to the actuator, the coupler having a first thermal conductivity and the insulator having a second thermal conductivity, the second thermal conductivity being lower than the first thermal conductivity.

[0010] Optionally, the coupler may have a recess configured to receive the insulator.

[0011] Optionally, the coupler may have a first portion coupled to the actuator and a second portion coupled to the engagement member, the first portion being spaced apart from the second portion.

[0012] Optionally, the first portion may have a first recess and the second portion may have a second recess. An insulator may be provided within the first and second recesses.

[0013] Optionally, an insulator may be provided between the first and second portions.

[0014] Optionally, the insulator may include mica plates and / or engineering polymers such as polyimide, polyamide-imide, polyetheretherketone, polyphenylene sulfide, polybenzimidazole, polyetherimide, fluoropolymers.

[0015] Optionally, the actuator, coupler and engagement member may be coupled together to form a set of components. The lip adjustment assembly may include a plurality of sets of components, each set of components including at least one actuator, at least one coupler and at least one engagement member.

[0016] Optionally, the lip adjustment assembly may include a housing configured to at least partially enclose the actuator.

[0017] Optionally, an air vent may be provided extending through the housing and configured to allow air to flow in and out of the housing.

[0018] Optionally, the lip adjustment assembly may include an air mover configured to actively move air toward or away from the actuator.

[0019] Optionally, the lip adjustment assembly may include a controller configured to control operation of the actuator.

[0020] Optionally, the lip adjustment assembly may include a plurality of actuators arranged in a linear array, with each actuator of the plurality of actuators spaced from at least one other adjacent actuator by a distance of about 1 inch (2.54 cm) to about 4 inches (10.16 cm) measured between the centerlines of each actuator and at least one other adjacent actuator. In other applications, each actuator may have a different spacing.

[0021] In another aspect, an extrusion die for an extrusion die system is disclosed. The extrusion die is configured to receive a material, the extrusion die having a first die body with a first lip, a second die body with a second lip, and a gap formed between the first lip and the second lip, the gap configured to receive and extrude the material. The extrusion die is configured to be operatively coupled to a lip adjustment assembly for adjusting a thickness of the extruded material. The lip adjustment assembly may include an engagement member operatively coupled to one of the first lip and the second lip and movable in a first direction and movable in a second direction opposite the first direction, an actuator configured to selectively move the engagement member in the first direction and the second direction, and a coupler operatively coupled to both the engagement member and the actuator, the coupler being adapted to be disposed between the engagement member and the actuator. A lip adjustment assembly is coupled to the extrusion die, and when an engagement member of the lip adjustment assembly is moved in a first direction, one of the first lip and the second lip is brought closer to the other of the first lip and the second lip, and when the engagement member is moved in a second direction, one of the first lip and the second lip is moved away from the other of the first lip and the second lip.

[0022] Optionally, the extrusion die can include an insulator configured to prevent heat transfer from the extrusion die to the lip adjustment assembly when the lip adjustment assembly is coupled to the extrusion die. The coupler can have a first thermal conductivity and the insulator can have a second thermal conductivity, the second thermal conductivity being lower than the first thermal conductivity.

[0023] Optionally, the insulator may include a mica plate. The insulator may include engineering polymers such as polyimide, polyamide-imide, polyetheretherketone, polyphenylene sulfide, polybenzimidazole, polyetherimide, and fluoropolymers.

[0024] Optionally, one of the first lip and the second lip may be configured to deform non-linearly along its length by a plurality of actuators, a plurality of couplers and a plurality of engagement members of the lip adjustment assembly.

[0025] Optionally, the extrusion die may include a heater configured to heat the material within the extrusion die. Optionally, the extrusion die may include a heater assembly configured to heat the material within the extrusion die.

[0026] Optionally, one of the first die body and the second die body may have a flexible hinge located adjacent the corresponding first or second lip, the flexible hinge being configured to deform when one of the first lip and the second lip is moved toward or away from the other of the first lip and the second lip.

[0027] Optionally, one of the first lip and the second lip may be configured to be moved by the lip adjustment assembly when the other of the first lip and the second lip cannot be moved by the lip adjustment assembly.

[0028] In another aspect, an extrusion die system for forming an extrusion product from a material is disclosed. The extrusion die system includes an extrusion die having a first die body with a first lip, a second die body with a second lip, and a gap formed between the first lip and the second lip, the gap configured to receive and extrude the material. The extrusion die system further includes a heater configured to heat the material within the extrusion die and a lip adjustment assembly. The lip adjustment assembly may include an engagement member operably coupled to one of the first lip and the second lip and movable in a first direction and movable in a second direction opposite the first direction, an actuator configured to selectively move the engagement member in the first direction and the second direction, and a coupler operably coupled to both the engagement member and the actuator, the coupler being adapted to be disposed between the engagement member and the actuator. When the engagement member is moved in a first direction, one of the first and second lips is moved toward the other of the first and second lips, and when the engagement member is moved in a second direction, one of the first and second lips is moved away from the other of the first and second lips. The extrusion die system further includes a controller configured to control operation of the heater and the lip adjustment assembly. Optionally, the extrusion die may include a heater configured to heat material within the extrusion die.

[0029] Optionally, the actuator may include a stepper motor having a rotational component and a linear component, where movement of the rotational component in a first rotational direction results in movement of the linear component in a first linear direction and movement of the rotational component in a second rotational direction opposite to the first rotational direction results in movement of the linear component in a second linear direction opposite to the first linear direction.

[0030] Optionally, the linear component may be arranged to be moved a predetermined linear distance proportional to a predetermined rotational distance of the rotational component.

[0031] Optionally, the lip adjustment assembly may further include an insulator disposed on the coupler, the insulator configured to inhibit conduction of heat from the engagement member to the actuator, the coupler having a first thermal conductivity and the insulator having a second thermal conductivity, the second thermal conductivity being lower than the first thermal conductivity.

[0032] Optionally, the coupler may have a recess configured to receive the insulator.

[0033] Optionally, the coupler has a first portion coupled to the actuator and a second portion coupled to the engagement member, the first portion being spaced apart from the second portion.

[0034] Optionally, the first portion may have a first recess and the second portion may have a second recess, and the insulator may be provided within the first and second recesses.

[0035] Optionally, an insulator may be provided between the first and second portions.

[0036] Optionally, the insulator may include a mica plate or another material. The insulator may include engineering polymers such as polyimide, polyamide-imide, polyetheretherketone, polyphenylene sulfide, polybenzimidazole, polyetherimide, fluoropolymers.

[0037] Optionally, the actuator, coupler and engagement member, which are interconnected, may form a set of components, and the lip adjustment assembly may include multiple sets of components, each set of components including at least one actuator, at least one coupler and at least one engagement member.

[0038] Optionally, the extrusion die system may include a housing configured to at least partially enclose the actuator.

[0039] Optionally, an air vent may be provided extending through the housing and configured to allow air to flow in and out of the housing.

[0040] Optionally, the extrusion die system may include an air mover configured to actively move air toward or away from the actuator.

[0041] Optionally, the extrusion die system may include multiple controllers.

[0042] Optionally, the actuator is spaced at least 6 inches (15.24 cm) from the extrusion die.

[0043] Optionally, the extrusion die system may include a plurality of actuators arranged in a linear array, with each actuator of the plurality of actuators spaced from at least one adjacent actuator by a distance of about 1 inch (2.54 cm) to about 4 inches (10.16 cm) measured between the centerlines of each actuator and at least one adjacent actuator. In other applications, each actuator may have a different spacing.

[0044] Optionally, the extrusion die system may include a heater configured to heat the material in the extrusion die. Optionally, the extrusion die system may include a heater assembly configured to heat the material in the extrusion die.

[0045] Optionally, one of the first die body and the second die body may have a flexible hinge located adjacent the corresponding first or second lip, the flexible hinge being configured to deform when one of the first lip and the second lip is moved toward or away from the other of the first lip and the second lip.

[0046] Optionally, one of the first lip and the second lip may be configured to be moved by the lip adjustment assembly when the other of the first lip and the second lip cannot be moved by the lip adjustment assembly.

[0047] Optionally, the extrusion die system may include an air source spaced from the extrusion die and the lip adjustment assembly.

[0048] Optionally, the extrusion die system may include a material source configured to discharge material into the extrusion die.

[0049] According to another aspect, there is provided a method of adjusting a size of a gap between a first lip and a second lip of an extrusion die in an extrusion die system, the method including the steps of determining a desired gap distance between the first lip and the second lip, and actuating an actuator of a lip adjustment assembly to cause translation in a first direction of an engagement member coupled to the actuator, the translation of the engagement member causing one of the first lip and the second lip to move toward or away from the other of the first lip and the second lip, the method further including continuing actuation of the actuator until the engagement member translates a predetermined distance, the predetermined distance being associated with the desired gap distance, and the method further including deactivating the actuator to stop translation of the engagement member, whereby one of the first lip and the second lip stops moving toward or away from the other of the first lip and the second lip.

[0050] Optionally, the method may include the step of cooling the actuator by removing heated air in contact with the actuator.

[0051] Optionally, the method may include the step of cooling the actuator by introducing a coolant and contacting the actuator with such coolant.

[0052] Optionally, the extrusion die system includes a controller having a processor and memory, and the method may include storing operating parameters in the memory, the operating parameters including the predetermined desired gap and the predetermined distance associated with the desired gap in the memory.

[0053] Optionally, the method may include the steps of retrieving operating parameters from a memory, and operating the actuator so that the actuator corresponds to the retrieved operating parameters.

[0054] Optionally, the extrusion die system may include a plurality of actuators and the method may include repeating the identifying, activating, continuing and deactivating steps for each of the plurality of actuators.

[0055] In one general aspect, a method is provided that includes identifying a neutral gap distance between a first lip and a second lip. The method further includes adjusting the neutral die lip gap by actuating an actuator of a lip adjustment assembly to cause translation in a first direction of an engagement member coupled to the actuator, the translation of the engagement member moving one of the first lip and the second lip closer to or farther from the other of the first lip and the second lip. The method further includes adjusting the die lip gap to a secondary value by actuating an actuator of a lip adjustment assembly to cause translation in a first direction of an engagement member coupled to the actuator, the translation of the engagement member moving one of the first lip and the second lip closer to or farther from the other of the first lip and the second lip. The method further includes determining the die lip gap to the secondary value. The method includes storing the die lip gap value. The method further includes generating a control value for a next actuation of the lip adjustment assembly based on the die lip gap value.

[0056] The invention will be better understood when read in conjunction with the accompanying drawings, in which: For the purpose of illustrating the subject matter of the invention, there are shown in the drawings exemplary aspects of the subject matter of the invention, but the subject matter disclosed herein is not limited to the specific methods, specific apparatus, and specific systems disclosed. [Brief description of the drawings]

[0057] [Figure 1] 1 is a perspective view of a portion of an extrusion die system according to one aspect of the present invention. [Diagram 2] FIG. 2 is a side cross-sectional view of the extrusion die system of FIG. 1. [Diagram 3] 2 is a side cross-sectional view of a portion of the extrusion die system of FIG. 1. [Figure 4A] FIG. 1 is a perspective view of a coupler according to one aspect of the present invention. [Figure 4B] FIG. 2 is a perspective view of a coupler according to another aspect of the present invention. [Figure 4C]FIG. 4C is an exploded view of the coupler of FIG. 4B. [Diagram 5] 2 is a perspective view of a portion of the extrusion die system of FIG. 1 according to another aspect of the present invention. [Figure 6A] FIG. 2 is a schematic top perspective view of a lip adjustment assembly according to one aspect of the present invention; [Figure 6B] FIG. 11 is a schematic top perspective view of a lip adjustment assembly according to another aspect of the present invention. [Figure 6C] FIG. 13 is a schematic front perspective view of a lip adjustment assembly according to yet another aspect of the present invention. [Figure 7] 1 is a flow diagram illustrating a method of operating an extrusion die system according to one aspect of the present invention. [Figure 8] 1 illustrates an exemplary method for calibrating die lip clearance in accordance with aspects of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0058] Aspects of the present invention will now be described in detail with reference to the drawings, in which like reference numbers refer to like elements throughout the drawings unless otherwise specified.

[0059] Throughout this specification, terms are intended to have their ordinary meanings as understood by those of ordinary skill in the relevant art. However, to avoid any doubt, the meaning of certain terms is specifically defined or clarified.

[0060] As used herein, the term "plurality" means two or more. The singular forms "a," "an," and "the" include the plural, and reference to a particular numerical value includes at least that particular value unless the context clearly dictates otherwise. Thus, for example, reference to "an material" is a reference to at least one of such material and equivalents and so forth known to those of skill in the art.

[0061] Typical automatic control of lip gap profile for extrusion dies is embodied by thermally actuated translator blocks. These are effective in controlling the thickness profile of the extrudate, but do not provide an indication of the actual lip gap. Thermally actuated translator blocks also take time to expand and stabilize. Thermal crosstalk between the environment, die body, translator block, and / or others also adds to the control noise. The time constant (time to 62.7% of full expansion) can be 3 minutes to 12 minutes depending on the design. Aspects of the present invention, on the other hand, utilize stepper motors that can change the profile in milliseconds. By counting the number of revolutions, the lip gap profile can be known with high accuracy. Aspects of the present invention can store lip profile recipes that ramp up with great accuracy and speed, thereby minimizing waste when making changes from one product to another.

[0062] Additionally, extrusion dies typically operate at temperatures ranging from 300°F (148.9°C) to 630°F (332.2°C). Heat can be transferred from the die body to the lip adjustment system. The air around the extrusion die can be quite warm and may contain fumes of low molecular weight polymer or monomer. It is desirable to protect the stepper motor from excess heat and contamination resulting from condensation of process off-gases. As described herein, various schemes are provided to protect the stepper motor from excess heat and contamination. Additionally, aspects of the present invention include embodiments in which the stepper motor may be removably mounted on the die body at a distance that sufficiently reduces heat transfer. Additionally, aspects of the present invention may embody an array of stepper motors that may be housed in a forced air cooled box with an air inlet fan and an air outlet vent to safely keep the temperature of the stepper motors below design limits. Additionally, aspects of the present invention may include a fan air inlet that may have ducts and hoses so that the air supply comes from a cooler area, such as a cooler area of ​​a factory that has significantly less process fumes than the area where the extrusion die is located.

[0063] Additionally, aspects of the invention include the implementation of a stepper motor, which is a relatively expensive component. Thus, aspects of the invention are configured with a lip adjustment system that includes a minimum number of these parts and is of suitable specification to keep costs down. Furthermore, aspects of the invention may implement an array of stepper motors spaced close enough together on center to allow the processor to adequately distort the lip of the system. Aspects of the invention may avoid spacing the motors so far apart that there is sufficient deflection between adjustments to cause thickness control problems. In one aspect of the invention, the moment of inertia of a typical flex lip design results in an optimal separation from a 2 inch centerline up to a 3.5 inch centerline (where 1 inch = 2.54 cm). Various aspects of the invention may implement a DC stepper motor that rotates a shaft, thereby simplifying function and controlling costs. This rotational motion may be converted to linear motion by a spool, which turns a screw thread to profile the flex lip of the die. In various aspects of the invention, a particular motor torque range may be used to deflect the flexing lip to overcome the hydraulic force from the pressurized polymer in the lip gap. For example, in one or more aspects, a 12 ft-lb torque motor may be used as a minimum for low pressure applications, up to a maximum of 25 ft-lb torque motors for high pressure applications (where 1 ft-lb = 1.355 N m). In various aspects, the motor may be embodied with a torque of 5 ft-lbs to 100 ft-lbs, 5 ft-lbs to 10 ft-lbs, 10 ft-lbs to 20 ft-lbs, 20 ft-lbs to 30 ft-lbs, 30 ft-lbs to 40 ft-lbs, 40 ft-lbs to 50 ft-lbs, 50 ft-lbs to 60 ft-lbs, 60 ft-lbs to 70 ft-lbs, 70 ft-lbs to 80 ft-lbs, 80 ft-lbs to 90 ft-lbs, 90 ft-lbs to 100 ft-lbs, and / or other torques.

[0064] In another aspect of the invention, the motor may need to be periodically removed from the die for maintenance or replacement. Thus, the disclosed system is configured to simplify the removal or disassembly process so that periodic maintenance can be convenient and effective. In aspects of the invention, the motor may be removed from the die body in a modular subassembly. This may be beneficial since it is not necessary to remove many parts to get to a particular motor for processor maintenance.

[0065] In various aspects of the invention, an array of stepper motors may be attached to the extrusion die flex lip body that can be used to distort the flex lip so that the gap created between the flex lip and the fixed lip can be profiled to fine tune the thickness distribution of the extrusion. Aspects of the invention may incorporate a DC stepper motor that turns a shaft for functional simplicity and cost control. In aspects of the invention, the rotary motion of the stepper motor may be converted to linear motion by a spool that turns a screw thread to profile the flex lip of the die. Aspects of the invention may incorporate a stepper motor or a servo motor to respond to commands from a thickness measurement and control system. Additionally, various aspects of the invention may incorporate temperature isolation, spacing, torque, subassemblies, and / or others as further described herein.

[0066] 1 and 2, an extrusion die system 1 for forming a polymer film or extrudate is shown. The extrusion die system 1 is configured to receive a flowable material (e.g., a polymeric material) from a source 8 (shown in FIG. 2) and discharge the flowable material into an extrudate. The extrudate may be discharged onto a substrate (not shown). The extrusion die system 1 includes an extrusion die 10 and a lip adjustment assembly 100 attached to the extrusion die 10. The lip adjustment assembly 100 may control the thickness of the extrudate being dispensed from the extrusion die 10. The lip adjustment assembly 100 may be configured to vary the size and shape of the extrudate. In some aspects, the lip adjustment assembly 100 may vary the size and shape of the extrudate at one location or multiple locations of the formed extrudate, as described below.

[0067] The extrusion die system 1 may include a heater 12 (shown in FIG. 2) configured to heat a molten material, e.g., a material received into the extrusion die system 1 to form a molten polymer. The molten material may then be moved into and discharged from the extrusion die 10. As will be appreciated, the material may be introduced into, heated, and flowed through the extrusion die system 1 according to any known mechanism or method. The material used herein may be a polymeric material, which may include thermoplastic polymers, synthetic resins, liquid crystal polymers, and / or others. It will be appreciated that other suitable flowable materials, e.g., adhesives, may be processed using the extrusion die system 1. The extrusion die system 1 may be configured to process a single type of polymer or multiple types of polymers. For example, the extrusion die 10 may include multiple different passages, each configured to process and guide a different material, thereby forming a multicomponent extrudate or film. Additionally, it will be appreciated that the extrusion die 10 may be used to process non-polymeric materials.

[0068] As shown in Figures 1 and 2, the extrusion die 10 may include a first die body 14 and a second die body 22 having a gap 30 (shown in Figure 2) formed therebetween through which the extrudate may exit the extrusion die 10. The first die body 14 includes a first lip 18 and the second die body 22 includes a second lip 26 (shown in phantom in Figure 2). The first lip 18 and the second lip 26 together define an exit opening of the extrusion die 10 in the form of the gap 30. The first die body 14 and the second die body 22 are positioned opposite one another along the first direction 2. In this regard, the first lip 18 is positioned opposite and adjacent to the second lip 26. A gap 30 is formed between the first lip 18 and the second lip 26, the gap extending along a first direction 2 from the first lip 18 to the second lip 26. The gap 30 extends along a second direction 3 perpendicular to the first direction 2. During use, the extrusion may exit the gap 30 along a third direction 4 perpendicular to the first direction 2 and the second direction 3. In this disclosure, the first direction 2 may be referred to as the thickness direction, the second direction 3 may be referred to as the width direction, and the third direction 4 may be referred to as the machine direction.

[0069] The gap 30 defines a gap thickness or gap distance 32 between the first die body 14 and the second die body 22, specifically between the first lip 18 and the second lip 26, as measured along the first direction 2. As shown, the gap 30 has a gap distance 32 defined between the first die body 14 and the second die body 22. The gap distance 32 is a dimension of the gap 30 that corresponds to a distance that separates the first lip 18 and the second lip 26 at a given location along the extrusion die 10, for example, along the first direction 2. The lip adjustment assembly 100 is configured to move at least one of the first lip 18 and the second lip 26 to increase or decrease the gap distance 32, thereby adjusting the thickness of the extrudate. In some aspects, the lip adjustment assembly 100 may be configured to move the first lip 18 while the second lip 26 remains stationary. The gap distance 32 may be uniform along the second direction 3 throughout the extrusion die 10. In some aspects, the gap distance 32 may vary along the second direction 3. The lip adjustment assembly 100 may be configured to vary the gap distance 32 by either the same rate of change or a different rate of change along the second direction 3. That is, the gap 30 may be a straight line or a non-linear curve when viewed along the third direction 4 in a plane defined by the first direction 2 and the second direction 3.

[0070] As best shown in FIG. 2, at least one of the first lip 18 and the second lip 26 may be movable to allow adjustment of the gap distance 32. In the illustrated embodiment, the first die body 14 may have a movable lip, shown as the first lip 18. The first lip 18 may be fixedly attached to the remainder of the first die body 14 by a flex hinge 34. The flex hinge 34 may be configured to deform by a lip adjustment assembly 100 such that the first lip 18 may be selectively moved toward or away from the second lip 26. Moving the first lip 18 away from the second lip 26 increases the gap distance 32, thus increasing the size of the gap 30, and moving the first lip 18 closer to the second lip 26 decreases the gap distance 32, thus decreasing the size of the gap 30. As will be appreciated, the flexure hinge 34 may be constructed of a suitable deformable material configured to withstand many repeated deformations without substantially losing its structural integrity. The flexure hinge 34 may be thin enough to bend in response to forces applied to the first lip 18 by the lip adjustment assembly 100.

[0071] The lip adjustment assembly 100 may be operatively coupled to the first lip 18. The first lip 18 may be selectively moved toward or away from the second lip 26, thereby decreasing or increasing the gap distance 32, respectively. As will be appreciated, while the illustrated embodiment shows the lip adjustment assembly 100 configured to contact and move the first lip 18, other embodiments are contemplated in which the lip adjustment assembly 100 may be configured to contact and move the second lip 26. In some embodiments, the extrusion die system 1 may include multiple lip adjustment assemblies 100, with each of the first lip 18 and the second lip 26 being operatively coupled to and movable by a separate embodiment of the lip adjustment assembly 100. In another embodiment, a single lip embodiment of the lip adjustment assembly 100 may be configured to move both the first lip 18 and the second lip 26.

[0072] The lip adjustment assembly 100 may include an engagement member 104 configured to move a movable lip, e.g., the first lip 18. At least a portion of the first lip 18 may be movable relative to the second lip 26 along an actuation direction 5. The actuation direction 5 may include movement toward the second lip 26 and in a reverse direction away from the second lip 26. The engagement member 104 may include a rod, bar, shaft, dowel, pole, pin, and / or the like configured to receive force from the lip adjustment assembly 100 and transmit force from the lip adjustment assembly 100 to the first lip 18. The engagement member 104 may receive a compressive force that moves the first lip 18 toward the second lip 26 along the actuation direction 5 and / or a tensile force that pulls the first lip 18 away from the second lip 26 along the actuation direction 5.

[0073] The lip adjustment assembly 100 may further include an actuator 108 configured to move the first lip 18 via the engagement member 104. The actuator 108 may include a motor configured to move the engagement member 104. The actuator 108 may include a linear actuator, such as a stepper motor, a servo motor, and / or the like.

[0074] The actuator 108 may be embodied as a machine actuator, an electric actuator, a pneumatic actuator, a hydraulic actuator, and / or the like. Electric actuators as examples of actuator 108 include DC motors, AC motors, self-excited motors, brushed DC motors, electronic commutator (EC) motors, universal AC / DC motors, externally commutated AC machines, induction motors, synchronous motors, doubly-fed electric machines, rotary motors, linear motors, stepper motors, step (pulse) motors, stepping motors, and / or the like. Pneumatic actuators as examples of actuator 108 include air motors, air motors, compressed air engines, linear motors, rotary vane motors, turbine motors, and / or the like. Pneumatic actuators as examples of actuator 108 include vane motors, gear motors, gerotor motors, axial plunger motors, radial piston motors, and / or the like. In aspects, the actuator 108 may be embodied as an electrically powered actuator to beneficially achieve, control, improve, and / or the like, speed, precision, accuracy, stability, repeatability, and / or the like of the actuator 108, the lip adjustment assembly 100, and / or the like. Moreover, in aspects of the invention, the actuator 108 embodied as an electrically powered actuator may be configured to overcome the challenges of utilizing an electrically powered actuator in a lip adjustment assembly by incorporating a number of features, including thermal insulation means utilizing thermally insulating components as described herein.

[0075] In one aspect, the actuator 108 may be embodied as a stepper motor, step (pulse) motor, stepping motor, and / or the like that divides a full rotation into many steps. An actuator 108 that embodies a stepper motor controls and / or commands the stepping motor so that it can move or stay at one of multiple steps without the use of any position sensor for feedback (open loop controller).

[0076] In one aspect, the lip adjustment assembly 100 controls the actuator 108 and / or issues commands to the actuator 108 to move or stay using feedback (closed loop feedback controller). In this regard, the closed loop feedback control scheme may be responsive to a sensor, controller, and / or the like. In aspects, the sensor, controller, and / or the like may detect and / or calculate a current product thickness uniformity, a current coat thickness uniformity, a current film thickness uniformity, a current sheet thickness uniformity, and / or the like. Then, in aspects, the sensor, controller, and / or the like may send commands to the actuator 108 to improve the current product thickness uniformity, the current coat thickness uniformity, the current film thickness uniformity, the current sheet thickness uniformity, and / or the like. Thereafter, a sensor, controller, and / or the like can detect and / or calculate the change in thickness uniformity, change in coat thickness uniformity, change in film thickness uniformity, change in sheet thickness uniformity, and / or the like, and repeat the process of commanding the actuator 108 as necessary. In one aspect, the lip adjustment assembly 100 can control and / or command the actuator 108 to move or stay with feedback at a stored lip profile recipe to be ramped up with great accuracy and speed, factoring in minimizing waste when switching from one product to another (closed loop feedback control).

[0077] The actuator 108, embodying a stepper motor, can convert a train of input pulses, which may be square waves, into precisely defined incremental and resulting rotational positions. Each pulse provided to the stepper motor can rotate the stepper motor shaft a fixed angle. The stepper motor can be a permanent magnet stepper motor, a variable reluctance stepper motor, a hybrid synchronous stepper motor, a unipolar stepper motor, a bipolar stepper motor, and others. The actuator 108 and / or the stepper motor can have one or more drive circuits. The actuator 108 can receive power from a power source (not shown) connected to the lip adjustment assembly 100. The lip adjustment assembly 100 can include multiple engagement members 104 and / or multiple actuators 108. Each engagement member 104 can be operatively coupled to a separate embodiment of the actuator 108.

[0078] In aspects, one or more of the engagement members 104 may be operatively coupled to a separate embodiment of the actuator 108 in a push configuration that pushes the actuator 108. In aspects, one or more of the engagement members 104 may be operatively coupled to a separate embodiment of the actuator 108 in a pull configuration that pulls the actuator 108. In aspects, one or more of the engagement members 104 may be operatively coupled to a separate embodiment of the actuator 108 in a push-pull configuration that both pushes and pulls the actuator 108. Alternatively or additionally, two or more of the engagement members 104 may be movable by a single embodiment of the actuator 108. Each actuator 108 may have a torque capacity of about 10 N-m to about 50 N-m, or about 12 N-m to about 40 N-m.

[0079] The actuator 108 may include a rotational component (not shown) configured to translate a linear component 110 (shown in FIG. 3 ). The rotational component may include one or more types of mechanisms, including a spool that rotates a screw thread, a screw, a lead screw, a screw jack, a ball screw, a roller screw, and / or others. The linear component may be translatable along an actuation direction 5 toward or away from the second lip 26. The linear component 110 may be coupled to the engagement member 104 such that when the linear component 110 is moved toward the second lip 26, the engagement member 104 is also moved in the same direction, and when the linear component 110 is moved away from the second lip 26, the engagement member 104 is also moved away from the second lip 26 in the same direction as the linear component 110.

[0080] Utilizing the disclosed actuator 108, e.g., a stepper motor, in the lip adjustment assembly 100 can improve the accuracy and precision of the adjustment of the first lip 18 and the gap 30. The stepper motor operates by turning a rotary component, which causes a proportional translation of the linear component 110 a desired distance. The linear component 110 can translate a fixed linear distance that corresponds to a fixed rotational distance of the rotary component. That is, rotationally moving the rotary component a first increment results in a translation of the linear component 110 a second increment. This configuration allows for high precision and accurate adjustment of the engagement member 104 coupled to the actuator 108. In use, a user may wish to move the engagement member 104 a desired distance toward or away from the second lip 26 to decrease or increase the gap distance 32, respectively. Because the engagement member 104 can move by translation of the linear component 110, which can be translated based on a ratio of known rotational movements of the rotational component, the user can cause the actuator 108 to rotate the rotational component a desired rotational distance in a first or second direction, resulting in a known and desired translational movement of the linear component 110 and the engagement member coupled thereto toward or away from the second lip 26.

[0081] In the existing technology, thermal bolts connected to the engaging members are heated or cooled to cause expansion or contraction, respectively. When the thermal bolts are expanding, they cause the engaging members to move in the opposite direction to reduce the gap, and when the thermal bolts are contracting, they cause the engaging members to move in the opposite direction to increase the gap. However, since the thermal bolts need time to absorb or radiate heat and expand or contract, respectively, such designs often require at least several minutes to adjust the gap. In addition, it is difficult to properly time when to stop heating or cooling the thermal bolts, and the thermal bolts often receive or release too much heat, resulting in overshooting of the target expansion or contraction and making the gap distance larger or smaller, respectively. Furthermore, the existing process is undesirably affected by external variables, such as the ambient temperature. For example, if the ambient temperature is higher than the desired temperature, the thermal bolts will be at a high starting temperature before heat is applied, and conversely, if the ambient temperature is lower than the desired temperature, the thermal bolts will be at a low starting temperature, which will require a large amount of heat and heating time to reach the desired temperature. Furthermore, the use of existing thermal bolt adjustments requires heating of the thermal bolts, where the heat used to heat the thermal bolts may be conducted or radiated from each thermal bolt toward the extrusion die. This heat may then add unnecessary heat to the extrusion die and the material flowing therethrough, thus changing the viscosity, consistency, and / or other flow parameters of the extruded material. This undesirable excess heat may result in less precision in dispensing the material and may result in unintended thickness and / or composition of the resulting extrusion sheet.

[0082] The undesirable results of the existing thermal bolt adjustment techniques described above can be avoided by utilizing the disclosed actuator 108. The actuator 108 allows for instantaneous adjustment without the delays associated with the existing thermal bolt techniques described above. Additionally, the disclosed actuator 108 allows for precise adjustment of the gap 30 without the risk of overshooting due to over-expansion or over-contraction of the existing thermal bolts described above. The actuator 108 further allows for precise adjustment of the gap 30 by the user. The user can determine the exact linear translation of the engagement members 104 along the actuation direction 5 for any given increment of rotational movement of the rotating member of the actuator 108. The determined ratio allows the user to make precise adjustments to each engagement member 104 by having the actuator 108 move the rotating component by the desired increment. The determined ratio can also be utilized at a later point in time to allow the user to make precise and repeatable adjustments to the gap 30 over different operating cycles of the extrusion die system 1. Additionally, because the actuator 108 does not require the addition of heat, there is no excess heat introduced into the extrusion die 10 that could otherwise negatively affect melt flow characteristics, such as with existing solutions that utilize thermal bolts.

[0083] During operation, the extrusion die 10 is configured to be heated to a desired temperature so that the material being extruded can be maintained at a desired temperature, viscosity, consistency, and / or other condition. Components of the extrusion die system 1 that are in contact with or otherwise located next to or in close proximity to the heated extrusion die 10 can absorb heat from the extrusion die 10. Heat can be transferred via direct contact between the components and the extrusion die 10 by being located in close proximity to the heated extrusion die 10, through thermal conduction, thermal convection, and / or otherwise. In some aspects, it may be beneficial to minimize the amount of heat transferred to components of the extrusion die system 1 that are external to the extrusion die 10. For example, it may be beneficial to minimize or reduce the amount of heat transferred from the extrusion die 10 to the lip adjustment assembly 100. Excessive heat may cause damage to components of the lip adjustment assembly 100, such as the actuator 108. The present invention allows for the option of reducing heat transfer from the extrusion die 10 to the actuator 108, at least through the concept of spacing or spacing the actuator 108 away from the heated extrusion die 10 to reduce heat transfer by convection, and insulating the components to reduce heat transfer by conduction. In some aspects, additional considerations are provided for actively or passively cooling the components of the lip adjustment assembly 100, as will be further described below.

[0084] One mechanism for protecting the actuator 108 from heat is to position the actuator 108 an appropriate distance away from the heated extrusion die 10. In some aspects, the actuator 108 may be positioned at least 4 inches (10.16 cm), 5 inches (12.70 cm), 6 inches (15.24 cm), ... or 24 inches (60.96 cm) from the extrusion die 10, or another suitable distance that sufficiently separates the actuator 108 from the extrusion die 10 so that it does not receive more than a predetermined threshold amount of heat.

[0085] In some aspects, the actuator 108 and the engagement member 104 may be directly coupled to one another. In an alternative embodiment, the actuator 108 may be coupled to the engagement member 104 via a coupler 112. The coupler 112 may be coupled to the actuator 108 on one side and to the engagement member 104 on the other side. The coupler 112 may comprise any suitable material configured to withstand the forces being transmitted between the actuator 108 and the engagement member 104. It should be understood that the coupler 112 should be configured to withstand the desired temperature range of the extrusion die system 1. In some aspects, the coupler 112 may comprise steel, such as stainless steel.

[0086] 3, 4A, 4B, and 4C, an insulator or thermal insulation component 122 may be provided on or within the coupler 112. The thermal insulation component 122 may be configured to limit, block, reduce, and / or otherwise effect heat transfer from the extrusion die 10 along the engagement member 104 to the actuator 108. In aspects, the thermal insulation component 122 may be configured to thermally isolate the extrusion die 10 from the actuator 108. The thermal insulation component 122 may include one or more insulator or thermal insulation components, devices, features, thermal isolation components, and / or the like. The thermal insulation component 122 may include mica boards, mica sheets with muscovite or phlogopite paper bonded with high quality heat resistant silicone resin, and / or other materials to limit heat transfer. In some aspects, the insulating component 122 can include an engineering polymer, such as polyimide, polyamide-imide, polyetheretherketone, polyphenylene sulfide, polybenzimidazole, polyetherimide, fluoropolymer, and / or others. The insulating component 122 can include a material having a lower thermal conductivity than the material comprising the coupler 112. That is, the coupler 112 can have a first thermal conductivity and the insulating component 122 can have a second thermal conductivity that is lower than the first thermal conductivity. Some exemplary insulating materials include one or more products manufactured and / or sold by Brandenburger Firmengruppe under the names KV®3, KV®3eco, BRA-GLA®3, BRA-GLA®N, and S4000®. It should be understood that the products listed are merely exemplary. The particular material used for the insulating component 122 may be selected based on the expected use and expected temperature range of the components described herein, and this specification is not intended to be limited by the range of any particular insulating material.The insulating component 122 may be an insulating assembly including multiple insulating components 122 or similar components (see, for example, the exploded view of FIG. 4C ), where one or more of the multiple components may be embodied as individual implementations of the insulating component 122, and the components may be separable from one another.

[0087] In some aspects, the coupler 112 may have a first portion 116 fixedly attached to the engagement member 104 and a second portion 120 fixedly attached to the actuator 108, e.g., the linear component 110. The first portion 116 may be separate from and spaced apart from the second portion 120. The insulating component 122 may be disposed at least partially between the first portion 116 and the second portion 120. In some aspects, the coupler 112 may have a groove, notch, recess, and / or the like, hereinafter generally referred to as a recess 114. The recess 114 may extend through a portion of the coupler 112 along the actuation direction 5. The recess 114 may be configured to receive the insulating component 122. The coupler 112 may have a plurality of recesses 114. As shown in Figures 3 and 4A, in some aspects, the first portion 116 of the coupler 112 may have a first recess 114A and the second portion 120 of the coupler 112 may have a second recess 114B. The thermal insulation component 122 may be disposed in both the first recess 114A and the second recess 114B, and the thermal insulation component may extend between the first portion 116 and the second portion 120. The first recess 114A and the second recess 114B may be disposed at approximately the geometric center (as viewed along the actuation direction 5) of the first portion 116 and the second portion 120 of the coupler 112. Such an arrangement of the recesses 114A may help dissipate heat present in the coupler 112 by providing additional surface area for heat to radiate. Disposing the thermal insulation component 122 in the first recess 114A and the second recess 114B may help reduce the amount of heat transferred through the coupler 112. An insulating component 122 located at or near the geometric center of the coupler 112 can prevent heat from migrating to the centerline of the coupler 112 and then spreading radially outward toward the outer edge of the coupler 112. Locating an insulating component 122 between the first portion 116 and the second portion 120 of the coupler 112 can also prevent heat from migrating upward through the coupler 112 toward the actuator 108 along the actuation direction 5.It should be understood that the insulating component 122 must be configured to withstand the compressive, tensile, rotational, and shear stresses applied thereto by the coupler 112 during installation, removal, or use of any of the components described herein.

[0088] The extrusion die system 1 may include rigid structural members that support and / or connect various components of the extrusion die system 1, such as one or more components of the extrusion die 10 and one or more components of the lip adjustment assembly 100. Referring again to FIGS. 1 and 2, a frame 144 may extend between the extrusion die 10 and the lip adjustment assembly 100. The frame 144 may be fixedly attached at one end to the extrusion die 10 and / or at another end to the lip adjustment assembly 100. The frame 144 may be configured to be separable from the extrusion die 10, from the lip adjustment assembly 100, or from both the extrusion die 10 and the lip adjustment assembly 100. In some aspects, the frame 144 may be configured to selectively engage different embodiments of the extrusion die 10 and / or different embodiments of the lip adjustment assembly 100. It should be understood that the frame 144 should be designed and manufactured to withstand the physical forces and pressures associated with supporting the lip adjustment assembly 100 relative to the extrusion die 10 (or vice versa), as well as any other components attached to or provided within the frame 144.

[0089] In some aspects, the frame 144 may define an interior volume that may at least partially accommodate one or more of the components of the lip adjustment assembly 100, such as, but not limited to, the engagement member 104, the coupler 112, and / or the actuator 108. As shown in the exemplary embodiment of FIGS. 1 and 2, at least a portion of the engagement member 104 and each coupler 112 may be disposed within the frame 144 between the extrusion die 10 and the actuator 108. In some aspects, the frame 144 may be provided with one or more openings 148. Each opening 148 may extend through at least a portion of the frame 144 such that the opening 148 is in communication with the interior volume of the frame 144 and with an environment external to the frame 144. The openings 148 may be round, rectangular, triangular, oval, and / or of another geometric shape. The frame 144 may have a plurality of openings 148. During operation of the extrusion die system 1, heat may be generated by movement of the engagement member 104 and / or coupler 112. Additionally, heat may be transferred from the extrusion die 10 to the engagement member 104 and / or coupler 112 as described throughout this specification. When components within the frame 144 are heated, heat may be transferred along those components and through the frame 144 toward the actuator 108. The presence of one or more openings 148 in the frame 144 allows at least some of the heat to exit the frame 144 and dissipate from the lip adjustment assembly 100, thereby reducing the amount of heat transferred to the actuator 108. In some aspects, one or more coolants may be introduced to the engagement member 104 and / or coupler 112 in the frame 144 through the one or more openings 148. For example, one or more fans 128 may be configured to direct a cooling fluid, such as air, through one or more openings 148 into the frame 144 to contact the engagement members 104 and / or couplers 112 therein. Alternatively, or additionally, the one or more fans 128 may be configured to extract heated air from the frame 144 via the one or more openings 148.

[0090] The lip adjustment assembly 100 may include one or more of the actuators 108, the engagement members 104, the couplers 112, and / or the like. In some aspects, the lip adjustment assembly 100 may include a plurality of sets of interconnected components, each set including one actuator 108, one engagement member 104, and one coupler 112 operatively coupled to one another. Each set of interconnected components may be disposed adjacent to at least one other set of components. As shown in FIG. 5, for example, the plurality of sets of engagement members 104, couplers 112, and actuators 108 may be disposed adjacent to one another in a substantially linear array along an array direction 6. The array direction 6 may be substantially orthogonal to the actuator direction 5. In some aspects, the array direction 6 may be parallel to the second direction 3 of the extrusion die system 1. 5 includes labeling of some of the actuators 108, couplers 112, and engagement members 104, it should be understood that the illustrated reference numbers apply equally to all like components shown in this figure. As shown, the lip adjustment assembly 100 may include 14 sets of interconnected components, each set including an actuator 108, coupler 112, and engagement member 104. It should be understood that other embodiments are contemplated and that the lip adjustment assembly 100 may include 1, 2, ..., 30, or another suitable number of sets of components, as discussed above.

[0091] In some aspects, the lip adjustment assembly 100 may include multiple array arrangements of sets of interconnected components. Each set of components in each array may be positioned relative to another set of components or other components of the extrusion die system 1. The components are described with respect to an actuation direction 5, an array direction 6, and an offset direction 7. The offset direction 7 may be orthogonal to the array direction 6 and the actuation direction 5. By way of example, and referring to Figures 6A-6C, schematic diagrams of various embodiments of the lip adjustment assembly 100 are shown. Figure 6A shows an example implementation of the lip adjustment assembly 100 including 14 sets of actuators 108, couplers 112, and engagement members 104. The embodiment shown in Figure 6A is shown in a plane defined by the array direction 6 and the offset direction 7. Figure 6A shows all of the sets (identified by actuators 108) arranged in a first array 101 along the array direction 6.

[0092] 6B illustrates an alternative embodiment lip adjustment assembly 100′ that includes two linear array arrangements of the above-described component sets. The two array arrangements are shown as a first array 101 and a second array 102. The second array 102 may be spaced apart from the first array 101 along the offset direction 7.

[0093] FIG. 6C illustrates yet another embodiment of a lip adjustment assembly 100″, shown in a plane defined by the actuation direction 5 and the array direction 6. The lip adjustment assembly 100″ may include two linear arrays of the set of components described above, with a first array 101 spaced apart from a second array 102 along the actuation direction 5. It should be understood that, as illustrated, when one or more actuators 108 are spaced apart further from the extrusion die 10 than one or more other embodiments of the actuators 108, the further apart actuators may include longer engagement members 104 and / or longer couplers 112. In some aspects, it may be preferable for the actuators 108 to be spaced apart from the extrusion die 10 by at least a minimum threshold distance to reduce the amount of heat that can be transferred from the heated extrusion die 10 to the actuators 108. The actuator 108 may be spaced at least 2 inches (5.08 cm), 3 inches (7.62 cm), 4 inches (10.16 cm), ..., 24 inches (60.96 cm), or another suitable distance from the extrusion die 10. In some particular embodiments, the actuator 108 may be spaced about 6 inches (15.24 cm) from the extrusion die 10.

[0094] 6A-6C depict three embodiments exhibiting different numbers and arrangements of the arrays of components, it is understood that the lip adjustment assembly 100 may include more arrays in other embodiments, including three, four, five, or another suitable number. It should also be understood that embodiments can include combinations of the illustrated embodiments, i.e., lip adjustment assembly 100, lip adjustment assembly 100', and lip adjustment assembly 100", for example, lip adjustment assembly 100 can include a first array 101 spaced apart from a second array 102 along both the actuation direction 5 and the offset direction 7.

[0095] The embodiment including multiple actuators 108 allows for fine adjustment of the first lip 18 relative to the second lip 26. Each actuator 108 can cause movement of the interlocking engagement members 104, thereby moving a portion of the first lip 18 toward or away from the second lip 26, while one or more adjacent portions of the first lip 18 are not moved or are moved to a different extent. This allows the overall length of the first lip 18 to be adjusted along the second direction 3 as needed to form the desired gap 30.

[0096] The actuators 108 from adjacent sets of components may be spaced a predetermined distance from each other. For example, each embodiment, or one or more embodiments, of the actuator 108 may be spaced a distance of approximately 1 inch (2.54 cm) to approximately 4 inches (10.16 cm) from any other embodiment of the actuator 108 of the lip adjustment assembly 100. In some particular embodiments, the actuators 108 may be spaced from each other by approximately 2.25 inches (5.72 cm). These distances may be defined as the distance between centerlines of the actuators 108, which may extend parallel to the actuation direction 5.

[0097] Each actuator 108 may be at least partially disposed within an actuator housing 124. Referring again to Figures 1 and 2, the actuator housing 124 may be attached to the extrusion die system 1, for example, the lip adjustment assembly 100. The actuator housing 124 may be removably coupled to the lip adjustment assembly 100 such that the actuator housing 124 may be removed as needed to provide access to the actuators 108. The actuator housing 124 may be made of metal, polymer, and / or the like. It should be understood that the actuator housing 124 should be configured to withstand heat radiating from the heated extrusion die 10 or conducted along the lip adjustment assembly 100 from the heated extrusion die 10.

[0098] The lip adjustment assembly 100 may include a single embodiment of an actuator housing 124 that is sized and shaped to at least partially enclose all of the actuators 108 of the lip adjustment assembly 100. In some aspects, the lip adjustment assembly 100 may include multiple actuator housings 124, with each actuator housing 124 configured to house one or more of the multiple actuators 108.

[0099] The actuator housing 124 may include a vent 132. The vent 132 may comprise an opening through at least one surface of the actuator housing 124. The vent 132 allows air to enter and exit the actuator housing 124. Airflow around the actuator 108 within the actuator housing 124 may facilitate cooling of the actuator 108. The vent 132 may include a grate, lattice, grid, and / or another suitable design of opening. The actuator housing 124 may include multiple vents 132.

[0100] An air or coolant mover may be provided on the actuator housing 124. The air or coolant mover may include a fan 128. The fan 128 may move air into and / or out of the actuator housing 124. Moving air toward and / or away from the actuator 108 may facilitate cooling of the actuator 108. The fan 128 may be coupled to a power source and controller 9 (shown in FIG. 2 ) configured to operate the fan 128. The lip adjustment assembly 100 may include a plurality of fans 128. In some aspects, one or more of the plurality of fans 128 may be configured to move air into the actuator housing 124, while one or more others of the plurality of fans 128 may be configured to move air out of the actuator housing 124. Such air movement can create air flow paths that can move through and / or over the actuator 108, thus cooling the actuator 108.

[0101] The air moved into the actuator housing 124 by the fan 128 and / or vent 132 may be sourced from immediately outside and adjacent to the actuator housing 124. In some aspects, as shown generally in FIG. 2, the air moved into the actuator housing 124 may be delivered via a conduit 136 from an air source 140 spaced far from the extrusion die system 1. The conduit 136 may include a hose, duct, and / or the like. The ambient air located in close proximity to the actuator housing 124 may be heated by heat radiating from the heated extrusion die 10. Thus, it may be preferable to move air into the actuator housing 124 that is cooler than the ambient air located immediately adjacent to the actuator housing 124. In such aspects, the air source 140 may be located a sufficient distance from the heated extrusion die 10 such that the air source 140 is not heated by the heated extrusion die 10 beyond a predetermined value. In some aspects, the environment immediately surrounding the extrusion die 10 may include various volatile gases that evaporate from the extrusion die system 1 during use. The evaporated volatile gases may condense and leave a residue on the actuator 108. It may therefore be preferable to avoid introducing cooling air containing such volatiles into the actuator housing 124, and instead introduce cooling air from a remote air source 140 that is substantially free of undesirable volatiles. For example, the air source 140 may include ambient air. It should be understood that although the above description specifically relates to air, any other suitable coolant may be used.

[0102] The extrusion die system 1 may include a controller 9 configured to control the operation of various components of the extrusion die system 1, such as, but not limited to, the heater 12, the extrusion die 10, the components of the lip adjustment assembly 100, and / or other components connected thereto, such as, but not limited to, the actuator 108, the fan 128, the air source 140, and / or other components connected thereto. The controller 9 may include an input interface for receiving and processing input from a number of input devices, such as, but not limited to, a keyboard, a mouse, a touch pad, a touch screen, an electronic stylus, or other types of input devices. Similarly, the controller 9 may include an output interface for providing output to an output display, such as, but not limited to, a computer monitor, a flat panel display, a digital projector, a printer, a plotter, a touch screen, or other types of output devices. The controller 9 may include driver circuitry for controlling components of the extrusion die system 1, such as the heater 12, the extrusion die 10, the lip adjustment assembly 100, and / or other coupled components, such as, but not limited to, the actuator 108, the fan 128, the air source 140, and / or other coupled components. The extrusion die system 1 may include one or more sensors, such as, but not limited to, temperature sensors, flow rate sensors, position sensors, and / or other. The controller 9 may include input devices for receiving sensor readings from one or more sensors associated with one or more of the extrusion die system 1, such as, but not limited to, the heater 12, the extrusion die 10, the lip adjustment assembly 100, and / or other coupled components, such as, but not limited to, the actuator 108, the fan 128, the air source 140, and / or other coupled components. The controller 9 may include a computing device, which may be a physical computing device or a virtual machine host process and one or more virtual machine instances. The computer-executable instructions may be executed indirectly by the physical hardware of the computing device through interpretation and / or execution of instructions stored and executed in the context of a virtual machine. The controller 9 may include a processor and a memory.The processor may include one or more devices selected from a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a state machine, a logic circuit, an analog circuit, a digital circuit, or other devices that manipulate signals (analog or digital) based on operational instructions stored in the memory. The memory may be a single memory device or may include multiple memory devices, such as, but not limited to, a read only memory (ROM), a random access memory (RAM), a volatile memory, a non-volatile memory, a static random access memory (SRAM), a dynamic random access memory (DRAM), a flash memory, a cache memory, or any other device capable of storing digital information. The memory may further include a mass storage device (not shown), such as a hard drive, an optical drive, a tape drive, a non-volatile solid state device, or any other device capable of storing digital information. The processor may operate under the control of an operating system resident in the memory. The extrusion die system 1 may include a number of controllers 9, and the various components described above and throughout this specification may be controlled by one or more of the number of controllers 9.

[0103] Any of the extrusion die system 1 or components thereof described throughout this specification may be operated by a user. Figure 7 illustrates an exemplary method of operation 200 for adjusting the size of the gap 30 between the first lip 18 and the second lip 26. In step 204, the user determines a desired gap distance 32 that defines the gap 30 between the first lip 18 and the second lip 26. The desired gap distance 32 may correspond to a size of the gap 30 that results in a desired extrudate shape, pattern, consistency, and / or the like. The user may make this determination based on previously identified data or by monitoring the gap 30 prior to adjustment and determining that the gap distance 32 needs to be changed.

[0104] In step 208, a user and / or the extrusion die system 1 may actuate the actuator 108. In some aspects, for example, if the actuator 108 includes a stepper motor, actuation may include rotating a rotary component of the actuator 108 by a number of steps. Rotation of the rotary component results in translation of the linear component 110 as described above. Rotation of the rotary component may be embodied by a predetermined number of steps, a rotation distance, a speed, and / or the like. Small movements of the rotary component, for example, the movements may be proportionally linked to small translational movements of the linear component 110. Actuation of the actuator 108 may include a user manually turning the rotary component. In some aspects, actuation may include a user inputting commands into the extrusion die system 1, for example, the controller 9, to electronically cause the actuator 108 to rotate the rotary component. Actuation may be performed in a first rotational direction resulting in translation of the linear component 110 in a first translational direction along the actuation direction 5, or in a second rotational direction opposite to the first rotational direction resulting in translation of the linear component 110 along the actuation direction 5 in a second translational direction opposite to the first translational direction. One of the first and second translational directions may correspond to movement of the linear component 110 towards the extrusion die 10, and the other of the first and second translational directions may correspond to movement of the linear component 110 away from the extrusion die 10.

[0105] In step 212, the user and / or extrusion die system 1 may determine the actuation time of actuator 108 and / or the translation distance of linear component 110 based on the desired gap distance 32. Linear component 110 may be coupled to engagement member 104 as described above, thereby moving one of first lip 18 and second lip 26 closer to or farther from the other of first lip 18 and second lip 26. The more adjustment required to gap distance 32, the longer actuator 108 may operate and / or the faster actuator 108 may operate. In this regard, the desired effect may be a desired product thickness, a desired coating thickness, a desired film thickness, a desired sheet thickness, and / or the like.

[0106] In step 216, the user and / or extrusion die system 1 may terminate actuation of actuator 108. When actuator 108 is deactivated, translation of coupled engagement member 104 also stops. When engagement member 104 is no longer moving, first lip 18 or second lip 26 coupled to engagement member 104 also stops moving toward or away from the other of first lip 18 and second lip 26. At this point, a gap distance 32 between first lip 18 and second lip 26 is established. As will be appreciated, the gap distance 32 referred to in this step only applies to the distance along the first direction 2 between a point on the first lip 18 and a point on the second lip 26 that is spaced apart from the point on the first lip 18 along the first direction 2. In view of the fact that the lip adjustment assembly 100 includes multiple actuators 108 and is configured such that at least one of the first lip 18 and the second lip 26 is distorted non-linearly (as viewed in the plane defined by the first direction 2 and the second direction 3), the gap distance 32 between adjacent points on the first lip 18 and the second lip 26 along the first direction 2 may still be in the adjustment process or may have already been determined earlier.

[0107] The example method 200 may include actuating a plurality of actuators 108 to adjust a gap distance 32 between a set of different points on the first lip 18 and the second lip 26 that are spaced apart from one another along the first direction 2. One or more of the above steps may be performed one or more times to achieve a desired gap 30 along the entire length of the extrusion die 10 as measured along the second direction 3.

[0108] A user and / or the extrusion die system 1 may also operate one or more cooling mechanisms configured to cool one or more actuators 108 in the lip adjustment assembly 100. The cooling step may include operating one or more fans 128 to move cooling air or other coolant fluid towards the one or more actuators 108. In some aspects, the cooling step may include operating one or more fans 128 to move heated air that has received heat from the actuators 108 away from the actuators 108, thus allowing radiation of heat from the actuators 108 and cooling the actuators 108.

[0109] In some aspects, the cooling step may involve introducing cooling air or other coolant from an external embodiment of the air source 140. In some aspects, users may open or otherwise introduce one or more vents 132 in the lip adjustment assembly 100 to allow for better airflow around the actuator 108, thus cooling the actuator 108.

[0110] The cooling step may include spacing the actuator 108 at least a predetermined minimum distance from the extrusion die 10 to reduce the amount of heat transferred from the heated extrusion die 10 to the actuator 108. In some aspects, the cooling step may include introducing one or more embodiments of a thermal insulating component 122 into the lip adjustment assembly 100, such as the coupler 112 disposed between the engagement member 104 and the actuator 108.

[0111] The method may further include identifying a desired adjustment distance and / or degree of actuation of the actuator 108 to result in the desired gap distance 32. The identified information may be stored within the controller 9 or an associated controller or computing system for future use. The method may further include retrieving previously stored information regarding the desired gap distance 32 and associated duration, speed, and other actuation parameters of a particular implementation of the actuator 108. By utilizing the previously stored information, the system may be calibrated and set up for use much more quickly than if a user had to identify the necessary actuation parameters to consistently achieve the desired gap 30 without the previously stored information.

[0112] FIG. 8 illustrates an exemplary method for calibrating die lip clearance in accordance with aspects of the present invention.

[0113] Specifically, FIG. 8 illustrates an exemplary method 300 of calibrating the die lip clearance of the present invention. In this regard, the method 300 of calibrating the die lip clearance may include a method of calibrating the lip adjustment assembly 100. In particular, it should be noted that the method 300 of calibrating the die lip clearance is exemplary only and may be modified in accordance with various aspects disclosed herein. It should be noted that the method 300 of calibrating the die lip clearance may be performed in a different order in accordance with the above-mentioned aspects. Furthermore, the method 300 of calibrating the die lip clearance may be modified to have more or fewer process steps in accordance with various aspects disclosed herein.

[0114] Additionally, the method 300 for calibrating the die lip clearance may be performed during manufacturing, during initial use, at times during use, and / or otherwise. The various values ​​determined by the method 300 for calibrating the die lip clearance may provide for rapid operation of the lip adjustment assembly 100 and / or may be utilized for future operation of the lip adjustment assembly 100.

[0115] The die lip clearance calibration method 300 of the present invention may include determining a neutral die lip clearance 302. In this regard, the neutral die lip clearance determination 302 may include any one or more of the materials, structures, configurations, processes, and / or the like as described herein. Additionally, one or more preceding or succeeding processes may be implemented with respect to determining the neutral die lip clearance 302 consistent with the present invention.

[0116] The neutral die lip clearance of the lip adjustment assembly 100 may be checked by feeler gauges, sensors as described herein, and / or the like after it has been heated to operating temperature.

[0117] The die lip gap calibration method 300 of the present invention may include adjusting the neutral die lip gap 304. In this regard, adjusting the neutral die lip gap 304 may include any one or more of the materials, structures, configurations, processes, and / or the like as described herein. Additionally, one or more preceding or subsequent processes may be implemented with respect to adjusting the neutral die lip gap 304 consistent with the present invention.

[0118] In this regard, the lip adjustment assembly 100 may then be adjusted. In some aspects, the actuator 108 may be adjusted until the gap is fairly uniform at the desired neutral gap. These settings may be specified as the maximum lip gap for the lip adjustment assembly 100. For example, the maximum lip gap for the lip adjustment assembly 100 may typically be 0.040 inches (0.102 cm) for a cast film die. In some aspects, the actuator 108 may achieve a linear relationship with the lip gap. In other aspects, the actuator 108 may achieve a non-linear relationship with the lip gap.

[0119] For example, when the actuator 108 is actuated, the lip gap does not change exactly proportionally to the movement of the actuator 108 because the adjustment is at an angle to the lip gap and the flexing lip may move in an arc due to mechanical bending of the hinge in the die body. In a particular aspect of the actuator 108, when the motor engages the adjustment threads, the lip gap does not change exactly proportionally to the number of rotations because the adjustment is at an angle to the lip gap (typically 45°) and the flexing lip may move in an arc due to mechanical bending of the hinge in the die body.

[0120] The die lip clearance calibration method 300 of the present invention may include a step 306 of adjusting the die lip clearance to a secondary value. In this regard, the adjustment 306 of the die lip clearance to a secondary value may include any one or more of the materials, structures, arrangements, processes, and / or the like as described herein. Additionally, one or more preceding or subsequent processes may be implemented with respect to the adjustment 306 of the die lip clearance to a secondary value consistent with the present invention. In this regard, the lip adjustment assembly 100 may configure the actuator 108 to obtain the secondary gap value.

[0121] The die lip clearance calibration method 300 of the present invention may include determining 308 the die lip clearance to a secondary value. In this regard, adjusting 308 the die lip clearance to a secondary value may include any one or more of the materials, structures, arrangements, processes, and / or the like as described herein. Additionally, one or more preceding or succeeding processes may be implemented with respect to determining 308 the die lip clearance to a secondary value consistent with the present invention. The secondary die lip clearance of the lip adjustment assembly 100 may be determined by feeler gauges, sensors as described herein, and / or the like after heating to an operating temperature.

[0122] In this regard, other gaps need to be set and checked with feeler gauges or sensors in view of accurately calibrating the lip adjustment assembly 100. For example, the set gaps can be 0.030 inches (0.076 cm), 0.020 inches (0.051 cm), and 0.010 inches (0.025 cm), and the actual results can be checked with feeler gauges or sensors.

[0123] The die lip clearance calibrating method 300 of the present invention may include storing 310 the die lip clearance at a secondary value. In this regard, storing 310 the die lip clearance at a secondary value may include any one or more of the materials, structures, configurations, processes, and / or others as described herein. Additionally, one or more prior or subsequent processes may be implemented with respect to storing 310 the die lip clearance at a secondary value consistent with the present invention. Additionally, the die lip clearance calibrating method 300 may include repeating 306 the die lip clearance to a secondary value and 308 the die lip clearance to a secondary value to obtain additional secondary values.

[0124] The die lip clearance calibration method 300 of the present invention may include generating 312 a control value for a next operation of the lip adjusting assembly based on the die lip clearance value. In this regard, generating 312 a control value for a next operation of the lip adjusting assembly based on the die lip clearance value may include any one or more of the materials, structures, configurations, processes, and / or the like as described herein. Additionally, one or more preceding or succeeding processes may be implemented with respect to generating 312 a control value for a next operation of the lip adjusting assembly based on the die lip clearance value consistent with the present invention.

[0125] In view of this, a set of data points (representing the relationship between the intended and measured clearances) can be used to generate a polynomial curve fit so that after applying this fitted curve to the control system, the future intended clearance and the actual clearance match very accurately over the normal operating range. Once this calibration is completed, there is no need to use the gap measuring device in the future. The user can input the desired clearance and the system will achieve that clearance accurately and repeatably.

[0126] In various aspects, a set of data points (representing the relationship between intended and measured clearances) can be used to create a look-up table, which can then be utilized to very accurately match future intended and actual clearances over the normal operating range.

[0127] Thus, the present disclosure describes an improved lip adjustment assembly that increases the accuracy of the lip adjustment without adversely affecting the extrusion product, reducing the length of time to perform the adjustment and / or otherwise.

[0128] While the systems and methods have been described in conjunction with various embodiments in the various figures, those skilled in the art will recognize that modifications can be made to such embodiments without departing from the inventive concept in its broader aspects. It is understood, therefore, that the invention is not limited to the particular embodiments disclosed, but is intended to cover modifications within the spirit and scope of the invention as set forth in the appended claims.

[0129] When values ​​are expressed as approximations by use of the preceding term "about", it is understood that the particular value constitutes another embodiment. In general, the use of the term "about" indicates approximations that may vary depending on the desired properties sought to be obtained by the disclosed invention and should be interpreted in the specific context in which it is used based on its function, and can be interpreted as such by those skilled in the art. In some cases, the number of significant figures used for a particular value may be one non-limiting way of determining the scope of the term "about". In other cases, the scale used in a series of values ​​may be used to determine the anticipated range available for the term "about" for each value. When present, all ranges are inclusive and combinable. That is, when values ​​are referred to in a range, this includes each and every value within that range.

[0130] Where lists are provided, unless otherwise specified, each individual element of the list, and every combination of the list, is a separate embodiment. For example, a list of embodiments expressed as "A, B, or C" should be understood to include the embodiments "A," "B," "C," "A or B," "A or C," "B or C," or "A, B, or C."

Claims

1. 1. A lip adjustment assembly for adjusting the thickness of an extrusion, said lip adjustment assembly comprising: an engagement member operably connected to a movable lip of the extrusion die, said engagement member being movable in a first direction and a second direction opposite to said first direction; an actuator configured to selectively move the engagement member in a first direction and in the second direction; a coupler including a first portion fixedly attached to the engaging member and having a first recess, and a second portion fixedly attached to the actuator and having a second recess, the first portion being spaced apart from the second portion such that the coupler is disposed between the engaging member and the actuator, the coupler further including an insulator configured to inhibit heat conduction from the engaging member to the actuator, the insulator being disposed between the first portion and the second portion and disposed within the first recess and the second recess; When the engaging member is moved in the first direction, the movable lip is moved toward a second lip of the extrusion die, and when the engaging member is moved in the second direction, the movable lip is moved away from the second lip.

2. 2. The lip adjustment assembly of claim 1, wherein the actuator includes a stepper motor having a rotary component and a linear component, wherein movement of the rotary component in a first rotational direction results in movement of the linear component in a first linear direction, and movement of the rotary component in a second rotational direction opposite the first rotational direction results in movement of the linear component in a second linear direction opposite the first linear direction.

3. The lip adjustment assembly of claim 2 , wherein the linear component is configured to move a predetermined linear distance proportional to a predetermined rotational distance of the rotary component.

4. A lip adjustment assembly as described in claim 1, wherein the first recess is located approximately at the geometric center of the first portion, and the second recess is located approximately at the geometric center of the second portion.

5. The lip adjustment assembly of claim 1 , wherein the coupler has a first thermal conductivity and the insulator has a second thermal conductivity, the second thermal conductivity being lower than the first thermal conductivity.

6. 2. The lip adjustment assembly of claim 1, wherein the actuator, the coupler, and the engagement member, which are coupled to one another, constitute a set of components, and the lip adjustment assembly includes a plurality of sets of components, each set of components including at least one actuator, at least one coupler, and at least one engagement member.

7. The lip adjustment assembly of claim 1 , further comprising a housing configured to at least partially enclose the actuator.

8. The lip adjustment assembly of claim 7 , further comprising an air vent extending through the housing, the air vent configured to allow air to enter and exit the housing.

9. The lip adjustment assembly of claim 1 , further comprising an air mover configured to actively move air toward or away from the actuator.

10. The lip adjustment assembly of claim 1 , further comprising a controller configured to control operation of the actuator.

11. 10. The lip adjustment assembly of claim 1, further comprising a plurality of actuators arranged in a linear array, each actuator of the plurality of actuators being spaced apart from at least one adjacent actuator of the plurality of actuators by a distance of between about 1 inch (2.54 cm) and about 4 inches (10.16 cm) measured between centerlines of at least one adjacent actuator of the plurality of actuators.

12. 1. An extrusion die for an extrusion die system, the extrusion die configured to receive a material, the extrusion die comprising: a first die body having a first lip; a second die body having a second lip; a gap formed between the first lip and the second lip, the gap configured to receive the material and to expel the material; The extrusion die is configured to be operably coupled to a lip adjustment assembly for adjusting a thickness of the extruded material, the lip adjustment assembly comprising: an engagement member operably coupled to one of the first lip and the second lip, the engagement member being movable in a first direction and movable in a second direction opposite the first direction; an actuator configured to selectively move the engagement member in the first direction and the second direction; a coupler including a first portion fixedly attached to the engaging member and having a first recess, and a second portion fixedly attached to the actuator and having a second recess, the first portion being spaced apart from the second portion such that the coupler is disposed between the engaging member and the actuator, the coupler further including an insulator configured to prevent heat transfer from the engaging member to the actuator, the insulator being disposed between the first portion and the second portion and disposed within the first recess and the second recess; the lip adjustment assembly is coupled to the extrusion die, and the engagement member of the lip adjustment assembly is moved in the first direction to bring one of the first lip and the second lip closer to the other of the first lip and the second lip, and the engagement member is moved in the second direction to move one of the first lip and the second lip away from the other of the first lip and the second lip.

13. A lip adjustment assembly as described in claim 12, wherein the first recess is located approximately at the geometric center of the first portion and the second recess is located approximately at the geometric center of the second portion.

14. The lip adjustment assembly of claim 12 , wherein the coupler has a first thermal conductivity and the insulator has a second thermal conductivity, the second thermal conductivity being lower than the first thermal conductivity.

15. 13. The extrusion die of claim 12, wherein one of the first lip and the second lip is configured to deform non-linearly along its length by a plurality of actuators, a plurality of couplers, and a plurality of engagement members of the lip adjustment assembly.

16. The extrusion die of claim 12 , further comprising a heater configured to heat the material within the extrusion die.

17. 13. The extrusion die of claim 12, wherein one of the first die body and the second die body has a flexible hinge located adjacent the corresponding first or second lip, the flexible hinge configured to deform when one of the first lip and the second lip is moved toward or away from the other of the first lip and the second lip.

18. 13. The extrusion die of claim 12, wherein one of the first lip and the second lip is configured to be moved by the lip adjustment assembly while the other of the first lip and the second lip cannot be moved by the lip adjustment assembly.

19. 1. An extrusion die system for forming an extrudate from a material, the extrusion die system comprising: an extrusion die, the extrusion die comprising: a first die body having a first lip; a second die body having a second lip; a gap formed between the first lip and the second lip, the gap configured to receive the material and to expel the material; a heater configured to heat the material within the extrusion die; a lip adjustment assembly, the lip adjustment assembly comprising: an engagement member operably coupled to one of the first lip and the second lip, the engagement member being movable in a first direction and movable in a second direction opposite the first direction; an actuator configured to selectively move the engagement member in the first direction and the second direction; a coupler including a first portion fixedly attached to the engaging member and having a first recess, and a second portion fixedly attached to the actuator and having a second recess, the first portion being spaced apart from the second portion such that the coupler is disposed between the engaging member and the actuator, the coupler further including an insulator configured to prevent heat transfer from the engaging member to the actuator, the insulator being disposed between the first portion and the second portion and disposed within the first recess and the second recess; when the engaging member is moved in the first direction, the one of the first lip and the second lip is moved toward the other of the first lip and the second lip, and when the engaging member is moved in the second direction, the one of the first lip and the second lip is moved away from the other of the first lip and the second lip; An extrusion die system including a controller configured to control operation of the heater and the lip adjustment assembly.

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