Polymer extrusion apparatus and method using polycrystalline diamond elements

Abstract

A die plate for polymer extrusion may include a die plate having an inlet face for receiving a polymer stream and an outlet face for extruding one or more polymer strands, the outlet face comprising at least one element made of polycrystalline diamond. A system for extruding a polymer may include an extruder, a die plate attached to the outlet of the extruder, the die plate having (i) an inlet face for receiving a polymer stream and (ii) an outlet face for extruding one or more polymer strands, and an array of blades configured to rotate to contact and slide along a surface of the die outlet face, thereby cutting the one or more polymer strands extruded through the die outlet face, wherein each of (a) the outlet face, (b) the blade array, or (c) the outlet face and the blade array comprises at least one element made of polycrystalline diamond.

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 231,046, entitled "POLYMER EXTRUSION WITH POLYCRYSTALLINE DIAMOND ELEMENTS," filed August 9, 2021, which is incorporated herein by reference in its entirety.

[0002] The subject matter of this disclosure relates to extruder systems and die face and pelletizer designs that enhance performance and wear resistance. [Background technology]

[0003] In a polymer extrusion system, a polymer may be molten and forced at high pressure through an extrusion die or die plate having several (e.g., tens, hundreds, or thousands) flow passages that terminate in small orifices (e.g., approximately 3 mm) that shape the molten polymer. As the polymer product exits the die plate, it contacts a cooling medium (usually water) and begins to solidify. The extrusion system may also include a pelletizer containing an array of rotating blades that cuts the polymer as it leaves the die into small pellets. The pelletized polymer may then be conveyed by process water flowing across the die face to a centrifugal dryer where the water is removed and the dried pellets are discharged.

[0004] During operation, the pelletizer's rotating blades are positioned near the die plate's exit face and may occasionally engage and contact the surface of the exit face. The shearing action of the pelletizer blades can cause wear on the die surface, the edges of the die holes, the inner diameter of the die holes, and the pelletizer blades themselves. In addition to mechanical wear, other failure modes include cavitation pitting, corrosion, delamination and detachment of nibs and other wear elements on the die face, warping, and damage from polymer additives. Die damage can lead to improper contact between the blades and the die face, which can result in adverse changes in the bulk density or pellet appearance of the final product. To mitigate damage to the die face, the extruder must be shut down and disassembled to remove and replace the die, which can halt production for periods ranging from several hours to several days. Dies are often made of conventional materials such as stainless steel, tungsten, or titanium, and die plates must be replaced every 2 to 18 months, depending on the specific manufacturing technique.

[0005] References of potential interest in this regard include U.S. Pat. No. 8,485,284, U.S. Pat. No. 8,672,061, U.S. Pat. No. 9,067,340, U.S. Pat. No. 9,149,954, U.S. Pat. No. 9,314,985, U.S. Pat. No. 9,481,121, U.S. Pat. No. 9,764,387, U.S. Pat. No. 10,124,523, U.S. Patent Application Publication No. 2010 / 0129479, U.S. Patent Application Publication No. 2014 / 0147590, U.S. Patent Application Publication No. 2016 / 0151952, WO 2017 / 21407, as well as Chinese Patent No. 110468385, Chinese Patent No. 105538536, and Korean Patent No. 101822590. Summary of the Invention [Means for solving the problem]

[0006] The present invention is directed to extruder systems and die face designs that incorporate one or more polycrystalline diamond elements.

[0007] In one aspect, a die plate for polymer extrusion can include a die plate having an inlet face for receiving a polymer stream and an outlet face for extruding one or more polymer strands, the outlet face including at least one element made of polycrystalline diamond.

[0008] In another aspect, a system for extruding a polymer may include an extruder, a die plate attached to an outlet of the extruder, the die plate having (i) an inlet face for receiving a polymer stream and (ii) an outlet face for extruding one or more polymer strands, and an array of blades configured to rotate to contact and slide along a surface of the die outlet face, thereby cutting the one or more polymer strands extruded through the die outlet face, wherein each of (a) the outlet face, (b) the blade array, or (c) the outlet face and the blade array comprises at least one element made of polycrystalline diamond. Further provided herein are methods for extruding a molten polymer through such a system for extruding a polymer.

[0009] In yet another aspect, a method of extruding a polymer includes extruding a molten polymer through a die including an exit face made at least in part of polycrystalline diamond and attached to an outlet of an extruder. [Brief explanation of the drawings]

[0010] [Figure 1A] FIG. 2 is a view showing the outlet face of a die plate assembled in an extruder. [Figure 1B] FIG. 10 shows a pelletizer engaging the die exit face. [Figure 1C] FIG. 1 is a diagram of a pelletizer blade. [Figure 2] 1 is a cross-sectional view of a portion of a die plate showing an example of a flow channel having a pocket terminating in a single land and extrusion orifice. FIG. [Figure 3] 1 is a cross-sectional view of a portion of a die plate showing an example of a flow channel having multiple lands and pockets terminating in extrusion orifices. FIG. [Figure 4] FIG. 1 is a cutaway view of the interior of a pelletizer engaging a die exit face having multiple extrusion orifices per wear surface element, according to some embodiments. [Figure 5] FIG. 1 is a cutaway view of the interior of a pelletizer engaging a die exit face having a plurality of wear surface elements in the form of tiles, according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present disclosure is directed to extruder systems and die face designs that enhance performance and wear resistance, as well as related methods of extruding polymers through such systems and die faces. In particular, the systems and die face designs may incorporate one or more wear surface components made of polycrystalline diamond (PCD), which improves the wear resistance and service life of the die plate.

[0012] During the polymer extrusion process, a polymer is passed through the body of an extruder, where it is heated above its melting point or glass transition temperature to a molten state. The molten polymer is then transferred to a die plate and forced through a series of passages or channels having relatively small cross-sectional areas. FIG. 1A is a schematic end view of an exemplary extruder assembly 100 equipped with a die plate 102. The die exit face 104 of the die plate 102 includes a die center cover plate 106 and an outer covering ring 108, which provide a number of features, including extrusion orifices that shape the extruded polymer product. As shown in FIG. 1B, the die plate 102 may also be engaged with a pelletizer array 105 having an array of blades 107 that contact (or are adjacent to) the die exit face 104. During operation, as polymer strands are extruded from the die exit face 104, the pelletizer array 105 cuts the extruded polymer, which is then collected and processed to form the final polymer pellet product.

[0013] 1C is a detailed view of an individual pelletizer blade 107, showing the cutting surface 109 and the shank 111 for securely securing the pelletizer blade 107 to the pelletizer array 105. The pelletizer blade 107 can be a monoblock (monolithic) structure, in which the cutting surface 109 and the blade 107 are made from a single material, such as a PCD material. The pelletizer blade 107 can also be a composite or multi-material structure. In one example, the cutting surface 109 can be a first material, such as a PCD material, and the remainder of the blade 107 can be made from a different metal or alloy.

[0014] Referring again to FIG. 1A, the die plate 102 may include or otherwise define numerous channels and passages that serve to collect and shape the molten polymer during the extrusion process. FIG. 2 is a side cross-sectional view of a segment of the die plate 102. As shown, the die plate 102 provides an inlet face 212 positioned opposite the die exit face 104. Additionally, the die plate 102 may define extrusion channels 210 extending between the inlet face 212 and the die exit face 104, thus forming a passageway for material to flow through the die plate 102. During extrusion, the molten polymer is driven through the extruder, where the polymer encounters the inlet face 212 and begins to collect in one or more pockets (or slots) 214. The collected polymer is then directed by a tapered section 216 to one or more landings 218 that terminate at extrusion orifices 220 defined in the die exit face 104.

[0015] The die exit face 104 may also include a wear surface 222 or other element affixed to the die exit face 104 and defining an orifice 224 collinear with the extrusion orifice 220. The type of wear surface 222 is not particularly limited, and the die plates disclosed herein may include a single-hole nib (such as that shown in FIG. 2) embedded in the die exit face 104 adjacent to the single extrusion orifice 220, but may also include wear surfaces defining multiple orifices assembled to or embedded in the exit face 104, including tiles, multi-hole nibs, or monolithic wear surfaces that substantially cover the die exit face 104. In another variation, the die exit face 104 may be formed from a wear-resistant material such that the die exit face 104 and the wear surface 222 are of the same construction.

[0016] Alternative die plate designs can include extrusion orifices with angled or offset landings, such as when multiple extrusion orifices and lands originate (extend) from a single pocket 214 provided in the die plate. FIG. 3 is a side cross-sectional view of a die wear face segment 300 illustrating a die variation in which multiple lands 218a and 218b extend from a single pocket 214. Similar to the structure shown in FIG. 2, the extrusion flow channel 210 extends between the inlet face 212 and the outlet face 104 of the die plate 102. During extrusion, molten polymer is driven through the extruder, where it encounters the inlet face 102 and collects within the pocket (or slot) 214. However, once the polymer collects within the pocket 214, a tapered section 216 feeds the molten polymer into multiple lands 218a and 218b, which extend to orifices 224a and 224b, respectively. In this example, the die exit face 104 may also include wear surfaces 222a and 222b that define extrusion orifices 224a and 224b.

[0017] Figure 4 shows another possible die plate design 400 in which the die exit face 104 has a plurality of wear surface elements 422 in the form of perforated nibs with a plurality of extrusion orifices per wear surface element 422. Yet another possible die plate design is shown in Figure 5, which shows a die plate design 500 in which the die exit face 104 is formed from a plurality of wear surface elements 522 in the form of tiles.

[0018] During normal operation of an extruder equipped with a pelletizer system, control of the size and distribution of polymer pellets is achieved in a number of ways, including designing the internal die geometry and monitoring the pressure and polymer flow at the die face for changes during production. Over time, pellet size and product quality can be affected by many process conditions, including damage to the die exit face and wear surface components due to mechanical wear and abrasion from interaction with the pelletizer blades. Over time, mechanical damage to the die face and extrusion orifice can lead to detachment of the wear surface and damage to the pelletizer system.

[0019] The condition of the die face may be monitored while the extruder is running, and in some cases, the extrusion dies are inspected, removed, and cleaned after or during a production run to prevent damage to the die plate and pelletizer system. In some cases, extrusion dies may require maintenance before the end of the production run due to mechanical failure or if product quality deteriorates to an unacceptable level. In either scenario, die maintenance typically involves stopping production and removing the die plate for nib and tile replacement, and / or repair by manual sanding, paste sanding, grinding, etc.

[0020] The systems and die face designs disclosed herein can include wear surface elements made of PCD (such as the single-hole nib 222 in FIG. 2, the multi-hole nib 422 in FIG. 4, or the tile 522 in FIG. 5) that improve the wear resistance and service life of the die plate. PCD, also known as diamond abrasive compacts, is composed of agglomerates of diamond particles, assembled by direct diamond-to-diamond bonding. PCD can contain about 85% to about 95% by volume diamond, with the remainder being a second phase containing a metallic binder, such as cobalt, nickel, iron, or an alloy containing one or more such metals, disposed in the interstitial regions of the PCD microstructure. Optionally, PCD can be processed to remove substantially all of the metallic binder, thereby forming a thermally stable PCD.

[0021] The PCD materials disclosed herein can be used to make one or more die face elements and / or other components subjected to mechanical wear, which can improve the mechanical strength and service life of polymer extrusion systems. PCD elements (including PCD wear face elements) have many mechanical properties suitable for extrusion applications, including high hardness and toughness values, low coefficients of friction, and improved wear resistance, especially compared to components made from stainless steel and similar metals.

[0022] In particular, the inclusion of PCD elements in the die face can increase the wear resistance of the surface that contacts the pelletizer blades during extrusion. Similarly, the inclusion of PCD elements in one or more pelletizer blades that contact (or are near) the die face can have the same effect. Accordingly, embodiments herein also contemplate the inclusion of PCD elements in (1) the die face, (2) one or more of the pelletizer blades, or (3) both. With respect to die plates, PCD elements and materials can be used to create any portion of the die plate, including the exit face or any of the wear surfaces described above, including single- and multi-hole nibs, tiles, monolithic wear surfaces, and any other wear surface variants compatible with the selected extruder and pelletizer. A specific example for pelletizer blades is the use of PCD elements to create monolithic pelletizer blades or any of their components, such as cutting surfaces or inserts.

[0023] During manufacturing, PCD elements can be made by contacting diamond powder with a metal substrate, such as a cobalt-carbide tungsten carbide substrate. Suitable diamond powders useful for forming PCD elements include those with average particle sizes ranging from submicrometer (e.g., nanoscale) to 100 μm, such as a minimum of 1, 10, or 15 μm to a maximum of 40, 50, 60, 70, 80, 90, or 100 μm. Diamond powders can contain particles with a unimodal or multimodal size distribution. When diamond powders with different particle sizes are used, the diamond particles can be mixed together by conventional processes, such as by ball milling or attritor milling, for a time sufficient to ensure good and uniform distribution. The diamond powder and metal substrate are processed under heat and pressure to infiltrate the metal into the diamond powder. During this process, additional diamonds can form on the crystallographic planes between the diamond particles, forming a network of interlocked diamonds and a continuous metal phase bonding the diamond to the substrate. The PCD elements may be formed into any shape suitable for mating with a die face and / or pelletizer blade using any acceptable method known in the art.

[0024] The PCD element may have a layered structure with a PCD layer fixed to a metal substrate, the thickness of the PCD layer being in the range of about 0.3 mm to about 7 mm (such as a minimum of any one of 0.3, 0.4, or 0.5 mm to a maximum of any one of 5, 6, or 7 mm). The PCD element may have a total thickness (including both the substrate layer and the PCD layer) of about 1 mm to about 10 mm (such as a minimum of any one of 1, 1.5, 2, or 2.2 mm to a maximum of any one of 5, 6, 7, 8, 9, or 10 mm).

[0025] When incorporated into a pelletizer blade, the PCD blade element (including both the substrate layer and the PCD layer) can have a total thickness ranging from about 5 mm to about 20 mm, from about 5 mm to about 17 mm, or from about 5 mm to about 15 mm. When used to make a monolithic pelletizer blade, the total thickness of the PCD element can have any suitable dimension to fit the selected pelletizer.

[0026] Attachment of the PCD element (or PCD wear surface or PCD exit face) to the die plate can be by any suitable technique, including attaching the PCD element to the die plate by high-pressure, high-temperature (HPHT) processing, welding, brazing, adhesive bonding, bolting, or friction-based attachment (e.g., shrink fit or interference fit). Attachment methods can vary depending on the composition of the metallic die plate, which is often made of metals such as stainless steel, tungsten alloys, etc. In some cases, the PCD element may be removable from the die plate, allowing an operator to replace the die plate or the PCD wear surface element individually. Removal of the wear surface element from the die face can occur when the die plate is removed or installed in the extruder.

[0027] The systems and die face designs disclosed herein can extend the useful life of extruder dies beyond that of comparable designs made from other metals, where useful life is defined as the period from installation of a new or refurbished die to removal of the die. Die life can be measured in months, or in some cases, in tons processed per die hole. Die plates incorporating PCD elements can improve die life by at least about 10%, at least about 20%, or at least about 30%, or in the range of about 10% to about 30%. While exemplary ranges are given, useful life may be more or less dependent on many factors, such as polymer type and grade, die geometry, pelletizer settings, and extruder type.

[0028] Polymer-based The die plate and exit face designs disclosed herein can be used with any suitable extruder die face, and the type of polymer system being extruded is not particularly limited. The polymer system can include any thermoplastic and / or elastomer suitable for extrusion. Examples of suitable polymer systems include polyolefins such as low-density polyethylene, medium-density polyethylene, or high-density polyethylene, polypropylene, polybutene-1, poly-3-methylbutene-1, and poly-4-methylpentene-1; copolymers of monoolefins with other olefins (mono- or diolefins) or vinyl monomers such as ethylene-propylene copolymers, or with one or more additional monomers, such as ethylene-propylene-diene monomer rubber, ethylene / butylene copolymer, ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, and propylene / 4-methylpentene-1 copolymer.

[0029] Other polymer systems include thermoplastic elastomers such as "block" copolyesters from terephthalate, 1,4-butanediol, and poly(tetramethylene ether) glycol; polystyrene; polystyrene-polyphenylene oxide blends; polyesters such as polyethylene terephthalate, poly 1,4-butylene terephthalate, poly 1,4-cyclohexyldimethylene terephthalate, and poly 1,3-propylene terephthalate; polyamides such as nylon-6,6, nylon-6, nylon-12, nylon-11, and aromatic-aliphatic copolyamides; poly Examples of suitable polymers include polycarbonates such as bisphenol A carbonate; fluorinated polymers such as copolymers of tetrafluoroethylene and hexafluoropropylene, polyvinyl fluoride, copolymers of ethylene and vinylidene fluoride or vinyl fluoride; polysulfides such as poly-p-phenylene sulfide; polyether ketone; polyether ether ketone; polyether ketone ketone; polyether imide; acrylonitrile-1,3-butadiene-styrene copolymer; (meth)acrylic polymers such as polymethyl methacrylate; and chlorinated polymers such as polyvinyl chloride.

[0030] Polymer systems may also include extrudable elastomers, including natural rubber, polyisobutylene, butyl, chlorobutyl, polybutadiene, butadiene-styrene, ethylene-propylene, ethylene-propylene diene terpolymer elastomers, and mixtures thereof with each other and with thermoplastic polymers. Blends of any of the above suitable polymer systems are also within the scope of the present disclosure. Particular embodiments may involve the extrusion of polyethylene polymers, i.e., polymers having at least 85% by weight, e.g., at least 87% by weight, or at least 90% by weight, of units derived from ethylene (as in the case of ethylene-α-olefin copolymers such as ethylene-butene, ethylene-hexene, or ethylene-octene copolymers), such as Ziegler-Natta or metallocene-catalyzed linear low-density polyethylene polymers (LLDPE). Furthermore, polymers for extrusion (including the aforementioned polyethylene polymers) can be produced using any suitable polymerization process for producing extrudable polymer products, including (1) gas phase polymerization processes, including fluidized bed reactors, horizontal stirred bed reactors, and vertical stirred bed reactors; (2) bulk processes, including liquid pool reactors and loop reactors; (3) slurry processes, including continuous stirred tanks, batch stirred tanks, loop reactors, and boiling butane reactors; (4) tubular processes; (5) autoclave processes; and / or (6) solution processes.

[0031] Embodiments disclosed herein include the following.

[0032] A. A die plate for polymer extrusion, comprising: a die plate having an inlet face for receiving a polymer stream and an outlet face for extruding one or more polymer strands, the outlet face comprising at least one element made of polycrystalline diamond.

[0033] B. A system for extruding a polymer, comprising: an extruder; a die plate attached to an outlet of the extruder, the die plate having (i) an inlet face for receiving a polymer stream and (ii) an outlet face for extruding one or more polymer strands; and an array of blades configured to rotate to contact and slide along a surface of the die outlet face, thereby cutting the one or more polymer strands extruded through the die outlet face, wherein each of (a) the outlet face, (b) the blade array, or (c) the outlet face and the blade array comprises at least one element made of polycrystalline diamond.

[0034] C. A method of extruding a polymer, comprising extruding a molten polymer through a die including an exit face made at least in part of polycrystalline diamond and attached to the exit of an extruder.

[0035] Embodiments A, B, and C may have one or more of the following additional elements in any combination.

[0036] Element 1: At least one element includes a nib embedded in the exit face to define at least one extrusion orifice.

[0037] Element 2: At least one element includes a perforated nib embedded in the exit face and defining at least one extrusion orifice.

[0038] Element 3: At least one element includes a tile embedded in the exit face to define at least one extrusion orifice.

[0039] Element 4: At least one element is secured to the outlet face by welding, brazing, adhesive, bolting, or friction-based attachment.

[0040] Element 5: At least one element is a monolithic wear surface that substantially covers the outlet face.

[0041] Element 6: At least one element has a total thickness in the range of about 1 mm to about 10 mm.

[0042] Element 7: At least one element is secured to the outlet face by welding, brazing, gluing, bolting, or friction-based attachment.

[0043] Element 8: A polycrystalline diamond element is secured to the exit face or one or more blades in the blade array by welding, brazing, adhesive bonding, bolting, or friction-based attachment.

[0044] Element 9: The molten polymer is selected from the group consisting of low density polyethylene, medium density polyethylene, high density polyethylene, polypropylene, polybutene-1, poly-3-methylbutene-1, poly-4-methylpentane-1, ethylene-propylene, ethylene propylene diene monomer rubber, ethylene / butylene copolymer, ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, propylene / 4-methylpentene-1 copolymer, poly(tetramethylene ether) glycol, polystyrene, polystyrene polyphenylene oxide blend, polyester, polyamide, aromatic-aliphatic copolyamide, polycarbonate, polyvinyl fluoride, copolymer of ethylene and vinylidene fluoride or vinyl fluoride, polysulfide, polyether ketone, polyether ether ketone, polyether ketone ketone, polyetherimide, acrylonitrile-1,3-butadinene-styrene copolymer, (meth)acrylic polymer, and chlorinated polymer.

[0045] Element 10: The method further includes pelletizing the molten polymer exiting the die by contacting the molten polymer with a pelletizer array made at least in part of polycrystalline diamond.

[0046] As a non-limiting example, exemplary combinations applicable to A, B, and C include 1 and any one or more of 2-9; 2 and 1 and any one or more of 3-9; 3 and 1-2 and any one or more of 4-9; 4 and 1-3 and any one or more of 5-9; 5 and 1-4 and any one or more of 6-9; 6 and 1-5 and any one or more of 7-9; 7 and 1-6 and any one or more of 8-9; 8 and 1-7 and any one or more of 9; and 9 and any one or more of 1-8. Additional combinations applicable to C include 10 and any one or more of 1-9.

[0047] The disclosed systems and methods are therefore well adapted to attain the ends and advantages mentioned, as well as those inherent therein. The specific embodiments disclosed above are merely exemplary, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, there is no intention to be limited to the details of construction or design shown herein, other than as set forth in the claims below. It is therefore evident that the specific exemplary embodiments disclosed above may be altered, combined, or modified, and all such variations are contemplated within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element not specifically disclosed herein and / or any optional element disclosed herein. While compositions and methods are described in terms "comprising," "containing," or "including" various components or steps, the compositions and methods may also "consist essentially of" or "consist of" the various components and steps. All numbers and ranges disclosed above may vary somewhat. Whenever a numerical range with a lower and upper limit is disclosed, any number within that range and any included range is specifically disclosed. In particular, all ranges of values ​​disclosed herein (in the form "from about a to about b," or, equivalently, "approximately a to b," or, equivalently, "from approximately a to b") should be understood to describe all numbers and ranges encompassed within that broad range of values. Furthermore, terms in the claims are to be given their plain and ordinary meaning unless expressly and unambiguously defined otherwise by the patentee. Moreover, when used in the claims, the indefinite articles "a" or "an" are defined to mean one or more of the element they introduce.In the event of any discrepancy between the usage of a word or term herein and the usage of that word or term in one or more patents or other documents that may be incorporated by reference herein, the consistent definition herein shall prevail. As used herein, the phrase "at least one of," preceding a list of items, with the word "and" or "or" separating any of the items, modifies the list as a whole, rather than each member (i.e., each item) of the list. The phrase "at least one" allows for the meaning to include at least one of any one of the items, and / or at least one of any combination of the items, and / or at least one of each of the items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" refer to A only, B only, or C only; A, B, and C in combination; and / or at least one of each of A, B, and C, respectively.

[0048] The use of directional terms such as up, down, upper, lower, upward, downward, left, right, etc. are used in connection with the exemplary embodiments as shown in the figures, with the up direction being toward the top of the corresponding figure and the down direction being toward the bottom of the corresponding figure.

Claims

1. 1. A die plate for polymer extrusion, comprising: a die plate having an inlet face for receiving a polymer stream and an outlet face for extruding one or more polymer strands, said outlet face comprising at least one element made of polycrystalline diamond; (a) the at least one element is a perforated nib embedded in the exit face and defining at least one extrusion orifice; or (b) including tiles embedded in said exit face defining at least one extrusion orifice; A die plate characterized by:

2. the at least one element is secured to the outlet face by welding, brazing, adhesive bonding, bolting, or friction-based attachment; The die plate according to claim 1 .

3. the at least one element being a monolithic wear surface covering the outlet surface; The die plate according to claim 2 .

4. the at least one element has a total thickness in the range of about 1 mm to about 10 mm; 3. The die plate according to claim 1 or 2.

5. 1. A system for extruding a polymer, comprising: an extruder; A die plate attached to the outlet of the extruder, (i) an inlet face for receiving a polymer stream; (ii) an exit face for extruding one or more polymer strands; an array of blades configured to rotate to contact and slide along a surface of the die exit face, thereby cutting the one or more polymer strands extruded through the die exit face; (a) the exit surface, (b) the blade array, or (c) each of the exit surface and the blade array includes at least one element made of polycrystalline diamond; the exit face includes: (a) at least one nib made of polycrystalline diamond; (b) at least one perforated nib made of polycrystalline diamond; and (c) at least one tile made of polycrystalline diamond; the nib, perforated nib, and tile define at least one extrusion orifice; A system characterized by:

6. 1. A method of extruding a polymer, comprising: extruding the molten polymer through a die including an exit face made at least in part of polycrystalline diamond and attached to an exit of the extruder; the outlet surface is provided with at least one nib made of polycrystalline diamond and / or a perforated nib made of polycrystalline diamond; A method characterized by:

7. the molten polymer is selected from the group consisting of low density polyethylene, medium density polyethylene, high density polyethylene, polypropylene, polybutene-1, poly-3-methylbutene-1, poly-4-methylpentane-1, ethylene-propylene, ethylene propylene diene monomer rubber, ethylene / butylene copolymer, ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, propylene / 4-methylpentene-1 copolymer, poly(tetramethylene ether) glycol, polystyrene, polystyrene polyphenylene oxide blend, polyester, polyamide, aromatic-aliphatic copolyamide, polycarbonate, polyvinyl fluoride, copolymer of ethylene and vinylidene fluoride or vinyl fluoride, polysulfide, polyether ketone, polyether ether ketone, polyether ketone ketone, polyetherimide, acrylonitrile-1,3-butadiene-styrene copolymer, (meth)acrylic polymer, and chlorinated polymer; The method of claim 6.

8. further comprising pelletizing the molten polymer exiting the die by contacting the molten polymer with a pelletizer array made at least in part of polycrystalline diamond.

8. The method according to claim 6 or 7.

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