Extrusion Die Aperture Layout for Reclosable Pouch Closure Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Designing a die plate for extruding multiple closure elements for reclosable pouches is challenging due to difficulties in controlling neck-in and shrinkage of the extruded elements, which affects the formation of accurate and functional closure mechanisms.
Innovation Solution
A method and apparatus where first and second closure elements are extruded directly onto a polymer film web using a die plate with strategically positioned apertures that allow lateral spacing and partial overlap to accommodate neck-in and shrinkage, ensuring proper alignment and spacing of closure elements without an interconnecting portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple closure elements are extruded through a single die plate aperture, then the closure elements can be formed simultaneously, but controlling neck-in and shrinkage becomes difficult affecting manufacturing precision
Solution Approach 1:
The single aperture is divided into multiple separate apertures in the die plate, with each aperture dedicated to extruding one closure element. This segmentation allows independent control of each extrusion stream, enabling precise control over neck-in and shrinkage for each closure element while maintaining simultaneous production of multiple elements.
Solution Approach 2:
The apertures are positioned at different lateral locations and vertical heights in the die plate, creating a three-dimensional arrangement. This spatial distribution allows the extruded closure elements to be laterally spaced on the web while accounting for neck-in and shrinkage forces acting in different directions, thereby maintaining manufacturing precision during simultaneous extrusion.
2Ease of operation
If closure elements are extruded with lateral spacing, then functionality and wide-track feel are improved, but aperture design and alignment become more complex
Solution Approach 1:
Each aperture in the die plate is designed with specific local characteristics including unique lateral positions, vertical heights, and dimensional specifications tailored to the requirements of each closure element. This localized customization of aperture properties enables optimal lateral spacing of closure elements for wide-track feel while managing the complexity through systematic local variations rather than uniform design.
Solution Approach 2:
The die plate serves as an intermediary structure that translates the desired lateral spacing and functional requirements into a coordinated aperture arrangement. By positioning apertures at specific lateral locations and vertical heights, the die plate mediates between the extrusion process and the final closure element configuration, achieving wide-track feel while providing a framework to manage design complexity.
3Manufacturing precision
If apertures are positioned to accommodate neck-in and shrinkage, then element spacing accuracy is improved, but the die plate design becomes more complex
Solution Approach 1:
The apertures are pre-positioned in the die plate at specific lateral locations and vertical heights that anticipate and accommodate the neck-in and shrinkage forces that will occur during extrusion. This preliminary positioning ensures that as the closure elements extrude and undergo dimensional changes, they naturally settle into the correct lateral spacing and alignment, achieving manufacturing precision without requiring complex real-time adjustments.
Solution Approach 2:
The die plate design incorporates varied aperture parameters including different lateral positions, vertical heights, and dimensions to account for and compensate for neck-in and shrinkage. By changing these aperture parameters systematically, the design achieves accurate element spacing while the complexity is managed through controlled parameter variation rather than unstructured design modifications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of reclosable pouches with multiple closure elements that provide a wide-track feel, allowing for precise control over the extrusion process to maintain element spacing and functionality, eliminating the need for an interconnecting portion and enhancing manufacturing flexibility.
Implementation Method 1
extruding the first and second closure elements at the same time directly onto the web
Implementation Method 2
difficulties encountered in controlling neck-in and shrinkage of the extruded elements
Data Source
AI summary
A method of extruding two or more closure elements onto a web includes extruding the closure elements through a die plate having a first aperture for a first closure element and a second aperture for a second closure element. The first aperture is spaced from and at least partially overlaps the second aperture in a lateral direction. The partial overlapping of the apertures allows the closure elements to be spaced very closely together on the web. The space between the apertures prevents extrudate streams forming the elements from bonding to each other. The closely spaced elements are extruded through the same die plate without an interconnecting portion therebetween.