Multilayer Feedblock Cartridge Inserts for Bio-Polymer Extrusion
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Solution Overview
Problem
Bio-based polymers, used in packaging due to their low carbon footprint and biodegradability, face challenges in high-speed extrusion due to low melt strength, requiring lower processing temperatures and resulting in speed-limited production when used in existing LDPE extruders, making them prohibitively expensive.
Innovation Solution
An extruder system with a multilayer feedblock and cartridge inserts, including vane and encapsulation inserts, allows for rapid switching between different melt strength polymers, forming edge encapsulated coatings that increase production speeds by stabilizing low melt strength polymers and enabling high-speed extrusion without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bio-based polymers are extruded using existing LDPE extruders, then production can utilize renewable resources, but processing temperatures must be lowered which limits extrusion speed
Solution Approach 1:
The feedblock is divided into multiple zones (first combining zone, second combining zone, die zone) with each zone performing a specific function. Cartridge inserts are placed in different zones to create localized flow patterns - vane inserts in the first zone create mixing flows while encapsulation inserts in the second zone create stabilizing flows at the die interface, allowing temperature reduction without sacrificing speed
Solution Approach 2:
The cartridge inserts act as intermediaries that modify polymer flow between the extruder and die. The vane inserts and encapsulation inserts create specific flow patterns that stabilize the polymer melt, enabling low melt strength bio-based polymers to be processed at high speeds without overheating or degrading
2Productivity
If specialty modified bio-polymers are used to increase extrusion speed, then production speed can improve, but material cost increases significantly
Solution Approach 1:
The system uses standard, commercially available bio-based polymers without requiring expensive specialty modifications. The flow control inserts enable the polymer to self-stabilize during processing through geometric flow patterns, eliminating the need for costly polymer chemistry modifications while maintaining high extrusion speeds
Solution Approach 2:
The invention changes the flow parameters and patterns within the feedblock using geometric inserts rather than changing the polymer chemistry itself. This allows standard bio-based polymers to be processed at high speeds by modifying the physical flow environment rather than the material properties, avoiding premium material costs
3Productivity
If feedscrew is changed to lower melt temperature, then extrusion speed can increase slightly, but screw change requires one shift process which reduces overall productivity
Solution Approach 1:
The system allows for rapid switching between different polymer types by changing only the cartridge inserts in the feedblock, which can be done quickly without stopping production for extended periods. This dynamic change capability eliminates the need for time-consuming screw changes while maintaining the ability to optimize processing parameters for different materials
Solution Approach 2:
The cartridge inserts are pre-configured with specific geometric patterns (vane and encapsulation designs) that are optimized for low melt strength polymers. This preliminary configuration allows the system to be ready for high-speed bio-based polymer processing without requiring screw changes, as the flow control geometry is already in place to stabilize the polymer melt
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
The system enables high-speed extrusion of bio-based polymers at temperatures below those causing overheating, allowing for rapid switching between conventional and bio-based polymers, significantly increasing production speeds and reducing costs by avoiding the need for specialty polymers and screw changes.
Implementation Method 1
edge encapsulation vane inserts... each cartridge insert arrangement in the second combining zone includes an encapsulation insert
Implementation Method 2
vane insert positioned therein... vane insert directing flow of a polymer from one of the polymer extruders
Data Source
AI summary
An extruder system for rapid change between different melt strength polymers is provided. The extruder system includes at least three polymer extruders; a flow spool; and a multilayer feedblock including a first combining zone, a second combining zone, and at least one cartridge insert arrangement in each of the first combining zone and the second combining zone; where each cartridge insert arrangement is configured to receive a cartridge insert, the cartridge insert directing flow of a polymer from one of the polymer extruders. Also provided are method of forming an encapsulated coating with the extruder system and an encapsulate coating formed with the extruder system.