Layer Multiplying Die for Polymer Film Uniformity

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Solution Overview

Problem

Current layer multiplying dies struggle to achieve uniformity and continuity of layered polymer films when the viscosities and elasticities of individual polymer components have significant differences, limiting the range of materials that can be used to produce films with enhanced properties.

Innovation Solution

A new multiplying die design that divides and recombines composite streams into branch streams, simultaneously expanding and contracting them to form a second composite stream with a greater number of discrete overlapping layers, allowing for improved layer uniformity and continuity across a broader range of polymer viscosities and elasticities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional layer multiplying dies are used to produce films with high viscosity and elasticity differences, then the range of materials that can be used is limited, but layer uniformity and continuity deteriorate

Engineering Contradiction:

Improverange of materialsVSAvoidlayer uniformity and continuity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The die is divided into multiple sub-elements (first sub-element for dividing, second sub-element for expanding/contracting, third sub-element for recombining) that work in sequence to process different aspects of the composite stream, allowing independent optimization of each function

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second sub-element changes the physical parameters of the branch streams by simultaneously expanding in one direction and contracting in another, which equalizes the flow characteristics of polymers with different viscosities and elasticities, enabling layer uniformity across a broader range of materials

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If polymers with high viscosity differences are processed in conventional dies, then material versatility is improved, but layer stability and continuity worsen due to slip film formation

Engineering Contradiction:

Improvepolymer viscosity rangeVSAvoidlayer stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The second sub-element applies parameter changes by simultaneously expanding the branch stream in the x-direction and contracting it in the y-direction, which equalizes the flow parameters of polymers with different viscosities, preventing slip film formation and maintaining layer stability across a wider viscosity range

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The second sub-element acts as an intermediary between the first sub-element (which divides the stream) and the third sub-element (which recombines the stream), mediating the flow characteristics of polymers with different viscosities through expansion and contraction to prevent direct instability at interfaces

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If normal stress differences are present in conventional dies, then processing of diverse polymers is enabled, but layer instability and breakup occur

Engineering Contradiction:

Improvepolymer elasticity rangeVSAvoidlayer continuity

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The second sub-element changes the flow parameters of branch streams through simultaneous expansion and contraction, which equalizes normal stress differences across polymers with different elasticities, preventing layer breakup while maintaining the ability to process diverse polymer combinations

Inventive Principle:

Principle #35Parameter changes

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 design enhances layer uniformity and continuity, enabling the production of films with improved properties for a wider range of polymers, including those with high viscosity and elasticity differences, while reducing pressure drops and interfacial instabilities.

Implementation Method 1

dividing and recombines composite streams into branch streams

Methodology Applied

Scientific EffectFluid flow division and recombination:

Implementation Method 2

simultaneously expanding and contracting them to form a second composite stream

Methodology Applied

Scientific EffectSimultaneous expansion and contraction:

Data Source

PatentUS9364988B2Layer multiplying die for generating interfacial surfaces

Publication Date: 2016.06.14 CASE WESTERN RESERVE UNIV

AI summary

A method for generating interfacial surfaces within a first composite stream having a generally planar layer interface lies generally in an x-z plane of an x-y-z coordinate system. The method includes dividing the first composite stream into a plurality of branch streams along the x-axis such that the pair of discrete overlapping layers and the generally planar layer interface are distributed among at least two branch streams. Within each individual branch stream of the at least two branch streams, the width dimension of the branch stream is expanded along the x-axis and the thickness dimension of the branch stream is simultaneously contracted along the y-axis. The branch streams are recombined in an overlapping relationship, after each of the at least two branch streams is simultaneously expanded and contracted, to form a second composite stream having a greater number of discrete overlapping layers of polymeric material than the first composite stream.