Modular Disk Coextrusion Die with Opposing Arrangement
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Solution Overview
Problem
Modular disk coextrusion dies are limited in producing multilayer blown films due to the number of entry ports and cells, restricting the number of layers and polymer resins that can be used, leading to limitations in layer uniformity and symmetry.
Innovation Solution
A modular disk coextrusion die with a stacked configuration of thin annular disks, featuring a central routing disk and symmetrical distribution disks, allows for the production of up to several hundred layers by directing multiple melt streams through sub-cells with 180-degree opposed distribution inlet openings, enhancing layer uniformity and symmetry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of entry ports and stacked cells is increased to produce higher layer counts, then the number of layers and polymer resins that can be used increases, but layer uniformity and symmetry deteriorate
Solution Approach 1:
The die is divided into multiple independent cells, each capable of processing one or more polymer streams. Each cell contains its own distribution disk and spreader disk assembly, allowing individual optimization of melt distribution while contributing to the overall multilayer film structure. This segmentation enables scaling to high layer counts while maintaining control over each layer's formation.
Solution Approach 2:
The distribution disks are positioned asymmetrically within each cell, with the first distribution disk closer to the entry ports than the second distribution disk. This asymmetric arrangement, combined with the 180-degree opposed inlet openings, creates symmetrical flow patterns that ensure uniform layer formation even as the number of layers increases.
2Quantity of substance
If more cells are stacked together to increase layer capacity, then the number of layers that can be produced increases, but device complexity increases
Solution Approach 1:
Each cell in the stack is designed with universal functionality, capable of processing one or more polymer streams through identical distribution and spreader disk assemblies. This modular universality allows the same cell design to be replicated and stacked to achieve different layer counts, reducing overall device complexity through standardization while maintaining high layer capacity.
Solution Approach 2:
Multiple cells are stacked in a nested configuration where the outlet of one cell connects to the inlet of the next cell in the stack. This nesting arrangement allows polymer streams to flow sequentially through multiple cells, enabling the production of high-layer-count films without requiring a proportional increase in the number of independent entry ports, thus managing device complexity.
3Device complexity
If entry openings are used for both polymer streams and bolt holes, then the number of entry ports is reduced, but the number of available polymer streams is limited
Solution Approach 1:
The die design utilizes the radial dimension of the circular distribution disks to accommodate multiple entry ports around the perimeter. By distributing entry openings around the entire circumference of each distribution disk rather than concentrating them in one location, the design can accommodate both polymer stream inlets and bolt holes without compromising the number of available polymer streams, as components can be positioned at different radial locations.
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
Enables the production of blown films with improved layer uniformity and symmetry, utilizing up to two dozen polymer resins, and allows for the creation of films with numerous layers by stacking cells, significantly increasing the layer capacity beyond previous limitations.
Implementation Method 1
Each distribution disk includes a distribution inlet opening, a plurality of outlet openings, and a plurality of channels connecting the distribution inlet opening with the plurality of outlet openings
Implementation Method 2
Each spreader disk includes a plurality of flow ports, each connected and leading into a flow region, wherein each melt stream is spread across a flow region in the respective spreader disk
Data Source
Figure 1~1(b)
Figure 2
Figure 3
AI summary
A modular disk coextrusion die (10) is formed of a plurality of cells (100A, 100D, 100G, 100, 200A) stacked together. Each cell (100A, 100B, 100D, 100E, 100G, 100J, 100L, 100, 200) includes a symmetrical arrangement of thin annular disks (19), including a central routing disk (5) and two distribution disks (402B, 4A, 4, 6A, 6) on both sides of the central routing disk (5). The distribution disks (402B, 4A, 4, 6A, 6) are oriented (180) so that their respective distribution inlet (402C, 402E, 602D, 602F) openings (102Q, 102, 502) oppose each other by about 180 degrees. The symmetrical arrangement permits each cell (100A, 100B, 100D, 100E, 100G, 100J, 100L, 100, 200) to process the melt streams (142, 152, 162, 172) in a manner that provides enhanced layer uniformity and bubble stability. By stacking (150) several cells (100A, 100D, 100G, 100, 200A), blown films having up to several hundred layers can be made using twelve, twenty-four or more polymer melt streams (142, 152, 162, 172).