Two-Section Polymer Die for Orientation and Void Prevention
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Solution Overview
Problem
The production of high-performance polymer films and foils from thermotropic and lyotropic liquid-crystalline polymers has been less successful due to challenges in achieving desired orientations and properties, particularly in elongational flow fields and in forming films with high tensile modulus and specific moduli.
Innovation Solution
A die design with a spinneret part and a second shaping part, where the surface area and dimensions of the outlet comply with specific formulas to ensure proper orientation and filling, preventing void formation and enhancing material properties, such as a polymer film with a width of at least 2 cm and a loss modulus greater than 0.75 GPa and a storage modulus greater than 20 GPa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high wind-up/extrusion speed ratios are applied to induce elongational flow fields, then polymer molecules orient in the direction of flow, but producing high-performance films and foils becomes less successful
Solution Approach 1:
The die is divided into two distinct sections: a first section for orienting the material and a second section for shaping the oriented material. This segmentation allows each section to perform its specific function optimally, resolving the contradiction between achieving orientation and producing successful films.
Solution Approach 2:
The first section of the die performs the orientation action preliminarily, orienting the polymer molecules before the material enters the second shaping section. This preliminary orientation ensures that the subsequent shaping process works with pre-oriented material, improving film production success.
2Productivity
If a large surface area is used for shaping oriented material, then more material can be processed, but void formation increases
Solution Approach 1:
The second section of the die has a limited surface area specifically designed for shaping the oriented material. This localized shaping area ensures proper filling without void formation, while the first section handles the orientation of larger volumes of material.
Solution Approach 2:
The die design transitions from a single large surface area to a two-section configuration with controlled surface areas in each section. This dimensional reorganization allows the shaping section to maintain appropriate surface area limits while the orienting section handles volume processing.
3Quantity of substance
If the die outlet surface area is increased, then more polymer fibers can be formed, but the orientation and filling control decreases
Solution Approach 1:
The die outlet is segmented into multiple orifices in the first section for generating multiple polymer fibers, while the second section provides a controlled shaping outlet. This segmentation allows high fiber output while maintaining orientation and filling control through the structured arrangement.
Solution Approach 2:
The first section with multiple orifices performs the preliminary action of forming individual oriented fibers, which then converge into the second shaping section. This preliminary fiber formation with inherent orientation control enables high quantity output while preserving precision.
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 die design effectively orients polymer materials, preventing voids and enhancing mechanical properties, resulting in high-performance polymer films with improved tensile and specific moduli, suitable for applications requiring high damping and stiffness.
Implementation Method 1
applying relatively high wind-up/extrusion speed (draw down) ratios that induce elongational flow fields causing the polymer molecules to orient in the direction of flow
Implementation Method 2
a second section for shaping the oriented material into a desired form
Data Source
AI summary
Provided are dies having a first section for orienting material being pressed through the die and a second section for shaping the oriented material into a desired form. In an embodiment, the surface area for shaping the oriented material into a desired form is limited. Also provided are polymer articles and processes for making the same. In an embodiment, the processes employ the dies.