Sheet Forming Die with Local Temperature Control
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Solution Overview
Problem
Conventional multi-manifold dies for laminated film production face difficulties in smoothly controlling the flow rates of molten resin for coating side edge portions, leading to inconsistent film formation.
Innovation Solution
A sheet forming die with a first passage for the first molten resin and a second passage that branches into multiple passageways, where the temperature of at least one passageway is controlled using a temperature controller to manage the flow rate of the second molten resin, and a tubular restrictor member is used to further regulate the flow, ensuring precise control of the resin flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the film is expanded to standard width and then the two side edge portions are encapsulated in the die with resin, then the laminated film structure is formed, but the resin to coat the two side edge portions cannot smoothly flow to join together with the film at the resin passage outlets, making it difficult to finely control the flow rates of the flowing resin
Solution Approach 1:
The second passage is divided into multiple branch passageways (19A, 19B) that connect to different portions of the lip part (23). This segmentation allows independent temperature control and flow rate adjustment for each passageway, enabling precise control of resin flow to different side edge portions of the film while maintaining smooth flow through optimized passage geometry.
Solution Approach 2:
Temperature controllers (21) are applied locally to specific midstream portions of the passageways (19A, 19B) rather than uniformly heating the entire passage system. This local temperature control enables independent adjustment of resin viscosity and flow rate for each side edge coating operation, resolving the contradiction between precise flow control and smooth flow by allowing optimization at each local location.
2Manufacturing precision
If conventional multi-manifold die structure is used, then the die structure is simple, but the flow rates of resin for coating side edge portions cannot be finely controlled
Solution Approach 1:
The die structure segments the second passage into multiple independently controllable passageways (19A, 19B) with separate temperature controllers (21). This segmentation provides fine flow rate control capability while maintaining relatively simple overall die structure by using individual temperature controllers rather than complex mechanical flow control mechanisms.
Solution Approach 2:
The invention controls resin flow rate by changing the temperature parameter in the midstream portions of the passageways. By locally adjusting temperature, the resin viscosity changes, which directly controls flow rate. This parameter-based control approach achieves fine flow rate adjustment without adding complex mechanical control structures to the die.
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 solution allows for precise control of the flow rates of the divided molten resin flows, ensuring consistent and uniform coating of the side edge portions, improving the quality of the laminated film by enabling fine adjustment of the resin flow rates and preventing backwater generation.
Implementation Method 1
a temperature controller (21) configured to locally control a temperature of a midstream portion of at least one of the passageways (19A, 19B) in order to control a flow rate of the second molten resin (A) in the passageway
Implementation Method 2
a tubular restrictor member (37) provided in a midstream portion of at least one of the passageways (19A, 19B)
Data Source
AI summary
Provided is a sheet forming die capable of finely controlling the flow rates of the respective divided flows of a molten resin with precision. The sheet forming die is a sheet forming die 3 configured to: receive a first molten resin B; to receive a second molten resin A; and to thus form a sheet-shaped resin-made product by discharging the molten resins A, B from a lip gap 15. The sheet forming die 3 includes: a first passage 17 provided to flow the supplied first molten resin B up to an upstream end of a lip part 23 located upstream of the lip gap 15; a second passage 19 provided to flow the supplied second molten resin A up to the lip part 23, the second passage branching out into a plurality of passageways 19A, 19B in a midstream portion thereof, downstream ends of these passageways 19A, 19B being connected to portions in an upstream end of the lip part 23, respectively; and temperature controller 21 configured to locally control a temperature of a midstream portion of at least one of the passageways 19A, 19B in order to control a flow rate of the second molten resin A in the passageways 19A, 19B.