Slot Die Actuator Control for Patterned Extrusion

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Solution Overview

Problem

Existing slot dies lack the ability to create patterned features in extruded products with precise control over the fluid flow path thickness, leading to inconsistent thickness profiles and limited flexibility in producing complex coatings or extrusions.

Innovation Solution

A slot die system equipped with a plurality of actuators spaced across the width of the die, controlled by a digital controller to adjust the position of choker bars or flexible die lips, allowing for continuous, periodic, or random variations in the fluid flow path thickness, enabling the creation of patterned features in extruded products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional slot dies with fixed or manually adjusted die lips are used, then the structure is simple and easy to operate, but the ability to create patterned features with precise control over fluid flow path thickness is limited

Engineering Contradiction:

Improvecontrol precision of fluid flow path thicknessVSAvoidcomplexity of actuator system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The die lip is divided into multiple independently controllable segments or zones, each equipped with its own actuator. This segmentation allows precise local control of the fluid flow path thickness at different positions across the die width, enabling creation of complex patterned features while maintaining overall system manageability through modular control architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The die lip transitions from a static or manually adjusted component to a dynamically controllable element through integration of multiple actuators. Each actuator can independently adjust the die lip position in real-time during operation, allowing continuous variation of the fluid flow path thickness to create diverse patterns including continuous, periodic, and random variations

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple actuators are added to control different positions of the die lip, then the ability to create patterned features is improved, but the device complexity and control difficulty increase

Engineering Contradiction:

Improveflexibility in producing complex coatingsVSAvoidease of individual actuator adjustment

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The actuator system is designed with universal control capabilities where a centralized controller manages all actuators through a unified interface. Each actuator can perform multiple functions including positioning, pattern creation, and real-time adjustment, allowing the system to produce various coating patterns (continuous, periodic, random) and thickness profiles without requiring separate control mechanisms for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system incorporates feedback mechanisms that monitor the actual fluid flow path thickness and actuator positions, comparing them against desired target values. The controller automatically adjusts actuator positions based on this feedback to maintain precise control over the thickness profile, eliminating the need for manual individual adjustment and simplifying operation while achieving high manufacturing precision

Inventive Principle:

Principle #23Feedback

3Stability of the object's composition

If continuous adjustment of actuator positions is implemented to create patterns, then the uniformity and consistency of extruded product thickness is improved, but the control system complexity increases

Engineering Contradiction:

Improveuniformity of extruded product thicknessVSAvoidcomplexity of digital control system

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical adjustment mechanisms with an automated digital control system. Digital controllers and algorithms manage the actuators to maintain consistent fluid flow path thickness and create desired patterns, providing stable and repeatable control over extruded product composition without requiring complex mechanical adjustment mechanisms for each actuator

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9216535B2Slot die position adjustments to facilitate patterned products

Publication Date: 2015.12.22 3M INNOVATIVE PROPERTIES CO

AI summary

A method of controlling a slot die comprises positioning actuators of the slot die with a controller according to a first set of discrete settings, operating the slot die by passing an extrudate through the fluid flow path and out the applicator slot with the actuators positioned according to the first set of discrete settings, and while passing the extrudate through the fluid flow path and out the applicator slot, changing the positions of the actuators with the controller to create patterned features in the extrudate.