Tubular Microlayer Extrusion via Deflector Perturbation
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Solution Overview
Problem
Conventional extrusion methods are limited to forming products with approximately twelve layers, and tubular products often result in weld lines or separations between microlayers, restricting the creation of complex geometries and properties.
Innovation Solution
The method involves passing multilayered or multi-component streams over deflectors such as spiral, bowtie, circumferential, or wrapping deflectors to transform them into tubular shapes before or during extrusion, allowing for the creation of products with thousands of layers and unique internal structures like annular rings or spirals, and enabling enhanced alignment of filler particles or fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion methods are used to form tubular products, then the process is simple and straightforward, but weld lines or separations appear between microlayers and the layer count is limited to approximately twelve layers
Solution Approach 1:
The extrusion process is segmented into multiple stages: first forming a flat microlayered sheet, then separately forming the tubular shape. This segmentation eliminates weld lines by completing the tubular formation after extrusion rather than during it, allowing each microlayer to remain continuous and intact throughout the process.
Solution Approach 2:
The microlayered structure is preliminarily formed as a flat sheet before tubular shaping occurs. This preliminary formation ensures that all microlayers are properly established and aligned before the tubular geometry is applied, preventing any separation or weld line formation during the shaping process.
2Manufacturing precision
If conventional extrusion methods are used, then the equipment and process are straightforward, but the product is limited to approximately twelve layers
Solution Approach 1:
The invention transitions from conventional single-dimension extrusion to a two-dimensional approach by first creating a flat microlayered sheet and then separately forming the tubular shape. This dimensional change allows for thousands of microlayers to be formed in the flat state without the geometric constraints that would limit layer count in direct tubular extrusion.
3Adaptability or versatility
If conventional extrusion is used to create tubular products, then the process is simple, but complex geometries and unique internal structures cannot be created
Solution Approach 1:
The formation process is segmented into distinct operations: microlayer formation, tubular shaping, and potential secondary structure formation. This segmentation allows each operation to be optimized independently, enabling complex geometries and internal structures to be created without overwhelming the extrusion die system with all requirements simultaneously.
Data Source
AI summary
The present invention relates to a method of transforming multilayered and/or multi-component streams into tubular shapes prior to or during extrusion by passing the streams over a deflector. The invention also relates to dies containing spiral, bowtie, circumferential and/or wrapping deflectors and products made by such methods.