Abstract: An extrusion die including a die body having a movable die lip, is provided with improved automated control of the exit orifice through which a flowable polymer is extruded. The automated control is provided by lip adjustment assemblies each of which includes a thermally responsive translator and each of which is in engagement with the movable die lip. Beneficially, the lip adjustment assemblies are also in engagement with a support structure located to reduce the effect of flow pressure-induced deflection. Improved automated control of the movable lip and the exit orifice gap provides a web having a prescribed thickness profile without manual intervention being required.

Abstract: The present invention provides an extrusion die that includes a manifold transition zone that comprises a varying included angle. The varying included angle provides unparalleled freedom of design to achieve diverse fluid dynamic objectives, such as reduced residence time across the manifold width, reduced transition stagnation, improved streamlining of the mass flowing through the manifold, and reduced differential clamshell deflection across the flow channel width. The manifold may be transformed from one cross-sectional shape to another cross-sectional shape beneficially related to the varying included angle, including change from a generally extended cross-sectional shape to a generally teardrop-shaped cross-section. The manifold may include a first transition zone portion that includes the varying included angle, and a second transition zone portion that includes a constant included angle, and that is particularly beneficial for receiving an internal deckle.

Abstract: The present invention provides an extrusion die that includes a manifold transition zone that comprises a varying included angle. The varying included angle provides unparalleled freedom of design to achieve diverse fluid dynamic objectives, such as reduced residence time across the manifold width, reduced transition stagnation, improved streamlining of the mass flowing through the manifold, and reduced differential clamshell deflection across the flow channel width. The manifold may be transformed from one cross-sectional shape to another cross-sectional shape beneficially related to the varying included angle, including change from a generally extended cross-sectional shape to a generally teardrop-shaped cross-section. The manifold may include a first transition zone portion that includes the varying included angle, and a second transition zone portion that includes a constant included angle, and that is particularly beneficial for receiving an internal deckle.

Abstract: The present invention provides a slot die that includes a flow passageway that includes a transverse flow-providing manifold, a flow metering section that provides a transverse flow metering gap, and an exit channel that includes an exit orifice. In accordance with the invention, a transverse flow metering gap may beneficially be selected independent of changing the gap or width of the exit office, using one or more normally non-adjustable die bodies.

Abstract: The present invention provides a slot die that includes a flow passageway that includes a transverse flow-providing manifold, a flow metering section that provides a transverse flow metering gap, and an exit channel that includes an exit orifice. In accordance with the invention, the transverse flow metering gap may beneficially be selected independent of changing the gap or width of the exit office, using one or more normally non-adjustable die bodies.

Abstract: The present invention provides a slot die that includes a flow passageway that includes a transverse flow-providing manifold, a flow metering section that provides a transverse flow metering gap, and an exit channel that includes an exit orifice. In accordance with the invention, the transverse flow metering gap may beneficially be selected independent of changing the gap or width of the exit office, using one or more normally non-adjustable die bodies.

Abstract: The present invention provides a slot die that includes a flow passageway that includes a transverse flow-providing manifold, a flow metering section that provides a transverse flow metering gap, and an exit channel that includes an exit orifice. In accordance with the invention, a transverse flow metering gap may beneficially be selected independent of changing the gap or width of the exit office, using one or more normally non-adjustable die bodies.

Abstract: A method and apparatus for the extrusion of multilayered composite products, is provided. The inventive apparatus includes a coextrusion structure and a partition member. In accordance with the inventive method, the relative orientation of a first shaped flow stream and a second shaped flow stream to one another is changed, and the reoriented shaped streams are melt-laminated to produce a layered composite formed independent of division of a layered precursor stream. The reorientation occurs via a flow sequencer, which may be removably disposed. Beneficially, layered flow streams that differ from one another may be used. The coextrusion structure may advantageously include one or more removably disposed, flow-shaping inserts, and the partition member may be a removably disposed, partition plate.

Abstract: A method and apparatus for the extrusion of multilayered composite products, is provided. In accordance with the inventive method, the relative orientation of a first shaped flow stream and a second shaped flow stream to one another is changed, and the reoriented shaped streams are melt-laminated to produce a layered composite formed independent of division of a layered precursor stream. Beneficially, layered flow streams that differ from one another may be used. Differences in volumetric or mass flow rates may also be used to advantage.

Abstract: An extrusion apparatus which simplifies changing the relative order of layers of a coextruded laminate, is provided. Advantageously, the apparatus includes an interchangeably disposed, layer sequence selecting device which can be changed out without disassembly of other extrusion apparatus.

Abstract: A thermal translator device providing improved performance and faster expansion response, is described. Also described is an extrusion apparatus including a plurality of thermal translator devices operatively arranged for thermally actuated, localized action upon the lip. The thermal translator device includes a thermal energy source disposed within a structural member. The thermal energy source and the structural member are an integral unit. Also described is an extrusion apparatus including tie rods for a support assembly otherwise without support.

Abstract: An extrusion apparatus having an internal deckle system, includes a deckle blade that extends through an end of the apparatus into a flow passageway. The apparatus may beneficially include a cold-formable, sealing member for preventing leakage through the apparatus end. In a variation, the apparatus may include an upstream deckle plug that includes a sealing member formable under heat and compression to prevent leakage transversely past the upper deckle plug. In a further variation, a full width, upper deckle plug may extend through an end of the main body into the manifold. A wavy or scalloped edge may be avoided by an extended portion that extends downwardly and terminates at or near the exit orifice.

Abstract: An improved extrusion apparatus having an internal deckle, includes a toothed rack and a rotatable gear for positioning the deckle. The apparatus may include an independently adjustable, upstream deckle. A brake mechanism that assists the control of deckle movement, is also provided. A tongue and groove, sliding fit of the deckles may be used.

Abstract: The present invention provides a novel process for preparing composites including layers having thermally distinct processing requirements. Beneficially, the process may use a single manifold die. By the process, useful containers may be manufactured.

Abstract: An improved extrusion apparatus having an internal deckle system, is provided. The extrusion apparatus includes a body portion which includes a flow passageway. The deckle system includes a deckle member having a full width, manifold plug portion and a fin-shaped plug portion, each extending through an end of the body portion into the flow passageway.

Abstract: An improved extrusion apparatus includes an adjustable deckle and a flow channel in the deckle that makes possible extrusion of a composite stream, and in particular a side-by-side composite stream. Beneficially, an end plate of the apparatus includes an inwardly projecting portion disposed in precision sliding fit within the deckle channel. Also provided is a process for composite extrusion with width adjustment.

Abstract: An improved apparatus providing for uniformity of web thickness is disclosed. In one aspect, the apparatus includes a plurality of gap-controlling, thermal energy sources, and in heat-exchange communication with the thermal energy sources, an assembly for compensating for temperature variation proximate to the thermal energy sources and across the apparatus width. The thermal compensating assembly includes a heat exchange jacket, and in combination therewith, a heat-exchanging, working fluid that undergoes a phase change in performing its heat exchange function.

Abstract: An improved apparatus providing for uniformity of web thickness. In one aspect, the apparatus includes a plurality of gap-controlling, thermal energy sources, and in heat-exchange communication with the thermal energy sources, an assembly for compensating for temperature variation proximate to the thermal energy sources and across the apparatus width. The thermal compensating assembly includes a heat exchange jacket, and in combination therewith, a heat-exchanging, working fluid that undergoes a phase change in performing its heat exchange function.In another aspect of the invention, the apparatus includes an element disposed along an exit slot-forming lip, that reduces localized thermal gradients along the lip. This element functions as a heat sink and a heat source proximate to the lip gap, and likewise includes a heat-exchanging, working fluid that undergoes a phase change.

Abstract: The present invention provides a novel extrusion apparatus including a flow channel having a modified preland channel that functions as a flow transition zone. The flow transition zone changes the widthwise flow volume of a stream passing therethrough so as to provide for substantially equal flow volume of the stream across the flow channel width as the stream exits from the transition zone.

Abstract: A thermal translator device providing improved performance and faster expansion response, is described. Also described is an extrusion apparatus including a plurality of thermal translator devices operatively arranged for thermally actuated, localized action upon the lip. The thermal translator device includes a thermal energy source disposed within a structural member. The thermal energy source and the structural member are an integral unit. Also described is an extrusion apparatus including tie rods for a support assembly otherwise without support.