Multi-manifold extrusion die with deckle system and method of using same

Patent metadata

Field	Value
Publication number	US-10040234-B2
Application number	US-201414288062-A
Country	US
Kind code	B2
Filing date	May 27, 2014
Priority date	May 27, 2014
Publication date	Aug 7, 2018
Grant date	Aug 7, 2018

Abstract

A multi-manifold extrusion die having a fully independent internal deckle system. The die can selectively produce a composite extrudate having a full-width arrangement, an encapsulation arrangement, or a naked-edge arrangement. Methods are also provided for producing a composite extrudate having a full-width arrangement, an encapsulation arrangement, or a naked-edge arrangement.

First claim

What is claimed is:

1. An extrusion die, comprising:
first and second manifolds,
converging first and second internal flow passageways extending respectively from said first and second manifolds,
a downstream flow channel extending from a convergence of said first and second internal flow passageways,
an outlet orifice, and
an internal deckle system comprising a first internal deckle member received in both said first manifold and said first internal flow passageway, a second internal deckle member received in both said second manifold and said second internal flow passageway, and a third internal deckle member received in said downstream flow channel, said internal deckle system having an encapsulation position, a full-width position, and a naked-edge position, wherein:
when in said encapsulation position, said internal deckle system configures said extrusion die to produce an encapsulated composite extrudate comprising a core layer and a skin layer of greater width than the core layer such that the skin layer defines lateral edges of the encapsulated composite extrudate,
when in said full-width position, said internal deckle system configures said extrusion die to produce a full width composite extrudate comprising a core layer and a skin layer both extending over a full width of the full width composite extrudate, and
when in said naked-edge position, said internal deckle system configures said extrusion die to produce a naked edge composite extrudate comprising a skin layer and a core layer of greater width than the skin layer such that the core layer defines lateral edges of the naked edge composite extrudate.

2. The extrusion die of claim 1 ,
wherein said extrusion die further comprises a deckle control system comprising a movable deckle carrier to which said first, second, and third internal deckle members are mounted,
said first, second, and third internal deckle members being conjointly moveable together with said deckle carrier relative to said extrusion die in response to conjoint actuation of said deckle control system, said first and second internal deckle members being independently moveable relative to said extrusion die, relative to said deckle carrier, and relative to each other in response to independent actuation of said deckle control system.

3. The extrusion die of claim 2 , wherein:
when said internal deckle system is in said full-width position, said first and second internal deckle members extend substantially equal distances into said extrusion die,
when said internal deckle system is in said encapsulation position, said first internal deckle member extends a greater distance into said extrusion die than does said second internal deckle member, and
when said internal deckle system is in said naked-edge position, said second internal deckle member extends a greater distance into said extrusion die than does said first internal deckle member.

4. The extrusion die of claim 2 , wherein said deckle carrier has a height and a width, said first and second internal deckle members being mounted to said deckle carrier at locations spaced apart along said width of said deckle carrier,
said first internal deckle member having a first body portion and a first tail portion, said first body portion received in said first manifold, said first tail portion received in said first internal flow passageway,
said second internal deckle member having a second body portion and a second tail portion, said second body portion received in said second manifold, said second tail portion received in said second internal flow passageway,
said first body portion having a greater width than said first tail portion, and said second body portion having a greater width than said second tail portion.

5. The extrusion die of claim 4 , wherein:
said first tail portion has a first downstream tip region, and
said second tail portion has a second downstream tip region, said first and second downstream tip regions contacting each other at said convergence of said first and second internal flow passageways.

6. The extrusion die of claim 2 , wherein:
said internal deckle system further comprises a first stationary end plate mounted to said extrusion die, and
said deckle carrier further comprises a carrier plate movable transversely relative to said first stationary end plate.

7. The extrusion die of claim 6 , wherein said internal deckle system further comprises a second stationary end plate spaced apart from said first stationary end plate,
said first stationary end plate, said second stationary end plate, and said carrier plate each have a die side face and a distal side face,
said deckle control system further comprising first and second deckle actuators operably connected respectively to said first and second internal deckle members, said first and second deckle actuators located on said distal side face of said carrier plate, and
said deckle control system further comprising a carrier actuator operably connected to said carrier plate and located on said distal side face of said second stationary end plate.

8. The extrusion die of claim 6 , wherein said internal deckle system further comprises a second stationary end plate and a plurality of alignment shafts, said second stationary end plate spaced apart from said first stationary end plate, said alignment shafts extending transversely between said first and second stationary end plates, said carrier plate located between said first and second stationary end plates and movable along said alignment shafts.

9. The extrusion die of claim 6 , wherein said internal deckle system further comprises first, second, and third fastening systems respectfully attaching said first, second, and third internal deckle members to said carrier plate such that each of said first and second internal deckle members can selectively either be retained in a fixed position relative to said carrier plate or moved transversely relative to said carrier plate,
said third fastening system attaching said third internal deckle member to said carrier plate in a fixed position such that said third internal deckle member is not movable transversely relative to said carrier plate.

Assignees

• Nordson Extrusion Dies Ind Llc
• Nordson Corp

Inventors

• Sedivy Jordan L

Classifications

• B29C48/21 Primary

  the layers being joined at their surfaces · CPC title

• B29C48/3001

  characterised by the material or their manufacturing process · CPC title

• B29C48/30

  Extrusion nozzles or dies (extrusion characterised by the shape or cross-section of the extruded article B29C48/03) · CPC title

• B29C48/307

  specially adapted for bringing together components, e.g. melts within the die · CPC title

• B29C48/2556

  provided in or in the proximity of dies (B29C48/302, B29C48/31, B29C48/325 take precedence) · CPC title