Method and apparatus for feeding a plurality of molten resin jet streams into T die

• US 5,211,898 A
• Filed: 05/28/1991
• Issued: 05/18/1993
• Est. Priority Date: 07/27/1988
• Status: Expired due to Fees

• Current Assignee: TOMY Machinery Manufacturing Company Limited
• Original Assignee: TOMY Machinery Manufacturing Company Limited
• Inventors: Shinmoto, Jitsumi
• Primary Examiner(s): Thurlow, Jeffrey
• Application Number:
  US07/706,568
• Time in Patent Office: 721 Days
• Field of Search: 264/171, 264/245, 264/40.7, 425/131.1, 425/133.5, 425/462, 425/197
• US Class Current: 264/173.12
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/22 with means connecting the layers, e.g. tie layers or undercuts
• CPC Class Codes: B29C 48/307 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29C 48/313 by positioning the die lips
• CPC Class Codes: B29C 48/49 using two or more extruders to feed one die or nozzle

Abstract

The present invention feeds a plurality of different molten resin jet streams into a T die adapted to produce film members such as plastic films. A plurality of molten jet streams extruded from a plurality of extruders, respectively, are fed from their predetermined directions into one resin feed passage in communication with the T die and combined or united without causing the mixture with each other. The relative positional relationship between the intersurfaces between the adjacent molten resin jet streams defined when the molten resin jet streams are combined or united on the one hand and an elongated discharge port of the T die can be adjusted so that the relative positional relationship between a plurality of extruders and the T die can be freely changed.

Claims

1. A method for combining a plurality of at least three molten resin streams in an axially elongated tubular passageway into a single united resin stream without mixing said streams of said plurality to produce, upon extrusion, a laminated multilayer film of variably selectably ordered lamina with each layer of said film made of one of said resin streams, comprising:

a. combining two of said streams without mixing after successively laterally displacing said uncombined unmixed streams within and respecting said passageway to provide a first combined stream having unmixed component streams, with stream interfaces therebetween angularly oriented according to a selected configuration of said lamina to be produced on said film;

b. thereafter uniting the combined stream with an additional one of said plurality of streams after angularly orienting and laterally displacing said combined and said additional streams within said passageway respecting one another to provide a second angularly oriented combined stream for input to an extruder for producing said laminated multilayer film having the variably selected order of said lamina.

2. Apparatus for combining a plurality of molten resin streams into a single stream without mixing together to produce, upon extrusion, a laminated multilayer web or film with each layer made of resin from one of said streams, comprising:

a. a body, having an axial passageway therethrough, individually receiving said streams;

b. a first axially rotatable valve member within said body for selectably permitting the flow of a second resin stream and for combining and angularly orienting two of said streams, including said second stream, into a first combined stream having unmixed stream components with interfaces therebetween angularly oriented according to a selected configuration of said lamina on said film, with at least one of said streams flowing through said first rotatable valve member, comprising;

i. a rotatable collar, through which at least one of said streams flows; and

ii. a member fixed to, rotatable unitarily therewith and axially projecting from said collar into said passageway into which said first stream flows through said collar and in which said two streams combine into said first combined stream, comprising;

(1) an angular surface portion rotatable unitarily with said valve member for controlling the combining of said two streams to provide said first combined stream having unmixed components angularly oriented according to a selected configuration of said lamina as they are combined into said first combined stream;

c. a second axially rotatable valve member within said body for selectably permitting flow of another resin stream and for combining and angularly orienting said first combined stream and said another stream of said plurality of streams into a second combined stream having unmixed components angularly oriented according to said selected configuration of said lamina on said film, said first combined stream and said additional stream flowing separately through at least part of said second rotatable valve member within said body and downstream of said first rotatable valve member, comprising;

i. a collar through which said first combined stream and said additional stream flow at least part way therethrough separated from each other; and

ii. a member fixedly connected to, rotatable unitarily with and axially projecting from said collar into said passageway, including

(1) an angular surface portion movable unitarily with said second valve member for controlling the combining of said two streams to provide said second united stream having unmixed components angularly oriented according to said selected configuration of said lamina as they are combined into said second combined stream.

3. A method for combining a plurality of molten resin streams into a single stream prior to extrusion to produce a multilayer film having respective layers defined by said streams, comprising:

a. laterally displacing a first one of said streams flowing in an axially elongated passageway into a transverse cross-sectional area of said passageway of substantially about half the transverse cross-sectional area of said passageway prior to displacement of said first stream by contacting said first stream with a surface inclined at a first angle respecting said passageway axis;

b. laterally displacing a second one of said streams flowing into said passageway into transverse cross-sectional area of said passageway downstream of said position of lateral displacement of said first stream and being of substantially about half the transverse cross-sectional area of said passageway prior to displacement of said first stream by contacting said second stream with a surface inclined at said first angle respecting said passageway axis;

c. combining said two laterally displaced streams in said passageway downstream of said position of lateral displacement of said second stream to provide a single stream having unmixed components with interfaces therebetween oriented according to a selected configuration of said layers in said film.

4. A method for combining a plurality of molten resin streams into a single stream prior to extrusion to produce a multilayer film having respective layers defined by said streams, comprising:

a. laterally displacing a first stream flowing in an axially elongated passageway into a transverse cross-sectional area of said passageway of substantially about half the transverse cross-sectional area of said passageway prior to displacement by contacting said first stream with a surface inclined respecting said passageway axis;

b. laterally displacing succeeding ones of said streams flowing into said passageway, at positions downstream of where said first stream is laterally displaced, into transverse cross-sectional area of said passageway unoccupied by said stream resulting from previous lateral displacement(s) and being of substantially about half the transverse cross-sectional area of said passageway occupied by said stream resulting from said prior lateral displacement(s) by contacting said succeeding streams with surfaces inclined respecting said passageway axis;

c. successively combining said laterally displaced streams in said passageway downstream of said position of lateral displacement of said succeeding streams to provide a single stream having unmixed components with interfaces therebetween oriented according to a selected configuration of said layers in said film.

31. The method of claim 4 further comprising:

a. adjusting orientation of interfaces of adjacent resin streams relative to a longitudinally elongated discharge port through which said combined streams are extruded to produce a desired configuration in said multilayer film by twisting said streams to a desired orientation through contacting said streams with a twisted plate-like member within said passageway prior to successively combining said laterally displaced streams and thereafter extruding the same.

32. The method of claim 4 further comprising:

a. contacting said laterally displaced streams with respective surfaces of a perforate member for resin communication between said streams on respective sides of said member via orifices therethrough prior to combining said streams.

33. The method of claim 4 further comprising:

a. contacting said laterally displaced streams with a curved surface having passageways, for flow of resin from said respective contacting streams therethrough, connecting portions of said curved surface contacted by respective ones of said streams with a region of said passageway downstream of said curved surface at which said streams are combined.

5. Apparatus for combining a plurality of molten resin streams into a single stream without mixing prior to extrusion to produce a multilayer film with layers defined by resins of said respective streams, comprising:

a. a body having an axially elongated passageway therewithin;

b. a first flow control valve axially rotatably disposed within said passageway, having an axial bore forming a portion of said passageway, including;

i. means substantially positioned within said passageway portion defined by said axial bore and axially rotatable unitarily with said control valve for laterally displacing a first resin stream flowing through said passageway and said valve;

ii. means for selectably permitting flow of a second resin stream into said passageway;

iii. means for laterally displacing said second resin stream joining said passageway downstream of said valve in a direction opposite that of displacement of said first resin stream flowing through said passageway;

c. a second flow control valve axially rotatably disposed within said passageway, having an axial bore therewithin forming a portion of said passageway, having an axially offset second bore connecting exterior of said second valve with said passageway for feeding a third molten resin stream into position for combining with a combined resin stream flowing through said passageway, including;

i. means substantially positioned within said passageway and axially rotatable unitarily with said second flow control valve for laterally displacing said combined resin stream flowing through said passageway and said valve at a position upstream of a position at which said combined resin stream flowing through said passageway and said third resin stream flowing through said axially offset second bore are combined.

6. Apparatus of claim 5 wherein said control valves comprise:

a. generally cylindrical collars having central cylindrical bores substantially coaxial with and defining portions of said axial passageway; and

with

said axially offset second bore of said second valve being skew to said axis and connecting an annular surface of said collar with said cylindrical bore.

7. Apparatus of claim 6 wherein said displacing means comprise:

a. axially elongated tongues connected to said collars, rotatable unitarily therewith and extending axially therefrom into said passageway downstream of said collars.

8. Apparatus of claim 7 wherein said tongues comprise:

a. upstream facing resin flow displacement surfaces which are angularly inclined to said axial passageway and have projected area in the axial direction of substantially half the transverse cross-sectional area of said axial passageway.

9. Apparatus of claim 8 wherein said surfaces of said tongues are inclined at a common angle.

10. Apparatus of claim 7 wherein said tongues include upstream facing resin flow displacing surfaces angularly inclined to said axial passageway and have projected area in the axial direction of substantially half the transverse cross-sectional area of said axial passageway.

11. Apparatus of claim 10 wherein said surfaces of said tongues are inclined at a common angle.

12. Apparatus for combining a plurality of at least three molten resin streams into a single stream without mixing prior to extrusion to produce a multilayer film with layers defined by resins of said respective streams, comprising:

a. a body having an axially elongated passageway therewith;

b. first flow control valve means axially rotatably disposed within said body, comprising;

i. a generally cylindrical collar having a substantially axial bore therewithin forming a portion of said passageway;

ii. means, substantially positioned within said passageway portion defined by said bore, extending radially inwardly from and fixedly connected to said collar, for laterally displacing a first resin stream flowing axially through said passageway and said collar of said first valve means, comprising;

(1) a substantially planar resin displacement surface facing axially upstream in said passageway and being inclined to the passageway axis at a preselected angle;

iii. tongue means, fixedly connected to and extending from said resin stream lateral displacement means substantially axially away from said collar, for laterally displacing a second resin stream of said plurality joining said passageway downstream of said first flow control valve means in a lateral direction opposite that of said resin stream flowing through said collar of said first flow control valve means, comprising;

(1) a substantially planar resin displacement surface facing axially downstream in said passageway and being inclined to the passageway axis at said preselected angle;

c. at least one second flow control valve means axially rotatably disposed within said body, comprising;

i. a generally cylindrical collar having a substantially axial bore therethrough forming a portion of said passageway downstream of said first flow control valve means and having a second bore therethrough connecting an exterior surface of said collar contacting said body to said passageway defined by said axial bore through said collar;

ii. means fixedly connected to said collar, substantially positioned within said passageway portion defined by said bore for laterally displacing a united resin stream, defined by individual resin streams combined upstream of said second flow control valve, flowing axially through said passageway and through said bore of said collar of said second flow control valve means, comprising;

(1) a substantially planar resin displacement surface facing axially upstream in said passageway and being inclined to the passageway axis at an angle;

iii. tongue means, fixedly extending downstream from said resin stream lateral displacement means substantially axially from said collar, for maintaining separation of an additional resin stream of said plurality from said united resin stream in said passageway after joining said united resin stream in said passageway by passage through said second bore for a distance sufficiently downstream of said collar that individual streams of said united resin stream in said passageway are sufficiently united that substantially no mixing thereof occurs when said additional resin stream joins therewith.

13. Apparatus of claim 12 wherein said resin stream displacing means of said second flow control valve laterally displaces said united resin stream flowing axially through said passageway in the direction said tongue means of said first flow control valve displaces said second resin stream.

14. Apparatus of claim 12 further comprising means for adjusting pressure of said resin stream flowing through said second bore of said second flow control valve.

15. Apparatus of claim 14 wherein said pressure adjusting means further comprises rod means selectably insertable into said second bore to regulate size of a throat portion of said second bore.

16. Apparatus of claim 15 wherein said pressure adjusting means is within said body.

17. Apparatus of claim 12 wherein said tongue means of said second flow control valve is plate-shaped having thickness of about one-fourth the diameter of said resin feed passageway at a position substantially aligned with a downstream facing surface of said cylindrical collar of said second flow control valve and tapers to a knife edge at the extremity of said tongue means remote from said cylindrical collar.

18. Apparatus of claim 17 wherein said knife edge is substantially perpendicular to the axial direction.

19. Apparatus of claim 12 wherein said tongue means of said second control valve is plate shaped, axially elongated and twisted substantially 180 degrees about the axis of elongation between said resin displacement means and the extremity of said tongue means remote from said cylindrical collar.

20. Apparatus of claim 12 wherein said tongue means of said second control valve is plate shaped, axially elongated and twisted substantially 90 degrees about the axis of elongation between said resin displacement means and the extremity of said tongue means remote from said cylindrical collar.

21. Apparatus of claim 12 wherein said tongue means of said second control valve is plate shaped, axially elongated and twisted substantially less than 90 degrees about the axis of elongation between said resin displacement means and the extremity of said tongue means remote from said cylindrical collar.

22. Apparatus of claim 12 wherein said tongue means of said second control valve is substantially plate-shaped at juncture with said resin displacement means, is axially elongated and is conically-shaped at the extremity of said tongue means remote from said cylindrical collar.

23. Apparatus of claim 12 wherein said tongue means of said second control valve is substantially plate-shaped at juncture with said resin displacement means, is axially elongated, tapers to a knife edge at the extremity of said tongue means remote from said cylindrical collar and is perforate in the transverse direction proximate to said knife edge.

24. Apparatus of claim 12 wherein said tongue means of said second control valve is substantially plate-shaped at juncture with said resin displacement means, is axially elongated, tapers to a knife edge at the extremity of said tongue means remote from said cylindrical collar and is of zig-zag axial cross-section proximate said knife edge.

25. Apparatus of claim 24 wherein said zig-zag is defined by equal length legs.

26. Apparatus of claim 25 wherein said zig-zag is formed of 90 degree angles.

27. Apparatus of claim 26 wherein legs of said zig-zag are of two different lengths.

28. Apparatus of claim 22 wherein said conical extremity of said tongue means is axially slotted.

29. Apparatus of claim 28 wherein alternate ones of said slots communicate with one another and with respective laterally facing surfaces of said plate-shaped portion of said tongue means.

30. Apparatus of claim 22 wherein said conical extremity of said tongue means includes a sinuous axial slot communicating with one laterally facing surface of said plate-shaped portion of said tongue means.