Liquid flow converging device and method of manufacturing multi-layer film

• US 8,388,331 B2
• Filed: 05/26/2005
• Issued: 03/05/2013
• Est. Priority Date: 05/31/2004
• Status: Active Grant

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Osada, Syunichi, Furuno, Yoshiharu, Nomura, Fumiyasu
• Primary Examiner(s): Gupta, Yogendra
• Assistant Examiner(s): Leyson, Joseph
• Application Number:
  US11/628,135
• Publication Number:
  US 20080067712A1
• Time in Patent Office: 2,840 Days
• Field of Search: 425/133.5, 425/192.R, 425/462, 264/173.16, 264/176.1
• US Class Current: 425/133.5
• 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 48/307 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29C 48/70 comprising means for dividing, distributing and recombining melt flows

Abstract

A liquid flow converging device and a method of manufacturing a multi-layer film. The converging device comprises an element (A) having a large number of slits for passing two liquid flows to be converged therethrough and an element (B) having a first converging part for converging, in a laminar form, a large number of laminar liquid flows formed by passing the liquid flows through the large number of slits to form a first laminar liquid flow. The converging device for the liquid flow comprises a first confluence forming device having two or more elements (A) installed independently of each other and two or more elements (B) installed independently of each other.

Claims

1. A liquid stream combining apparatus for combining at least two liquid streams in layers, comprising

(a) a component A having numerous slits therein through which the respective liquid streams are passed, each slit having a length in the respective liquid stream flow direction, a width in a slit width direction perpendicular to the respective liquid stream flow direction, and a clearance in a direction perpendicular to both the respective liquid stream flow direction and the slit width direction, the clearance being smaller than the width,

(b) a component B having a first stream combining section therein for combining numerous layered liquid streams in a predetermined order each of which is formed with each of the liquid streams only upon passing the respective slits and for forming a first layered liquid stream,

(c) wherein two or more of the component A are provided independently of each other in a direction along the slit width direction and two or more of the component B are also provided independently of each other in a direction along the slit width direction,

(d) components C each of which has a liquid retaining section therein for receiving the respective liquid stream to be supplied to the liquid stream combining apparatus and for supplying the respective liquid streams to the respective components A, and

(e) a component D which has a second stream combining section therein for combining the first layered liquid streams formed by the respective components B, in layers in a predetermined order, to form a second layered liquid stream

further comprising slit plates and liquid stream introducing plates, wherein components A are formed in respective slit plates and components C are formed in respective liquid stream introducing plates, each liquid stream introducing plate being positioned for the flow of liquid from the component C of the liquid stream introducing plate to the component A of at least one of the slit plates.

2. The liquid stream combining apparatus, according to claim 1, wherein the number of slits formed in the components A is in the range of 10 to 400.

3. The liquid stream combining apparatus, according to claim 1, wherein the clearance of each of the slits formed in the component A is in the range of 10 μ

m to 30,000 μ

m.

4. The liquid stream combining apparatus, according to claim 1, wherein three or more components C are provided, and a passage dividing section for supplying the liquid streams of the same material to two or more of the component C is installed between a supply source of the liquid streams of the same material and the respective components C.

5. The liquid stream combining apparatus, according to claim 1, wherein among pairs, each comprising the component A and the component B, at least two pairs are disposed in such a manner that interfaces of the respective liquid streams in the first layered liquid stream formed by the component B are kept in parallel to each other.

6. The liquid stream combining apparatus, according to claim 1, wherein the component C is disposed between the adjacent components A.

7. The liquid stream combining apparatus, according to claim 1, wherein passages for supplying the liquid streams from the components C to the respective slits formed in the component A are formed as fine holes.

8. The liquid stream combining apparatus, according to claim 1, wherein the vertical sectional area of each of the slits formed in the component A on a liquid supply face side is different from that on a liquid non-supply face side.

9. The liquid stream combining apparatus, according to claim 1, wherein the width of each of the slits formed in the component A is in the range of 10 mm to 200 mm.

10. The liquid stream combining apparatus, according to claim 1, wherein the length of each of the slits formed in the component A is in the range of 20 mm to 200 mm.

11. The liquid stream combining apparatus, according to claim 1, wherein a form of each of the slits provided in the component A includes a portion in which the form is changed in stepwise in a slit clearance direction.

12. The liquid stream combining apparatus, according to claim 1, wherein a sectional form of a passage of the first layered liquid stream from the component B to the component D is rectangle.

13. The liquid stream combining apparatus, according to claim 12, wherein the radius R of each corner of the rectangle is in the range of 10 μ

m to 1 mm.

14. A method for producing a multilayered film comprises the steps of supplying at least two liquid streams into the liquid stream combining apparatus in any one of claims 1 through 13, and forming a multilayered film from a second layered liquid stream delivered from the liquid stream combining apparatus.

15. The liquid stream combining apparatus, according to claim 6, at least one of said liquid stream introducing plates is disposed between the adjacent components A.

16. The liquid stream combining apparatus, according to claim 1, wherein the slits of component A extend in the same liquid stream flow direction.

17. The liquid stream combining apparatus, according to claim 1, wherein each of the liquid retaining sections of respective components C is positioned to supply the respective liquid streams to the respective components A in the slit width direction.

18. The liquid stream combining apparatus, according to claim 1, wherein the liquid streams enter the first stream combining section of component B from the slits of component A at the same location along the respective liquid stream flow directions.