Chapter 6

6
Coextrusion equipment for
multilayer flat films and sheets

Eldridge Mount III The most general configuration for coextrusion

EMMOUNT Technologies systems consist of the individual extrusion and melt
systems used to prepare the molten polymers
(extruders, filters and melt pumps), the melt pipes
used to deliver the polymers from the extruders, the
Designing and manufacturing adapter to gather and route the melts from the
extruders, a coextrusion feedblock to shape and
multilayer flexible plastic films combine the melts and a die to spread,
with multilayer coextrusion die
technology Multilayer Flexible Packaging; ISBN: 9780815520214
thin and distribute uniformly the melt to form the
coextruded film.
Overview
In producing flat multilayer films, there are two
principal approaches, feedblock coextrusion and
Several generations of coextrusion film dies exist for multicavity die coextrusion. In addition, it is
both tubular and flat dies, as well as several techniques possible and, oftentimes advantageous, to
for combining molten polymers for the production of combine feedblock and multicavity dies together.
multilayer polymer films. For this discussion we will In some instances, the adapter and feedblock can
focus solely on the production of flat sheets and films. be combined together into a single structure and,
The purpose of a film or sheet die is to produce a if this is done, it becomes especially important to
polymer film with uniform thickness dimensions across determine the adapter/feedblock size to permit
its width which is suitable for any subsequent film future coextrusion system changes without
process. For a multilayer system, the production of disturbing the melt pipe and extrusion systems.
uniform layer dimensions is added to the overall
Because of this ability to combine sections and
requirement of uniform total thickness. The number of
technologies for multilayer films and sheets
polymers which can be combined is limited primarily
together, there is a fair amount of strategy which
by the ability to locate extruders to feed the molten
must be developed when establishing a
polymers to the coextrusion system and will depend in
coextrusion system, especially in relationship to
part on the method used to perform the melt
the number and thicknesses of the layers to be
combination.
combined. Care should be taken to define
adequately the products necessary or desired to
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

be manufactured so that initial equipment choices ch were available were not melt extrudable and it
do not inadvertently limit equipment changes for was not possible to produce multilayer products
future products or prevent cost effective directly as it is today by coextrusion. At times, the
modifications to the equipment layout. It is of multilayer structures were produced containing
primary importance to size and locate properly the non-polymer materials such as aluminum foil to
adapter used to collect and route the melt streams supply the desired packaging properties
to the feedblock and/or die to permit the use of suchaslightandgasbarriersnotavailableinpolymerfil
different feedblock and die combinations without ms.
the need to replace existing melt pipes or to
Coextrusion of multilayer films became possible as
disturb the existing extruder layouts. Changes
new polymers were developed which expanded
which require new melt pipes and extruder
the available polymer properties and, as new
relocations are costly and time consuming and
copolymerization technologies were
potential costs or lost production may prevent the
commercialized, the compatible polymers were
changes from being made due to costs. To a large
increased. At the same time, new film
extent, the adapter can be viewed as a simple
manufacturing technologies were developed
extension of the melt pipes, but adapters can also
which further enhanced the polymer properties
serve the function of routing various melt streams
and permitted the production of thinner film
to various inlet locations on feedblocks or dies.
combinations. As polymer layers became thinner,
This routing feature has been added to various
it became impractical to combine the layers
adapter designs using interchangeable flow plates
together after they were produced as films and, in
or selector plugs and adds a great deal of flexibility
some cases, the required polymer thickness
to coextrusion systems, especially when polymer
necessary for the layer was far less than would be
specific extrusion systems are required. This
practical to produce and handle as a single layer
feature permits changing a polymer from one
for subsequent lamination. In these cases,
surface layer to another surface or interior layer
lamination resulted in more expensive
without the need to change extruders. This can be
combinations than were necessary. All of these
important, for instance, if the screw design or melt
factors drove early film developers to look for
transfer pipes are optimized for the particular
better ways to combine various polymers together
material being extruded and cannot be easily
without the need to produce individual free
extruded with another screw or melt pipe design.
standing film layers for later combination and
The alternative to routing in the adapter would be
coextrusion was born.
to change the screw in the extrusion system, a
more difficult and time consuming operation than Polymer processing of thermoplastic materials consists
changing an adapter system or adapter plate. of transforming solid polymers in easy to transport
pellet form into useful shapes and combinations and is
most often performed by an extrusion-based process
Introduction where the solid polymer is melted, mixed if necessary
to form a homogeneous melt and then pumped to a
Multilayerfilmshaveevolvedoverthelastseveraldeca die where it is shaped and, on exiting the die, is
des as new polymers and processing technologies solidified by cooling. It is the shaping of the polymer by
have become available. Originally, multilayer the die which differentiates the many polymer
packaging structures were produced from single processes from each other and which is critically
layer film products which were glued together by important in producing multilayer films. It should be
several lamination processes or were coated with noted at this point that once the polymer leaves the
additional polymer layers.
Oftentimes,thepolymerfilms,suchascellophane,whi
2
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

extruder and enters the coextrusion flow system the General coextrusion equipment overview
flow process is pressure flow or Poiseuille flow.

In this chapter, we will focus on the production of thin A coextrusion system is a combination of parts which
multilayer films. In some instances, the films will be takes molten polymer from two or more extruders,
later oriented and therefore the film passes through a routes and shapes the melt and delivers it to the
relatively thick sheet stage as it exits the die after the combination point where the melts are stacked and
coextrusion process. This cast sheet, which is formed then delivered to a die for spreading to the final width
as a precursor to the multilayer film orientation step, (Fig. 6-1). In its most general configuration, the
is, in many regards, similar to the multilayer sheets coextrusion system will consist of an adapter, a
formed for subsequent thermoforming. Consequently, feedblock and a single or multicavity die. Each of these
much of what is discussed here is applicable to the components and their functions will now be described
coextrusion of multilayer sheet products as well. in turn.
The molten polymers produced in extrusion are, in
The adapter
general, high viscosity fluids which exhibit low
The adapter is designed to collect and route the
Reynolds numbers or a general description might be
various melt streams to the feedblock and/or die used
that of creeping, laminar flow in the various materials
to produce the multilayer film and sheet.
and flow geometries and therefore it would appear
Consequently, the adaptor’s selection is a key strategic
that the combinations of various polymer layers would
decision in selecting a coextrusion system and of
be straightforward. However, the polymers are
critical importance as it can be the key to future
generally viscoelastic which will add some complexity
changes in coextruded product design because it can
to the flow of the polymer layer combinations and the
control the magnitude of the equipment change
choice of the layer combination methods. But, in
necessary. Adaptors can be stand alone parts or can be
general, the combination of polymer melts into layered
made integral with feedblocks or dies. The adaptor is
flows is fairly straightforward and has been developed
the bridge between the extrusion system and the
successfully over the years into a highly evolved set of
coextrusion system. The adaptor can be viewed as an
techniques and equipment categories. In general,
extension of the melt system or as the coupling of the
many polymer melts may be successfully combined
melt system to the coextrusion system.
before a single cavity film die followed by melt
spreading in the die by what is known as feedblock The adaptor should be sized such that it permits the
coextrusion technology. Alternatively, the melts may future addition of layers to an existing coextrusion
be extruded in multicavity dies where the individual system without the need to replace existing melt
molten polymers are first spread and distributed prior system components (melt pipes, filters, melt pumps
to their combination. Both feedblocks and multicavity etc.). For example, in the production of five-layer films
dies are common today and are also used in and sheets by the use of a three-layer feedblock
combination together; both technologies have their attached to a threecavity die. In this case, the adapter
advantages and disadvantages in terms of cost and should be physically sized such that it permits the
performance as well as process flexibility. future addition of two additional feedblocks to the
Consequently, care should be taken to define the most system without the need to change the adaptor
appropriate technology or combination of technologies dimensions. If this is not done during the initial
when establishing or modifying a coextrusion system coextrusion system design, the larger physical
so that future modifications in die and feedblock dimensions, typical of a feedblock system for multiple
technology, product designs and infrastructure of the die cavities, compared to a single cavity feedblock
film lines are not compromised or excessively costly. system, will generally require that new melt pipes be
Today, films with two to several hundred individual obtained to replace the existing melt pipes. An
layers are common. alternative to new melt pipes would be to
3
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

relocate the extrusion or downstream equipment to In fixed geometry adaptors (Fig. 6-2), there is little
accommodate the increased adaptor section to no chance of melt stream cross contamination.
dimensions. This can significantly increase the cost and However, changing polymer layer positions
installation time for an upgraded coextrusion system requires either a change in adaptor or changes in
and, in some cases, makes the change economically resin feed streams (and perhaps screw designs) to
unjustifiable. the extruders. Both require some down time to
make the change and to re-establish the
Adaptors can have fixed flow channels or can be
manufacture of acceptable product.
made such that they allow multiple flow paths of
the melts between the adaptor inlet and the With interchangeable flow path adapters (Fig. 6-3),
adaptor exit to the feedblock and/or die. This can there is, perhaps, some possibility of cross-
be accomplished with segmented adaptors with contamination between melt streams, but this is
interchangeable body segments to reroute flow or generally not a problem.
with removable plugs. The decision between fixed However,theincreaseineaseoflayerpositionchanges
and interchangeable adaptors is a balance can
between product and process flexibility and melt
stream integrity.

Fig. 6-2 Fixed geometry adapter showing inflow from extruders A,

B, C, D and E and the outflow of each extruder to the feed block.
The adapter flow locations cannot be changed without replacing
the adapter.
Fig. 6-1 General configuration the coextrusion system consisting of an
adapter, a feedblock and a single or multicavity die (courtesy Cloeren
Company).
be dramatically increased depending on the adapter
design.

Fig. 6-3 Adapter with removable flow selector showing position in

adapter and the polymer flow paths (Courtesy of Cloeren, Inc.).

4
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

For segmented adapters (Fig. 6-4), the change will and Welex and the variable geometry feedblock,
require removal and rebuilding the adapter while Cloeren. All three feedblocks can be modified by the
adapters with interchangeable inserts will only use of interchangeable parts, but only the Cloeren
require removal, some cleaning and reinsertion of vane feedblock may be adjusted during operation.
the new flow insert and can be accomplished with
Feedblock technology has evolved over the last several
minimal losses in production.
decades from simple beginnings to the current art
Therefore, as with adapter sizing, adapter flow where feedblocks are very flexible and effective. The
path control is a strategic decision which is understanding of the design goals for feedblocks has
dependent on the expected number and also evolved and a better understanding of how to
frequency of product design changes, the accommodate interface migration and layer
sensitivity of layer polymers to extrusion (screw) encapsulation, which is common in simple feedblocks,
technology, the infrastructure of the plant for has evolved. While not a lot of analytical work has
resin rerouting and the ability of the die cavities to been published, recent experimental efforts are
maintain acceptable layer dimensions across the highlighting the impact of flow channel geometry and
film or sheet as polymers are changed. melt elasticity [1] and elongational viscosity [2] as key
factors in maintaining layer integrity.

The feedblock
The purpose of the feedblock is to shape and combine
the multiple polymers entering from the adapter into a
well-defined stack of polymers for delivery to the flat
die. Feedblock technology exists in several basic
geometries and combination philosophies ranging from
the segmented flow of the Dow feedblocks (Fig. 6-5),
the stepwise addition of the Welex modular designs
(Fig. 6-6) with interchangeable cassette inserts and the
Cloeren style feedblock with adjustable vane designs
(Fig. 6-7).

Overall, these feedblock designs can be broken down

into two design types: fixed geometry feed blocks, Dow
5

to the ready availability of multilayer dies with as many as

 individual flow cavities in a die is somewhat limited by
the die width as the cost and mechanical complexity of
the die increases with each additional cavity.
CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets
Theoretical understanding of die
and feedblock design parameters

hended before the attempt is made to describe key die

Fig. 6-4 Segmented adapter with removable programming plates for re-routing of melt flow from the adapter to the feedblock.
Fig. 6-5 Three-layer Dow feedblock showing segmented flow plates.
Rheological background
There are several concepts which must be compre-
Fig. 6-6 WELEX modular adapter showing various interchangeable textbooks on the subjects and find the derivations and
cassette inserts. Adapters may be combined sequentially to permit
multiple layer addition. (Courtesy of Frank Nissel). background assumptions. Our first observation is that,
within the scope of this chapter, we are dealing with
fluids and that the fluids are forced to flow through the
The die coextrusion equipment by pressure alone. Because the
As with feedblocks, the dies have evolved from simple flow is a pressure-driven flow, we will be interested in
forms to the modern coextrusion dies. In general, the relationship between the volumetric output (Q)
there are two principal approaches to coextrusion with and the pressure or pressure drop (DP), required to
dies: the single manifold die combined with a sustain it. It will be from the solutions to the
feedblock and the multimanifold coextrusion die. The conservation equations (mass, energy and momentum)
multimanifold die may also be combined with a from which we obtain the various flow models used to
feedblock. Originally, the use of multimanifold dies was design and trouble shoot coextrusion feedblocks and
limited more by manufacturing methods and the dies.
difficulty in producing multiple die body sections,
which greatly increased their costs relative to single
manifold dies. However, with the revolution of
multiaxis computer numerical controlled (CNC)
machining capabilities, the machining difficulties have
been greatly diminished and their availability has
increased. The improved CNC capabilities also permit
the machining of the die manifolds to the optimum
flow design with fewer limitations imposed on
manifold and preland geometry by the die
manufacturer. This has led and feedblock design
parameters. These concepts relate to the material
science of polymer melts and the science of rheology.
While a complete description of polymer melts and
rheology is beyond the scope of this chapter, it should
be possible to state and highlight the key concepts and
the interested reader can then turn to the literature or

6
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

The development of the flow models also requires

the use of a constitutive equation for the material
and an equation of state if the material is
compressible. The constitutive equation relates
the material flow behavior in a stress field and
defines the relationship between the stress
components and the rate of strain (deformation)
in the fluid. This constitutive relationship must be
determined experimentally for each material and
is generally depicted as the flow curve which plots
the stress versus the rate of deformation or, more
commonly, the shear rate. The shear rateisderived
fromthe first invariant of the rate of deformation
tensor which will be dependent on the geometry
of the flow. For complex flows, the material
behavior is difficult to measure and, therefore, it is
common practice to use rheologically ‘simple’
flows to characterize the materials. Flows which
meet this rheologically ‘simple’ requirement

Fig. 6-7 Cloeren five-layer adjustable vane feedblock (courtesy of Cloeren, Inc.).
uniquely relate the stress (sxy) components in the
fluid to the shear rate by a single material
constant, the shear viscosity (h). The viscosity is
defined as the ratio of the shear stress to the shear
rate.

Shear Stress
Shear viscosity ¼

Shear rate (6.1)

s
xy h ¼

g_

7
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Representative simple flows are the pressure flow

in a tube (Poiseuille flow), the drag flow in a
narrow gap between rotating cylinders (Couette
flow) and the flow in a narrow gap between a flat
plate and a low angle cone. These three flows
form the basis for instruments used to measure
material viscosity as a function of temperature and
shear rate and each instrument has an effective
range of shear rates over which it can operate.
Shear rates of 0.0001 s1 to 0.1 s1 for a cone and
plate, 0.001 s1 to perhaps 10 s1 for a Couette
Fig. 6-9 Newtonian to pseudoplastis flow for EVOH polymer.
viscometer and 0.1 s1 to 10 000 s1 for a capillary
rheometer.
As explained above, it is necessary to obtain the Also noted in Fig. 6-8 is n, the power-law index which is
fluid flow behavior in order to perform the die the slope of the log (shear stress) versus log (shear
design calculations as well as to derive the rate) curve.
theoretical flow models used in the die design. Fig. An example of a dilatent material would be wet sand
6-8 displays the flow curve, log shear stress versus or fluid–particle mixtures, such as ketchup, and the
log shear rate, for various types of flow properties shear stress increases in a shear field due to the
found for real materials. building or forming of an internal structure in the fluid
In Fig. 6-8, we see the flow curves for a shear which retards flow. Newtonian fluids, such as water,
thickening, or dilatent fluid (n > 1), a Newtonian show a linear relationship between increasing shear
fluid (n ¼ 1) and a shear thinning (n < 1) or stress and shear rate while pseudoplastic materials,
pseudoplastic material. representative of many polymer melts, show a shear
thinning behavior where the shear stress decreases
with increasing shear rate due to breakdown of the
entangled chain molecular structure generally assumed
for polymer melts. Real polymer melts show a
Newtonian viscosity at very low or zero shear rates
with a transition to a pseudoplastic behavior as the
shear rate is increased (Fig. 6-9).

In general, the Newtonian, or zero shear viscosity, the

shear rate where the transition to shear thinning
behavior occurs, is different for different polymers and
can occur at shear rates as low as 0.01 s1 to as high as
several hundred s1 as shown for various materials in
Fig. 6-8 Flow curves of ideal materials. Fig. 6-10. As we will see later, this variation in apparent
shear thinning between shear rates of 10 s 1 and 1000 s1
will have an impact on successfully maintaining
uniform

8
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Fig. 6-10 Comparison of flow behavior of several resin types.

Fig. 6-11 Shear rate ranges in various locations in multilayer extrusion

equipment.

Fig. 6-12 The viscosity versus shear rate for a Newtonian, a power law and a typical polypropylene (PP) melt.
layer distribution and the interchangeability of cone-and-plate experiments at low shear rates are
polymers in existing dies and feedblocks. extremely time consuming and not readily available. A
useful approximation of the zero shear viscosity can be
In polymer melt processing, it is a common engineering
obtained using the method described by Gillespie [3]
practice to use the flow data collected from a capillary
and would permit an engineering approximation of the
rheometer, because the shear rate range of the
zero shear viscosity from capillary data if it were not
instruments, approximately 0.1 s1 to 10 000 s1, covers
possible to measure the low shear rate data directly.
the practical range of shear rates observed in most
equipment (Fig. 6-11). It has been a common practice in the development of
polymer flow modeling to assume either a Newtonian
The capillary rheometer also permits the
or power law constitutive equation for the model
determination of the fluid viscosity without the need
development. Fig. 6-12 plots the viscosity versus shear
to assume its constitutive behavior by the use of the
rate for a Newtonian, a power law and a typical
Rabinowitsch method or correction. Because of this,
polymer melt.
the Rabinowitsch correction should always be applied
to capillary data, eliminating the need to use the It is clear from Fig. 6-12 that neither the Newtonian or
apparent viscosity (assumed Newtonian fluid model). power law fluid accurately represents the real behavior
However, to characterize completely a polymer melt, it of the polymer melt over the measured shear rate
is necessary to obtain cone-and-plate as well as range but, in general, the power law is a much better
capillary data. Capillary data are generally available general representation of the polymer melt at high
and the equipment is relatively easy to operate, but shear rates.

9
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

The flow curve can also be piecewise

approximated by a series of power law sections
and point wise by the first derivative (slope) of the
flow curve.

Another aspect of the rheology of dies and

feedblocks which will be important in
understanding the design and performance of
coextrusion equipment is the solutions obtained
for the flow in channels with various cross-
sections. Dies and feedblocks are comprised Fig. 6-13 Desired uniform volumetric flow rate (Qi) across width of
die.
primarily of circular, rectangular and converging
flow channels. In addition, die manifolds may have
tear drop cross-section flow channels. Therefore, it
will be important to understand the relationships
between the polymer flow rate, the pressure
drops and the die geometry. This is done by
solving the flow problem for the fluid constitutive
equation in the geometry describing the die or
feedblock. This can be a very complicated
calculation and can be done with advanced
computer algorithms, a description of which is Fig. 6-14 Flow problem for circular pipe.
beyond the scope of this chapter. Instead, we will
focus on the analytical solutions obtained from pipe and Fig. 6-15 shows the flow problem for flow
simpler constitutive equations, to gain an in a rectangular slit.
improved understanding of the factors relating to
the geometry and the fluid characteristics and how Writing the differential equation for the flow in the
they combine to determine the die design. This pipe we find:
understanding will aid us in determining when it is dP 1 d½rsrz
possible to interchange two different polymers in a
¼ (6.2)
die and what outcome we might expect in terms of
dz r dz
system pressure drop as well as layer distribution
uniformity. Integrating from r ¼ 0 to r ¼ R yields,

The primary goal of the feedblock and die designs r dP

is to stack and spread the melt layers and have a srz ¼ (6.3)
uniform product exit the die. This is done by 2 dz
designing for a uniform flow rate across the final Equation (6.3) shows that the shear stress varies
exit plane of the die (Fig. 6-13). Because the flow is linearly with position across the tube diameter
pressure driven, the flow rate is controlled by the from a value
pressure drop along all the flow paths from the die
entrance to the die exit.

Therefore, understanding the model results for

circular and rectangular flow channels will be
important. Fig. 6-14 shows the flow problem for
flow in a circular

10
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

r2
vz ¼ v 0 1
R
(6.7)
pR DP
4

Q¼
8mL

Fig. 6-15 Flow problem for parallel plates.

And for a power law fluid:
of zero at the center line to a maximum at the wall
where r ¼ R. It should be noted that this result is Vz ¼ V01 rðn1Þ=n R
independent of the fluid type. The material
npR3g_0 RDP 1=n (6.8) Q ¼
constitutive behavior will be important in determining
3n þ 1 2h0g_0L
the velocity profile in the tube. The velocity profile
(equation (6.4)) is determined by substituting the shear And when n ¼ 1 the power law results yields the
stress definition into equation (6.3), rearranging and
solving for the velocity profile and, at this point, the Newtonian results.
fluid type, Newtonian, power law or other fluid type, Fig. 6-16 displays the velocity profiles in a tube for a
will be important in determining the velocity profile Newtonian fluid and for various values of the power
shape. law index, n. For flow of the Newtonian fluid, the

srz ¼ hg_
dVz r dP h ¼ dr 2 dz (6.4) ðR r dP=dz
VzðrÞ ¼ dr
0 2 hðT;g_Þ

In order to relate the output, Q, of the tube to the

pressure gradient driving the flow, it is necessary to
integrate the velocity profile at the tube exit across the
radius of the tube, ðR
Q¼ Vz r dr (6.5)
0

Substituting in the definitions for a Newtonian and a Fig. 6-16 Plot of reduced velocity profiles for flow in a tube as a function
of the power law index, n showing the blunt flow (plug flow) front
power law fluid (equation (6.6)) into equation (6.4) and increasing as n decreases.
solving equation (6.5) gives equation (6.7) and
equation (6.8) respectively;
velocity profile is parabolic with a maximum melt
h ¼ m Newtonian fluid
velocity at the center line of the tube and a zero
g_ n1 (6.6) velocity at the wall. As the slope of the velocity profile
h ¼ h0 Power law fluid represents the shear rate in the fluid, we find that the
g_0 shear rate at the tube center line is zero and the shear
rate at the wall is a maximum. For the power law fluid,
For the case of the tube the results for a Newtonian the velocity profile is a blunt or plug-like flow with the
fluid are:

11
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

plug-like nature of the velocity profile increasing with Q¼ 1þ 2n 2hL

decreasing power law index. 2 n

Recalling the flow curve for a real polymer in Fig. 6-10,

we understand from the shear rate dependence of the And when n ¼ 1 is substituted into the power law
viscosity that the melt viscosity will not be uniform results the Newtonian results are recovered.
across the tube and will be at a maximum viscosity at Fig. 6-17 plots the velocity profiles for flow in a
the center and a minimum viscosity at the wall, even thin wide slit and, as was found for the tube, the
for a single polymer at a uniform temperature. This will velocity profiles are parabolic for the Newtonian
be an important point to recall when understanding fluid and pluglike for the power law fluid. Also the
the need to maintain a decreasing viscosity across the shear rate will be zero at the slit center line and a
flow of a coextruded structure and the driving force for maximum at the slit walls with a maximum
flow rearrangement and encapsulation flow in viscosity at the center and a minimum viscosity at
feedblocks and die manifolds to be discussed later. the slit walls.
For flow in a thin, wide slit the differential equation
describing the flow in Fig. 6-15 is: Feedblock designs

dP dszy
¼ (6.9) In general, the feedblock is designed to arrange
dz dy the melt layers prior to entry into a die where the
layer stack is spread to a much wider and thinner
which on integration from -H/2 to H/2 yields geometry than that in the feedblock. As we will
dP see in the discussion on dies, the die manifold
szy ¼ y (6.10) dz geometry into which the feedblock delivers the
melt stack will have a profound impact on the final
Again, the solution gives a linear dependence of stress coextrusion quality.
with position in the slit with a zero shear stress at the
center line and a maximum stress at the wall of the slit.
Performing the same analysis for the slit as was done
for the tube to determine the velocity profile in the slit
and output from the slit for a Newtonian fluid yields:

vz ¼ v0 1 2Hy2

(6.11)
WH3DP Q ¼
12mL
And for a power law fluid:
Fig. 6-17 Plot of reduced velocity profiles for flow in a slit as a
function of the power law index, n showing the blunt flow (plug
vz ¼ v01 2Hynþn1 flow) front increasing as n decreases.
WH2 HDP1n (6.12)
There are several feedblock designs generally
available for use in coextrusion systems today. In
general, the melt is combined in rather large cross-
sections characterized by low shear rates. In
general, the melt stack delivered to a
12
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

die channel for subsequent spreading can have a 4”

round or rectangular cross-section. Rectangular
flows will have an aspect ratio of width to
thickness from 2 1 to 4 1 and the corners of the
rectangle will be rounded to remove stagnation
1”
points and in the limit are oval in cross-section
(Fig. 6-18) and are often times described as a
racetrack entrance.
found to be thin and less melt in regions found to be
The first and still common feedblock design is the
thick so that after spreading there is more material
‘Dow’ feedblock shown in Fig. 6-5. The primary
remaining at the thin point and less in the thick point
parts to this feedblock are:
and the average distribution is thereby improved. This
the layer arrangement plate where the melt from is due to flow rearrangements called ‘encapsulation’
each extruder is brought to the combination which will be explained below.
point
All feedblocks permit this melt profiling to improve
the flow dividing section where each stream is layer distribution. In general, this profiling is used to
divided into an equal volume overcome poor viscosity matching of the various
layers. However, it might also have been possible to
the adapter section where the combined layers
improve the layer uniformity with an existing feedblock
are combined and transported to the die
by modification of the polymer viscosity level.
manifold entrance.
However, profiling is a powerful means of overcoming
There are many forms of the ‘Dow’ feedblock some flow problems, especially when polymer
produced and used by many companies because replacement is not an option. If it is not possible to
they are simple in conception and manufacturing. overcome the poor layer distribution by profiling or
In some instances, where rheological problems are polymer selection then the feedblock/die combination
encountered, the vanes are sometimes extended should be replaced by a multimanifold die.
into the die adapter section. This is a difficult and
expensive approach to implement but is at times Another widely used feedblock designs are the WELEX
effective. designs where polymers are layered using a circular
cross-section. This permits the easy adaptation to
In the ‘Dow’ feedblock, the primary design existing dies with circular entrances. Fig. 6-6 shows this
principle is that the velocity of the various layers in feedblock concept. This feedblock is simple in
the combination should be the same when they conception and is easy to machine and they can be
are combined. This is accomplished by inserting stacked in sequence to permit the addition of as many
flow dividing plates into the flow to divide the flow additional layers as space permits. Shaping of the melt
into perhaps 10 equal volumes. Because the layer is accomplished with removable inserts at each
geometry is uniform in cross-section of the plates, combination point. Fig. 6-19 shows another WELEX
the velocity at the exit is uniform. A feature of this, feedblock design where the flows are divided and
and all feedblocks, is that if the layer uniformity stacked around a central torpedo. In this case, one
exiting the die manifold is poor, then the plates stream is extruded against the flow and is then divided
can be replaced with vanes that are machined to as it is swept down stream by the existing polymer
various shapes such that more melt is placed in flow. Then a central layer is injected at the
the regions which are downstream exit of the torpedo

13
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Fig. 6-18 Racetrack exit from feed block to match die entrance with rounded corners to prevent degradation.
Fig. 6-19 WELEX center layer block for introducing an adhesive/ barrier/adhesive structure in the center of a flow stream, creating five layers from
three flows. Principal flow from left to right and adhesive exits counter the primary flow to encapsulate the barrier flow (Courtesy Frank Nissel).
producing a symmetrical ABA combination into the Die designs
center of the flow. This could be used to add a central
incompatible polymer surrounded by two adhesive
polymer layers in to an existing single or multilayer Die designs for film and sheet have evolved over the
extrusion system. years to improve the distribution of polymer melt
across the width of the film or sheet being extruded.
An adjustable feedblock was invented by the Cloeren Initially, the dies were developed for single layer films
Company (see Fig. 6-7) which permits the adjustment and, initially, these designs were used for coextruded
of the feedblock geometry while the coextrusion products. Since the beginning of coextrusion, further
system is in operation. The principle behind this design developments have resulted in die modifications
is that the geometry of the combination point can be specific to coextruded stacks delivered to the die from
changed at constant output rate to change the average coextrusion feedblocks. Recent experimental studies
melt velocity and shear rate in the melt stream at the have demonstrated the importance of these die
point of combination. This permits the modification of changes to coextrusion flows and the maintenance of
the melt viscosity in each layer at the combination undisturbed coextruded layer structures [1].
point and can be used to eliminate coextrusion defects
due to viscosity matching without the need to stop and Initial film dies were ‘crosshead’ slit dies which were
rebuild the feedblock assembly. This feedblock fed from one end into a circular manifold and
technology has evolved over the years and been discharged melt through a narrow slit (land) (Fig. 6-20);
continuously improved with the addition of profiling these are sometimes called infinite cavity designs.
pins as well as models where fixed but removable End fed dies later evolved into center fed or ‘T-slot’
insets can be used in place of the adjusting vanes. The dies where the melt typically entered at the center of a
Cloeren feedblock systems have been very widely circular manifold, spread in two directions and the melt
accepted in the coextrusion industry and are extremely discharged from a slit. It is to be noted that the T-slot
versatile. die is symmetrical about the entrance port and the
Extrusion Dies, Inc. also supplies an adjustable feed as analysis of the manifold can be done as two end fed
well as fixed feedblock designs which are modular in dies and, therefore, it is only necessary to evaluate the
design. flow performance of one half of a center feed die. A die
is, in essence, a pipe (or manifold) open at one end and
Feed Slot

14
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Distribution
Channel (Manifold)
essential findings of flat die analysis. The analysis
was focused on determining the uniformity of the
flow from the die lips across the width of the die
R
IN
and defined a uniformity index (UI), which is the
Z ratio of extrusion rate at the end of the manifold
OUT
to the flow rate at the manifold entrance. The
results were expressed in terms of the flow index
X (m), the width of the die manifold (W) and a die
Fig. 6-20 Schematic diagram of end feed die showing flow into and
constant alpha (a) with dimensions of inch1 for all
through the manifold and die land. values of m and which contains the die geometry
dimensions of the manifold radius (R), the die gap
height, (H) and the die land length, L.
closed at the other with a slit cut along its length
½ð1 þ 0:05mÞmaWðmþ1=mÞm
through which the melt leaks. As the melt flows
UI ¼ 1
along the manifold, the internal manifold pressure
changes due to viscous losses and changing fluid mðþ1 þ3 0H:05mþm2Þðm þ 1Þ
momentum. The viscous resistance will tend to (6.14)
cause the manifold pressure to drop while the
momentum changes will tend to increase the amþ1 ¼ 2pm m þ 2 LmRmþ3
manifold pressure and the driving force for flow
will vary across the length of the manifold [4]. For
The expression for UI is a function of the
a simple crosshead die with uniform manifold
dimensionless group aW and is only dependent on
diameter and slot width and gap height, this will
the dimensions of the die and m, the flow index (or
result in variable flow across the manifold width
the power law index as m ¼ 1/n) and not the fluid
and a variable product thickness which is not
viscosity or the manifold pressure.
desirable. What is desired is a film of uniform
thickness across the die width. This result was compared to the exact solution
obtained for the Newtonian uniformity index
The initial analysis of the crosshead die was
(equation (6.15)) and it was shown that for m ¼ 1,
performed by Carley [5] for isothermal, Newtonian
UI resembles the first two terms of the expansion
and power law fluids defined as:
of the Newtonian result giving increased
confidence in the result.
dv sm
g_ ¼ ¼f UI ¼ 1 3 ¼ sec hðaWÞ
dx s0 (6.13)
1 d lng_ for m¼1 2 (6.15)
m¼¼ ð1:05aWÞ

n d lns UI ¼ 1
Where m, the flow index, varies from 1 to 6 for 2:10
most polymer melts and is more commonly
The result of this flow uniformity analysis has all of
expressed today as 1/n where n is the power law
the essential features of subsequent die design
index. Inertial effects were ignored in the analysis.
analyses. The Newtonian and power law results
It is instructive to review the analysis for it show that flow uniformity is independent of the
highlights the basis for a good die design fluid viscosity and the manifold pressure and
procedure and the results demonstrate the dependent on the die geometry and the flow
index.
15
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Polymer viscosity is important in the analysis only In the design of flat film and sheet dies, what is critical
through the flow index (m) and we can expect to controlling uniform flow from the die across its
that, for a given die design, the extrusion of entire width is a uniform pressure drop for all flow
different polymers with the same value of m (m ¼ paths from the manifold entrance to the die lip exit
1/n) will yield similar flow distributions while the (see Fig. 6-13). This is the primary goal of all die design
substitution of a polymer with a different power procedures and, when combined with minimizing the
law index would be expected to give a different polymer residence time by reducing the manifold
flow distribution and, therefore, thickness profile, volume across the die width and varying the die land
across the die exit. length, results in the ‘coat hanger’ design (Fig. 6-22a).
In the coat hanger die, the manifold is tapered as well
A key learning from this analysis is that, for any
as curved to permit the final land length of the die to
given film width, a center feed die will give better
vary in length to control the pressure drop. The coat
overall uniformity due to the decrease in manifold
hanger design is a natural outcome from the analysis of
width as the results show that flow uniformity
McKelvey and Ito [6].
decreases with increasing manifold width, W. The
results also demonstrate a decrease in uniformity When the coat hanger manifold concepts were first
with increasing die gap, H. Improvements to die developed it was difficult and expensive to machine
flow uniformity may be achieved by increasing the such dies and, therefore, a series of design
manifold radius, R, or the die land length, L. These compromises were developed to aid in the
changes to R and L improve flow uniformity by manufacturing and operating characteristics of the flat
minimizing the pressure drop differences across film die. Die manifolds were generally circular in cross-
the width of the manifold and die land. However, a section with a streamlined flow from the manifold into
balance must be met as the increase in uniformity the coat hanger gap (giving a tear drop shape manifold)
is offset by an increase in residence time in the die and die land gaps generally decrease as the die exit is
as the manifold radius increases and an increase in approached to accelerate the melt as it moves through
extrusion pressure, at constant output (or a the die to aid in preventing plate out from the melt
decrease in output, at constant extrusion onto die surfaces.
pressure), as the die land length L increases.

McKelvey and Ito [6] next proposed a die with a

straight tapered circular manifold and a three gap
die land where the three land lengths were a
function of position across the die width (Fig. 6-
21).

Again, the results of the analysis of this die’s

performance, the flow uniformity across the die width,
showed a dependence only on the die geometry and
the flow (power law) index m, as was found by Carley
[5]. The analysis showed the flow variation across the Fig. 6-21 Schematic diagram of die with a straight tapered circular
width as a function of m the flow index for fixed die manifold and a three gap die land where the three land lengths were a
function of position across the die width (Redrawn from [6]).
geometry where the die land gaps varied linearly
across the die width. In principle, based upon this
analysis, it should be possible to find a die land gap
profile combined with a reducing diameter manifold,
such that the flow deviations across the die width are
reduced to zero.

16
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

2sinQ
Here, again, we find that the power law index n is the
most significant factor in determining flow uniformity
from a film and sheet die.

Coat hanger die manifold designs, which are

independent of operating point and material and which
give uniform flow rate and uniform stress on the melt,
may be designed [9] as well as coat hanger dies with
uniform flow rate and residence times [10]. But these
designs typically give a die with long coat hanger
lengths and, as the width increases such that the dies
becomes physically too long, are difficult to seal to
prevent leakage.

The limitation in building dies with circular

crosssection manifolds are twofold as discussed by
Chung and Lohkamp [8] and Dooley [1]. First, in
Fig. 6-22(a) Coat hanger die with three variable depth lands (Yi,Xi,Li) as
in [6]; (b) coat hanger die of Chung and Lohkamp (redrawn from [8]). the transition from the manifold to the exit slit, the
flow is not streamlined due to the abrupt
transition from the manifold to the thin land area
A compromise coat hanger design is the ‘fish tail’
(see Fig. 6-21). Therefore, it was typical of die
manifold configuration, where the manifold diameter
manufacturers to create a streamlined transition
and the die land height is reduced linearly across the
(Fig. 6-23).
die width. These dies have better flow uniformity than
T-slot dies but, generally, do not give a uniform melt Also, as described by Chung and Lohkamp [8], it is
distribution across the die width [7] as does the true difficult and expensive to fabricate coat hanger
coat hanger. dies with circular manifolds with varying radii from
fixed radii cutting tools. Consequently, the back
Chung and Lohkamp [8] present a die and analysis
plane of the manifold was often cut with a flat
aimed at improving the design of fixed angle coat
back using rectangular cutters and the corners cut
hanger dies with circular cross-section manifolds (Fig.
with a radius cutter to produce the familiar tear
6-22b) to give uniform flow rates across the width of
drop manifold often found for die manifolds. As
the die. The analysis yields a variable manifold radius
will be explained later, the shape of the manifold
R(x) where the manifold radius is found to be a
has a profound effect on the flow of coextruded
function of reduced manifold position (x) and the
structures entering the die manifold from a
power law index (n).
feedblock. As disclosed by Cloeren [11] and later
confirmed experimentally by Dooley [1], it has
Rð ¼ð 1 þ xÞ
x R0 x been shown experimentally that the rectangular
Þ x ¼ Lm (6.16) feedblock is optimum for coextruded structures
n=ð W entering a die manifold from a multilayer
3 Lm ¼ feedblock and that the tear drop manifold creates
n
þ layer non-uniformities.
1Þ
These findings led to the invention of the ‘inverted
preland’ die [12] for coextruded structures (Fig. 6-
24) which combines the rectangular manifold with
a constant length land of various gap
17
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

heights, as found in McKelvey and Ito [6], with the being extruded as was found by McKelvey and Ito
exception that the initial land of the die is of a [6].
narrower gap than the second land and the
Aside from the design for uniform flow across the
exit, it has been established that there are several
other important considerations for a die design
which are polymer dependent, such as uniform
residence time or a maximum residence time for
temperature sensitive polymers, maintaining die
cleanliness with a minimum melt velocity to
prevent component or degraded polymer plate out
on the die surfaces and lip, as well as to minimize
internal die pressures to prevent die body
distortion and to maintain stress levels below
critical stress for melt disturbance etc. From all
these considerations have come a series of die
designs which are represented in the literature as
the T-slot, the fishtail, various coat hanger and
inverted preland dies.

All die designs require compromises in the

Fig. 6-23 Streamlined manifold design eliminating sharp transition from
fabrication due to limitations in machining
manifold to land as in Fig. 6-21
capabilities. Early in the evolution of dies, these
compromises were more significant in magnitude
due to limitations from the manual set up of
machining. Such design and fabrication
compromises resulted in dies which were not
optimum for the polymers available and had to be
made mechanically adjustable to overcome the
design and fabrication limitations. Such a
mechanical compromise was the incorporation of
an intermediate, adjustable flow restriction, called
a choker bar, downstream of the manifold but
Fig. 6-24 Cloeren Inc. inverted preland die design (Figure 3 of US before the final die land and the flex lip. The idea
Patent 5,256,052) showing initial damming land (60) followed by
deeper lands 64 and 68. The transition from 60 to 64 is a function of a choker bar is to have an internal die gap which
of position across the die width and is dependent on the melt is adjustable across the die width so that any
rheology.
deficiencies in the manifold design, or machining,
or changes in the polymer power law index, poor
polymer temperature uniformity, significant
shape of the transition between the first and
output changes etc. might be accommodated by
second damming zones of the preland are
adjustment and a flat film profile obtained. Choker
rheology dependent.
bars have been used for many years and can be
From our earlier review of die design calculation difficult to adjust and create a potential source of
models, it should be understood that the shape of polymer degradation in sensitive polymers or
the inverted preland transition will be dependent critical products. However, with multicavity
only on the power law index (n) of the polymer coextrusion dies, it becomes very difficult to
incorporate choker bars easily and
18
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

inexpensively into the die construction as the to the difficulties associated with the machining of the
number of die manifolds increases. Consequently, relatively complex combination of body parts required
better die design procedures should be used to for the multicavity dies. Today, with CNC machining
eliminate the need for a choker bar. It is my capabilities, the machining of five (or more) cavity dies
personal opinion that their use should be avoided has been greatly improved and five cavity dies are
whenever possible and the newer die designs and readily available. Therefore, the choice of coextrusion
the improvement in fabrication capabilities of CNC system has been broadened and the coextrusion
machining permit the elimination of choker bars. system choice becomes strategic in terms of current
and future products and the ultimate flexibility
While the coat hanger die is the only manifold and land
required for the system. If a single coextruded product
combination which, theoretically, may be designed to
is to be run without modification, then the simplest
give uniform flow across the die width such that the
system capable of supplying the desired product
manifold design is independent of the operating point
quality can be chosen relatively straightforwardly. The
[7], previous observations [13] of the performance of
following examples will illustrate this.
layer spreading with teardrop manifold dies in
combination with feedblocks and recent experimental For combinations of polymers with similar flow curves
work in coextruded structures related to the secondary and viscosity levels, the use of a feedblock with a single
flows in these manifolds [14] indicate that they should cavity die can be an effective choice for the
be avoided when used in combination with the stacked coextrusion. However, based upon the work of Dooley
multilayer melt streams exiting a feedblock. et al [1, 14], the use of teardrop manifolds should be
avoided to minimize layer rearrangement and
spreading problems due to secondary flows in the
Coextrusion systems for flat films and manifold. The amount of layer rearrangement seen in
sheet the manifold is related to the inherent elasticity of the
material, with polystyrene being greater than
polyethylene and polycarbonate showing little
As described above, the choice of die design and its rearrangement in the study of Dooley et al [14].
impact on spreading of melt stacks should be taken
into consideration when feedblocks are combined with If, however, the polymers in each layer have widely
a die. However, the coextrusion of flat films and sheets different viscosity levels and flow curves, then the layer
can be successfully accomplished with multilayer spreading in the single cavity due to viscous effects
feedblocks and single cavity dies, multicavity dies and alone will lead to poor layer uniformity and, perhaps,
combinations of feedblocks and multicavity dies. Which to other flow defects. In this case, the individual layers
system is the best choice for any given application is should be separated and individually spread to the final
dependent upon: width and layer thickness in a single die cavity designed
the specifics of the application specifically for that polymer, prior to combining the
layers.
the polymers to be combined

and the uniformity or quality requirements of the

Layer instabilities, causes and prevention
coextrusion which is to be produced.
Combinations of multicavity dies and feedblocks give
the most flexible systems when multiple products are Coextrusion layer instability is often times called a
to be produced with a wide range of polymer types. ‘melt disturbance’ and there can be several sources,
some of which are not directly related to the flow of
Originally, feedblocks with single cavity dies were the the layers structure in the die, but rather to other
most cost effective form of coextrusion system as the processing problems. Therefore, it is important to
use of multicavity dies was prohibitively expensive due eliminate all sources of poor melt quality
19
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

which can be causing defects in the sheet or film, such be a minimum due to the increase in shear rate at
as unmolten polymer, gels in the resin, large the wall. This decreased viscosity at the wall is a
temperature gradients in the melt stream etc., before self-lubricating effect in the flow as it will lower
assuming that a rheological problem exists. the pressure drop in the system and is therefore
the lowest energy state for the flow.
When you are trouble-shooting a ‘melt disturbance’,
the first approach should be to determine ‘what has Therefore, when we stack polymers in a layered
broken’ in the process, especially if the problem has coextrusion flow, we should ensure that the
recently arisen in an existing product or process. You viscosity of the individual layers decreases as the
should first determine that all temperature controllers flow channel wall is approached. If this is not done,
are functioning properly and that there are no over the layers will attempt to rearrange themselves to
temperature or burned out heaters causing large place the lowest viscosity layer on the outside of
temperature gradients in the melt entering the die. the flow against the wall, at the region of highest
Next, you should determine that the screw is still shear rate, to lower the shear stress (pressure
performing correctly and that there is no unmolten drop) in the system. This flow problem, where the
polymer in the melt stream and that the melt viscosities are not properly stacked, leads to layer
temperature and pressure entering the die or rearrangement or encapsulation.
feedblock is uniform. Then, you should determine if
Encapsulation has been reported and
there has been a change in the resin, either a resin
demonstrated experimentally in a tube and slot by
grade change or an out of specification resin lot. Once
several authors [15–
this is done, it is possible to begin troubleshooting the
17]bystackinghighandlowviscositymeltstogether.It
rheological problems causing the melt disturbance.
has been found that the lower viscosity material
There are several coextrusion problems associated will encapsulate the higher viscosity material given
with the flow of layered polymer melts which are sufficient time. Han
generally related to the relative viscosity of the [17]hasdemonstratedaflowinversioninatubebystac
various layers and their relationship to each other. king a high and low viscosity melt together with
This is easily illustrated by considering the flow of a the high viscosity melt against the tube wall and a
single, polymer material with a homogeneous low viscosity melt in the core of the flow. He
make up and temperature in a gap or pipe. demonstrated that, if the flow channel is long
Recalling the discussion above for flow in a gap or enough, the lowest viscosity material will migrate
pipe, the velocity profile of the flow may be to the wall of the flow channel and completely
calculated and is displayed in Figs. 6-16 and 6-17. surround (encapsulate) the higher viscosity
Because polymer melts are generally pseudoplastic components of the flow. This encapsulating effect
or ‘shear thinning’, we can examine the viscosity of is often seen in feedblock coextrusion and in die
this single fluid across the flow profile. Recalling manifolds and die lands when the layer viscosities
that the slope of the velocity profile is the shear are not well matched or improperly
rate, we find that the shear rate at the center of
the flow is zero (0) and that the shear rate at the
wall is a maximum. This will mean that, due to the
shear rate dependence of the polymer, the
viscosity of a single fluid at uniform temperature is
not uniform across the flow channel and the flow
will show a viscosity profile (h(y)) across the flow
channel. In particular, we can see that the viscosity
at the center line will be at the maximum or zero
shear viscosity, ho and the viscosity at the wall will
20
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Fig. 6-25 Fig. 2 of US Patent 2,269,995 showing square cross-section flow channels used for flow dividing and stacking to produce
multilayer flows.

positioned. This is the effect which feedblock profiling,

described earlier, is attempting to accommodate.

Layer rearrangement in coextrusion flows in die

manifolds and transfer conduits (piping) can also
be due to viscoelastic effects as has been shown by
Dooley et al [18, 19]. In these instances, circular
transfer piping causes the least layer
rearrangement due to balanced stresses resulting
from melt elasticity forces. In rectangular melt
transfer systems, as are sometimes used in
multilayer combining adapters to give many layers
from dividing and stacking simpler structures [20]
(Fig. 6-25).

The layer rearrangements are driven by the

secondary elastic flows and are quite spectacular
giving multilobed, flower-like layer structures from
circular feed streams in the rectangular flow
channels (Fig. 6-26).

Of course, the extent of layer rearrangement will

depend upon the length of the transfer conduit.
This

21
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

or film dimensions, manifest themselves in many

forms. At its onset, the sheet may still maintain good
dimensional characteristics but the optical properties
begin to deteriorate such that the clarity or ‘see
through’ properties, of the film are impacted [21]. This
instability exists primarily at the interface of the
flowing polymers and is termed an ‘interfacial
instability’ which is used

melt elasticity driven layer rearrangement is also a

significant problem in tear drop shaped die manifolds
[18]. Therefore, when producing layered sheets or
films in single cavity dies being fed by multilayer
feedblocks, it is desirable to have rectangular
manifolds to minimize layer rearrangement due to the
more balanced shear stresses at the polymer/metal
surfaces of the die.

Layer instabilities or ‘melt disturbance’ which result in

a deformation of the interface and perhaps the sheet
Fig. 6-26 Secondary flow impact on layer rearrangement in square melt pipe flow (redrawn Fig. 5-33, from Dooley PhD Thesis, University of
Eindhoven, 2002).
Fig. 6-27 Melt disturbance of a three-layer sheet showing distortion of the sheet and the chevron appearance of the flow.
Fig. 6-28 Looking through a film containing melt disturbance and held ‘chevron’, depending on their severity. Looking
approximately 8 inches in from of the lettering, showing the image
distortion caused by the variable film thickness from the melt through the film, this instability may appear as a wide
disturbance. parabolic wave front extending across the full width of
the film (Fig. 6-30) and result in a pronounced
interchangeably with melt disturbance. This incipient thickness variation in the sheet.
interfacial instability manifests itself as a wavy or Alternatively, the wave may be broken into several
sinusoidal interface (Fig. 6-27) which results in light narrower bands of waves or into high frequency
scattering of the image passing through the film giving smaller waves which look like fish scales or arrow
a blurred image. heads etc.
An example of the optical defect formed is shown in This defect has been isolated to the final die land
Fig. 6-28. and appears to be due to exceeding a critical shear
As the level of the instability increases, the interface stress for the coextruded polymer pair in the final
can begin to form a pronounced wave which, on die land, as was demonstrated experimentally [22]
crosssection, appears to be breaking over itself (Fig. 6- and is shown schematically in Fig. 6-31.
29). This defect is addressed by lowering the shear
As the level of the instability increases, the interfacial stress in the final land by several approaches
instability can propagate to the surface deforming the including, lowering extrusion rate, increasing melt
sheet. This larger instability is known by several names or die temperatures, opening the die gap and
such as ‘zig-zag’, ‘arrow heads’, ‘fish scales’ or lowering the polymer viscosity with resin
replacements.

22
 CHAPTER 6
Coextrusion equipment forFig.
multilayer flat films
6-30 Schematic and sheets
diagram of two-layer flow showing the
transition from stable to heavy melt disturbance with film distortion.
Coextrusion instabilities and defects related to extruder due to decreasing energy efficiencies of
viscosity mismatching of layers is the most higher speed and larger diameter extruders [23].
common form of coextrusion defect which I Screw design and its impact on average melt
encounter. In general, the only acceptable level of temperature as a function of output level will
interfacial flow defect is ‘none’ as a light and therefore be an important consideration when
sporadic appearance of the defect will often times increasing the extrusion
render the product unusable for both technical or rateofinteriorlayers.Also,theinteriorlayersmayinclu
a esthetic reasons depending on the application. de reclaimed polymer, which is generally lower in
For instance, an incipient interfacial defect viscosity due to the additional extrusion history
appearing in a lane or sporadically across a film used to make it. Therefore, the combined effects
may not be readily visible in transmitted light in of higher melt temperature and lower component
the clear film but, if the film is printed with a dark viscosity can result in a situation where the
ink or metallized, the contrast between the film viscosity of the core layer becomes lower than that
regions containing the defect and defect-free of the outer layers as overall output is increased.
regions will enhance contrast between the defect
Therefore, as productivity is increased, it becomes
and surrounding film which can make it very
important to monitor the changes in rheological
prominent.
properties of the various layers’ materials at the
In many commercial film and sheet products, increased rates. If an interfacial instability appears,
coextrusion is used to modify the surface regions it must be addressed by process (extrusion
of a product by making use of thinner outer layers temperatures, die temperatures, reclaim levels,
of special or modified polymers. Because the outer line speeds etc), product design (layer
layers tend to be thin to minimize the use of the thicknesses), material (reclaim quality, average
surface polymers, the interfaces of these thin viscosity changes) or equipment changes (screw
layers are generally located near the flow surfaces design, die or feedblock) which result in a proper
where the shear rates are highest and changing balance of layer viscosity and interfacial stresses.
rapidly as was shown in Figs. 6-16 and 6-17 and, in
general, the interfacial instability will appear in a Practical examples
product as outputs are increased. This is because
the die and interfacial shear stresses at the higher Example 1
rates increase and due to changes in the average
It is desired to produce coextruded films containing
melt temperatures of the various layers as the
from three to five polymers. The film may contain
extruder’s screws are increased in speed as the
layers of Nylon and/or ethylene vinyl alcohol polymer
overall layer output is increased. Usually, the
(EVOH) barrier layers, either separately or in
increased extrusion rate will impact the thicker,
combination, adhesive resins and various polyolefins.
interior layers more significantly than the outer
The films are to be 2000 mm (78 in) wide and range in
layers as the extrusion rate is increased, resulting
thickness from 0.051 to 0.178 mm (2–7 mils).
in an increase in melt temperature and a drop in
Structures are to include split barrier layers and both
melt viscosity of the thick interior layers, while the
buried and surface nylon layers and symmetric and
outer layers may change only a small amount.
asymmetric structures such as:
With higher production rates, the thicker interior Nylon/tie/nylon/tie/LLDPE/LLDPE/m-LLDPE
layers’ viscosity tends to drop faster than the
thinner outer layers for several reasons. First, the Nylon/tie/nylon/tie/PP/PP/EP copolymer
higher screw speeds and generally larger diameter
Nylon/EVOH/nylon/tie/LLDPE/LLDPE/ m-LLDPE
extruders of the interior layers will heat the
polymer melt more than with a smaller diameter LLDPE/tie/nylon/EVOH/nylon/tie/m-LLDPE

23
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

PP/tie/nylon/EVOH/nylon/tie/EP copolymer However, the third option, a three-cavity coextrusion

die with two two-layer and one three-layer feedblock
LLDPE/tie/nylon/EVOH/nylon/tie/LLDPE
would likely be the most versatile combination
PP/tie/nylon/EVOH/nylon/tie/PP
because of the ability to combine various skin and tie
LLDPE/tie/EVOH/tie/EVOH/tie/LLDPE. resins with various core barrier combinations
There are several possible coextrusion equipment permitting independent control of layer distributions of
combinations which can be contemplated to produce the various combinations prior to the final combination
these various film combinations and, while not all will to form the seven-layer combination. Three to five
be practical, several potential combinations are: cavity dies are readily produced and the 2000 mm
a seven-cavity coextrusion die width is not a machining or mechanical constraint.

a five-cavity coextrusion die combined with a three- While there are many five-cavity and some sevencavity
layer feedblock dies being produced at this time, they are mechanically
complex, large in physical dimensions and increased
a three-cavity coextrusion die with two, two-layer and weight and the challenge of insuring the large area
one three-layer feedblock sealing surfaces between the multiple manifolds for a
2000 mm wide die would make manufacturing and the
a seven-layer feedblock and a single cavity die.
routine cleaning and reassembly of the die very
Choosing between the various combinations, the difficult. In addition, it is generally more time
rheological compatibility, die mechanical complexity as consuming to heat the multicavity dies at start up.
well as the total equipment cost must be considered Also, as the number of cavities increases, there is a
when selecting the coextrusion equipment. If we significant increase in the internal surface areas wet by
assume as a rough rule of thumb die cavities cost polymer, which creates increased opportunities for
approximately $1000/25.4 mm ($1000/inch) and polymer degradation, contamination and film defects.
feedblocks approximately $20 000/layer, then the These reasons, as well as the lower cost, are why the
approximate capital cost of each of the four ways to seven-layer feedblock in combination with a single
product the 2000 mm (78 inch) wide seven-layer films cavity die is the favored approach in applications of
can be estimated and are approximately: this type.
7 $78 000 ¼ $546 000 for a seven-cavity coextrusion
die Example 2
It is desired to produce a 3 to 5 polymer, 5-layer
5 $78 000 þ 3 $20 000 ¼ $507 000 for a
oriented polypropylene film containing a continuous or
five-cavity coextrusion die combined with a three cavitated PP core, clear or pigmented layers and
layer feedblock various surface layer combinations where possible
surface layers are PP, ethylene propylene (EP)
3 $78 000 þ 7 $20 000 ¼ $374 000 for a
copolymer, ethylene propylene butene (EPB)
three-cavity coextrusion die with two, two-layer terpolymer, HDPE, LLDPE, EVOH,
and one three-layer feedblock
Nylon:
1 $78 000 þ 7 $20 000 ¼ $218 000 for a seven-layer EP copolymer/PP/PP/PP/EPB terpolymer
feedblock and a single cavity die.
EVOH/tie/PP/PP/EPB terpolymer [24, 25]
Therefore, the most cost effective way to produce this
film would be with the fourth option, a seven-layer EVOH/tie/cavitated PP/pigment PP/EPB terpolymer
feedblock and a single cavity die and this is the option HDPE/PP/PP/PP/EPB terpolymer
most often found in practice.

24
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

EP copolymer/PP/EP copolymer/LLDPE/ EP When deciding on which feedblock/die cavity

copolymer Nylon/tie/PP/PP/EPB terpolymer combination to choose, it is possible that by
PP/PP/PP/PP/PP. properly sizing the feedblock, several feedblocks
There are several possible coextrusion equipment could be purchased and all of the potential
combinations which can be contemplated to produce feedblock/die cavity combinations could be
these various film combinations: possible. This illustrates that a good deal of
product design strategy needs to be taken into
a five-cavity coextrusion die
consideration when choosing the coextrusion
a three-cavity coextrusion die combined with a three- equipment combination. To ensure the maximum
layer feedblock flexibility in future product manufacturing, the
feedblock/adapter combination should be sized
a three-cavity coextrusion die combined with two,
such that the various potential feedblock/die
two-cavity feedblocks
cavity combinations can be substituted for each
a five-layer feedblock and a single cavity die. other without the need to modify or change
extruder melt pipe connections to the
While the cost considerations are still important,
adapter/feedblock combination. If this is not done
these dies will generally be 40 inches or narrower
initially, then changes between one feedblock/die
in width (depending on the width of the orienting
cavity combinations to another may be
line) and, in the context of a PP orienting film line
economically difficult due to a need to replace all
costing from $20 000 000 to $40 000 000, will be a
existing melt pipe connections between the
relatively small cost. Therefore, in this particular
extruders and the adapter/feedblock.
instance, improved layer uniformity, resin change
flexibility and layer rheological considerations In the first three options, the full range of
generally outweigh coextrusion feedblock and die potential resins to be employed will likely require
cost considerations. the use of more than one die if layer uniformity is
to be optimized for all resins. This is because the
Currently, the first and second options are widely
die cavity designs for optimum layer uniformity
used to produce these films. The last option would
are dependent on the shear thinning (power law
be a potential candidate if the desired film layer
index n) behavior of the various polymers as
combinations were significantly limited to
previously discussed. Fig. 6-10 displays the flow
combinations of PP, EP copolymer, EPB
characteristics of various polymers contemplated
terpolymer, HDPE only. Depending on its layer
for this example. What is easily seen on Fig. 6-10 is
location, the addition of an LLDPE layer might be
that the PP, EP copolymer, EPB terpolymer and
possible with minimal modifications to the
HDPE resins show very similar shear thinning
feedblock or to the outer die cavity if it was to be a
behavior (n values) while the EVOH and LLDPE
surface layer.
show a significant difference (reduction or higher n
In my opinion, the second and third options are values) in shear thinning. This means that if the
the most flexible approaches for this example EVOH or LLDPE resins are extruded through a die
because they permit the widest possible cavity designed for a PP based polymer (or a PP
combination of materials with minimum die based polymer extruded through a die cavity
modifications. In the second case, the three-layer designed for an EVOH or LLDPE based polymer),
feedblock could be located on the central die the layer distribution will not be optimum.
cavity or one of the outer die cavities while, in the Therefore, it may be necessary to have more than
third case, the two-layer feedblocks could be one die with various die cavities designed for a
located on both of the outer flow cavities or on an range of polymer products. Alternatively,
outer die cavity and the central die cavity. depending on the polymer layer combinations,
modifications to the feedblock combination
25
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

geometry might be possible to profile the shape of a three-cavity coextrusion die with two two-layer and
the melt stack exiting the feedblock to permit one three-layer feedblock
improved layer distributions with existing die
a three-cavity coextrusion die, with a five-layer
cavities. Which approach is best, acceptable or
feedblock
necessary, will be dependent on the permissible
layer thickness variations permitted by the product a seven-layer feedblock and a single cavity die
end use application.
a five-cavity coextrusion die combined with a three-
layer feedblock
Example 3: Production of a three- to sevenlayer
a two-cavity die with a five-layer and two-layer
sheet for thermoforming.
feedblock.
It is desired to produce coextruded thermoforming
sheet containing from three to five polymers. The While no single system will be able to produce all
sheet may contain layers of Nylon, EVOH, possible layer combinations and thickness ranges, a
polyvinylidene chloride (PVDC) or other barrier wide range of products is possible with the three-cavity
layers separately or in combination, adhesive die and various multilayer feedblock combinations.
resins and various polyolefins. The sheets are to be
1143 mm (45 in) wide and range in thickness from
Summary
12 to 45 mils. Structures are to include monolithic
and split barrier layers and symmetric and
asymmetric structures such as: Multilayer coextrusion systems for flat film and sheet
LLDPE/tie/nylon/tie/nylon/tie/LLDPE products are well developed and readily available in
many configurations and from many suppliers. Care
PP/tie/nylon/tie/nylon/tie/EP copolymer
should be exercised in determining the physical
LLDPE/tie/nylon/EVOH/nylon/tie/LLDPE configuration of the installation to minimize costs and
physical constraints for future product configurations.
LLDPE/tie/nylon/EVOH/nylon/tie/m-LLDPE
Also, a great deal of thought should go into the
PP/tie/nylon/EVOH/nylon/ ethylene vinyl acetate specification for the system and accurate information
should be supplied to the manufacturer (polymer type,
(EVA)/LDPE viscosity curves, melt temperatures etc.) to insure the
LLDPE/tie/EVOH/tie/EVOH/tie/LLDPE best outcome.

HDPE/tie/EVOH/tie/EVOH/tie/HDPE When choosing a coextrusion supplier, it is important

to interview and judge them based upon the science
and technology used for the design and manufacture
PS/scrap/tie/PVDC/Tie/scrap/PS of the system as well as the range of coextrusion
PP/scrap/tie/EVOH/tie/scrap/PP technology which they employ. For instance, if a
Filled PP/Scrap/filled PP. manufacturer is not interested in the polymer
As with the film example, there are several rheology, it is hard to imagine that they are truly
possible coextrusion equipment combinations designing the coextrusion system but rather just
which can be contemplated to produce these building it. If the supplier offers only limited
various film combinations. However, because the possibilities, such as multicavity dies and no
layers are relatively thick, layer uniformity in layers feedblocks, then they are likely not able to design
other than the barrier layers are less critical. This coextrusion feedblocks successfully or cannot design
permits the assumption that the coextrusion the feedblock/die cavity combination.
system will contain a combination of feedblocks
and multicavity or single cavity dies:
26
 CHAPTER 6
Coextrusion equipment for multilayer flat films and sheets

Coextrusion is a powerful method to produce are usually capable of producing a wide range of
multilayer films and sheets for a wide range of products within limitations. A thorough understanding
applications. There are a wide range of approaches of the coextrusion science and technology is required
which can be used to produce these products and all to achieve the best results.

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