KR20070022136A - Mechanical interlocking die - Google Patents

Abstract

The present invention relates to a mechanical interlock die comprising a first side, a second side, a plurality of extruded features 34 and a plurality of channels. Each of the first and second surfaces extends in the longitudinal direction. Each extruded feature includes a substrate portion extending in cross section from the first side, where the cross section is substantially perpendicular to the longitudinal direction, and an arm portion extending at an angle in cross section from the substrate portion. Each channel extends at an angle relative to the longitudinal direction from the second face and is disposed between the pair of extruded features.

Description

Mechanical interlock die {MECHANICAL INTERLOCKING DIE}

The present invention relates to an extrusion die for use with an extrusion and molding system. More specifically, the present invention relates to an extrusion die for mechanically interlocking an extruded polymer layer.

Composite articles, such as multilayer films and tubes, are typically produced by sequential extrusion or coextrusion through an extrusion process. Based on the design of the extrusion system and the extrusion die (s), various geometric shapes can be obtained. After extrusion, the layers of the composite article require a moderate degree of interlayer adhesion to prevent detachment. This relates in particular to composite articles having bonding layers of different thermoplastic materials, in particular when the thermoplastic materials are different. Different materials have chemical compositions that exhibit a low degree of interlayer adhesion without the use of additional bonding means. Examples of different materials include layers of fluoropolymers and layers of conventional non-fluorinated organic polymers. Such layer combinations are common for various industrial applications such as fuel line tubes.

Chemical methods such as tie layers, binders and chemical modifications have been used to improve the interlayer adhesion between different materials. For example, tie layers are generally layers of materials that, when directly bonded to each other, exhibit a degree of adhesion to all of the different materials that is greater than the degree of adhesion between the different materials. Nevertheless, the means for improving this interlayer adhesion typically increase the complexity of the process, the price of the composite article, the time and labor required to manufacture the composite article, and the like. In addition, such interlayer adhesion means are undesirable because they can degrade the physical and mechanical properties of the composite article.

In addition to chemical bonding, mechanical fasteners have also been used to prevent delamination. However, this type of mechanical interaction does not use themselves in multilayer film extrusion processing. Thus, a significant change in the extrusion process is required, which increases manufacturing cost and time.

There is still a continuing need for means for increased interlayer adhesion of different thermoplastic materials that do not require tie layers, binders or chemical modifications and provide an effective extrusion process.

Summary of the Invention

The present invention relates to a mechanical interlock die capable of making a composite article using a mechanical interlock layer. The mechanical interlock die includes a plurality of extrusion features and a plurality of channels. Each extruded feature includes a substrate portion extending in a cross section from the first side and an arm portion extending at an angle in the cross section from the substrate portion. The cross section is almost perpendicular to the longitudinal direction of the first face. Each channel extends at an angle relative to the longitudinal direction from the second face and is disposed between the pair of extruded features. The second surface also extends in the longitudinal direction.

The present invention relates to a mechanical interlock die comprising a longitudinally extending first side for extruding a first polymer layer and a longitudinally extending second side for extruding a second polymer layer. The mechanical linkage die also includes a plurality of extruded features and a plurality of channels. Each extruded feature includes a substrate portion extending from the first face and an arm portion extending at an angle from the substrate portion. Each channel extends at an angle relative to the longitudinal direction from the second face and is disposed between the pair of extruded features. The extruded feature creates a plurality of ribs longitudinally along the first polymer layer. The channel is substantially conformed to the ribs with a portion of the second polymer layer. This creates a composite article having a mechanical interlocking layer.

The present invention relates to a method of extruding a material using a mechanical interlock die, wherein the mechanical interlock die comprises a plurality of extruded features and a plurality of channels. Each extruded feature includes a substrate portion extending in a cross section from the first side and an arm portion extending at an angle in the cross section from the substrate portion. The cross section is almost perpendicular to the longitudinal direction of the first face. Each channel extends at an angle relative to the longitudinal direction from the second face and is disposed between the pair of extruded features. The second surface also extends in the longitudinal direction.

This method includes extruding a portion of the first polymer layer through an extrusion feature to form a plurality of ribs, and extruding a portion of the second polymer layer through the channel. This substantially conforms the second material to the rib that mechanically links the first polymer layer to the second polymer layer.

Brief description of the drawings

1 shows a schematic diagram of a mechanical interlock die of the present invention.

2A shows a schematic of the mechanical interlock die of the present invention used with a die head of an extrusion system.

FIG. 2B shows a longitudinal cross section taken along section 2B-2B in FIG. 2A.

2C shows a schematic of the mechanical interlock die of the present invention used with an extrusion system.

FIG. 3 shows an enlarged schematic view of the zone 3 in FIG. 2C.

4 shows an enlarged schematic view of the distal end of the mechanical interlock die of the present invention.

Figure 5 shows an enlarged front view of a portion of the distal end of the mechanical interlock die of the present invention.

6 shows a schematic view of a composite article made using the mechanical interlock die of the present invention, with a portion dismantled for illustration.

7 shows a schematic view of the distal end of a mechanical interlock die of a second embodiment of the present invention, showing another extrusion feature.

8 shows an enlarged front view of a portion of the distal end of the mechanical interlock die of the second embodiment of the present invention, showing another extrusion feature.

9 shows a schematic diagram of a mechanical interlock die of a third embodiment of the present invention.

10 shows a rear side view of a mechanical interlock die of a third embodiment of the present invention.

Figure 11 shows an enlarged front view of a portion of the distal end of a mechanical interlock die of a third embodiment of the present invention.

12 shows a schematic diagram of a mechanical interlock die of a fourth embodiment of the present invention.

The drawings described above illustrate several embodiments of the invention and, as discussed, intend to include other embodiments in the invention. In all cases, the disclosure of the present invention is presented for purposes of illustration and not limitation. Numerous other variations and embodiments may be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. Scales may not be shown in the drawings. In the drawings, like reference numerals are used to indicate like parts.

details

1 shows a schematic diagram of a mechanical interlock die 20 of the present invention, which can produce a composite article having a mechanical interlock layer. The mechanical interlock die 20 is an annular extrusion die (ie, wedge ring) for use with the extrusion system and includes a feature portion 22, a conical portion 24, a support portion 26, a proximal end 28 and a distal portion. End 30. The feature portion 22 is disposed at the distal end 30 of the mechanical linkage die 20 and is connected to the conical portion 24. Feature portion 22 and conical portion 24 define an outer surface 32 shown by outer surface portions 32a, 32b, 32c. The conical portion 24 further intersects axially with the support portion 26, where the support portion 26 is disposed at the proximal end 28 of the mechanical linkage die 20. The feature portion 22 includes a plurality of extruded features 34 and a plurality of channels 36 circumferentially alternating around the feature portion 22 at the distal end 30 of the mechanical linkage die 20. Extrusion features 34 and channel 36 serve to partition and facilitate mechanical interlocking of the extruded polymer layer with mechanical interlock die 20. Composite articles made by mechanical interlock provided by the mechanical interlock die 20 are excellent in interlayer adhesion without tie layers, binders or chemical modifications.

As further shown in FIGS. 2A-2C, the mechanical interlock die 20 may be mounted in a variety of systems, including extrusion systems, injection molding systems, and blow molding systems, without requiring significant changes. 2A shows a mechanical interlock die 20 used with a die head 38 and extrusion pin 40 of an extrusion system. Die head 38 is a conventional three layer die head that engages with the rest of the extrusion system (not shown). The die head 38 is shown in cross section to clarify the placement of the mechanical interlock die 20. FIG. 2B is a longitudinal cross sectional view taken along section 2B-2B in FIG. 2A (and further shows part of the extrusion system). FIG. 2C shows a mechanical interlock die 20 (without extrusion pin 40) used with die head 38 as in FIG. 2A, where the mechanical interlock die 20 shows a cross section. .

The mechanical linkage die 20 is supported by the support portion 26 in the die head 38. The support portion 26 is inserted into the die head 38 in a conventional manner by placing the mechanical linkage die 20 such that the outer surface portions 32a, 32b, 32c do not contact the die head 38. Thus, the die head 38 and the outer surface portions 32a, 32b, 32c are first annular paths 42 extending circumferentially around the outer surface portions 32a, 32b, 32c to extrude the first layer. Partition The polymeric material is fed to the first annular path 42 from an annular inlet 44 in the die head 38 connected to the first annular path 42.

As shown in detail in FIG. 2B, the mechanical linkage die 20 further includes an inner surface 48 disposed adjacent to the extrusion pin 40. Extrusion pin 40 is a straight extrusion pin, which extends through mechanical interlock die 20 along longitudinal axis 50. The extrusion pin 40 includes a first end 40a fixed to the socket 52 of the extrusion system and a second end 40b extending through the distal end 30 of the mechanical linkage die 20. The extrusion pin 40 is supported by the socket 52 such that the extrusion pin 40 does not contact the inner surface 48 of the mechanical linkage die 20. The socket 52 includes an annular wall 54, which is generally disposed adjacent to the support portion 26 of the mechanical linkage die 20. The annular wall 54, the extrusion pin 40 and the inner surface 48 of the mechanical interlock die 20 define a second annular path 56, which is an extrusion pin 40 for extrusion of the second layer and It extends circumferentially around the annular wall 54. The polymeric material is fed into the second annular path 56 from an annular inlet 58 connected to the second annular path 56.

During the coextrusion process, different polymeric materials flow through the first annular path 42 and the second annular path 56 to the distal end 30 of the mechanical linkage die 20 to produce first and second layers, respectively. can do. Suitable examples of polymeric materials are described in co-pending applications under the names "Composite Articles and Methods of Making thereof" (Agent No. 59620US002) and "Composite Articles with Tie Layers and Methods of Making thereof" (Agent No. 59652US002). . Once the first and second layers are extruded, the extruded features 34 and channel 36 of the feature portion 22 mechanically interlock the first and second layers. Mechanical interlocking of the first and second layers increases the interlayer adhesion, thereby reducing or potentially eliminating detachment of the composite article. This is particularly useful when extruding different thermoplastic materials, which have poor interlayer adhesion.

2A-2C show any third annular path 60 and annular inlet 61 for extruding the third layer. The first annular path 42 and the third annular path 60 generally meet at the intersection 62. The third layer may be bonded to the opposite surface of the first layer from the surface interacting with the second layer. The polymeric material is fed from the annular inlet 61 to the third annular path 60.

As shown in detail in FIG. 2C, the inner surface 48 is divided into inner surface portions 48a and 48b. The inner surface portion 48a extends circumferentially within the conical portion 24 and the support portion 26 and generally provides a smooth surface for the second annular path 56. The inner surface portion 48b extends in the circumferential direction within the feature portion 22.

3 shows an enlarged schematic view of the zone 3 of FIG. 2C. As shown, the inner surface portion 48b includes a plurality of wall segments 68 separated by extrusion features 34. Wall segment 68 and extrusion feature 34 extend along inner surface portion 48b in the longitudinal axis 50 direction.

At the intersection 70 of the inner surface portions 48a, 48b, the wall segment 68 "rises" from the inner surface portion 48a. As such, the " rising up " or annular shoulder portion reduces the inner diameter of the inner surface portion 48b relative to the inner diameter of the inner surface portion 48a and is generally a second annular path 56 which flows around the wall segment 68. To the second layer in. However, the extrusion feature 34 is exposed to the second annular path 56 at the intersection 70. The second layer flows near the wall segment 68, and a portion of the second layer also flows through the extrusion feature 34. This creates a plurality of ribs extending along the surface of the second layer, where the ribs exhibit a cross-sectional shape partitioned by the extrusion feature 34. The terms "cross section", "cross direction" and the like are defined herein as a plane perpendicular to the longitudinal axis 50 of the mechanical linkage die 20.

As shown in FIG. 4, which is an enlarged schematic view of the distal end 30 of the mechanical interlock die 20, the extruded features 34 have an extrusion feature 34 and a channel 36 circumferentially near the feature portion 22. On each side of the channel 36 to alternate in the direction. The number of extruded features 34 and channels 36 disposed in the vicinity of the feature portion 22 can vary as each requires. Suitable numbers for each extruded feature 34 and channel 36 are about 4 to about 50, in particular about 5 to about 20. In one embodiment, the extruded features 34 are evenly spaced near the feature portion 22 to maximize the mechanical interlock of the composite article.

While the second layer is extruded through the second annular path 56, the first layer is directed towards the distal end 30 along the outer surface portions 32b, 32c of the mechanical linkage die 20. 42) (generally indicated by arrow 42 in FIG. 4). As shown in FIGS. 4 and 5, FIG. 5 shows a further enlarged front view of the distal end 30, in which the first annular path 42 has a first portion of the first layer extruded features 34. ) Flows to the top surface 72 of, and the second portion flows to the channel 36. Top surface 72 is a portion of outer surface 32a that extends from distal end 30 to extrusion feature 34. Channel 36 is a portion of outer surface 32a disposed circumferentially between extruded features 34. Each channel 36 includes a circumferentially narrow portion 36a adjacent to the outer surface 32b. As the channel 36 extends along the outer surface 32a in the direction of the longitudinal axis 50 towards the distal end 30, each channel 36 widens in the circumferential direction. At the distal end 30, each channel 36 extends below the neighboring extrusion feature 34 at point 36b. The second portion of the first layer flowing into the channel 36 extends along it to the widening dimension of the channel 36 and further extends below the extrusion feature 34 at point 36b. Thus, the channel 36 allows a portion of the first layer to flow between portions of the second layer (ie, between the face of the second layer and the portion of the second layer in the extruded feature 34). As the first and second layers exit the mechanical linkage die 20 at the distal end 30, the first layer substantially mates with the face of the ribs (formed by the extrusion feature 34) and the second layer. In this specification, the terms “substantially matched to”, “substantially matched to”, and the like are defined while at least 75% of the ribs and the face of the second layer are in intimate contact. Upon cooling, the first and second layers form a composite article, wherein the ribs of the second layer extend into the first layer. This provides mechanical interlocking of the first and second layers, which increases the interlayer adhesion of the composite article.

The extrusion feature (eg, extrusion feature 34) of the mechanical interlock die 20 may include various cross-sectional shapes that define the cross-sectional shape of the ribs of the second layer. In addition, each extruded feature may exhibit a different cross-sectional shape than the extruded features of other mechanical interlock dies 20. However, to provide proper mechanical linkage, each extruded feature of the mechanical linkage die 20 includes a substrate portion and one or more arm portions extending at an angle in cross section from the substrate portion.

5, neighboring extruded features 34a and 34b are shown which are the same and are examples of the extruded features 34 of the mechanical interlock die 20. In the example shown in FIG. 5, the extruded feature 34 exhibits a “Y” shaped cross section. As illustrated by the extruded features 34a, each extruded feature 34 includes a substrate portion 76 and arm portions 78, 80 extending at an angle from the substrate portion 76. For each extruded feature 34, the cross-sectional shape of the substrate portion 76 and the arm portions 78, 80 is retained at the intersection 70 in the direction of the longitudinal axis 50 along the extruded feature 34 (FIG. Shown in 3). A portion of the second layer flowing through the extruded features 34a creates a rib that exhibits a cross-sectional shape partitioned by the substrate portion 76 and the arm portions 78, 80.

The substrate portion 76 is an opening extending between the pair of wall segments 68 (ie, wall segments 68a, 68b) of the inner surface portion 48b. Substrate portion 76 is generally partitioned by faces 82 and 84 and extends outwardly from wall segments 68a and 68b in cross section, respectively. Faces 82 and 84 are shown in FIG. 5 as extending in a direction substantially perpendicular to wall segments 68a and 68b, which face 82 and 84 are also other than wall segments 68a and 68b in cross section. May extend at an angle of (eg, 45 °).

The arm portion 78 is an opening extending at an angle from the substrate portion 76 in the cross section and is generally defined by the bottom surface 86 and the top surface 88. The bottom face 86 extends at an angle α with respect to the face 82 from the intersection 92 of the face 82 and the bottom face 86. Examples of suitable angles α with respect to face 82 are from about 30 ° to less than about 180 °, where 180 ° is parallel to face 82. Examples of particularly suitable angles a with respect to face 82 are from about 90 ° to about 135 °. As shown in FIG. 5, the angle α is about 120 ° from the face 82.

In addition, the arm portion 80 is an opening extending at an angle from the substrate portion 76 in the cross section and is generally defined by the lower surface 94 and the upper surface 96. The bottom surface 94 extends at an angle β with respect to the face 84 from the intersection 100 of the face 84 and the bottom face 94. Examples of suitable angles β with respect to face 84 are from about 30 ° to less than about 180 ° (where 180 ° is parallel to face 84). Examples of particularly suitable angles β with respect to face 84 are from about 90 ° to about 135 °. The angle β is shown at about 120 ° from face 84 in FIG. 5.

Since the angles α and β are about 120 ° from the planes 82 and 84, respectively, the extruded features 34 exhibit a transverse “Y” shape. However, it is noted that the angle α may have a different value from the angle β depending on each need. Thus, different angles a, beta produce arm portions 78, 80 extending at different angles from the substrate portion 76.

Each extruded feature (eg, extruded feature 34) of the mechanical interlock die 20 includes a height and a total arm length of a substrate portion (eg, substrate portion 76), where the total arm length is the arm portion [ Eg, the sum of the lengths of each of the arm portions 78, 80. When mechanically interlocking the first and second layers, the one or more extruded features 34 preferably have a total arm length greater than the height of the substrate portion 76. In addition, mechanical interlock is improved when most extruded features 34 have a total arm length greater than the height of the substrate portion 76.

As used herein, the “total arm length” can be calculated by the following method with reference to what is shown in FIG. 5: First, the planar cross section through the feature portion 22 perpendicular to the longitudinal axis 50. (Detailed in Figure 3). This gives a cross section of the type shown in FIG. 5. Reference is then made to the arm portion 78 to provide a line 102 extending from the intersection 92 at an angle α with respect to the face 82. Thus, line 102 is parallel to bottom surface 86. It then provides a line 104 that extends from the intersection point 92 and is perpendicular to the line 102.

Next, the face of the arm portion 78 that provides the maximum length for the line that extends vertically from the line 104 (and parallel to the line 102) to the placed point (eg, the bottom face 86). And top surface 88]. As shown in FIG. 5, the arm portion 78 has a point 106 that provides a maximum length for the line (ie, line 108) between the face of the arm portion 78 and the line 104. Where line 108 is perpendicular to line 104. The length of the line 108 between the disposed point 106 and the line 104 is defined as "the length of the arm portion 78".

Similarly, for arm portion 80, it provides a line 112 extending from intersection 100 at an angle β with respect to face 84. Thus, the line 112 is parallel to the bottom surface 94 of the arm portion 80. It then provides a line 114 extending from the intersection 100 and perpendicular to the line 112.

Then, the face of the arm portion 80 (ie, the bottom face 94) that provides the maximum length for the line extending vertically from the line 114 (and parallel to the line 112) to the point at which it is placed. And top surface 96]. As shown in FIG. 5, arm portion 80 has a point 116 that provides the maximum length for the line (ie, line 118) between the face of arm portion 80 and line 114. Where line 118 is perpendicular to line 114. The length of the line 118 between the arranged point 116 and the line 114 is defined as "the length of the arm part 80".

The "total arm length" for the extrusion feature 34a is then the sum of the length of the arm portion 78 and the length of the arm portion 80. If the extrusion feature 34a includes only a single arm portion, the total arm length of the extrusion feature 34a is the length of the single arm portion. Alternatively, if the extrusion feature 34a includes more than two arm portions, the total arm length of the extrusion feature 34a is the sum of the lengths of all arm portions of the extrusion feature 34a.

Extruded features 34b equally refer to extruded features 34a and are provided for reference to calculate the height of substrate portion 76. As used herein, the height of the substrate portion 76 is calculated in the following manner: First, the segmentation line 120 partitioned by points 122 and 124 using the planar cross-section derived for the total arm length calculation. Where point 122 is placed at the intersection of face 82 and wall segment 68b, and point 124 is placed at the intersection of face 84 and wall segment 68c. As used herein, the terms "vertical", "vertically" and the like refer to the direction perpendicular to the dividing line 120 and towards the extrusion feature 34b, and the terms "horizontal", "horizontally" and the like It refers to a direction parallel to the cut line 120.

An extrusion feature 34b which then provides the maximum length of the line extending vertically from the horizontal line 120 between the points 122 and 124 to the point placed (not intersecting with another point in the plane). The points are placed along the planes of (ie, along planes 82, 84, bottom surfaces 86, 94, and top surfaces 88, 96). The vertical lines from the dividing line 120 generally do not intersect the lower surfaces 86 and 94 without the first intersecting surfaces 82 and 84, respectively. As shown in FIG. 5, the extruded feature 34b has two points 126 located between the points 122 and 124, and is perpendicular to the plane of the extruded feature 34b and the dashed line 120. Ie, the maximum length for line 128]. Two points 126 are obtained in FIG. 5 due to the symmetrical shape of the extruded features 34b. The length of one of the lines 128 between the point 126 and the dividing line 120 is defined as the "height of the substrate portion 76".

As provided above, the calculation of the total arm length for the arm portions 78, 80 and the height of the substrate portion 76 is a general method applicable to various cross-sectional shapes for the extruded features of the mechanical linkage die 20. . For example, when faces 82 and 84 of substrate portion 76 extend from wall segments 68a and 68b in cross section at a 45 ° angle, vertical lines extending from dashed line 120 are top surfaces 88 and 96. May intersect face 82 or face 84 other than). Thus, the height of the base portion extends only to the point disposed from the cut line on the face 82 or face 84 of the base portion 76.

FIG. 6 shows a schematic diagram of a composite article 132 coextruded with a mechanical linkage die 20 having an extrusion feature 34 and a channel 36 (shown in FIG. 5). Composite article 132 includes a first layer 134 (from first annular path 42) and a second layer 136 (from second annular path 56). The first layer 134 has a face 134a that meshes with the face 136a of the second layer 136 at the interface 138. The second layer 136 further includes a plurality of ribs 140 extending from the face 136a to the first layer 134. Each rib 140 includes a wall portion 142 and protruding portions 144, 146. As discussed below, the ribs 140 exhibit a transverse "T" shape rather than a transverse "Y" shape of the extruded features 34.

For each rib 140, the wall portion 142 represents the height and the protruding portions 144, 146 represent the protruding width, respectively. The application filed simultaneously under the names "Composite article and its manufacturing method" (Agent No. 59620US002) and "Composite article with tie layer and its manufacturing method" (Agent No. 59652US002) uses a mechanical interlock die 20 In addition to the manufacturable composite article, a method of calculating the protrusion width and height of the wall portion 142 is provided. As discussed in the concurrently filed application, it is preferable that at least one protrusion width of the protrusion portions 144, 146 is greater than the height of the wall portion 142.

As shown in FIG. 6, the portion 134 of the first layer is disposed below the protruding portions 144, 146 adjacent to the face 136a and the wall portion 142 of the second layer 136. Extrusion features 34 and channel 36 allow first layer 134 to substantially conform to rib 140 and face 136a. In particular, the substrate portion 76 of the extruded features 34 forms the wall portion 142 of the rib 140, which offsets the corresponding protruding portions 144, 146 from the face 136a. This allows a greater amount of the first layer 134 to be disposed below the protruding portions 144 and 146. The channel 36 of the mechanical interlock die 20 allows a portion of the first layer 134 to flow easily under the protruding portions 144, 146, thus substantially on the ribs 140 and face 136a. Match. In addition, the arm portions 78, 80 of the extruded features exhibit significant total arm length (which is preferably greater than the height of the substrate portion 76 in question). This produces protrusions 144, 146 that exhibit a significant protrusion width such that the portion of the first layer 134 disposed below the protrusions 144, 146 is trapped. Thus, the mechanical linkage die 20 creates a mechanical linkage between the first layer 134 and the second layer 136, which reduces the likelihood of detachment of the composite article 132.

5 and 6, it is noted that the rib 140 produced by the extruded feature 34 exhibits a cross “T” shape that is different from the cross “Y” shape of the extruded feature 34. It has been found that when the first layer 134 substantially matches the face 136a of the rib 140 and the second layer 136, it is caused by the general lowering of the protruding portions 144, 146. The portion 134 of the first layer that flows on the top surface 72 of the extruded features 34 is generally from the angular position of the arm portions 78, 80 to the cross-sectional shape provided in FIG. 6 (ie, from the “Y” shape). The extruded protrusions 144, 146 in a "T" shape. Thus, the transverse "Y" shape of the extruded features 34 is beneficial to maximize the projected width of the projected portions 144, 146. In addition, the first layer may compress the wall portion 142 towards the side 136a of the second layer 136. This reduces the height of the wall portion 142 relative to the height of the substrate portion 76. Various factors can affect the degree to which the protruding portions 144 and 146 descend and the degree to which the wall portions 142 are compressed, such as layer composition, flow rate, viscosity, temperature, linear velocity and combinations thereof.

7 shows a schematic view of the distal end 30 of the mechanical interlock die 20, illustrating another cross-sectional shape for the extrusion feature of the mechanical interlock die 20, referred to as the extrusion feature 148. As discussed above, the extruded features of the mechanical interlock die 20 may include a variety of cross-sectional shapes, as long as each extruded feature includes a substrate portion and one or more arm portions extending at an angle from the substrate portion. . As shown in FIG. 7, the extruded feature 148 exhibits a transverse "T" shape instead of the transverse "Y" shape of the extruded feature 34. The plurality of extruded features 148 separates the wall segment 68, where the wall segments 68 and the extruded features 148 extend along the inner surface portion 48b in the direction of the longitudinal axis 50. For each extruded feature 148, the transverse “T” shape is retained along the extruded feature 148 at an intersection 70 (generally shown in FIG. 3). Extrusion feature 148 is exposed to second annular path 56 at intersection 70 to allow a portion of the second layer to flow through extrusion feature 148. This produces a plurality of ribs extending radially outward along the second layer as the second layer is extruded, where the ribs exhibit a cross-sectional shape partitioned by the extrusion feature 148.

Extruded features 148 are disposed on each side of channel 36 such that extruded features 148 and channel 36 alternate in the circumferential direction around feature portion 22. The first and second layers interact with the channel 36 and the extrusion feature 148 in a similar manner as described above with respect to the extrusion feature 34. The first annular path 42 allows the first portion of the first layer to flow to the top surface 72 of the extrusion feature 148 and the second portion to flow into the channel 36. Top surface 72 is a portion of outer surface 32a that extends from distal end 30 to extrusion feature 148. Channel 36 is a portion of outer surface 32a disposed circumferentially between extrusion features 148. Each channel 36 includes a circumferentially narrow portion 36a adjacent to the outer surface 32b. As the channel 36 extends along the outer surface 32a in the direction of the longitudinal axis 50 towards the distal end 30, each channel 36 extends in the circumferential direction. Channel 36 at distal end 30 extends below extrusion feature 148 at point 36b. The second portion of the first layer flowing into the channel 36 is enlarged according to the enlarged dimension of the channel 36 and further enlarged below the extrusion feature 148 at point 36b.

As the first and second layers exit the mechanical linkage die 20 at the distal end 30, the channel 36 has a first layer of ribs (formed by the extrusion feature 148) and the face of the second layer. To be practically consistent with This creates a rib of the second layer extending into the first layer, thus mechanically interlocking the first and second layers together.

8 is an enlarged front view of a portion of the distal end 30 of the mechanical interlock die 20, illustrating an extruded feature 148 of the mechanical interlock die 20 and illustrating the same extrusion features 148a, 148b. Illustrated. As illustrated by the extruded features 148a, each extruded feature 148 includes arm portions 152, 154 and substrate portion 150 extending at an angle from the substrate portion 150. The rib created by the extruded feature 148 extends along the face of the second layer and has a cross-sectional shape partitioned by the substrate portion 150 and the arm portions 152 and 154.

The substrate portion 150 is an opening extending between the wall segments 68a and 68b of the inner surface portion 48b and generally faces outwardly extending from the wall segments 68a and 68b in the cross section, respectively. Is partitioned by). Arm portion 152 is an opening extending at a predetermined angle from substrate portion 150 in cross section and is generally defined by bottom surface 160, end surface 162 and top surface 164. As described above with respect to the extruded features 34, the bottom surface 160 extends at an angle α with respect to the face 156 from the intersection 168 of the face 156 and the bottom face 160. Similarly, arm portion 154 is also an opening that extends at an angle from substrate portion 150 in cross section and is generally defined by bottom surface 170, end surface 172 and top surface 174. . Bottom surface 170 extends at an angle β with respect to the intersection 178 of face 158 and bottom face 170 from face 170.

Examples of suitable angles α with respect to face 156 are from about 30 ° to less than about 180 °, where 180 ° is parallel to face 156. Examples of particularly suitable angles a with respect to face 156 are from about 90 ° to about 135 °. Examples of suitable angles β with respect to face 158 are from about 30 ° to less than about 180 °, where 180 ° is parallel to face 158. Examples of particularly suitable angles β with respect to face 158 are from about 90 ° to about 135 °. The extruded features 148a in FIG. 8 provide examples of alternating angles α, β with the arm portions 152, 154 extending, respectively. As shown, angles α and β are about 90 ° with respect to faces 156 and 158, respectively. This creates a transverse "T" shape of the extrusion feature 148a.

Similar to the extruded features 34, each extruded feature 148 includes a height and a total arm length of a substrate portion (eg, substrate portion 150), where the total arm length is an arm portion [eg, arm portion]. (152, 154), respectively. The total arm length and the height of the substrate portion 150 are calculated using the method described in FIG. 5. First, a planar cross section is taken through the feature portion 22 perpendicular to the longitudinal axis 50 (shown in detail in FIG. 3). This provides a cross section of the type shown in FIG. 8. Referring now to arm portion 152 in extrusion feature 148a, provides line 179 extending from intersection 168 at an angle α with respect to face 156. Thus, line 179 is parallel to bottom surface 160. It then provides a line 180 that extends from the intersection 168 and is perpendicular to the line 179.

Next, the face of the arm portion 152 (eg, the bottom surface 160, which provides the maximum length of the line extending vertically to a point disposed from the line 180 (and parallel to the line 179)). End face 162, and top face 164]. As shown in FIG. 8, since the end face 162 is parallel to the line 180, any point along the end face 162 may be in the line (randomly shown by line 182). Provide the maximum length. Thus, the length of line 182 between end face 162 and line 180 is defined as "length of arm portion 152".

Similarly, for arm portion 154, it provides a line 183 extending from intersection 178 at an angle β with respect to face 158. Thus, line 183 is parallel to bottom surface 170. It then provides a line 184 extending from the intersection 178 and perpendicular to the line 183.

Next, the face of the arm portion 154 (i.e., the lower surface 170, provided that the maximum length of the line extends vertically (and parallel to the line 176) to a point disposed from the line 184) Points 172 and top 174]. As shown in FIG. 8, because the end face 172 is parallel to the line 184, any point along the end face 172 is the maximum length of the line (shown randomly by line 186). To provide. The length of line 186 between end face 172 and line 184 is defined as “arm portion 154 is length”. The total arm length for the extrusion feature 148a is then the sum of the length of the arm portion 152 and the length of the arm portion 154.

In order to calculate the height of the substrate portion 150 (referred to as extrusion feature 148b), first, a segmented line 188 divided by points 190 and 192 is provided using the planar cross-sectional area generated for the calculation of the total arm length. Where point 190 is disposed at the intersection of face 156 and wall segment 68b, and point 192 is disposed at the intersection of face 158 and wall segment 68c. Extruded features 148 then provide a maximum length of the vertically extending line between the horizontal lines 188 between the points 190 and 192 to the point at which they are placed (other points in the plane do not intersect). Place points along the plane of (ie, along planes 156, 158, bottom planes 160, 170, end faces 162, 172, and top planes 164, 174). As shown in FIG. 8, any point along the top surface 164, 174 that is horizontal between the points 190, 192 provides the maximum length of the vertical line (shown randomly by line 194). . The length of the line 194 between the top surface (ie, top surfaces 164 and 174) and the cut line 188 is defined as the "height of the substrate portion 150."

In order to mechanically interlock the first and second layers, the one or more extruded features 148 preferably exhibit a total arm length that is greater than the height of the substrate portion 150. In addition, mechanical interlock is improved when most extruded features 148 exhibit a total arm length that is greater than the height of the substrate portion 150. As discussed generally in connection with FIG. 6, the rib 140 produced by the extrusion feature 148 may exhibit a general lowering of the protruding portions 144, 146 from the position of the arm portions 152, 154. . The rib 140 may exhibit a cross-sectional shape similar to an arrow head that traps a portion 134 of the first layer for mechanically interlocking the first and second layers 134, 136.

As described above, the mechanical interlock die 20 is an example of the mechanical interlock die of the present invention capable of producing a composite article having a mechanical interlock layer. However, it is not intended to limit the mechanical interlock die 20 to specific dimensions. Due to the various designs of existing extrusion systems, the required extrusion die dimensions may vary depending on the extrusion system. Thus, various embodiments of the mechanical interlock die 20 may exhibit various dimensions for compatibility with existing extrusion systems. In particular, the conical portion 24 and the support portion 26 can be any component if not needed for use with a particular extrusion system. Examples of suitable lengths for the mechanical linkage die 20 in the direction of the longitudinal axis 50 include a length of the feature portion 22 of about 4.6 cm, a length of the conical portion 24 of about 4.1 cm and a support portion of about 1.6 cm ( 26) and the like.

Examples of suitable outer diameters for the mechanical linkage die 20 in the cross section (ie, in the radial direction with respect to the longitudinal axis 50) include an outer diameter of the feature portion 22 that increases from distal to proximal from about 2.3 cm to about 2.7 cm, about Outer diameter of the conical portion 24 increasing from distal to proximal from 2.7 cm to about 5.4 cm, outer diameter of the support portion 26 of about 8.2 cm. Examples of suitable inner diameters for the mechanical linkage die 20 in the cross section include the inner diameter of the feature portion 22 at the inner surface 48b of about 1.9 cm, and the distal to proximal interior from about 2.3 cm to about 4.8 cm. Inner surface of conical portion 24 and support portion 26, etc. on face 48a.

9 shows a schematic diagram of a mechanical interlock die 200, showing another embodiment of the present invention for a mechanical interlock die 20. The mechanical interlock die 200 produces a composite article having a mechanical interlocking layer in the same manner as the mechanical interlock die 20, except that the composite article is a flat film rather than a composite tubular article. As shown, the mechanical interlock die 200 includes a three layer comprising a first feature portion 202, a second feature portion 204, a support portion 206, a proximal end 208, and a distal end 210. Extrusion die. The first feature portion 202 and the second feature portion 204 are connected with the support portion 206 at the proximal end 208 of the mechanical linkage die 200 and are generally parallel at the distal end 210. The first feature portion 202 includes an outer surface 212 and an inner surface 214, and the second feature portion 204 includes an outer surface 216 and an inner surface 218.

The first feature portion 202 further includes a plurality of extruded features 220 and a plurality of channels 222. Extruded features 220 and channel 222 alternate across first feature portion 202 at distal end 210 of mechanical linkage die 200 in the direction of transverse axis 224. As shown, the transverse axis 224 is perpendicular to the longitudinal axis 226, where the longitudinal axis 226 extends in a direction including the proximal end 208 and the distal end 210 of the mechanical linkage die 200, Generally, the direction of flow of the polymeric material is shown through the first feature portion 202 and the second feature portion 204. The second feature portion 204 further includes a plurality of extruded features 228 and a plurality of channels 230. The extruded features 228 and the channels 230 alternate across the second feature portion 204 at the distal end 210 of the mechanical linkage die 200 in the direction of the transverse axis 224.

Extrusion features 220, 228 and channels 222, 230 mechanically interlock the extruded polymer layer using mechanical interlock die 200 in a manner similar to extrusion feature 148 of mechanical interlock die 20. Planar composite articles made using mechanical interlocks provided by mechanical interlock dies 200 have been shown to have good interlayer adhesion without requiring tie layers, binders or chemical modifications.

The number of extruded features 220 and channels 222 disposed along the first feature portion 202 can each vary as needed. Suitable numbers for the extruded features 220 and the channels 222 are each about 4 to about 50, particularly suitably about 5 to about 20. In one embodiment, the extruded features 220 are evenly spaced along the first feature portion 202 to maximize the mechanical interlock of the composite article. Similarly, the number of extruded features 228 and channels 230 disposed along the second feature portion 204 may vary as needed. Suitable numbers for the extrusion features 228 and the channels 230 are each about 4 to about 50, and particularly suitable numbers are about 5 to about 20. In one embodiment, the extruded features 228 are evenly spaced along the second feature portion 204 to maximize the mechanical interlock of the composite article. The extruded features 220, 228 may be placed directly on one another (shown in FIG. 9), staggered, or asymmetrically disposed.

In addition, the mechanical interlock die 200 can be installed using a variety of systems, including extrusion systems, injection molding systems, and blow molding systems, without requiring significant modifications. The outer surface 212 of the first feature portion 202 partially defines a first path 232 (shown by arrow 232) for extruding the first layer towards the distal end 210. The inner surfaces 214, 218 define a second path 234 (shown by arrow 234) for extruding the second layer (ie, core layer) towards the distal end 210. The outer surface 216 of the second feature portion 204 partially partitions a third path 236 (shown by arrow 236) for extruding the third layer towards the distal end 210.

During the coextrusion process, various polymeric materials flow through the first path 232, the second path 234, and the third path 236 toward the distal end 210 to form the first, second, and third layers. Each can be created. Examples of suitable polymeric materials are described in co-pending applications under the names "Composite Articles and Methods of Making thereof" (Agent No. 59620US002) and "Composite Articles with Tie Layers and Methods of Making thereof" (Agent No. 59652US002). . Once the first and second layers are extruded, the extruded features 220 and the channels 222 of the first feature portion 202 mechanically interlock the first and second layers. Similarly, when the third layer is extruded along with the second layer, the extrusion feature 228 and the channel 230 of the second feature portion 204 mechanically interlock the second and third layers. Mechanical interlocking of the layers is carried out in the same manner as described above for the mechanical interlocking die 20. This increases the interlayer adhesion, thus reducing and potentially eliminating the detachment of the composite article.

FIG. 10 shows a rear view of the mechanical interlock die 200 showing the inner surfaces 214, 218. Inner surface 214 is divided into inner surface portions 214a and 214b and inner surface 218 is divided into inner surface portions 218a and 218b. Inner surface portions 214a and 218a are disposed between proximal end 208 (not shown) and distal end 210 and provide a generally smooth surface for second path 234. Inner surface portions 214b and 218b are disposed near distal end 210. As shown in FIG. 10, the inner surface portion 214b is “elevated” at the intersection of the inner surface portions 214a and 214b or at the shoulder portion 238, and the inner surface portion 218b is connected to the inner surface portion 218a, "Elevated" at the intersection or shoulder portion 240 of 218b). This “elevated” corresponds to the “elevated” or annular shoulder portion partitioned between the inner surface portions 48a, 48b of the mechanical linkage die 20 shown in FIG. 3. Each "elevated" decreases the distance between the inner surfaces 214, 218. Thus, this reduces the dimensions of the second path 234 and generally allows the second layer in the second path 234 to flow around the inner surface portions 214b and 218b.

As shown, the extruded feature 220 is exposed to the second path 234 at the intersection 238. The second layer flows around the inner surface portion 214b, and the portion of the second layer also flows through the extrusion feature 220. This creates a first set of ribs extending along the face of the second layer (facing the first layer), where the first set of ribs exhibit a cross-sectional shape partitioned by the extrusion feature 220. In addition, extrusion feature 228 is exposed to second path 234 at intersection 240. The second layer flows around the inner surface portion 218b, and the portion of the second layer is also udonted through the extrusion feature 228. This produces a second set of ribs extending along the face of the second layer (facing the third layer), where the second set of ribs exhibit a cross-sectional shape partitioned by the extrusion feature 228.

FIG. 11 shows an enlarged front view of a portion of the distal end 210 of the mechanical linkage die 200 illustrating the extrusion features 220, 228 and the channels 222, 230. As shown, the extruded features 220, 228 exhibit a transverse "T" shape, which corresponds to the extruded features 148 described in FIG. 8. However, the extruded features 220 and 228 need not exhibit uniform cross-sectional shapes. For example, the extruded feature 220 can exhibit a transverse "T" shape, and the extruded feature 228 can exhibit a transverse "Y" shape. In addition, each extruded feature 220 extending along the first feature portion 202 may each exhibit a variety of cross-sectional shapes (this also applies to the extruded feature 228).

In a manner similar to that described above in FIGS. 7 and 8 with respect to the extrusion feature 148 and the channel 36 of the mechanical linkage die 20, the first and second layers are formed of the extrusion feature 220 and the channel 222. And the second and third layers interact with the extrusion feature 228 and the channel 230. This produces a planar composite article exhibiting mechanical interlock between the first and second layers and between the second and third layers.

As shown in FIG. 11, the extruded features 220 are disposed on each side of the channel 222 such that the extruded features 220 and the channels 222 alternate sideways along the first feature portion 202. The second layer is extruded through the second path 234, and the first layer is extruded through the first path 232 along the outer surface 212 toward the distal end 210. The first path 232 flows the first portion of the first layer to the top surface 242 of the extrusion feature 220, and the second portion flows into the channel 222. Top surface 242 is a portion of outer surface 212 extending from distal end 210 to extrusion feature 220. Channel 222 is a portion of outer surface 212 laterally disposed between extruded features 220. Each channel 222 includes a narrow portion 222a in the lateral direction at a position furthest from the distal end 210. As the channels 222 extend along the outer surface 212 in the direction of the longitudinal axis 226 towards the distal end 210, each channel 222 expands in the lateral direction. At distal end 210, channel 222 extends below extrusion feature 220 at point 222b.

The second portion of the first layer flowing into the channel 222 expands along the enlarged dimension of the channel 222 and further expands below the extrusion feature 220 at point 222b. Thus, the channel 222 allows a portion of the first layer to flow between the portions of the second layer (ie, between the face of the second layer and the portion of the second layer in the extrusion feature 220).

In addition, extruded features 228 are disposed on each side of channel 230 such that extruded features 228 and channel 230 alternate laterally along second feature portion 204. The second layer is extruded through the second path 234, and the third layer is extruded through the third path 236 along the outer surface 216 toward the distal end 210. The third path 236 allows the first portion of the third layer to flow to the top surface 244 of the extrusion feature 228 and the second portion to flow into the channel 230. As shown in FIG. 11, the extruded features 228 and the channels 230 are in the reverse direction with respect to the extruded features 220 and the channels 222. However, for consistency, the same term definition for orientation applies to all of them (eg, “on”, “under”, etc.) Top surface 244 is extruded feature 228 at distal end 210. Is a portion of outer surface 216 that extends laterally between extrusion features 228. Each channel 230 is a distal end 210. As shown in FIG. And laterally narrow portions 230a at the most distal position from the channel 230. When the channel 230 extends along the outer surface 216 in the direction of the longitudinal axis 226 towards the distal end 210, each channel 230 extends laterally, at distal end 210, channel 230 extends below extrusion feature 228 at point 230b.

The second portion of the third layer flowing into the channel 230 is enlarged according to the enlarged dimension of the channel 230 and further enlarged below the extrusion feature 228 at point 230b. Thus, channel 230 allows a portion of the third layer to flow between portions of the second layer (ie, between the face of the second layer and the portion of the second layer in the extrusion feature 228).

When the first, second and third layers exit the mechanical interlock die 200 at the distal end 210, the first layer is the first set of ribs (formed by the extrusion feature 220) and the second layer. Substantially conforms to the face of the second layer, and the third layer substantially conforms to the second set of ribs (formed by the extrusion feature 228) and the opposite face of the second layer. Upon cooling, the first, second and third layers form a planar composite article, wherein the first set of ribs extends to the first layer and the second set of ribs extends to the third layer. This provides mechanical interlocking of the first and second layers and mechanical interlocking of the second and third layers, which increases the interlayer adhesion of the composite article.

The extruded features of the mechanical interlock die 200 (eg, extruded features 220, 228) may include various cross-sectional shapes that define the cross-sectional shapes of the first rib set and the second rib set. With respect to the extruded features of the mechanical interlock die 20, each extruded feature of the mechanical interlock die 200 includes a substrate portion and one or more arm portions extending at an angle from the substrate portion. As shown in FIG. 11, the extrusion features 220, 228 are the same as the extrusion features 148 of the mechanical linkage die 20 as discussed in FIGS. 7 and 8. Each extruded feature 220 includes a substrate portion 246 and arm portions 248 and 250 extending at an angle from the substrate portion 246. For each extruded feature 220, the cross-sectional shape of the substrate portion 246 and the arm portions 248, 250 is maintained at the intersection 238 in the direction of the longitudinal axis 226 along the extruded feature 220 (FIG. Shown in figure 10). The portion of the second layer flowing through the extrusion feature 220 produces a first set of ribs that exhibit a cross-sectional shape partitioned by the substrate portion 246 and the arm portions 248 and 250.

Similarly, each extruded feature 228 includes a substrate portion 252 and arm portions 254, 256 extending at an angle from the substrate portion 252. For each extruded feature 228, the cross-sectional shape of the substrate portion 252 and the arm portions 254, 256 is retained at the intersection 240 in the direction of the longitudinal axis 226 along the extruded feature 228 (FIG. Shown in figure 10). The portion of the second layer flowing through the extruded features 228 creates a second set of ribs that exhibit a cross-sectional shape partitioned by the substrate portion 252 and the arm portions 254 and 256.

Each extruded feature of the mechanical linkage die 200 includes the height of the substrate portion and the total arm length, where the total arm length is the sum of the respective lengths of the arm portions. For the extruded features 220, 228, the total arm length and the height of the substrate portion are calculated using the method described in FIG. 5, with the results as discussed for the extruded feature 148 in FIG. 8. When mechanically interlocking the first, second and third layers, the one or more extruded features 220 preferably have a total arm length greater than the height of the substrate portion 246, and the one or more extruded features ( 228 preferably has a total arm length greater than the height of the substrate portion 252. In addition, mechanical interlocking results in a total arm length where most extruded features 220 are greater than the height of the substrate portion 246, and most extruded features 228 are greater than the height of the substrate portion 252. It is improved when showing a large total arm length.

In another embodiment of the mechanical interlock die 200 shown in FIG. 12, the extruded features and channels may be present in only one of the feature portions (ie, the first feature portion 202). In such embodiments, the second feature portion 204 is smooth in surface and does not include any extruded features or channels. This is useful if only two layers are extruded or if no mechanical interlock is required between the second and third layers. The third layer may be chemically bonded to the opposite side of the second layer from the side interacting with the first layer.

The mechanical interlock die of the present invention can produce various shapes for extruded multilayer articles. In addition to the embodiments described above (ie mechanical interlock die 20 for tubular composite articles and mechanical interlock die 200 for flat composite articles), suitable examples of extrusion shapes include extruded " L " -shaped films, Arcuate films, “U” -shaped films, irregularly shaped films, wavelike films, cylindrical composite articles, rectangular shaped films and other geometrically shaped composite articles, and the like.

The height of the substrate portion relative to the extruded features (eg, extruded features 34, 148, 220, 228) can be changed as needed. In particular, variables such as layer thickness, number of extruded features and diameter of the composite article can determine the required height. However, the height is preferably small enough so that the ribs formed by the extruded features do not pass through the first layer. An example of a suitable height of the substrate portion for the extrusion feature of the mechanical linkage dies 20, 200 is less than about 25.0 mm in height, particularly suitably less than about 10.0 mm in height. However, for use with very thin layers, the height of the substrate portion may be less than 0.5 mm. The arm portion preferably has a total arm length greater than the height of the substrate portion and can be determined by variables such as the number of extrusion features and the diameter of the composite article.

Mechanical interlock dies 20 and 200 are generally cast from 15/5 steel. The extrusion feature is then formed by wire discharge machining (EDM) to partition the extrusion feature. Similarly, the channel is formed by a sinker EDM that partitions the channel.

As described above for tubular and planar composite articles, in addition to coextrusion of the polymer layer, the polymer layer may also be prepared in a separate step (eg, a sequential extrusion process). The second layer can be extruded in a first step using the mechanical linkage die of the present invention to form ribs extending from the face of the second layer, wherein the ribs are shaped in a cross-sectional shape partitioned by the extrusion feature of the mechanical linkage die. Have Then, in the second step, the first layer (and the third layer, if used) is coated on the second layer to substantially conform to the faces of the ribs and the second layer. Coating can be carried out by conventional methods such as extruding the first layer to the profile second layer through a crosshead die. It also mechanically interlocks the first and second layers. However, coextrusion allows for single step production, which simplifies the initiation and regulation of the line and also provides greater quality control for composite articles.

Since many variations and modifications within the scope of the invention will be apparent to those skilled in the art, the invention will be described in more detail in the following examples which are intended to be presented by way of example only. Unless otherwise noted, all parts, percentages and ratios mentioned in the examples below are by weight and all reagents used in the examples are available or obtainable from the suppliers described below or in conventional methods. Can be synthesized.

The abbreviations for the following compositions were used in the examples below.

"THV 500": Fluorinated terpolymer available under the trade designation "Dyneon THV 500 Fluorothermoplastic" from Dyneon, L.C., Oakdale, Minnesota, USA.

"THV 815": A fluoroplasticizer available under the trade designation "Dyneon THV 815 Fluorothermoplastic" from Dyneon, L.C., Oakdale, Minnesota, USA.

"VFEPX 6815G": A fluoroplasticizer available under the trade designation "Dyneon VFEPX 6815G Fluorothermoplastic" from Dyneon, L.C., Oakdale, Minnesota, USA.

"Ultramid B3": polyamide (nylon) available under the trade name "Ultramid B3" from BASF Corporation in Mount Olive, NJ, USA 6.

"EMS L25W40X": polyamide (nylon) available under the trade name "Grilamid L25W40X" from EMS-Kemi N., Inc., Sumter, SC, USA 12.

Example 1

Example 1 relates to a three layer tubular composite article co-extruded using the mechanical interlock die of the present invention. The mechanical interlock die has dimensions as described above for the mechanical interlock die 20 and includes an extrusion feature that exhibits a transverse "Y" shape as described above for the extrusion feature 34.

The inner tubular layer consists of THV 815 with a ratio of length to diameter of 26 and a temperature profile of 255/275/285 ° C., 3.8 cm (available from Harrell, Incorporated, East Norwalk, Conn., USA). Extruded from a 1.5 in) Harrel single screw extruder using the mechanical interlock die of the present invention. The extrusion produces ribs extending radially along the inner tubular layer.

The intermediate layer consists of EMS L25W40X, each with a length-to-diameter ratio of 26 and a temperature profile of 180/195/210 ° C., 2.5 cm (available from Harrell, Incorporated, East Norwalk, Conn., USA). Extruded from a 1 in) Harrel single screw extruder using the mechanical interlock die of the present invention.

The outer tubular layer consists of EMS L25W40X, each with a length-to-diameter ratio of 26 and a temperature profile of 180/195/210 ° C., 5.1 available from Harrell, Incorporated, East Norwalk, Conn. Extruded from a 2 in. Harrel single screw extruder using the mechanical interlock die of the present invention. The outer tubular layer does not interact directly with the mechanical interlock die of the present invention. Since the middle and outer tubular layers are made of the same polymer, the tubular composite article of Example 1 effectively acts as a two layer composite article.

The resulting tubular composite article of Example 1 was cooled in a water bath, fed through a web handling device, and wound up at a linear speed of 3.4 m / min (11 ft / min).

Example 2

Example 2 relates to a three layer tubular composite article co-extruded by the procedure described in Example 1 except that the inner tubular layer consists of VFEPX 6815G instead of THV 815.

Example 3

Example 3 relates to the three-layer tubular composite article of Example 2, coextruded according to the procedure described in Example 1 except that the linear velocity is 10.1 m / min (33 ft / min).

Example 4

Example 4 relates to the three-layer tubular composite article of Examples 2 and 3 coextruded according to the procedure described in Example 1, except that the linear velocity is 15.5 m / min (51 ft / min).

Example 5

Example 5 relates to a three layer tubular composite article co-extruded using the mechanical interlock die of the present invention. The mechanical interlock die has dimensions as described above for the mechanical interlock die 20 and includes an extrusion feature that exhibits a transverse "T" shape as described above for the extrusion feature 148.

The inner tubular layer consists of THV 500, has a ratio of length to diameter of 26, a temperature profile of 255/275/285 ° C., using a mechanical interlocking die of the present invention from a 1.5 in. Harrel single screw extruder. Extruded. The extrusion produces ribs extending radially along the inner tubular layer.

The intermediate and outer tubular layers each consist of Ultramid B3, each with a length-to-diameter ratio of 26, a temperature profile of 180/195/210 ° C., and the mechanical properties of the present invention from a 5.1 cm (2 in) Harrel single screw extruder. Extruded using a peristaltic die. The outer tubular layer does not interact directly with the mechanical interlock die of the present invention. Since the middle and outer tubular layers were made of the same polymer, the tubular composite article of Example 5 effectively acts as a two layer composite article.

The resulting tubular composite article of Example 5 was cooled in a water bath, fed through a web handling device, and wound up at a linear speed of 3.7 m / min (12 ft / min).

Example 6

Example 6 relates to the three-layer tubular composite article of Example 5, coextruded by the procedure described in Example 5, except that the linear velocity is 9.1 m / min (30 ft / min).

Example 7

Example 7 relates to the three-layer tubular composite article of Example 5, coextruded by the procedure described in Example 5, except that the linear velocity is 12.2 m / min (40 ft / min).

Example 8

Example 8 relates to the three-layer tubular composite article of Example 5, coextruded according to the procedure described in Example 5, except that the linear velocity is 14.6 m / min (48 ft / min).

Peel Strength Tests for Examples 1-8

The composite articles of Examples 1-8 were tested for peel strength by ASTM D1876 on Instron Model 5564 at a crosshead speed of 150 mm / min. Instron Model 5564 is available from Instron Corporation, Canton, Massachusetts. Table 1 below shows the peel strength results of Examples 1-8.

Inner layer Middle and outer layers Linear velocity (m / min) Peel Strength (N / cm) Standard deviation (N / cm) Example 1 THV 815 EMS L25W40X 3.4 13.9 2.7 Example 2 VFEPX 6815G EMS L25W40X 3.4 15.3 2.0 Example 3 VFEPX 6815G EMS L25W40X 10.1 15.9 0.8 Example 4 VFEPX 6815G EMS L25W40X 15.5 15.6 3.0 Example 5 THV 500 Ultramid B3 3.7 9.7 0.8 Example 6 THV 500 Ultramid B3 9.1 8.3 0.7 Example 7 THV 500 Ultramid B3 12.2 7.1 0.8 Example 8 THV 500 Ultramid B3 14.6 6.0 0.5

The inner layer of the composite article of Examples 1-8 consists of fluoropolymers (ie THV 815, VFEPX 6815G, and THV 500). In contrast, the middle (and outer) layer consists of a nylon polymer (ie EMS L25W40X and Ultramid B3). Fluoropolymers and nylon polymers are generally different materials with poor interlayer adhesion. Without using an auxiliary (eg, chemical or mechanical interlocking of different materials), composite articles with such layers have negligible peel strengths. However, as shown in Table 1 above, the composite articles of Examples 1-8 have a peel strength of about 6.0 N / cm to about 16 N / cm. This is due to the mechanical interlock of the ribs formed by the mechanical interlock die of the present invention.

As shown, the composite articles of Examples 5-8 generally showed lower peel strength than the composite articles of Examples 1-4. This was found to be due to deformation in the ribs of the composite articles of Examples 5-8. The “T” shape is substantially compressed to yield a lower amount of mechanical interlock between the layers. Nevertheless, the composite articles of Examples 5-8 exhibit moderate levels of interlayer adhesion, which is superior to similar composite articles that still do not use mechanical interlocks.

Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims (31)

First and second surfaces extending in a longitudinal direction; A plurality of extrusion features, each extrusion feature A portion of the substrate extending in a cross section from the first face, wherein the cross section is substantially perpendicular to the longitudinal direction; and A plurality of extruded features comprising an arm portion extending at an angle in cross section from the substrate portion; And A plurality of channels, each channel extending at an angle relative to the longitudinal direction from the second surface, each channel being disposed between a pair of extruded features Mechanical interlock die comprising a. The cross-sectional shape of claim 1, wherein the one or more extruded features further extend in the longitudinal direction, the extruded features exhibit a cross-sectional shape in the cross section, the cross-sectional shape is partitioned by the substrate portion and the arm portion, and the extruded feature in the cross-sectional shape along the longitudinal direction. Mechanically retaining die substantially. The mechanical linkage die of claim 1, wherein the at least one channel exhibits a transverse width in the cross section, the transverse width is narrowest at the intersection of the channel and the second surface, and the transverse width is increased along the longitudinal direction. The mechanical linkage die of claim 1, wherein a portion of one of the channels extends between the arm portion and the first face of the at least one extrusion feature. 2. The mechanical interlock die of claim 1 wherein, for at least one extruded feature, the substrate portion comprises a height, the arm portion comprises a total arm length, and the total arm length is greater than the height of the substrate portion. The mechanical interlock die of claim 1, wherein for at least one extruded feature, the arm portion extends from the substrate portion at an angle of less than about 90 ° to less than about 180 ° relative to the substrate portion. The mechanical interlock die of claim 6, wherein the arm portion extends from the substrate portion at an angle of about 90 ° to about 135 ° relative to the substrate portion. The mechanical interlock die of claim 1, wherein the first side and the second side are annular. The mechanical interlock die of claim 1, wherein the first and second surfaces are aligned to define a flow path that produces a flat film. The mechanical interlock die of claim 1, wherein the height of the substrate portion of each extruded feature is about 10.0 mm or less. 2. The mechanical linkage die of claim 1 wherein for at least one extruded feature, the arm portion is a first arm portion and the extruded feature further comprises a second arm portion extending at a second angle in cross section from the substrate portion. The method of claim 11, wherein the first arm portion comprises a first length, the second arm portion comprises a second length, the substrate portion comprises a height, and the sum of the first length and the second length is the substrate portion. A mechanical interlock die that is larger than its height. 12. The mechanical interlock die of claim 11 wherein the second angle is equal to the angle of the first arm portion and the second arm portion extends from the substrate portion in the opposite direction from the first arm portion. 14. The mechanical interlock die of claim 13 wherein the extrusion feature comprising the first arm portion and the second arm portion substantially defines a T shape in cross section. The mechanical linkage die of claim 13 wherein the extrusion feature comprising the first arm portion and the second arm portion substantially defines a Y shape in cross section. A longitudinally extending first surface for extruding the first polymer layer; A longitudinally extending second surface for extruding the second polymer layer; A plurality of extruded features for longitudinally creating a plurality of ribs along the first polymer layer, each extruded feature comprising a substrate portion extending from the first side and an arm portion extending at an angle from the substrate portion; A plurality of extrusion features; And A plurality of channels for substantially matching portions of the second polymer layer to the ribs, each channel extending at an angle relative to the longitudinal direction from the second surface, each channel being disposed between the pair of extruded features Channels Mechanical interlock die comprising a. 17. The substrate portion of claim 16, wherein the substrate portion of each extruded feature extends in cross section from the first face, and the arm portion of each extruded feature extends at an angle in cross section from the substrate portion, the cross section being substantially perpendicular to the longitudinal direction. Mechanical interlock die. 18. The cross-sectional shape of claim 17, wherein the one or more extruded features further extend in the longitudinal direction, the extruded features exhibit a cross-sectional shape in the cross section, the cross-sectional shape is partitioned by the substrate portion and the arm portion, and the extruded features in the cross-sectional shape along the longitudinal direction. Mechanically retaining die substantially. 18. The mechanical linkage die of claim 17 wherein at least one channel exhibits a transverse width in the cross section, the transverse width is narrowest at the intersection of the channel and the second surface, and the transverse width is increased along the longitudinal direction. 17. The mechanical interlock die of claim 16, wherein a portion of one of the channels extends between the arm portion and the first face of the at least one extrusion feature. The mechanical linkage die of claim 16, wherein for at least one extruded feature, the substrate portion comprises a height, the arm portion includes a total length, and the total length of the arm portion is greater than the height of the substrate portion. The mechanical linkage die of claim 16, wherein for at least one extruded feature, the arm portion is a first arm portion and the extruded feature further includes a second arm portion extending at a second angle from the substrate portion. 23. The substrate of claim 22 wherein the first arm portion comprises a first length, the second arm portion comprises a second length, the substrate portion comprises a height, and the sum of the first length and the second length is the substrate portion. Mechanical interlock die that is greater than the height of the. First and second faces extending in the longitudinal direction, A plurality of extruded features, each extruded feature comprising a substrate portion extending from the first face and an arm portion extending at an angle from the substrate portion, and A plurality of channels, each channel extending at an angle relative to the longitudinal direction from the second surface, each channel being disposed between a pair of extruded features Providing a mechanical interlock die comprising; Extruding a portion of the first polymer layer through an extrusion feature to form a plurality of ribs; And Extruding a portion of the second polymer layer through the channel to substantially conform the second material to the ribs, wherein substantially matching the second material to the ribs mechanically links the first polymer layer to the second polymer layer. Step Extrusion method of a material comprising a. The substrate portion of claim 24, wherein the substrate portion of each extruded feature extends in cross section from the first surface, and the arm portion of each extruded feature extends at an angle in cross section from the substrate portion, and the cross section is substantially perpendicular to the longitudinal direction. How to be. The method of claim 24, wherein for at least one extruded feature, the substrate portion comprises a height, the arm portion comprises a total length, and the total length of the arm portion is greater than the height of the substrate portion. The method of claim 24, wherein the height of the substrate portion of each extruded feature is about 10.0 mm or less. The method of claim 24, wherein the at least one extrusion feature substantially partitions the T shape in cross section. The method of claim 25, wherein the at least one extrusion feature substantially partitions the Y shape in cross section. The method of claim 29, wherein the at least one rib substantially partitions the T shape in the cross section of the first polymer layer and the second polymer layer. The method of claim 24, wherein the first polymer layer and the second polymer layer are coextruded.

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