Method for forming polymer materials utilizing modular die units

Abstract

The present invention is directed to a modular die unit comprising a plurality of individually shaped plates wherein the shaped plates are stacked in face to face juxtaposition, and when placed into such a juxtaposition exhibit useful polymer forming attributes heretofore unattainable by prior art practices. Single die plates are formed such that the plates exhibit a finite geometric relationship, which in turn provides resistance to flexural deformation of the individually shaped die plates and conversely, improved resistance to variability of the modular die unit and enhanced and predictable formation characteristics of the polymer material formed therewith. Each of said single die plates within the stack forming the modular die unit exhibit an x-direction, a y-direction, and a z-direction, wherein any one of said single die plates exhibit in said x-direction and y-direction to have at least a 50% planar continuity of the total planar continuity.

1 . A method of making a stack-plate comprising a plurality of single die plates oriented into face to face juxtaposition, each of said single die plates within the stack having an x-direction, a y-direction, and a z-direction, wherein said single die plates exhibit in said x-direction and y-direction to have at least 50% planar continuity of the total planar continuity.  
     
     
         2 . A method of making a stack-plate die as in  claim 1 , wherein the single die plates are designed in the x-direction and y-direction to have at least 75% planar continuity of the total planar.  
     
     
         3 . A method of making a stack-plate comprising a plurality of single die plates oriented into face to face juxtaposition, each of said single die plates within the stack having an x-direction, a y-direction, and a z-direction, said single die plates exhibit in said z-direction of the single die plates within the stack are planar in formation and designed in the z-direction to have at least 20% depth continuity of the total planar depth continuity at any given axis in the z-direction.  
     
     
         4 . A method of making a stack-plate as in  claim 3 , wherein the single die plates are designed in the z-direction to have at least 35% planar continuity of the total planar continuity at any given axis in the z-direction.  
     
     
         5 . A method of making a stack-plate as in  claim 3 , wherein the single die plates are designed in the z-direction to have at least 50% planar depth continuity of the total depth planar continuity at any given axis in the z-direction.  
     
     
         6 . A method of making a stack-plate wherein the single die plates within the stack are planar in formation comprising a combined planar continuity design of at least 35% planar continuity of the total planar continuity at any given axis in either the x- direction or y-direction and at least 20% planar depth continuity of the total depth continuity at any given axis in the z-direction.  
     
     
         7 . A method of making a stack-plate as in  claim 6 , wherein the single die plates are designed comprising a combined planar continuity of at least 50% planar continuity of the total planar continuity at any given axis in either the x-direction or y-direction and at least 35% planar depth continuity of the total depth continuity at any given axis in the z-direction.  
     
     
         8 . A method of making a stack-plate die as in  claim 6 , wherein the single die plates are designed comprising a combined planar continuity of at least 75% planar continuity of the total planar continuity at any given axis in either the x-direction or y-direction and at least 50% planar depth continuity of the total depth continuity at any given axis in the z-direction.  
     
     
         9 . A method of making a stack-plate die as in  claim 6 , wherein the single die plates are held together in the stack via compression tensioning.  
     
     
         10 . A method of making a stack-plate die as in  claim 9 , wherein said compression tensioning is provided in the form of an external clamping force.  
     
     
         11 . A method of making a stack-plate die as in  claim 9 , wherein said compression tensioning is provided in the form of an internal drawing force.  
     
     
         12 . A method of making a stack-plate melt extrusion die as in  claim 6 , wherein the single die plates comprise guide elements for precise alignment of plates.  
     
     
         13 . A method of making a stack-plate die as in  claim 12 , wherein said guide elements are alignment holes in one or more single die plates.  
     
     
         14 . A method of making a stack-plate die as in  claim 12 , wherein said guide elements are projections extending from one or more single die plates.  
     
     
         15 . A method of making a stack-plate die as in  claim 12 , wherein said guide holes of stacked plates are threaded onto cooled rods.  
     
     
         16 . A method of making a stack-plate die as in  claim 6 , wherein said die is stacked together to comprise a vacuum slit within the stack-plate die.  
     
     
         17 . A method of making a stack-plate die as in  claim 6 , wherein said stacked-plate die is used to dispense molten thermoplastics.  
     
     
         18 . A method of making a stack-plate die as in  claim 6 , wherein said stacked-plate die is used to form water jets.  
     
     
         19 . A method of making a stack-plate die as in  claim 6 , wherein said stacked-plate die is used to dispense adhesive.  
     
     
         20 . A method of making a stack-plate die, wherein the stack-plate die comprises a plurality of single plates, each of said single plates comprised of at least one fluid stream channel and at least one flow channel, wherein said stream impingement angle upon flow channel is between 3° and 87°  
     
     
         21 . A method of making a stack-plate die as in  claim 20 , wherein said fluid stream channel(s) have a length to diameter ratio that is greater than 1:10.  
     
     
         22 . A method of making a stack-plate die as in  claim 20 , wherein said fluid stream channel(s)have a length to diameter ratio that is greater than 1:50.  
     
     
         23 . A method of making a stack-plate die as in  claim 20 , wherein the fluid stream channel(s) have a length to diameter ratio that is greater than 1:100.  
     
     
         24 . A method of making a stack-plate die as in  claim 20 , wherein said die comprises more than one fluid stream channel.  
     
     
         25 . A method of making a stack-plate die as in  claim 20 , wherein said fluid stream channel(s) are comprised of differential pressures.  
     
     
         26 . A method of making a stack-plate die as in  claim 20 , wherein said fluid stream channel(s) express differing materials.  
     
     
         27 . A method of making a stack-plate die as in  claim 20 , wherein said flow channel extrudes a refractory fiber mix.  
     
     
         28 . A method of making a stack-plate die as in  claim 27 , wherein said refractory fiber mix comprises ceramic fibers.  
     
     
         29 . A method of making a stack-plate die as in  claim 20 , wherein said flow channel extrudes a thermoplastic polymer.  
     
     
         30 . A method of making a stack-plate die as in  claim 20 , wherein said flow channel extrudes a thermoset polymer.  
     
     
         31 . A method of continuously spinning melt extruded filaments comprising the steps of: 
 a. providing a stack-plate melt extrusion die, wherein the single die plates within the stack are planar in formation comprising at least one air stream channel and at least one melt flow channel, wherein said air stream has an impingement angle upon the melt flow between 3° and 85°, as well as a combined planar continuity of at least 35% planar continuity of the total planar continuity at any given axis in either the x- direction or y-direction and at least 20% depth continuity of the total continuity at any given axis in the z-direction;    b. providing at least one thermoplastic melt; and    c. extruding said thermoplastic melt through said die so as to form filaments.    
     
     
         32 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said die plates of side die are staggered to form filaments with varying denier.  
     
     
         33 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said die plates are stacked to comprise a means for the distribution of continuous filament extrusion within the stack-plate die.  
     
     
         34 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said extrusion die includes a means for disruption of the continuous melt flow.  
     
     
         35 . A method of continuously spinning melt extruded filaments as in  claim 33 , wherein said means for the disruption is an ultrasonic device.  
     
     
         36 . A method of continuously spinning melt extruded filaments as in  claim 31 , where said filaments are deposited on a foraminous surface.  
     
     
         37 . A method of continuously spinning melt extruded filaments as in  claim 36 , where said foraminous surface is an open weave mesh.  
     
     
         38 . A method of continuously spinning melt extruded filaments as in  claim 36 , where said foraminous surface is a three-dimensional surface.  
     
     
         39 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said die is stacked together to comprise at least one means for physical modification of the continuous filament extrusion from the stack-plate die.  
     
     
         40 . A method of continuously spinning melt extruded filaments as in  claim 39 , wherein said means for physical modification is selected from the group consisting of sensors, heating elements, cooling elements, and the combinations thereof.  
     
     
         41 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said plates of said die are stacked to extrude filaments that impart dissimilar physical characteristics within the formed filaments.  
     
     
         42 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein at least two different polymers are extruded from the die.  
     
     
         43 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said thermoplastic melt is a low melt flow rate polymer.  
     
     
         44 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments have a diameter of less than or about 200 micrometers.  
     
     
         45 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments have a diameter of less than or about 20 micrometers.  
     
     
         46 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments have a diameter of less than or about 1.0 micrometers.  
     
     
         47 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are flash-spun filaments.  
     
     
         48 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are solvent spun filaments.  
     
     
         49 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are hollow.  
     
     
         50 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are of symmetric geometric profiles.  
     
     
         51 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are of asymmetric geometric profiles.  
     
     
         52 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said die extrudes filaments of different geometric profiles across the die.  
     
     
         53 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are formed into a continuous tow.  
     
     
         54 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are coalesced into a nonwoven fabric  
     
     
         55 . A method of continuously spinning melt extruded filaments as in  claim 31 , wherein said filaments are woven into a textile product.  
     
     
         56 . A method of continuously spinning melt extruded filaments comprising an additive comprising the steps of: 
 a. providing a stack-plate melt extrusion die, wherein the single die plates within the stack are planar in formation comprising at least one air stream channel and at lest one melt flow channel, wherein said air stream has an impingement angle upon the melt flow between 3° and 85°, a combined planar continuity design of at least 35% planar continuity of the total planar continuity at any given axis in either the x-direction or y-direction and at least 20% dept continuity of the total continuity at any given axis in the z-direction;    b. providing at least one thermoplastic melt;    c. providing at least one melt additive;    d. combining said thermoplastic melt and said melt additive into a homogeneous mixture; and    e. extruding said homogeneous mixture through said die so as to form filaments.    
     
     
         57 . A method of continuously spinning melt extruded filaments comprising an additive comprising the steps of: 
 a. providing a stack-plate melt extrusion die, wherein the single die plates within the stack are planar in formation comprising at least one air stream channel and at lest one melt flow channel, wherein said air stream has an impingement angle upon the melt flow between 3° and 75°, as well as a combined planar continuity design of at least 35% planar continuity of the total planar continuity at any given axis in either the x-direction or y-direction and at least 20% dept continuity of the total continuity at any given axis in the z-direction;    b. providing at least one thermoplastic melt;    c. providing at least one physical or aesthetic modifying agent;    d. extruding said homogeneous mixture through said die so as to form filaments; and    e. applying at the time of extrusion said modifying agent onto said filaments.    
     
     
         58 . A method of continuously spinning melt extruded filaments comprising an additive as in  claim 57 , wherein said melt additive is a dipolar solvent to induce a static charge.  
     
     
         59 . A method of continuously spinning melt extruded filaments comprising an additive as in  claim 58 , wherein said dipolar solvent is dimethyl sulfoxide.  
     
     
         60 . A method of continuously spinning melt extruded filaments comprising an additive as in  claim 57 , wherein said nonwoven fabric is a component in an absorbent article.  
     
     
         61 . A method of continuously spinning melt extruded filaments comprising an additive as in  claim 57 , wherein said nonwoven fabric is a battery separator.  
     
     
         62 . A method for making a thermoplastic film comprising the steps of: 
 a. providing a stack-plate melt extrusion die, wherein the single die plates within the stack are planar in formation comprising at least one air stream channel and at lest one melt flow channel, wherein said air stream has an impingement angle upon the melt flow between 3° and 75°, as well as a combined planar continuity design of at least 35% planar continuity of the total planar continuity at any given axis in either the x-direction or y-direction and at least 20% planar continuity of the total continuity at any given axis in the z-direction;    b. providing a thermoplastic melt;    c. extruding said thermoplastic melt into a continuous sheet; and    d. collecting said continuous sheet on support surface.