Design of dies for the extrusion of sheets and annular parisons: The distribution problem

Abstract A systematic design of the classical “coat hanger” die is proposed and tested experimentally. The objectives of the design are 1. distribution of the polymer over the width of the die before it reaches the final lip section for thickness adjustment, 2. invariance of distribution to flow rate, 3. invariance to changes in polymer viscosity, and 4. uniform average residence time. The die design is based on a flow model which assumes power‐law viscosity, steady shear flow In each cross‐section, uniform temperature, and separation of the flows into a manifold component and a component in a slit section of uniform height. The design corrects for an oversimplification of the pressure gradient that was applied in previous studies; and it differs from previous designs by suggesting a rectangular cross‐section for the manifold. Applications to side‐fed dies for extrusion blow molding and to a sheet extrusion die achieved uniform distribution and did not require any additional flow corrections (such as choker bars or flexible lips). With the new design, the lip region of the die can freely be used for thickness control, fine tuning, or further shaping of the extrudate.