Systems, devices and methods are provided for fabricating anisotropic polymer materials. According to various embodiments, a fluidic device is employed to distribute a polymer solution and a flow-confining solution in order to generate a layered flow, where the layered flow is formed such that a polymer liquid sheet is sheathed on opposing sides by flow-confining liquid sheets. The fluidic device includes first and second fluid conduits, where the first fluid conduit receives the layered flow. The second fluid conduit has a reduced height relative to the first fluid conduit, such that the layered flow is constricted as it flows through the second fluid conduit. The constriction formed by the second flow conduit causes hydrodynamic focusing, reducing the thickness of the polymer liquid sheet, and inducing molecular alignment and anisotropy within the polymer liquid sheet as it is hardened and as strain is applied during extrusion of the sheet.

A modular disk coextrusion die is formed of a plurality of cells stacked together. Each cell includes a symmetrical arrangement of thin annular disks, including a central routing disk and two distribution disks on both sides of the central routing disk. The distribution disks are oriented so that their respective distribution inlet openings oppose each other by about 180 degrees. The symmetrical arrangement permits each cell to process the melt streams in a manner that provides enhanced layer uniformity and bubble stability. By stacking several cells, blown films having up to several hundred layers can be made using twelve, twenty-four or more polymer melt streams. Complex films made from the modular disk coextrusion die are also provided.

A device for influencing the volume flow of extruded plastically deformable material conveyed to an outlet nozzle. A flange arranged between an extrusion unit and an outlet nozzle and is connected to the extrusion unit and the outlet nozzle. A duct from the extrusion unit and the outlet nozzle is incorporated in the flange. A piston is mounted in the flange to be rotatable perpendicular to the longitudinal axis of the duct and is located through the duct. In the piston there is a hole which opens into a bypass duct routed to a bypass nozzle. On the outer lateral surface of the piston there is at least one groove in the region of the duct so that, depending on the angular positions of the piston, material can be conveyed through the at least one groove to the outlet nozzle or through the hole to the bypass nozzle.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) passing polymer flakes through a crystalliers; (2) melting the polymer to create a first single stream of polymer melt; (3) separating the first single stream of polymer melt into multiple streams of polymer melt; (4) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 25 millibars in a chamber; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) passing polymer flakes through a crystalliers; (2) melting the polymer to create a first single stream of polymer melt; (3) separating the first single stream of polymer melt into multiple streams of polymer melt; (4) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 25 millibars in a chamber; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.

A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.

Modular fluid processing apparatuses, modular components and related methods are provided. A fluid processing apparatus for use in fluid processing systems can include a housing comprising first body half and a second body halves that are secured together. The first body half has one or more half bores that extend along a length of the first body half and the second body half has one or more half bores that extend along a length of the second body half with the one or more half bores in the first body half aligning with the one or more half bores in the second body half forming one or more full sleeve-receiving bores. The fluid processing apparatus can include one or more sleeves that are securable between the first and second body halves within the one or more sleeve-receiving bores to form piston pathways within the housing for receiving pistons.

Modular fluid processing apparatuses, modular components and related methods are provided. A fluid processing apparatus for use in fluid processing systems can include a housing comprising first body half and a second body halves that are secured together. The first body half has one or more half bores that extend along a length of the first body half and the second body half has one or more half bores that extend along a length of the second body half with the one or more half bores in the first body half aligning with the one or more half bores in the second body half forming one or more full sleeve-receiving bores. The fluid processing apparatus can include one or more sleeves that are securable between the first and second body halves within the one or more sleeve-receiving bores to form piston pathways within the housing for receiving pistons.

An extruding system includes a melting unit configured to convey a polymeric material, a mixing unit configured to mix the polymeric material with a blowing agent to form a mixture, an injection unit configured to inject the mixture, a first flow control element disposed between the melting unit and the mixing unit, and a second flow control element disposed between the mixing unit and the injection unit. A method of extruding includes conveying a polymeric material from a melting unit to a mixing unit, conveying a blowing agent into the mixing unit, mixing the polymeric material with the blowing agent to form a mixture, conveying the mixture from the mixing unit to an injection unit, and discharging the mixture from the injection unit, wherein flow of the polymeric material is controlled by a first flow control element, and flow of the mixture is controlled by a second flow control element.