EXTRUSION WRAPPING DEFLECTOR

Abstract

A method for wrapping a stream of material or stream of layers of materials includes feeding a stream of material or stream of layers of materials into a die containing a wrapping deflector which acts to wrap the stream into a tubular or profile shape.

Claims

1. A product comprising a wrapped stream of material or wrapped stream of layers of materials deposited evenly along a tubular or profile shape, wherein the product does not include a weld line.

2. The product according to claim 1 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

3. The product according to claim 1 wherein the wrapped stream of layers of materials includes 2-12 layers.

4. The product according to claim 3 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

5. The product according to claim 3 wherein the wrapped stream of layers of materials includes one or more of said layers in the micrometer thickness range.

6. The product according to claim 5 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

7. The product according to claim 3 wherein the wrapped stream of layers of materials includes one or more of said layers in the nanometer thickness range.

8. The product according to claim 7 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

9. The product according to claim 1 wherein the wrapped stream of layers of materials includes 10-1000 layers.

10. The product according to claim 9 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

11. The product according to claim 9 wherein the wrapped stream of layers of materials includes one or more of said layers in the micrometer thickness range.

12. The product according to claim 11 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

13. The product according to claim 9 wherein the wrapped stream of layers of materials includes one or more of said layers in the nanometer thickness range.

14. The product according to claim 13 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

15. The product according to claim 1 wherein the wrapped stream of layers of materials includes of 1000-100,000 layers.

16. The product according to claim 15 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

17. The product according to claim 15 wherein the wrapped stream of layers of materials includes one or more of said layers in the micrometer thickness range.

18. The product according to claim 17 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

19. The product according to claim 15 wherein the wrapped stream of layers of materials includes one or more of said layers in the nanometer thickness range.

20. The product according to claim 19 wherein multiple streams of the wrapped stream of material or wrapped stream of layers of materials are spirally nested within each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying drawings illustrate presently preferred embodiments of the present disclosure, and together with the general description given above and the detailed description given below, serve to explain the principles of the present disclosure. As shown throughout the drawings, like reference numerals designate like or corresponding parts.

[0020] FIG. 1 depicts an example of a wrapping deflector.

[0021] FIG. 2 depicts examples of products made by a deflector. FIG. 2(a) depicts a product with the seam winding around and through the product whereas FIG. 2(b) depicts a product with seams straight through the product.

[0022] FIG. 3 illustrates a wrapping deflector.

[0023] FIG. 4 depicts the example where there are two grooves intertwined with each groove wrapping around once.

[0024] FIG. 5 illustrates a product cross section made with many feeds and nested grooves with only minimal wrapping.

[0025] FIG. 6 illustrates a product produced wherein the grooves start to wrap but are then bent back to the original starting angle as they head radially inwards.

[0026] FIG. 7(a) illustrates a deflector with grooves which could make a product of FIG. 7(b) wherein three input streams in which two are imbedded in the third.

[0027] FIGS. 8(a) and (b) demonstrate how materials flowing through deflectors cascade over themselves to form multiple layers.

[0028] FIGS. 9(a) and (b) illustrate another variation of how materials flow through deflectors to form multiple layers.

[0029] FIGS. 10 (a) and 10 (b) offer two more example variations of a wrapping deflector.

[0030] FIG. 11 illustrates the path of the grooves.

[0031] FIG. 12 illustrates a dam cut on the inside diameter of the deflector.

[0032] FIG. 13 illustrates how a deflector could be integrated with a tip component.

[0033] FIG. 14 illustrates a plate with a near-ring groove.

[0034] FIG. 15 illustrates a deflector which would produce nested wrapping when used in an assembly of multiple plates.

[0035] FIG. 16 illustrates how material flowing through two stacked deflectors would look.

[0036] FIG. 17 illustrates several groove profiles.

DETAILED DESCRIPTION OF THE INVENTION

[0037] An example wrapping deflector is shown above in FIG. 1. In this example, a stream of material will travel spirally inwards while slowly flowing through the dam. The dam here is slowly getting shorter as the material makes its way through the groove. The shorter dam allows the material to flow through it easier which will help to form an even flow over different portions of the dam. While this example is spiraling inwards, it could also be made to spiral outwards.

[0038] An example product made by such a deflector which shows the seam winding around and through the product (FIG. 2(a)) next to a product with seams straight through the product (FIG. 2(b)).

[0039] FIG. 3 illustrates a wrapping deflector where the dam is widened as opposed to shortened in order to promote even flow along the length of the dam. The dam could also be located below the groove heading toward the central axis before turning into a section similar to what is now the dam.

[0040] Multiple grooves could also be spirally nested within each other. These grooves could hold the same materials or different materials. In FIG. 4, there are two grooves intertwined with each groove wrapping around once. Different numbers and lengths could be used to create a variety of shapes.

[0041] FIG. 5 illustrates a product cross section made with many feeds and nested grooves with only minimal wrapping.

[0042] The grooves in a deflector could also take other forms than simple spirals. The grooves could form bends or wrap in areas besides the central axis.

[0043] FIG. 6 illustrates a product produced wherein the grooves start to wrap but are then bent back to the original starting angle as they head radially inwards.

[0044] A deflector with grooves following the paths shown in FIG. 7(a) could make a product similar to FIG. 7(b). This example takes three input streams with two being imbedded in the third.

[0045] FIGS. 8(a) and (b) demonstrate how materials flowing through these deflectors cascade over themselves to form multiple layers. In this example the input stream is multilayered and wraps to form a four layer tube. The number of layers in input streams could be from one to thousands and could also take a multi-component approach with multiple cross sections merged together.

[0046] Profile shapes could be formed by drawing in the shape with the groove and maintaining separation of appendages or holes as the shape compresses to its final size and shape. In some cases certain areas of the dam could be tightened or opened to change the amount of material in different parts of the cross section. Some parts of the dam could also be blocked off completely.

[0047] FIGS. 10 (a) and 10 (b) offer two more example variations of a wrapping deflector. Rather than relying on a groove and dam to balance the flow of the material, the flow path moves forward while the material is wrapping to allow for the flow to expand in that direction. The flow path could also widen along this process as seen FIG. 10a to encourage the wrapping. The deflectors shown above maintain the separation while wrapping the materials. In subsequent sections of the extrusion die, the material will merge onto itself to form the desired tubular shape.

[0048] FIG. 11 illustrates the path of the grooves.

[0049] FIG. 12 illustrates a dam cut on the inside diameter of the deflector.

[0050] FIG. 13 illustrates how a deflector would be integrated with a tip component. In this embodiment, flow continues forwards in a groove while wrapping and spilling over a dam. Each wrap would act to add another layer to the annular stream being formed below.

[0051] Deflectors shown thus far are spirally wrapping shapes but they could also take stepped approaches to perform the wrapping. Such stepped approaches could include forming a nearly closed ring for each step. Instead of merging back the beginning of its own ring (or another ring if there were nested streams), there would be a change in direction to start another ring. The change in direction would depend on the deflector style.

[0052] A stepped approach of the most recent style could consist of a series of plates with grooves forming individual near-rings which would transition to the next plate at the end of the ring.

[0053] FIG. 14 illustrates a plate with a near-ring groove. The dam acts to create flow radially inwards. The groove starts on the top left and continues until the path through the plate on the top right. This path, which could be angled, could then lead to the start of another ring which would create the wrapping effect in the product.

[0054] FIG. 15 illustrates a deflector which would produce nested wrapping when used in an assembly of multiple plates. This plate would take two input streams.

[0055] FIG. 16 illustrates how material flowing through two stacked deflectors would look.

[0056] The grooves in wrapping deflectors could be any shape. Many of the examples shown in the figures are round or circular grooves. FIG. 17 illustrates several groove profiles.

[0057] These wrapping deflectors could be used to create products consisting of multiple layers with each layer being made by its own deflector or multiple materials could be used on the same deflector with separate grooves. A layer in this sense is distinct from sub layers in a stream of input material.

[0058] Thus, while there have been shown, described and pointed out, fundamental novel features of the invention as applied to the exemplary embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of devices and methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit or scope of the invention. Moreover, it is expressly intended that all combinations of those elements and/or method steps, which perform substantially the same function in substantially the same way to achieve the same results, are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.