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REDI - A New Blown Film Die Concept

What is so special about the REDI die:

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There is a 20%-25% unassisted reduction in film thickness variation (unassisted meaning without any gauge control devices.)
 

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Low residence time. It is impervious to material changes. How about a low profile which permits operators to make start-ups and adjustments from floor level rather than ladders, fixtures or perhaps even climbing on the die itself?

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Being a side fed die, the REDI die has a much lower profile than the spiral mandrel die. This in turn accounts also for low residence time and permits a greater number of materials with different properties to be processed.
 

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Binary division technology is used to divide the melt stream from the extruder evenly around the die. This assures similar melt parameters (pressure, shear, residence time) at any two points equidistant form the supply port.

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Whereas conventional pancake dies divide and combine the melt flow on a horizontal plane the REDI die divides in a vertical plane to reduce internal (horizontal) pressure, thus reducing the need for an excessive number of bolts to hold horizontal plates of the die together.
 

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After dividing the melt around the die, it is brought back together to eventually form a seamless tube and exit through the die lips. This is accomplished by feeding the melt in spirals toward the die's centre pin. In order to avoid film thickness variation, caused by "memorized" port patterns from the spirals, two sets of spirals are used on a horizontal die plate.

 

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The melt is alternately fed from the top and the bottom of the plate, producing a melt cross section wherein melt flows from the top are placed between those from the bottom, producing an even thickness throughout the circumference of the die lip.
 

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The concept can be best illustrated by the paintings of M.C. Escher, a 20th century Dutch painter. His works exemplify REgular DIvision.
 
To achieve optimum distribution to the die lips, mixing, and homogeneity, the melt is first divided into a number of melt streams, each time halved, until the desired number has been reached. It is then brought back together in a fashion that matches low flow patterns with high flow patterns, completely filling voids until, finally, the melt stream becomes one again, but in tubular fashion.

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