Investigation of the Polymer Coextrusion Process: A Review

A review of the different coextrusion processes and the related processing problems is presented. A one-dimensional bilayer coextrusion Poiseuille flow model is first developed with Newtonian and shear-thinning rheological behaviors. A transitory computation at the convergence between the two independent polymer layers shows that stationary interface position and velocity profile are established after a short distance of the order of the die gap which justifies the validity of the 1D stationary model. This model is then applied to multilayer temperature dependent coextrusion flows which correspond to realistic industrial coextrusion conditions. Marked interface instabilities may be observed depending on the rheology of the coextruded polymers and of their flow rate ratios. Experiments point clearly out that these instabilities may be amplified along the die land. Convective stability analysis as well as direct numerical computation discriminate flow situations which amplify or damp down instabilities. These 1D models are unable to account for the complex feedblock coat-hanger die geometries. A thin layer coextrusion model is then developed, based on the Hele-Shaw lubrication approximations already used for single layer extrusion problems. It allows to predict the location of the interfaces between the different layers in the whole die, and especially at die exit. This represents a major issue in feedblock die coextrusion. These thin layer approaches are unable to address the encapsulation of one polymer by the other in these complex die geometries with important gap thicknesses. Experiments conducted in dies of square section allow identifying the dynamics of encapsulation. 3D models are required to account for this phenomenon but the management of the sticking contact at the die wall poses difficult numerical problems.