EDI Extrusion Coating Technology - EKO-FORM

1 Your international partner in Extrusion die Technology , EDI provides a broad line of custom-engineered Extrusion dies and related system components for the Extrusion Coating & laminating market. Highly qualified engineers, with in-depth experience in both die manuacturing and processing, are available to discuss and help define your requirements and to work with you after your equipment is delivered. Extrusion Dies Industries, LLC EDI Extrusion Coating Technology Designers and manufacturers of high performance die systems Visit EDI at Wholly owned subsidiaries: Extrusion Dies Industries, LLC 911 Kurth Road Chippewa Falls, WI 54729 Tel: 715-726-1201 Fax: 715-726-2205 E-mail: Website: Rework website: Headquarters and Main Office: EDI GmbH Kastanienweg 8 51580 Reichshof Wehnrath Germany Tel: 49-2265-980627 Fax: 49-2265-980690 E-mail: EDI Precision Dies (Shanghai) Co.

2 , Ltd. Building No. 4, Dakun Industrial Park 860 Zhongde Road Songjiang, Shanghai 201614 China 201614 Tel. +86-21-57850918 Fax. +86-21-57850698 E-mail: Autoflex VI-R EPC Die EDI is a leading international supplier of Extrusion Coating & laminating die systems. The keys to our success have been a program of continuous investment in skilled human resources, advanced manufacturing hardware and sophisticated software tools, along with a relentless pursuit of technological innovation and uncompromising quality. Our success in the industry is a direct result of the excellence of our products and services.

3 This is especially true of recent developments in Extrusion Coating and laminating Technology that provide real solutions to problems that have plagued the industry for many years. Extrusion Die Developments Successful die designs for the Extrusion Coating and laminating industry need to address a specific set of today s performance needs: Trouble-free Coating width variation for versatility and efficiency. Ability to reduce edge bead size to minimize expensive waste. Precise control of coat-weight uniformity so that desired physical properties are achieved with the least amount of Coating material.

4 This precise control is required for a wide variety of Coating materials with differing rheological properties. Accurate coextrusion of materials with dissimilar melt temperatures or rheological characteristics, so that the composite structure provides the desired physical properties at a lower cost. Ease of maintenance for splitting and cleaning the system along with removing lip build-up in-between cleanings. Coating Width Variation Devices that adjust extrudate width, commonly called deckles , have been used by the industry for decades.

5 The most sophisticated version available today is shown below. The bronze components are the internal deckle plugs which completely seal-off the ends of the internal channels. This full plug approach eliminates stagnation or dead areas in the channel. The silver-gray colored component at the bottom of the figure is an external back-up deckling system. Autoflex VI-R H100 EPC Die withInternal/External Deckle and Air Cooling Feature External deckles are well known for their ability to provide highly effective sealing characteristics.

6 By combining these two deckle systems, which were previously thought to be mutually exclusive, EDI has developed a significantly better approach to deckling. Just like the coextrusion of two Coating materials leads to a higher performance product by combining the superior adhesive properties of one material with the superior strength properties of another, so does this new deckle concept lead to a dramatic performance improvement. Processors find that die systems equipped with only internal deckles require a great deal of experience and skill to adjust without leakage problems.

7 They also find that external-only deckle systems do not allow for edge profile control and are not as streamlined. EDI s dual deckle system allows for simple, convenient width adjustment procedures, without any leakage issue. Both systems are driven together either by a hand-wheel or by a motor drive. Linear bearings ensure alignment and smooth movement. Edge Profile Control One of the chief goals in Extrusion Coating is to maintain a uniform Coating thickness across the entire application width. This is not always easy.

8 The common problem of edge bead an increased thickness along both edges of the Coating makes it necessary to trim the edges to meet product specifications. Edge bead is particularly costly in Extrusion Coating because the scrap includes both Coating and substrate. The bead is formed by the imbalance of forces that is created when tension is applied to the Coating web. As the web becomes oriented in the machine direction, it necks-in (becomes narrower) resulting in a build-up of material on the edges. EDI sadjustable internal deckle components allow the operator to minimize the width and size of the edge bead.

9 The result is a minimal overcoat requirement, so waste is significantly reduced. Image of Material with a Heavy Untuned Edge Image of Material with a Tuned Edge Profile Control of Coat Weight Uniformity There are three key features that EDI has developed to maximize the amount of control the processor has over coat weight uniformity. x Lip land lengths that provide a significant response to an operator or gage control system adjustment. x A flow channel design is available that combines a varying geometry in the center of the die with a constant geometry on each end.

10 The constant geometry on each end allows for fully adjustable internal deckling and the varying geometry in the center helps to promote flow to the ends of the die. x A thermally isolated automatic lip adjusting system provides extremely accurate product tolerance. Lip Land Design Approach EDI s approach is to provide an appropriate lip land length, with a good balance between the pressure drop across the lip land compared to the pressure drop across the whole die. Depending on the materials and rates to be processed, lip lands can be provided in a range from 6 to 13mm.