Design and analysis of a dual‐cavity coat‐hanger die

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Abstract
A method for the design and analysis of a dual‐cavity coat‐hanger die is presented in this paper. A macroscopic material balance and a microscopic flow analysis using the finite element method are combined to simulate polymeric fluid flow inside the die. Leonard's macroscopic procedure was adopted to include inertial, gravitational, and viscous effects, and the finite element method was then applied to estimate the contributions of inertial and viscous terms. In addition, the flow patterns in the outer cavity were computed by the finite element method so that the appearance of an undesirable vortex could be predicted. The residence time distributions for flow in the die were approximated by a simple, statistical approach. It was found through a case study that a dual‐cavity coathanger die can effectively reduce the flow non‐uniformities caused by fluid inertia and viscosity variations.

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