Die for coextruding a plurality of fluid layers

1. A die for coextruding a plurality of fluid layers, comprising:

a. a primary forming stem;

b. one or more distribution plates, each of said plates having a fluid inlet and a fluid outlet, the fluid outlet from each of said plates being in fluid communication with said primary forming stem and structured to deposit a layer of fluid onto said primary forming stem having a thickness D; and

c. a microlayer assembly, comprising

(1) a microlayer forming stem, and

(2) a plurality of microlayer distribution plates, each of said microlayer plates having a fluid inlet and a fluid outlet, the fluid outlet from each of said microlayer plates being in fluid communication with said microlayer forming stem and structured to deposit a microlayer of fluid onto said microlayer forming stem having a thickness M, said microlayer plates being arranged to provide a predetermined order in which the microlayers are deposited onto said microlayer forming stem to form a substantially unified, microlayered fluid mass on said microlayer forming stem,

wherein, said thickness M of said microlayers is less than said thickness D of said fluid layer from said distribution plate, and

said microlayer forming stem is in fluid communication with said primary forming stem such that said microlayered fluid mass flows from said microlayer forming stem and onto said primary forming stem in order to minimize interfacial flow instabilities.

2. The die of claim 1 , wherein said distribution plate has a thickness ranging from about 0.5 to about 2 inches and said microlayer distribution plates have a thickness ranging from about 0.1 to about 0.5 inch.

3. The die of claim 1 , wherein said microlayer distribution plates have one or more flow channels connecting said fluid inlet with said fluid outlet, said flow channels having a spiral-shaped configuration.

4. The die of claim 1 , wherein

said microlayer distribution plates each have an orifice extending through said plate;

said fluid outlet of each of said microlayer distribution plates is positioned adjacent to said orifice; and

said microlayer forming stem extends through the orifice of each of said microlayer distribution plates.

5. The die of claim 1 , wherein said primary forming stem and said microlayer forming stem are substantially coaxially aligned with one another.

6. The die of claim 5 , wherein said microlayer forming stem is external to said primary forming stem.

7. The die of claim 1 , wherein

said distribution plates and said microlayer assembly are axially positioned along said primary forming stem; and

the fluids from said distribution plates and said microlayer assembly flow in an axial direction along said primary forming stem.

8. The die of claim 7 , wherein said distribution plates are located upstream of said microlayer assembly.

9. The die of claim 7 , wherein said microlayer assembly is located upstream of said distribution plates.

10. The die of claim 7 , wherein said microlayer assembly is positioned between one or more upstream distribution plates and one or more downstream distribution plates.

11. The die of claim 1 , wherein said microlayer assembly comprises at least about 5 microlayer plates.

12. The die of claim 11 , wherein said microlayer assembly comprises at least about 10 microlayer plates.

13. The die of claim 1 , further including one or more additional microlayer assemblies.

14. The die of claim 1 , wherein the ratio of M:D ranges from about 1:1 to about 1:8.

15. The die of claim 1 , wherein

said microlayer thickness M ranges from about 1-20 mils; and

said layer thickness D from said distribution plate ranges from about 20-100 mils.

16. The die of claim 1 , wherein

each of said microlayers that are deposited onto said microlayer forming stem have physical integrity and independent physical properties; and

said microlayered fluid mass merges with said fluid layer from said distribution plate on said primary forming stem with a mass flow rate that more closely approximates that of said distribution plate layer, thereby increasing an ability of said microlayers in said fluid mass to retain said physical integrity and independent physical properties.

17. The die of claim 1 , wherein said microlayer forming stem is separate from said primary forming stem.

18. The die of claim 1 , wherein said thickness M of said microlayers is substantially the same.

19. The die of claim 1 , wherein said thickness M of said microlayers is different among at least two of said microlayers.