Casting apparatus for manufacturing polymer film

1. A casting apparatus for manufacturing polymer film, the casting apparatus comprising:

a die for discharging a molten polymer, the die having a discharge direction oriented at a non-zero discharge angle offset from a first horizontal reference plane;

a pair of initial film receiving chill rolls comprising a first chill roll having a first diameter and a second chill roll having a second diameter, the second diameter being greater than the first diameter, and a first gap between the first chill roll and the second chill roll;

the non-zero discharge angle of the discharge direction of the die being of a predetermined magnitude to gravity assist delivery of the molten polymer to the first gap;

a first polishing roll positioned downstream of the pair of initial film receiving chill rolls, a second gap between the first polishing roll and the second chill roll, a first length of a first side of the polymer film extending from the first gap to the second gap along an outer circumferential surface of the second chill roll, and the first polishing roll engaging and cooling a second length of a second side of the polymer film, the second side being opposite the first side;

the second length extending from the second gap along an outer circumferential surface of the first polishing roll such that the first length is substantially equal to the second length; and

the second chill roll positioned to gravity support and be in constant contact with the polymer film exiting the first gap entirely along the first length.

2. The casting apparatus of claim 1 , further comprising a second polishing roll positioned downstream of the first polishing roll, a third gap between the first polishing roll and the second polishing roll, the second length extending from the second gap to the third gap.

3. The casting apparatus of claim 2 , further comprising a third polishing roll positioned downstream of the second polishing roll, a fourth gap between the second polishing roll and the third polishing roll, the first side of the polymer film engaging and extending a third length on the second polishing roll, the third length extending from the third gap to the fourth gap.

4. The casting apparatus of claim 3 , wherein the second side of the polymer film engages and extends a fourth length on the third polishing roll.

5. The casting apparatus of claim 3 , wherein the first length, the second length and the third length are substantially equal.

6. The casting apparatus of claim 4 , wherein the first length, the second length, the third length and the fourth length are substantially equal.

7. The casting apparatus of claim 3 , wherein the first length and the second length are established by positioning at least one of the first chill roll, the second chill roll and the first polishing roll, relative to one another.

8. The casting apparatus of claim 3 , wherein the first length, the second length, the third length and the fourth length are established by positioning at least one of the first chill roll, the second chill roll, the first polishing roll, the second polishing roll and the third polishing roll, relative to one another.

9. The casting apparatus of claim 3 , wherein the first length is a mathematical function of the second diameter of the second chill roll and the second length is a mathematical function of a third diameter of the first polishing roll.

10. The casting apparatus of claim 4 , wherein the fourth length extends on an exterior surface of the third polishing roll from the fourth gap such that the fourth length is substantially equal to the third length.

11. The casting apparatus of claim 3 , wherein the second chill roll and at least two of the first polishing roll, the second polishing roll and the third polishing roll are aligned along a first common plane oriented at a non-zero tilt angle offset from a second horizontal reference plane, wherein the second horizontal reference plane is parallel to the first horizontal reference plane and the first common plane slopes downward from the second chill roll in a direction of film processing.

12. The casting apparatus of claim 4 , wherein at least one of the first chill roll and the second chill roll are rotationally mounted on a frame and the frame comprises a system for moving the frame relative to the die.

13. A casting apparatus for manufacturing polymer film, the casting apparatus comprising:

a die for discharging a molten polymer, the die having a discharge direction oriented at a non-zero discharge angle offset from a first horizontal reference plane;

a pair of initial film receiving chill rolls comprising a first chill roll having a first diameter and a second chill roll having a second diameter, the second diameter being greater than the first diameter, and a first gap between the first chill roll and the second chill roll;

the non-zero discharge angle of the discharge direction of the die being of a predetermined magnitude to gravity assist delivery of the molten polymer to the first gap;

a first polishing roll positioned downstream of the pair of initial film receiving chill rolls, a second gap between the first polishing roll and the second chill roll, a first length of a first side of the polymer film extending from the first gap to the second gap along an outer circumferential surface of the second chill roll, and the first polishing roll engaging and cooling a second length of a second side of the polymer film, the second side being opposite the first side;

the second length extending from the second gap along an outer circumferential surface of the first polishing roll such that the first length is substantially equal to the second length;

the second chill roll positioned to gravity support and be in constant contact with the polymer film exiting the first gap entirely along the first length,

a second polishing roll positioned downstream of the first polishing roll, a third gap between the first polishing roll and the second polishing roll, the second length extending from the second gap to the third gap;

a third polishing roll positioned downstream of the second polishing roll, a fourth gap between the second polishing roll and the third polishing roll, the first side of the polymer film engaging and extending a third length on the second polishing roll, the third length extending from the third gap to the fourth gap;

the second chill roll and at least two of the first polishing roll, the second polishing roll, and the third polishing roll are fixed along and aligned along a first common plane oriented at a first non-zero tilt angle offset from a second horizontal reference plane, wherein the second horizontal reference plane is parallel to the first horizontal reference plane and the first common plane slopes downward from the second chill roll in a direction of film processing.

14. The casting apparatus of claim 13 , wherein the second side of the polymer film engages and extends a fourth length on the third polishing roll.

15. The casting apparatus of claim 13 , wherein the first length, the second length, and the third length are substantially equal.

16. The casting apparatus of claim 14 , wherein the first length, the second length, the third length, and the fourth length are substantially equal.

17. The casting apparatus of claim 13 , wherein the first length and the second length are established by positioning at least one of the first chill roll, the second chill roll, and the first polishing roll, relative to one another.

18. The casting apparatus of claim 13 , wherein the first length, the second length, the third length, and a fourth length are established by positioning at least one of the first chill roll, the second chill roll, the first polishing roll, the second polishing roll, and the third polishing roll, relative to one another.

19. The casting apparatus of claim 13 , wherein the first length is a mathematical function of the second diameter of the second chill roll and the second length is a mathematical function of a third diameter of the first polishing roll.

20. The casting apparatus of claim 14 , wherein the fourth length extends on an exterior surface of the third polishing roll from the fourth gap such that the fourth length is substantially equal to the third length.

21. The casting apparatus of claim 14 , wherein at least one of the first chill roll and the second chill roll are rotationally mounted on a frame and the frame comprises a system for moving the frame relative to the die.

22. The casting apparatus of claim 13 , wherein the first chill roll and the second chill roll are aligned along a second common plane oriented at a second non-zero tilt angle offset from a vertical plane, wherein the second common plane of the first chill roll and the second chill roll being perpendicular to the first common plane of the second chill roll and at least two of the first polishing roll, the second polishing roll, and the third polishing roll.

23. A casting apparatus for manufacturing polymer film, the casting apparatus comprising:

a die for discharging a molten polymer, the die having a discharge direction oriented at a non-zero discharge angle offset from a first horizontal reference plane;

a pair of initial film receiving chill rolls comprising a first chill roll having a first diameter and a second chill roll having a second diameter, the second diameter being greater than the first diameter, and a first gap between the first chill roll and the second chill roll;

the non-zero discharge angle of the discharge direction of the die being of a predetermined magnitude to gravity assist delivery of the molten polymer to the first gap;

a first polishing roll positioned downstream of the pair of initial film receiving chill rolls, a second gap between the first polishing roll and the second chill roll, a first length of a first side of the polymer film extending from the first gap to the second gap along an outer circumferential surface of the second chill roll, and the first polishing roll engaging and cooling a second length of a second side of the polymer film, the second side being opposite the first side;

the second length extending from the second gap along an outer circumferential surface of the first polishing roll such that the first length is substantially equal to the second length;

the second chill roll positioned to gravity support and be in constant contact with the polymer film exiting the first gap entirely along the first length;

the second chill roll and the first polishing roll are aligned along a first common plane oriented at a first non-zero tilt angle offset from a second horizontal reference plane, the second horizontal reference plane is parallel to the first horizontal reference plane;

the first chill roll and the second chill roll are aligned along a second common plane oriented at a second non-zero tilt angle offset from a vertical plane; and

the second common plane of the first chill roll and the second chill roll being perpendicular to the first common plane of the second chill roll and the first polishing roll.

24. The casting apparatus of claim 23 , further comprising a second polishing roll positioned downstream of the first polishing roll, a third gap between the first polishing roll and the second polishing roll, the second length extending from the second gap to the third gap.

25. The casting apparatus of claim 24 , further comprising a third polishing roll positioned downstream of the second polishing roll, a fourth gap between the second polishing roll and the third polishing roll, the first side of the polymer film engaging and extending a third length on the second polishing roll, the third length extending from the third gap and to the fourth gap.

26. The casting apparatus of claim 25 , wherein the second side of the polymer film engages and extends a fourth length on the third polishing roll.

27. The casting apparatus of claim 25 , wherein the first length, the second length and the third length are substantially equal.

28. The casting apparatus of claim 26 , wherein the first length, the second length, the third length and the fourth length are substantially equal.

29. The casting apparatus of claim 25 , wherein the first length and the second length are established by positioning at least one of the first chill roll, the second chill roll and the first polishing roll, relative to one another.

30. The casting apparatus of claim 25 , wherein the first length, the second length, the third length, and a fourth length are established by positioning at least one of the first chill roll, the second chill roll, the first polishing roll, the second polishing roll, and the third polishing roll, relative to one another.

31. The casting apparatus of claim 25 , wherein the first length is a mathematical function of the second diameter of the second chill roll and the second length is a mathematical function of a third diameter of the first polishing roll.

32. The casting apparatus of claim 26 , wherein the fourth length extends on an exterior surface of the third polishing roll from the fourth gap such that the fourth length is substantially equal to the third length.

33. The casting apparatus of claim 25 , wherein the second chill roll, the first polishing roll, and at least one of the second polishing roll and the third polishing roll are aligned along the first common plane oriented at the first non-zero tilt angle offset from the second horizontal reference plane, wherein the first common plane slopes downward from the second chill roll in a direction of film processing.

34. The casting apparatus of claim 26 , wherein at least one of the first chill roll and the second chill roll are rotationally mounted on a frame and the frame comprises a system for moving the frame relative to the die.