System and method for making multilayer films and a layer multiplication device

1. A layer multiplication device comprising a housing and at least one layer multiplication insert,

said housing having an inlet configured to receive a flow stream, an outlet configured to discharge the flow stream, and a flow cavity extending between said inlet and said outlet, and

said at least one layer multiplication insert positioned within said flow cavity, said layer multiplication insert being configured to divide the flow stream into at least a first flow stream and a second flow stream and recombine the first flow stream and the second flow stream by stacking the first flow stream on top of the second flow stream,

wherein said inlet has an inlet flow volume equivalent to a cross-sectional area of said housing at said inlet multiplied by a length of said flow cavity, said flow cavity has a cavity flow volume equal to or greater than said inlet flow volume, and said cavity flow volume is a free volume.

2. The layer multiplication device of claim 1 , wherein said housing has a sloped transition surface between said inlet and said flow cavity, said sloped transition surface enlarging said flow cavity relative to said inlet so that said cavity flow volume is equal to or greater than said inlet flow volume.

3. The layer multiplication device of claim 2 , wherein said at least one layer multiplication insert has a first side, a second side opposite said first side, a leading edge, and a trailing edge, said leading edge of said layer multiplication insert defines a downwardly directed divider and an adjacent upwardly directed divider, said downwardly directed divider is configured to direct the first flow stream on said first side of said layer multiplication insert and said upwardly directed divider is configured to direct the second flow stream on said second side of said layer multiplication insert.

4. The layer multiplication device of claim 3 , wherein at least one of said downwardly directed divider and said upwardly directed divider has a sloped leading edge configured to mate with said sloped transition surface of said housing.

5. The layer multiplication device of claim 1 , wherein said housing comprises a first portion and a second portion, and said first portion is configured to be mechanically attached to said second portion so as to sandwich said at least one layer multiplication insert between said first portion and said second portion.

6. A system comprising a feed block, a layer multiplication device, and a flow channel,

said feed block configured to receive a plurality of polymeric flows and discharge a primary multilayer flow stream having a plurality of layers, each layer of the primary multilayer flow stream including one of the plurality of polymeric flows;

said layer multiplication device including a housing and at least one layer multiplication insert positioned within said housing, wherein said housing has an inlet configured to receive the primary multilayer flow stream, an outlet configured to discharge a multiplied multilayer flow stream, and a flow cavity extending between said inlet and said outlet, and wherein said layer multiplication insert is configured to divide the primary multilayer flow stream into at least a first multilayer flow stream and a second multilayer flow stream and recombine the first multilayer flow stream and the second multilayer flow stream by stacking the first multilayer flow stream on top of the second multilayer flow stream; and

said flow channel connecting said feed block to said inlet of said housing,

wherein said flow channel has a flow channel volume equal to a volume of space in the flow channel through which the primary multilayer flow stream travels per unit of length, said flow cavity of said housing has a cavity flow volume, said cavity flow volume is equal to or greater than said flow channel volume, and said cavity flow volume is a free volume.

7. The system of claim 6 , wherein said housing has a sloped transition surface between said inlet and said flow cavity, said sloped transition surface enlarging said flow cavity relative to said inlet so that said cavity flow volume is equal to or greater than said flow channel volume.

8. The system of claim 7 , wherein said at least one layer multiplication insert has a first side, a second side opposite said first side, a leading edge, and a trailing edge, said leading edge of said layer multiplication insert defines a downwardly directed divider and an adjacent upwardly directed divider, said downwardly directed divider is configured to direct the first multilayer flow stream on said first side of said layer multiplication insert and said upwardly directed divider is configured to direct the second multilayer flow stream on said second side of said layer multiplication insert.

9. The system of claim 8 , wherein at least one of said downwardly directed divider and said upwardly directed divider has a sloped leading edge configured to mate with said sloped transition surface of said housing.

10. The system of claim 6 , further comprising an extrusion die positioned downstream of said layer multiplication device and a flow channel connecting said outlet to said extrusion die.

11. A method of multiplying a multilayer flow stream using a flow channel and a layer multiplication device with a flow cavity, the method comprising:

conveying said primary multilayer flow stream through the flow channel, wherein the flow channel has a flow channel volume;

receiving said primary multilayer flow stream from the flow channel in the flow cavity which has a cavity flow volume equal to or greater than the flow channel volume, said cavity flow volume being a free volume;

dividing said primary multilayer flow stream into at least a first multilayer flow stream and a second multilayer flow stream; and

recombining said first multilayer flow stream and said second multilayer flow stream inside the layer multiplication device by stacking said first multilayer flow stream on top of said second multilayer flow stream.