Interdigitated finger coextrusion device

A co-extrusion device, comprising:

• at least one first inlet port in a first plate of the device to receive a first material and distribute the first material to a first array of ports in a first fluid folding layer;
• a second fluid folding layer having a plurality of arrays of separation channels, wherein the first material from the first array of ports is routed into a first array of separation channels of the plurality of arrays of the second fluid layer;
• at least one second inlet port in a second plate of the device to receive a second material different from the first material and distribute the second material into a second array of ports in a third fluid folding layer, the second inlet port located on an opposite side of the device from the first inlet port;
• a fourth fluid folding layer having a plurality of arrays of separation channels, wherein the second material from the second array of ports is routed into a first array of separation channels of the plurality of arrays of the fourth fluid folding layer;
• a fifth fluid layer having a plurality of arrays of combining channels, wherein a first array of combining channels of the plurality of arrays is arranged to receive the first material from the first array of separation channels of the second fluid folding layer and the second material from the first array of separation channels of the fourth fluid folding layer and combine the first and second materials into a plurality of first laterally combined flows flowing in a first direction;
• the second fluid folding layer having a second array of separation channels of the plurality of arrays, the fourth fluid folding layer having a second array of separation channels of the plurality of arrays, the second array of separation channels of both the second and fourth folding layers arranged to receive the first laterally combined flows and to split the first laterally combined flows into split flows each flowing in a second direction at least partially orthogonal to the first direction, wherein each split flow consists of the first and second materials, respective split flows return to the second fluid folding layer by flowing into respective separation channels of the second array in the second fluid folding layer and respective split flows return to the fourth folding layer by flowing into respective separation channels of the second array in the fourth folding layer;
• a second array of combining channels of the plurality of arrays in the fifth folding layer of the device arranged to receive the split flows from the second array of separation channels of both the second and fourth fluid layers and combine the split flows into a plurality of second laterally combined flows in the first direction, wherein respective combining channels and respective separation channels which communicate with each other form a cascade;
• and
• at least one exit orifice in the device arranged to allow the materials to exit the device as a single lateral flow of multiple stripes of interdigitated materials horizontally across the exit orifice, wherein a number of stripes in the single flow is based upon a number of repetitions of the splitting and combining channels and a number of the cascades, and the device is formed of a stack of plates defined by the first plate, the second plate and the fluid folding layers.