Multilayer coextrusion die and method

An apparatus comprising:

• an interleaving block portion including:
• a series of first chambers each having outputs, the first chambers configured so as to contain a matrix material, wherein each first chamber acts to spread the matrix material to a pre-determined width, and constant thickness at each output;
• a series of second chambers configured so as to contain a fiber material, wherein the second chambers have a plurality of outputs disposed intermittently along the pre-determined width;
• and
• a die portion including a laminate chamber disposed generally perpendicular with respect to the series of first and second chambers in communication with the outputs of each first and second chambers and in communication with the outputs of each first and second chamber, wherein the die portion combines the matrix material and the fiber material so as to form extrudate at the pre-determined width.

A method for extruding a multi-layer extrudate comprising:

• moving a material through a plurality of generally parallel first chambers each first chamber having a length dimension, the first chambers being generally parallel along the length dimension in an interleaving block;
• moving the material through at least one output into a laminate chamber having a height dimension perpendicular to the length dimension of the first chambers;
• layering the material in the laminate chamber;
• and
• extruding the layered material from an output disposed at one end of the height dimension of the laminate chamber.