Hybrid disk-cone extrusion die module having a spillover surface surrounding a planar seal surface

A modular extrusion die assembly comprising:

• a plurality of extrusion die modules disposed in series having an upstream end and a downstream end, wherein a first extrusion die module comprises:
• a first mating portion comprising:
• a first planar seal surface defining a first plane, said first planar seal surface having an outer perimeter;
• a first spillover surface disposed outside of said outer perimeter of said first planar seal surface and, at least in part, outside of said first plane;
• at least one first distribution channel extending from said first seal surface to said first spillover surface;
• and
• at least one first seal surface boundary having a first end point and a second end point, wherein said at least one first seal surface boundary intersects said at least one first distribution channel at said first and second end points along said first plane.

A method of extruding molten plastic resin through an extrusion die assembly comprising the steps of:

• providing an extrusion die module comprising:
• a first mating portion comprising:
• a first planar seal surface defining a first plane, said first planar seal surface having an outer perimeter;
• a first spillover surface disposed outside of said outer perimeter of said first planar seal surface and, at least in part, outside of said first plane;
• at least one first distribution channel extending from said first seal surface to said first spillover surface;
• and
• at least one first seal surface boundary having a first end point and a second end point, wherein said at least one first seal surface boundary intersects said at least one first distribution channel at said first and second end points along said first plane;
• and
• extruding melt material through said extrusion die module to form an extrudate.

A method of forming a film having at least three layers comprising the steps of:

• providing a modular extrusion die assembly having at least three extrusion die modules, wherein a second extrusion die module is disposed between a first extrusion die module and a third extrusion die module, wherein said second extrusion die module and said third extrusion die module each comprise:
• a first mating portion comprising:
• a first planar seal surface defining a first plane, said first planar seal surface having an outer perimeter;
• a first spillover surface disposed outside of said outer perimeter of said first planar seal surface and, at least in part, outside of said first plane;
• at least one first distribution channel extending from said first seal surface to said first spillover surface;
• and
• at least one first seal surface boundary having a first end point and a second end point, wherein said at least one first seal surface boundary intersects said at least one first distribution channel at said first and second end points along said first plane;
• and
• extruding a first melt material through said first extrusion die module, a second melt material through said second extrusion die module, and a third melt material through said third extrusion die module to form an extrudate having at least three layers of material.