Abstract
Forced assembly polymer coextrusion utilizes layer multiplication to produce films with tens or thousands of micrometer to nanometer thick layers. The development of novel uneven split layer multiplying dies has produced gradient multilayer films with at least a 10 times difference between the thickest and thinnest layers. Coextrusion through a series of equal and uneven split multiplier dies allows for flexibility in the unique design of layer thickness distributions by: (1) altering the multiplier offset and (2) changing the sequence of a series of uneven split multiplying dies with different splitting ratios. This new technology has created highly reflective, multilayered photonic films with gradient layer thickness distributions exhibiting, as examples, a 600 nm wide reflection band and dual optical reflection bands within a single film. Also, gradient multilayers exhibit unique mechanical behavior. A layer thickness dependent craze to shear banding deformation mechanism was observed. In addition, gradient controlled buckling was observed across a single film due to foaming-induced layer delamination.
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