Patent Publication Number: US-2023158727-A1

Title: Method and apparatus for cooling

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     Embodiments of the present disclosure present a method and apparatus for blown film. Embodiments of the present disclosure more particularly present a method and apparatus for blown film with an air ring. 
     Description of Related Art 
     Various methods to manufacture thermoplastic blown films are well known in the plastics art. A blown film extrusion line consists of an extruder, which is used to create a pressurized melt stream that is fed into an annular die forming an annular melt stream. The annular melt stream passes through a cooling system consisting of one or more air rings that inflate and form a blown film bubble of a desired dimension and cool the annular melt stream until solidification at a frost line, where it then is laid flat and carried off as “lay-flat” through motorized squeeze rollers for further processing. 
     Many different cooling systems are used, both external and internal to the tube, which apply cooling gas, most typically air, through what is commonly referred to an as “air ring”, to flow generally along the surface of the molten film bubble and to create holding forces on the molten film bubble, providing for both stability and cooling of the molten film bubble. Blown film cooling systems employ motorized blowers to provide a source of pressurized air to an associated air ring. These air rings, generally annularly surround or are contained inside of the molten blown film bubble and provide one, or commonly more than one pressurized flow of air, each exiting the cooling system to flow alongside and cool the molten film bubble. 
     BRIEF SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an object of the present disclosure to provide a method and apparatus for cooling. 
     A first exemplary embodiment of the present disclosure presents an apparatus for cooling. The apparatus includes an annular cooling ring operable for receiving a flow of a molten film bubble and expelling a flow of cooling gas, the annular cooling ring comprising a middle lip and an adjacent radially spaced apart outer lip, the middle lip having an extended length longer than the outer lip, a radially inner surface of the outer lip and a radially outer surface of the middle lip define a channel operable to allow the flow of cooling gas along the radially outer surface of the middle lip, wherein the middle lip is located radially intermediate the channel and the molten film bubble, and wherein the middle lip isolates the molten film bubble from the flow of cooling gas until the flow of cooling gas passes beyond the extended length of the middle lip. 
     A second exemplary embodiment of the present disclosure includes an apparatus further including an open air zone defined by a portion of the extended length of the middle lip that extends beyond a length of the outer lip and an area radially outward from the radially outer surface of the middle lip. 
     A third exemplary embodiment of the present disclosure includes an apparatus wherein the open air zone allows the flow of cooling gas to flow along only the middle lip. 
     A fourth exemplary embodiment of the present disclosure includes an apparatus wherein the outer lip and middle lip are adjustable to increase and decrease the extended length. 
     A fifth exemplary embodiment of the present disclosure includes an apparatus wherein the outer lip and middle lip are adjustable to increase and decrease a length of the channel. 
     A sixth exemplary embodiment of the present disclosure includes an apparatus further including an inner lip located inwardly radially spaced from the middle lip, the inner lip and the middle lip defining an inner channel operable to expel a flow of lubricating cooling gas between the middle lip and the molten film bubble. 
     A seventh exemplary embodiment of the present disclosure includes an apparatus further including an annular collar removeably attached to the annular cooling ring, the annular collar spaced from the middle lip and outwardly radially adjacent the middle lip. 
     An eighth exemplary embodiment of the present disclosure includes an apparatus wherein an area between the radially outer surface of the extended length of the middle lip, the outer lip, and annular collar define an induction zone. 
     A ninth exemplary embodiment of the present disclosure includes an apparatus wherein the induction zone allows the flow of cooling gas from the channel to interact with only the radially outer surface of the middle lip. 
     A tenth exemplary embodiment of the present disclosure includes an apparatus wherein an annular gap formed between the annular collar and the middle lip define an induction gap to allow the flow of cooling gas. 
     An eleventh exemplary embodiment of the present disclosure includes an apparatus wherein the flow of cooling gas passing through the induction gap is operable to create a venturi effect to cause the flow of cooling gas and a flow of gas from the induction zone to pass through the induction gap. 
     A twelfth exemplary embodiment of the present disclosure presents an apparatus wherein an angle of the middle lip relative to the molten film bubble is adjustable to allow for different molten film bubble shapes and variable cooling air flow gaps. 
     A thirteenth exemplary embodiment of the present disclosure presents an apparatus wherein the middle lip is used on a height adjustable cooling system, incorporating variable air flows with variable speed cooling air supply blowers. 
     A fourteenth exemplary embodiment of the present disclosure presents an apparatus wherein the middle lip and the annular collar are adjustable to selectively adjust the induction gap and induction zone to alter a thickness of the molten film bubble. 
     A fifteenth exemplary embodiment of the present disclosure presents an apparatus wherein the induction gap is operable to receive heat to alter a thickness of the molten film bubble. 
     A sixteenth exemplary embodiment of the present disclosure presents a method of forming. The method includes forming an annular cooling ring operable for receiving a flow of a molten film bubble and expelling a flow of cooling gas, the annular cooling ring comprising a middle lip and an adjacent radially spaced apart outer lip, the middle lip having an extended length longer than the outer lip, a radially inner surface of the outer lip and a radially outer surface of the middle lip define a channel operable to allow the flow of cooling gas along the radially outer surface of the middle lip, wherein the middle lip is located radially intermediate the channel and the molten film bubble, and wherein the middle lip isolates the molten film bubble from the flow of cooling gas until the flow of cooling gas passes beyond the extended length of the middle lip. 
     The following will describe embodiments of the present invention, but it should be appreciated that the present invention is not limited to the described embodiments and various modifications of the invention are possible without departing from the basic principles. The scope of the present disclosure is therefore to be determined solely by the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG.  1    is a cross sectional view of a blown film bubble employing an exemplary device suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  2    is a close-up cross sectional view of an exemplary device suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  3    is a close-up cross sectional view of an alternative embodiment of a device suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  4    is a close-up view of an exemplary device with an induction collar suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  5    is close-up view of an exemplary device downwardly in combination with two flows upwardly directed suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  5   a    is close-up view of an exemplary device upwardly in combination with two flows downwardly directed suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  6    is a three dimensional perspective view of an exemplary device suitable for use in practicing exemplary embodiments of the present disclosure. 
         FIG.  7    is a cross sectional view of an alternative embodiment of more than one exemplary device having a middle lip and an induction collar suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG.  8    is a logic flow diagram in accordance with a method and apparatus for performing exemplary embodiments of this disclosure. 
         FIG.  9    is a block diagram of an exemplary apparatus suitable for use in practicing exemplary embodiments of this disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present disclosure provide an improved cooling system that significantly increases blown film production rate, aerodynamic holding forces, and stability by maximizing velocity and providing a large enough volumetric flow of air to maintain the temperature of the boundary layer temperature as low as possible. Embodiments further create sufficient turbulence to facilitate heat transfer from the blown film bubble, through the air flow boundary layer and into the bulk volume flow of cooling air, balanced by the need for maintaining bubble stability. Further, Embodiments provide an improved cooling system operable to adjust physical properties of a flow of a molten film bubble such as film thickness to the advantage of processors. 
     Exemplary embodiments of the present disclosure relate to an annular cooling device for a molten film bubble produced by a blown film tubular extrusion process providing increased throughput rate at high quality. Embodiments provide an annular cooling device operable to cool a molten film bubble having a throughput rate of between 5 and 50 pounds per hour per linear inch of circumference at the exit point from the die. Embodiments of the annular cooling device are operable to expel cooling gas, such as air, and/or cryogenic gas, and optionally water, from an outer lip, a middle lip, and optionally from an inner lip, that is operable to improve holding forces, cooling efficiency and stability of a molten film bubble, allowing for increased throughput rate of the molten film bubble. Embodiments include an induction collar positioned radially adjacent the middle lip. The induction collar is operable to induce additional air flow into the flow of cooling gas and to aid in holding forces on the molten film bubble, and efficiency and stability of the molten film bubble. Embodiments include an annular cooling device having adjustable or extendible lips to modify the air flow channels associated with the middle lip and the induction collar to allow for localized modification of molten film bubble properties, such as thickness of the molten film bubble. Embodiments provide significant increases in production speeds with improved film quality over an increased range of tubular film sizes. 
     Embodiments provide an annular cooling device with a middle lip having a length that extends beyond an outer lip. For example, the middle lip can have a length of at least ½ inch greater than an outer lip to provide improved molten film bubble flow rate performance. Embodiments include an annular cooling device with a middle lip having a length or extended length between ½ and 8 inches greater than or that extends beyond the outer lip. 
     Location terminology for this disclosure will apply as follows, inside or outside will mean relative to the inside or outside of the molten film bubble. As such, it is understood that embodiments of this disclosure incorporate locations both outside and inside of the molten film bubble  12 . Additionally, in general, cooling gas can be any gas, however it normally is air. Therefore, it will be referred to as air herein, and it is understood that it can be any suitable cooling gas medium, such air, gas, and/or cryogenic gas. Further, blown film extrusion lines described herein are oriented in a vertical orientation. However, any other orientations such as horizontal or downward are contemplated herein. As such, it is understood that embodiments of this disclosure incorporate all orientations and location descriptions would change accordingly. It is also understood that cooling air flow can be applied in a direction including in the same direction as the flow of molten film bubble or opposite the direction of the flow of the molten film bubble. Additionally, it is understood that embodiments described herein can be applied simultaneously in both directions. Further, it is understood that the disclosed embodiments equally apply to any shape (or material) used to produce a blown film bubble, such as in the pocket, high stalk, or anywhere in between, such as are commonly known in the industry. 
     Referring now to  FIG.  1   - FIG.  7   , all thin arrows indicating a direction are for illustrative purposes only, labeled for example as AF, and indicate a direction flow of a fluid (e.g. cooling gas, normally air). Further, thick arrows indicating a direction are for illustrative purposes only, labeled for example as MF, and indicate a direction flow of a plastic film material (e.g. molten film bubble). In addition, all double line arrows indicating direction are for illustrative purposes only, labeled for example as PA, and indicate an adjustable dimension or position of a mechanical part. Also, all thin broken lines in the form of a circle or oval, enclose areas that represent a grouping of components as labeled. 
       FIG.  1    shows a cross sectional view of blown film bubble employing an exemplary annular cooling device in accordance with embodiments of this disclosure. In practice, thermoplastic resin is introduced through feed hopper  2  into extruder  4  where the resin is melted, mixed and pressurized. Molten resin is conveyed through melt pipe  6  into a die means  8  that forms it into an annular molten flow that exits generally from the top surface of die means  8  as a molten film bubble  12 . 
     Internal air supply conduit  9  operably provides an internal cooling/inflating air through die means  8  exiting through internal cooling system  10  to the interior of molten film bubble  12  and solidified film bubble  16 . Internal air exhaust conduit  7  operably removes internal cooling/inflating air through die means  8  as required to maintain a desired trapped tube volume of air inside molten film bubble  12  and solidified film bubble  16 , further contained by nip rollers  20 . Air flow through internal air supply conduit  9  and internal air exhaust conduit  7  are controlled by blower, vacuum and/or suction devices (not shown). Embodiments include internal cooling system  10  alternately being removed, such that air is only (without intentional cooling) provided as required to inflate molten film bubble  12  to the desired dimension. 
     Molten film bubble  12  passes through annular cooling ring  100 , where it is cooled by cooling air expelled by annular cooling ring  100 . Upon exiting the influence of annular cooling ring  100 , molten film bubble  12  is free to either expand or contract as needed to reach the required product dimension around the trapped tube volume of air and is drawn upwardly by nip rollers  20  while being cooled to solidify at freeze line  14  forming solidified film bubble  16 . The longitudinal axis of molten film bubble  12  and solidified film bubble  16  is indicated by arrow  104 . The radial direction of molten film bubble  12  and solidified film bubble  16  is indicated by arrow  106 . Solidified film bubble  16  typically passes through a stabilizing cage  17  and is collapsed by flattening guides  18  before passing through nip rollers  20  forming lay-flat film  22 . Lay-flat film  22  is then conveyed to downstream equipment for conversion into usable products as desired. 
     Cooling system area  24  and final lip area  26  are generally annular portions of annular cooling ring  100 , arranged coaxial with molten film bubble  12 , and supplied with cooling air from a suitable external source, fed in general through air ring plenum  28 , although many implementations feed cooling air through multiple air ring plenums (not shown). Annular cooling ring  100  directs cooling air alongside molten film bubble  12 , generally in the same and/or opposite direction to the flow of molten film bubble  12 , acting to stabilize and cool molten film bubble  12 . Annular cooling ring  100  can be implemented in any of the several commonly used configurations found within the industry, such as stacked up, down on the die, and can be made height adjustable, inside or outside (or both) molten film bubble  12  as desired. 
       FIG.  2    is a close-up view of an exemplary annular cooling ring  100  suitable for practicing exemplary embodiments of this disclosure. Shown is annular cooling ring  100  having an air ring plenum  28 , a middle lip  30 , and an outer lip  31 . Annular cooling ring  100  further includes channel  102  defined by the space between the radially outer surface of the middle lip  30   b  and a radially inner surface of the outer lip  31   a.  Main air flow  27  supplied through air ring plenum  28 , to flow through channel  102  between middle lip  30  and main lip  31  and is influenced by two flow surfaces, the radially outer surface of the middle lip  30   b  and the radially inner surface of the outer lip  31   a.  Middle lip  30  has a length or extended length that is arranged to extend beyond main lip  31 , in the direction of flow of main air flow  27 , such that main air flow  27  leaves the influence of main lip  31 , creating open air zone  40 . Embodiments of middle lip  30  include middle lip  30  having a fixed length. Embodiments of middle lip  30  include middle lip  30  being adjustable such that it can extend or retract in length with respect to air ring plenum  28 . Open air zone  40  is defined by a portion of middle lip  30  that extends beyond the length of outer lip  31  and the area radially outward from the radially outer surface of the middle lip  30   b.  Open air zone  40  allows main air flow  27  to flow along only the middle lip  30 . The portion of middle lip  30  radially adjacent to the open air zone  40  acts to shield molten film bubble  12  from the effects (e.g., aerodynamic and cooling effects) of main air flow  27 . Further, the radially outer surface of the middle lip  30   b  contained within open air zone  40  interacts with main air flow  27 . This interaction causes main air flow  27  to move radially toward the radially outer surface of the middle lip  30   b,  which creates a higher velocity of air flow from main air flow  27  along the radially outer surface of the middle lip  30   b.  The higher velocity of air flow from main air flow  27  continues to flow past middle lip  30  as air flow  42  now influencing the molten film bubble  12  to provide improved cooling and stability of molten film bubble  12 . Outer lip  31  and middle lip  30  can be of any length with any aerodynamic shape, angled inward, outward, or straight up, provided middle lip  30  extends beyond outer lip  31  creating an open air zone  40 . 
     Cooling system area  24  is depicted in  FIG.  2    with no cooling air exiting that acts upon molten film bubble  12 . Main air flow  27 , exiting from channel  102  is the only flow of cooling air exiting from annular cooling ring  100  that acts upon molten film bubble  12 . For purposes of clarity, the configuration depicted in  FIG.  2    of an annular ring having a middle lip having a length greater than an outer lip defining a channel there between will be referred to herein as an extended middle lip configuration. 
     Referring to  FIG.  3   , shown is a close-up view of an exemplary device suitable for use in practicing exemplary embodiments of this disclosure. Illustrated in  FIG.  3    is annular cooling ring  300  having a middle lip  30 , outer lip  31 , and an inner lip  302 . All components function the same as described in  FIG.  2   , with the addition of a gap formed between middle lip  30  and inner lip  302  that defines an inner channel  304  operable to allow a flow of cooling air (i.e., lubricating air flow  25   a ) to flow there through. It should be appreciated that embodiments of annular cooling ring  300  are operable to expel cooling fluid through one of inner channel  304  and channel  102 . Embodiments of cooling fluid include water and/or cryogenic gas. Lubrication air flow  25   a  exits from inner channel  304 , to flow between a radially inner surface of the middle lip  30   a  and the outside surface of the molten film bubble  12 . Lubrication air flow  25   a  is operable to prevent molten film bubble  12  from contacting middle lip  30  to provide enhanced stability and cooling of molten film bubble  12 . Air flow  42  and lubrication air flow  25   a  combine together to cool molten film bubble  12  after passing over the tip of middle lip  30 . 
     Embodiments of outer lip  31  provide that outer lip  31  is operably affixed to air ring plenum  28  and the dimension and/or position of outer lip  31  extends and retracts in the direction shown as arrow PA in  FIGS.  2 - 3   . Embodiments of outer lip  31  are also fixed in length. In this regard, outer lip  31  remains affixed to air ring plenum  28  while the terminal end of outer lip  31  extends or retracts its position with respect to air ring plenum  28 . Embodiments include outer lip  31  being operable to extend and retract by ¼ inch or more provided that outer lip  31  does not extend further than the length of middle lip  30 . It should be appreciated that movement of outer lip  31  can thus increase or decrease the length open air zone  40  and can selectively act to adjust internal gaps within air ring plenum  28  to adjust the volume of main air flow  27  and/or lubrication air flow  25   a.  As is evident, annular cooling ring  300  includes the annular cooling ring  100  with the addition of a single flow of cooling gas from channel  304 . 
       FIG.  4    is a close up view of an exemplary device shown in  FIG.  3    with an induction collar suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG.  3    is annular cooling ring  300  with induction collar  44 . Induction collar  44  encircles molten film bubble  12  and is located radially outwardly spaced from middle lip  30 . Induction collar  44  can be fixedly or removeably affixed to annular cooling ring  300 . In this embodiment, open air zone  40  terminates at the bottom surface of induction collar  44 . Due to the location of induction collar  44 , main flow  27  causes a venturi effect through open air zone  40  (also referred to herein as an induction zone), which draws, pulls, or induces air flow  46  to flow together with main flow  27  through an induction gap  43  formed between the radially inner surface of induction collar  44  and the radially outer surface of the middle lip  30   b,  then continuing to flow as a combined air flow past middle lip  30 , now as air flow  42  and air flow  46 . Embodiments of induction collar  44  can be positioned at any location along the long axis of middle lip  30  provided induction collar  44  is outwardly radially spaced apart from middle lip  30 . Embodiments include induction collar  44  being located above outer lip  31 , so long as an open air zone  40  exists. Embodiments of induction collar  44  can be of any length, with any reasonable aerodynamic shape, angled inward, outward, or straight up, beginning and ending above or below the extent of middle lip  30 . Embodiments of induction collar  44  have a size (including a length) that is fixed. Embodiments of induction collar  44  are further adjustable (as indicated by arrows PA in  FIG.  4   ) to extend or retract such that the longitudinal length of induction collar  44  can be increased or decreased thereby increasing or decreasing the size of the open air zone  40 . Induction collar  44  is also moveable in its longitudinal location with respect to middle lip  30 . In this regard induction collar  44  is operable to move along the longitudinal axis of the molten film bubble  12  such that it can be fixed at a specified location during use. Induction collar  44  is further radially moveable with respect to middle lip  30  and molten film bubble  12 , for example by incorporating angles into the induction gap  43  flow surfaces, where longitudinal movement of the induction collar  44  acts to increase or decrease the radial distance between induction collar  44  and molten film bubble  12  such that it can be fixed at a specified radial location during use. It should be appreciated that movement and/or adjustment of induction collar  44  either through extending, retracting or location with respect to middle lip  30  may alter the size of open air zone  40  and the induction gap  43  between middle lip  30  and induction collar  44 . As shown in  FIG.  4   , air flow  42 , lubricating air flow  25   a,  and induced air flow  46  all combine together to form combined cooling flow  50 , which flows alongside and cools molten film bubble  12 . It should be appreciated the annular cooling ring  300  as depicted in  FIG.  4    includes an annular cooling ring  100  with an additional single flow of cooling gas from channel  304 , and an induction collar  44 . 
       FIG.  5    shows a close-up view of an exemplary device downwardly directed in combination with two flows upwardly directed suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG.  5    is annular cooling ring  500  having middle lip  30 , outer lip  31 , induction collar  44 , optional center lip  504 , middle lip  30   u,  outer lip  32 , and air collar  33 . It should be appreciated that cooling system area  24  functions the same as annular cooling ring  300  and induction collar  44  depicted in  FIG.  4   , except the upward and downward terminology is reversed. In  FIG.  5   , cooling system area  24  also includes optional center lip  504 , which acts to prevent air flow directly against molten film bubble  12  and provides a first air flow portion flowing downwardly through gap  506  between middle lip  30  and the molten film bubble  12  as lubrication air flow  25   a  and a second air flow portion flowing upwardly through gap  508  between middle lip  30   u  along the radially inner surface of the middle lip  30   u   2  and the radially outer surface of the molten film bubble  12  as lubrication air flow  25   u.  Lubrication air flow  25   a  and  25   u,  act to prevent instability in molten film bubble  12  and to prevent molten film bubble  12  contact with middle lip  30  and middle lip  30   u  respectively. Main air flow  27   u  flows between radially outer surface of the middle lip  30   u   1  and radially inner surface of the outer lip  32   a.  Outer lip  32  has a length that extends equal to or beyond middle lip  30   u.  Outer lip  32  and middle lip  30   u  define a channel  502  which allows the main air flow  27   u  to flow there through. Main air flow  27   u  exits from channel  502  and combines with lubricating air flow  25   u  after passing the terminal end of middle lip  30  to cool and stabilize molten film bubble  12 . Embodiments of outer lip  32  have a length that is fixed. Embodiments of outer lip  32  are operable to be adjustable to extend or retract in length (as indicated by arrows PA) by ¼ inch or more to adjust internal gaps within air ring plenum  28  to adjust the flow volume and/or balance between main air flow  27   u  and lubrication air flow  25   b.  In this regard, outer lip  32  is operable to extend or retract in length thereby also increasing or decreasing the length of channel  502 . 
     Also shown in  FIG.  5    is optional air collar  33 . Air collar  33  circumscribes the radially outer wall of outer lip  32  and extends upward above outer lip  32 . Further, air collar  33  is radially spaced apart from molten film bubble  12 . In practice, main air flow  27  flows between air collar  33  and molten film bubble  12 , acting to assist in pulling outward on molten film bubble  12  to enhance cooling and stability. In one embodiment, air collar  33  includes one or more holes (shown by line AF) that extend radially through air collar  33 . In other words, the one or more holes extend from the radially inner surface of air collar  33  to the radially outer surface of air collar  33 . Embodiments of the one or more holes aid in adjusting the intensity of air pulling forces from the flow of cooling air acting on molten film bubble  12 . Embodiments of air collar  33  have a size and location that are fixed with respect to middle lip  30 . Further, embodiments include air collar  33 , operable to be adjustable to extend or retract in position and/or length along the longitudinal axis (as indicated by arrows PA) by ¼ inch or more to adjust the shape of the molten film bubble  12  to allow for a greater range of sizes. Although not shown, embodiments contemplate additional optional air collars similar to air collar  33 , being stacked and further adjustable above or below the devices shown in  FIGS.  4  and  5   . Also shown in  FIG.  5    is internal cooling system  10  and internal air exhaust conduit  7 . Internal cooling system  10  is operable to expel air along the interior of molten film bubble  12 . Internal air exhaust conduit  7  is operable to remove air from the interior of molten film bubble  12 . Embodiments of internal cooling system  10  and internal air exhaust conduit  7  operate in conjunction with one another such that the diameter of the molten film bubble  12  is a desired size. 
     The annular cooling ring  500  as depicted in  FIG.  5    is shown as being spaced above die means  8 . This configuration can increase the surface area of molten film bubble  12  cooled by expelled cooling air from air flow  50 . The height above die means  8  is adjustable as depicted, although it can also be fixed in height above die means  8  without constraint. Additionally, embodiments described within cooling system area  26  of  FIG.  5    can selectively be replaced by a similar cooling system area contained within one of a commonly available single flow air ring, dual flow air ring, triple lip air ring, or multi-flow air ring. It should be appreciated that annular cooling ring  500  is annular cooling ring  100  with three additional channels operable to allow three additional flows of cooling gas. 
       FIG.  5   a    shows a close-up view of an exemplary device upwardly directed in combination with two flows downwardly directed suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG.  5   a    is annular cooling ring  550  having middle lip  30 , outer lip  31 , induction collar  44 , downward middle lip  555 , and downward outer lip  556 . Cooling system area  26  functions the same as cooling system area  26  of annular cooling ring  300  depicted in  FIG.  4   . Unlike in  FIG.  4   , cooling system area  24  does not include the optional center lip  504 , annular cooling ring  550  includes annular gap  554  that delivers air flow generally against molten film bubble  12 , where it divides into a first air flow portion flowing upwardly between middle lip  30  and the molten film bubble  12  as lubrication air flow  25   a  and a second air flow portion flowing downwardly between downward middle lip  555  and the molten film bubble  12  as lubrication air flow  25   b.  Annular gap  554  is defined by the space between middle lip  30  and downward middle lip  555  generally along the longitudinal axis. Similar to  FIG.  4   , lubrication air flow  25   a  and  25   b , act to prevent instability in molten film bubble  12  and to prevent molten film bubble  12  contact with middle lip  30  and downward middle lip  555  respectively. Downward outer lip  556  has a length that extends equal to or beyond downward middle lip  555 . Downward outer lip  556  and downward middle lip  555  define a channel  558  which allows a main air flow  27   b  to flow there through. Main air flow  27   b  exits from channel  558  after passing the terminal end of downward middle lip  555 , and combines with lubricating air flow  25   b  to form combined air flow  50   b  acting to cool and stabilize molten film bubble  12 . 
     Similar to  FIG.  4   , embodiments include downward middle lip  555  and/or downward outer lip outer  556  operable to be adjustable to extend or retract with respect to air ring plenum  28  (as indicated by arrows PA) by ¼ inch or more to adjust internal gaps within air ring plenum  28  to adjust the volume of main air flow  27   b  and/or lubrication air flow  25   b.  Embodiments of downward middle lip  555  have a size that is fixed. Additionally, the annular cooling ring  550  as depicted in  FIG.  5   a    is shown as being spaced above die means  8  to increase the surface area of molten film bubble  12  cooled by expelled cooling air from air flow  50   b.  Further, the height above die means  8  is adjustable as depicted, although it can also be fixed in height above die means  8  without constraint. Further, embodiments described within cooling system area  24  of  FIG.  5   a    can selectively be replaced by a similar cooling system area contained within one of a commonly available dual flow air ring (similar to  FIG.  4   , but now raised up), triple flow air ring, or multi-flow air ring. It should be appreciated that annular cooling ring  550  is annular cooling ring  100  with three additional flows of cooling gas from three additional channels. 
       FIG.  6    is a three dimensional perspective view of annular cooling ring  300  shown in  FIG.  3    suitable for use in practicing exemplary embodiments of the present disclosure. However, it should be appreciated that embodiments of annular cooling ring  300  shown in  FIG.  6    can be replaced with any annular cooling ring described herein. In addition to the elements shown in  FIG.  3   ,  FIG.  6    includes sensor  60  located along an outside surface of the molten film bubble  16 . Sensor  60  is operable to scan the solidified film bubble  16  to generate a film physical property profile, for example a thickness profile. It is further appreciated that sensor  60  can be located within flattening guides  18  or anywhere along lay-flat film  22 . Also shown in  FIG.  6    are one or more adjustable flow barriers  62  (one shown) positioned to locally block a portion of induced air flow  46  from open air zone  40  acting to locally affect the physical properties of the molten film bubble  12 , such as thickness. Embodiments of the one or more flow barriers  62  are operable to have a location that can be selectively fixed. Alternately (not shown), the one or more adjustable flow barriers  62  can be positioned to locally adjust induction gap  43 , acting to locally affect both main air flow  27  and induced air flow  46  that passes through induction gap  43  and change the localized physical properties of the molten film bubble  12 , such as thickness. Sensor  60  is operably coupled to a controller having at least one processor and at least one memory to interpret and determine the sensed physical property profiles such as thickness profiles generated by sensor  60 . In response to the determined physical properties, the controller is operable to control the position of the one or more adjustable flow barriers  62  with respect to angular position around molten film bubble  12  and to annular cooling ring  300  to obtain a desire physical property profile, such as thickness, around molten film bubble  12  and solidified film bubble  16 . The controller is operable to automatically adjust and/or move the one or more adjustable flow barriers  62  to create uniform a thickness profile in the molten film bubble  16  to improve the quality of solidified film bubble  16 . Alternatively, controller with sensor  60  are operable create a non-uniform thickness profile. 
     In yet another embodiment, the one or more adjustable flow barriers  62  can be replaced by one or more localized heating elements (not shown), which are operable to affect induced air flow  46  (or alternately air flow  42 ) and thus film physical properties, such as the localized thickness of solidified film bubble  16 . Additionally, the one or more adjustable flow barriers  62  (or heaters) can be can be made to orbit about molten film bubble  12 . As depicted in  FIG.  6   , the one or more adjustable flow barriers  62  (or heaters) are attached to induction collar  44  or alternately attached to main lip  31  (not shown). Embodiments include both collar  44  (or main lip  31 ) and/or the one or more adjustable flow barriers  62  being operable to rotate and selectively be synchronized with the position of other components on the blown film line that also rotate, such as orienting machines (not shown) or oscillating versions of nip rollers  20 . In one embodiment, the one or more adjustable flow barriers  62  (or heaters) are rotated and positioned as required to intentionally create a non-uniform thickness of the molten film bubble  12  such that after further processing the thick or thin portions of the molten film bubble  16  are combined or stretched such that the lay-flat film  22  will have a uniform thickness. Alternately, the one or more adjustable flow barriers  62  (or heaters) are rotated and positioned as required to intentionally create a non-uniform thickness of the molten film bubble  12  such that after further processing the thick or thin portions of the molten film bubble  16  remain, to create what is called “thick—thin” film. 
     Reference is now made to  FIG.  9   , which illustrates a simplified block diagram of the various elements of a device  902  suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG.  9    is an annular cooling ring (device  902 ) suitable to cool a molten film bubble  12 . Device  902  includes processing means such as a controller  904 , which includes at least one data processor  906 , storing means such as at least one computer-readable memory  908  storing at least one computer program  910 . Controller  904 , the at least one data processor  906 , and the at least one computer-readable memory  908  with the at least computer program  910  provide a mechanism to interpret and determine physical properties of a molten film bubble  12  and to adjust elements of annular cooling ring. The device  902  also includes at least one sensor  912  for sensing the physical properties of a molten film bubble  12  (e.g., film thickness). Sensor  912  is operably connected to controller  904  such that sensor  912  is able to transmit its sensed information to controller  904  and data processor  906 . Device  902  includes an annular cooling gaps  918  operable to expel cooling air on a molten film bubble. Device  902  further includes induction collar  914  with one or more flow barriers  916 . Induction collar  914  is operably coupled to flow barriers  916  such that induction collar  914  can cause flow barriers  916  to move rotatably around the circumference of molten film bubble  12 . Flow barriers  916  and induction collar  914  are operably connected to controller  904  such that they can receive instructions from controller  904  to move flow barriers  916  to specified positions and to rotatably move both flow barriers  904  together with induction collar  914  around the circumference of molten film bubble  12 . 
     The at least one computer program  910  in device  902  in exemplary embodiments is a set of program instructions that, when executed by the associated data processor  906 , enable the device  902  to operate in accordance with the exemplary embodiments of this disclosure, as detailed herein. In these regards, the exemplary embodiments of this disclosure may be implemented at least in part by a computer software stored in computer-readable memory  908 , which is executable by the data processor  906 . Devices  906  implementing these aspects of this disclosure need not be the entire devices as depicted in  FIG.  9    or may be one or more components of the above described tangibly stored software, hardware, and data processor. 
       FIG.  7    is a cross sectional view of yet another device suitable for use in practicing multiple exemplary embodiments of this disclosure from the outside, both upward and downward, as well as from the inside of the blown film bubble. Shown in  FIG.  7    is optional cooler  70  operably spaced along the long axis of the molten film bubble  12  from annular cooling ring  700 . Also shown is internal cooling system  10  including an internal cooling ring  702 , which now includes middle lip  30   i  having a length that extends beyond an inner lip  31   i.  Internal cooling system  10  includes components similar to that found in annular cooling ring  300  from  FIG.  4   , except the inside and outside terminology is reversed, and components are now mirror imaged to be within molten film bubble  12  and designated similarly with the suffix “i”. Further,  FIG.  7    shows the inside cooling system located down adjacent to die means  8 , but it should be appreciated that embodiments include internal cooling system  10  spaced from die means  8 . 
     Cooling system area  24  functions the same as annular cooling ring  300  with an induction collar  44  shown in  FIG.  4   , except the upward and downward terminology is reversed and similar components are now designated with the suffix “b”. Optional cooler  70  is operable to expel cooling air along the outside surface of the molten film bubble  12  in the direction of the flow of the molten film bubble  12 . Optional cooler  70  when provided, adds additional cooling to that provided by cooling flow  50   b,  now acting in concert to cool the molten film bubble  12 . It is further contemplated that optional cooler  70  can be one or more stacked cooling devices (e.g., single lip, dual lip, triple lip, multi lip, etc.) located above or below any of the annular cooling rings disclosed herein. Further, final lip area  26  is depicted and functions similar to  FIG.  4   , and can selectively be replaced by outer lip  32  as is described in  FIG.  5   . Multiple of the embodiments described in  FIG.  4    can be applied in one or more location, inside or outside of the bubble, in an upward or downward direction, or in any desired combination, to act in concert to cool the molten film bubble  12 . 
     Referring to  FIG.  8   , presented is a logic flow diagram in accordance with a method and apparatus for performing exemplary embodiments of this disclosure. Block  800  presents forming an annular cooling ring operable for receiving a flow of a molten film bubble and expelling a flow of cooling air, the annular cooling ring comprising a middle lip and an adjacent radially spaced apart outer lip, the middle lip having an extended length longer than the outer lip, a radially inner surface of the outer lip and a radially outer surface of the middle lip define a channel operable to allow the flow of cooling air along the radially outer surface of the middle lip, wherein the middle lip is located radially intermediate the channel and the molten film bubble, and wherein the middle lip isolates the molten film bubble from the flow of cooling air until the flow of cooling air passes beyond the extended length of the middle lip. Block  802  then relates to wherein the annular cooling ring comprises an open air zone defined by a portion of the extended length of the middle lip that extends beyond a length of the outer lip and an area radially outward from the radially outer surface of the middle lip. 
     Some of the non-limiting implementations detailed above are also summarized at  FIG.  8    following block  802 . Block  804  wherein the open air zone allows the flow of cooling gas to flow along only the middle lip. Then block  806  specifies the method further comprising forming an inner lip located inwardly radially spaced from the middle lip, the inner lip and the middle lip defining an inner channel operable to expel the flow of cooling gas directed to flow between the middle lip and the molten film bubble. Next block  808  indicates the method further comprising forming an annular collar removeably attached to the annular cooling ring, the annular collar spaced from the middle lip and outwardly radially adjacent the middle lip. Block  810  relates to wherein an area between the radially outer surface of the extended length of the middle lip, the outer lip, and annular collar define an induction zone. Then block  812  states wherein the annular cooling ring is operable to expel the flow of cooling gas on at least one of (i) a radially exterior surface of the molten film bubble with the flow of the molten film bubble, (ii) the radially exterior surface of the molten film bubble against the flow of the molten film bubble, (iii) a radially interior surface of the molten film bubble with the flow of the molten film bubble, and (iv) a radially interior surface of the molten film bubble against the flow of the molten film bubble. 
     The logic diagram of  FIG.  8    may be considered to illustrate the operation of a method of forming or a method of manufacture. The logic diagram of  FIG.  8    may also be considered a specific manner in which components of a device are configured to cause a device to be formed, whether such a device is an annular cooling element, or one or more components thereof. 
     This disclosure has been described with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.