Extrusion dies and methods and apparatuses for forming the same

Patent metadata

Field	Value
Publication number	US-11135740-B2
Application number	US-201615555780-A
Country	US
Kind code	B2
Filing date	Mar 4, 2016
Priority date	Mar 6, 2015
Publication date	Oct 5, 2021
Grant date	Oct 5, 2021

Abstract

A honeycomb extrusion die (100), a method of making the same, and an apparatus for forming the same. The die (100) includes: a feed hole plate (202) comprising an input surface (202A), an opposing output surface (202B), and feed holes (108) configured to guide a batch material from the input surface (202A) to the output surface (202B); and a pin assembly (204) comprising pins (300) disposed on the feed hole plate (202). At least one of the pins includes: a tail (304); a head (302) connected to the tail (304) and comprising alignment surfaces (314) configured to align the pins (300), flow surfaces (316) disposed between the alignment surfaces (314), and a tapered portion (310) comprising a contact surface (308) adhered to the output surface (202B) of the feed hole plate (202); and a first groove (306) disposed between the head (302) and the tail (304). In the pin assembly (204), the alignment surfaces (314) contact adjacent pins (300) to align the pins (300), such that discharge slots are at least partially defined by the tails (304) of the pins (300).

First claim

What is claimed is:

1. A honeycomb extrusion die comprising:
a feed hole plate comprising feed holes that extend through the feed hole plate, from an input surface of the feed hole plate to an opposing output surface of the feed hole plate; and
a pin assembly comprising pins disposed on an output surface of the feed hole plate, one or more of the pins comprising:
a head comprising alignment surfaces configured to align the pins, flow surfaces disposed between the alignment surfaces, and a tapered portion comprising a contact surface adhered to the output surface of the feed hole plate, wherein the contact surface is spaced axially from the alignment surfaces by the tapered portion, wherein the contact surface comprises a first cross-sectional width that is less than or equal to a distance between adjacent feed holes, such that the contact surfaces do not overlap the feed holes, and wherein a second cross-sectional width between opposing alignment surfaces is greater than the first cross-sectional width, such that the head is tapered by the tapered portion from the second cross-sectional width at the alignment surfaces to the first cross-sectional width at the contact surface;
a tail connected to the head and extending away from the feed hole plate; and
a first groove disposed between the head and the tail,

wherein the alignment surfaces of the pins contact adjacent pins, such that the tails of adjacent pins are spaced apart to at least partially define discharge slots, and the flow surfaces of adjacent pins are spaced apart to at least partially define channels.

2. The honeycomb extrusion die of claim 1 , wherein in each pin:
the head comprises a base comprising the alignment surfaces and the flow surfaces; and
the tapered portion extends from the base and ends at the contact surface.

3. The honeycomb extrusion die of claim 1 , wherein the discharge slots are disposed in a honeycomb pattern.

4. The honeycomb extrusion die of claim 1 , wherein, in one or more of the pins, a width of the head, taken between opposing alignment surfaces, is greater than a width of the tail taken between corresponding opposing sides of the tail.

5. The honeycomb extrusion die of claim 1 , wherein:
the flow surfaces are curved; and
the alignment surfaces are substantially flat.

6. The honeycomb extrusion die of claim 1 , wherein the pin assembly comprises a first plenum at least partially defined by the tapered portions of the pins.

7. The honeycomb extrusion die of claim 6 , wherein:
the pin assembly further comprises a second plenum at least partially defined by the first grooves; and
the channels between the flow surfaces are configured to guide the batch material from the first plenum to the second plenum.

8. The honeycomb extrusion die of claim 7 , wherein:
one or more of the tails comprises a second groove; and
the pin assembly comprises a third plenum at least partially defined by the second grooves.

9. The honeycomb extrusion die of claim 1 , wherein a ratio of the pins to the feed holes is 1:1 or 2:1.

10. The honeycomb extrusion die of claim 1 , wherein the contact surface adhered to the plate comprises a braze joint, a weld joint, or an adhesive joint.

11. A method of forming a honeycomb extrusion die, the method comprising:
aligning pins on an output surface of a feed hole plate comprising feed holes that extend through the feed hole plate, from an input surface of the plate to the output surface, one or more of the pins comprising:
a head comprising alignment surfaces configured to align the pins, flow surfaces disposed between the alignment surfaces, and a tapered portion comprising a contact surface adhered to the output surface of the feed hole plate, wherein the contact surface is spaced axially from the alignment surfaces by the tapered portion, wherein the contact surface comprises a first cross-sectional width that is less than or equal to a distance between adjacent feed holes, such that the contact surfaces do not overlap the feed holes, and wherein a second cross-sectional width between opposing alignment surfaces is greater than the first cross-sectional width, such that the head is tapered by the tapered portion from the second cross-sectional width at the alignment surfaces to the first cross-sectional width at the contact surface;
a tail connected to the head and extending away from the feed hole plate; and
a first groove disposed between the head and the tail; and

adhering the contact portions to the output surface of the feed hole plate.

12. The method of claim 11 , wherein the aligning comprises:
disposing the pins in a jig on the feed hole plate; and
biasing the pins together using the jig, such that the contact surfaces of the pins contact adjacent pins and align the pins into a pin assembly.

13. The method of claim 12 , wherein the biasing comprises biasing the pins in at least two different directions.

14. The method of claim 12 , wherein the biasing comprises biasing the pins towards the feed hole plate.

15. The method of claim 11 , wherein the adhering comprises brazing, using an adhesive, or welding.

16. The method of claim 11 , wherein the pins are individually coated prior to aligning the pins on the output surface of the feed hole plate.

17. A honeycomb extrusion die comprising:
a feed hole plate comprising feed holes that extend through the feed hole plate, from an input surface of the feed hole plate to an opposing output surface of the feed hole plate; and
a pin assembly comprising pins disposed on an output surface of the feed hole plate, one or more of the pins comprising:
a head comprising alignment surfaces configured to align the pins, flow surfaces disposed between the alignment surfaces, and a tapered portion comprising a contact surface adhered to the output surface of the feed hole plate, wherein the contact surface is spaced axially from the alignment surfaces by the tapered portion, wherein the contact surface comprises a first cross-sectional width that is less than or equal to a distance between adjacent feed holes, such that the contact surfaces do not overlap the feed holes, and wherein a second cross-sectional width between opposing alignment surfaces is greater than the first cross-sectional width, such that the head is tapered by the tapered portion from the second cross-sectional width at the alignment surfaces to the first cross-sectional width at the contact surface; and
a tail connected to the head and extending away from the feed hole plate,

wherein the alignment surfaces of the pins contact adjacent pins, such that the tails of adjacent pins are spaced apart to at least partially define discharge slots, and the flow surfaces of adjacent pins are spaced apart to at least partially define channels.

Assignees

• Corning Inc

Inventors

• Deming Scott Winfield
• Thomas John Christopher
• Wasson Kevin Lee

Classifications

• B29C48/11

  comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped · CPC title

• B28B3/269 Primary

  For multi-channeled structures, e.g. honeycomb structures · CPC title

• B29L2031/731

  Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres (cables B29L2031/707) · CPC title

• B23P15/243

  Honeycomb dies · CPC title

• B30B11/221

  extrusion dies · CPC title