Method of modifying a honeycomb-structure-forming extrusion die and modified extrusion dies

Patent metadata

Field	Value
Publication number	US-12005605-B2
Application number	US-202016790109-A
Country	US
Kind code	B2
Filing date	Feb 13, 2020
Priority date	Mar 18, 2019
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

Methods of manufacturing honeycomb-structure-forming extrusion dies having a number of slots for use in producing extruded articles having complex honeycomb patterns and extrusion dies for use in the manufacture of extruded honeycomb bodies. The method includes inserting a die insert having a runner and a number of teeth into a slot of an extrusion die such that each of the teeth blocks at least a portion of the slot of the extrusion die. The method further includes separating the runner from the teeth so that the teeth remain within the slot of the extrusion die.

First claim

What is claimed is:

1. A method of manufacturing a honeycomb-structure-forming extrusion die, comprising: inserting a die insert comprising a runner and a plurality of teeth extending from the runner into a slot of an extrusion die such that each of the plurality of teeth blocks at least a portion of the slot, wherein the extrusion die comprises a plurality of pins defined by a first plurality of slots extending in a first direction and a second plurality of slots extending in a second direction disposed at an angle to the first direction; and separating the runner from the plurality of teeth such that the plurality of teeth remain within the slot of the extrusion die, wherein inserting a plurality of teeth of the die insert into a slot of the plurality of slots such that the slit of each of the first plurality of teeth is arranged at an intersection of two slots.

2. The method of claim 1 , wherein the plurality of teeth of the die insert are spaced from one another along a longitudinal axis of the runner.

3. The method of claim 1 , further comprising:
forming the die insert comprising the runner and the plurality of teeth such that the plurality of teeth are arranged on the runner in a blocking configuration for blocking a plurality of portions of the slot.

4. The method of claim 3 , wherein forming the die insert comprises machining a stainless steel sheet.

5. The method of claim 3 , wherein forming the die insert comprises photochemical machining of a metal sheet.

6. The method of claim 5 , wherein forming the die insert further comprises coating the teeth of the die insert.

7. The method of claim 6 , wherein the coating comprises plating.

8. The method of claim 7 , wherein the plating comprises nickel plating.

9. The method of claim 6 , wherein prior to coating, a thickness of each tooth is less than a width of the slot, and after coating the thickness of each tooth is at least as thick as the width of the slot.

10. The method of claim 3 , wherein forming the die insert comprises forming each of the plurality of teeth with a thickness corresponding to a width of a slot of the plurality of slots of the extrusion die.

11. The method of claim 3 , wherein each of the plurality of teeth has a first end connected to the runner and a second end, and wherein forming the die insert comprises preparing each of the plurality of teeth such that a thickness of the first end of each of the plurality of teeth is greater than a thickness of the second end of each of the plurality of teeth.

12. The method of claim 1 , further comprising inserting a shim into a slot of the plurality of slots prior to inserting the die insert into the slot of the plurality of slots of the extrusion die.

13. The method of claim 12 , further comprising inserting the shim into the slot of the plurality of slots of the extrusion die in an orientation perpendicular to the die insert.

14. The method of claim 12 , further comprising removing the shim and subsequently securing the plurality of teeth to the extrusion die.

15. The method of claim 1 , wherein separating the runner from the plurality of teeth comprises separating the runner by wire electric discharge machining or plunge electric discharge machining.

16. The method of claim 1 , further comprising securing the plurality of the teeth to the extrusion die by plating the plurality of teeth and the extrusion die.

17. The method of claim 16 , wherein plating is performed using nickel or a nickel alloy.

18. The method of claim 1 , further comprising preparing a plurality of die inserts and inserting the plurality of teeth of each of the plurality of die inserts into the plurality of slots of the extrusion die.

19. An extrusion die formed by the method of claim 1 .

20. The method of claim 1 , wherein the plurality of teeth of the die insert block portions of the slot of the extrusion die such that the extrusion die defines the grid pattern comprises discontinuities.

21. A method of manufacturing a honeycomb-structure-forming extrusion die, comprising: inserting a first die insert into a first slot of a first plurality of slots of the extrusion die, wherein the extrusion die comprises a plurality of pins defining a grid pattern formed by the first plurality of slots that extend in a first direction and a second plurality of slots that extend in a second direction arranged at an angle to the first direction, such that each tooth of a first plurality of teeth of the first die insert blocks a portion of the first slot, the plurality of teeth extending from a first runner of the first die insert; separating the first runner from the plurality of teeth of the first die insert; inserting a second die insert into a second slot of the second plurality of slots such that each tooth of a second plurality of teeth of the second die insert blocks a portion of the second slot, and such that a tooth of the second plurality of teeth of the second die insert mates with a tooth of the first plurality of teeth of the first die insert, the second plurality of teeth extending from a second runner of the second die insert; and separating the second runner from the second plurality of teeth of the second die insert, wherein inserting the first plurality of teeth of the first die insert into a slot of the plurality of slots such that the slit of each of the first plurality of teeth is arranged at an intersection of two slots.

22. The method of claim 21 , wherein each of the first plurality of teeth of the first die insert has a first end connected to the first runner and a second end opposite the first end, wherein each of the first plurality of teeth comprises a slit extending from the first end towards the second end; and wherein each of the second plurality of teeth of the second die insert has a first end connected to the second runner and a second end, wherein each of the second plurality of teeth comprises a slit extending from the second end towards the first end, such that the first die insert and the second die insert mate by engaging the slits on the plurality of teeth of the first die insert with the slits of the plurality of teeth of the second die insert.

Assignees

• Corning Inc

Inventors

• Beall Douglas Munroe
• Miller Kenneth Richard
• Thompson David John

Classifications

• B28B7/346

  Manufacture of moulds · CPC title

• B28B3/2672

  Means for adjusting the flow inside the die, e.g. using choke means · CPC title

• C25D3/12

  of nickel or cobalt · CPC title

• B23P15/243

  Honeycomb dies · CPC title

• B28B2003/203

  for multi-channelled structures, e.g. honeycomb structures · CPC title