System and method for controlling flow distribution of extrudate source material for fabricating a honeycomb extrudate

Patent metadata

Field	Value
Publication number	US-12036698-B2
Application number	US-202016810081-A
Country	US
Kind code	B2
Filing date	Mar 5, 2020
Priority date	Mar 18, 2019
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

A system for controlling center-to-outer flow distribution of extrudate source material through an extrusion die suitable for production of a honeycomb extrudate, and a method for fabricating a honeycomb extrudate, are provided. Sequentially arranged first and second plates define first and second pluralities of openings through which extrudate source material may flow, wherein at least some openings of the second plurality of openings arranged at different radial positions differ in area. Relative movement between the first plate and the second plate may be effectuated to adjust overlap between corresponding openings of the plates, thereby adjusting a center-to-outer flow distribution of extrudate source material through an extrusion die arranged downstream of the first and second plates.

First claim

What is claimed is:

1. A system for controlling flow distribution of an extrudate source material upstream of an extrusion die configured for production of a honeycomb extrudate, the system comprising:
a first plate defining a first plurality of openings; and
a second plate defining a second plurality of openings, wherein at least some openings of the second plurality of openings arranged at different radial positions differ in area;
wherein the first plate and the second plate are arranged in series in a flow path of extrudate source material to cause the extrudate source material to flow through either (i) the first plurality of openings followed by the second plurality of openings, or (ii) the second plurality of openings followed by the first plurality of openings; and
wherein at least one of the first plate or the second plate is configured to move relative to the other by translation in a lateral direction that is perpendicular to a direction of flow of extrudate source material through the first plurality of openings and the second plurality of openings, and relative movement between the first plate and the second plate is configured to adjust a center-to-outer flow distribution of the extrudate source material through the extrusion die.

2. The system of claim 1 , wherein openings of the second plurality of openings are distributed among a central zone, a peripheral zone, and at least one intermediate zone that is arranged between the central zone and the peripheral zone, with each of the peripheral zone and the at least one intermediate zone surrounding the central zone.

3. The system of claim 2 , wherein individual openings of the second plurality of openings arranged in the peripheral zone are larger than individual openings of the second plurality of openings arranged in the at least one intermediate zone, and individual openings of the second plurality of openings arranged in the at least one intermediate zone are larger than individual openings of the second plurality of openings arranged in the central zone.

4. The system of claim 3 , wherein the at least one intermediate zone comprises a plurality of intermediate zones including an outermost intermediate zone and an innermost intermediate zone, and wherein the outermost intermediate zone comprises individual openings of the second plurality of openings that are larger than individual openings of the second plurality of openings provided in the innermost intermediate zone.

5. The system of claim 2 , wherein individual openings of the second plurality of openings arranged in the central zone are circular in shape, and individual openings of the second plurality of openings arranged in the peripheral zone and arranged in the at least one intermediate zone comprise geometric stadium shapes.

6. The system of claim 1 , wherein each of the first plate and the second plate extends across substantially an entire width of a single flow path of the extrudate source material upstream of the extrusion die.

7. The system of claim 1 , further comprising at least one mechanism configured to move one of the first plate or the second plate.

8. The system of claim 7 , wherein each of the first plate and the second plate is substantially circular in shape.

9. A method for fabricating a honeycomb extrudate, the method comprising:
flowing an extrudate source material through a serial flow path including a first plurality of openings defined in a first plate and including a second plurality of openings defined in a second plate, wherein at least some openings of the second plurality of openings arranged at different radial positions differ in area; and
effectuating relative movement between the first plate and the second plate to adjust a center-to-outer flow distribution of extrudate source material through an extrusion die arranged downstream of the first plate and the second plate,
wherein the effectuating of relative movement between the first plate and the second plate comprises translating one of the first plate or the second plate in a lateral direction that is perpendicular to a direction of flow of extrudate source material through the first plurality of openings and the second plurality of openings.

10. The method of claim 9 , wherein the extrudate source material comprises a ceramic material.

11. The method of claim 9 , wherein the serial flow path causes the extrudate source material to flow through the second plurality of openings followed by the first plurality of openings.

12. The method of claim 9 , wherein the serial flow path causes the extrudate source material to flow through the first plurality of openings followed by the second plurality of openings.

13. The method of claim 9 , wherein openings of the second plurality of openings are distributed among a central zone, a peripheral zone, and at least one intermediate zone that is arranged between the central zone and the peripheral zone, with each of the peripheral zone and the at least one intermediate zone surrounding the central zone.

14. The method of claim 13 , wherein individual openings of the second plurality of openings arranged in the peripheral zone are larger than individual openings of the second plurality of openings arranged in the at least one intermediate zone, and individual openings of the second plurality of openings arranged in the at least one intermediate zone are larger than individual openings of the second plurality of openings arranged in the central zone.

15. The method of claim 14 , wherein the at least one intermediate zone comprises a plurality of intermediate zones including an outermost intermediate zone and an innermost intermediate zone, and wherein the outermost intermediate zone comprises individual openings of the second plurality of openings that are larger than individual openings of the second plurality of openings provided in the innermost intermediate zone.

16. The method of claim 9 , wherein each of the first plate and the second plate extends across substantially an entire width of a single flow path of the extrudate source material upstream of the extrusion die.

Assignees

• Corning Inc

Inventors

• Jochum Dustin Andrew
• Mccauley Daniel Edward
• Volino Casey Allen

Classifications

• B29C48/2556

  provided in or in the proximity of dies (B29C48/302, B29C48/31, B29C48/325 take precedence) · CPC title

• B29C48/705

  in the die zone, e.g. to create flow homogeneity · CPC title

• B29C48/11

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

• B29C48/302

  being adjustable, i.e. having adjustable exit sections · CPC title

• B28B3/2681

  Adjustable dies, e.g. for altering the shape of the product · CPC title