Multi-piece layered honeycomb extrusion dies and methods of making same

Patent metadata

Field	Value
Publication number	US-12049022-B2
Application number	US-202318243929-A
Country	US
Kind code	B2
Filing date	Sep 8, 2023
Priority date	Nov 27, 2019
Publication date	Jul 30, 2024
Grant date	Jul 30, 2024

Abstract

Extrusion dies and methods of manufacturing extrusions dies, the extrusion die including a first plate and a second plate. The first plate has first upstream and downstream surfaces. A first material of the first plate has a first elastic modulus. The first plate includes pins formed between a plurality of slots. The pins and slots define a discharge face for the extrusion die at the first downstream surface of the first plate. The second plate has second upstream and downstream surfaces. The second plate is joined at the second downstream surface to the first upstream surface of the first plate. A second material of the second plate has a second elastic modulus. The second elastic modulus is greater than the first elastic modulus. A plurality of feed holes extend from the second upstream surface of the second plate through the extrusion die into communication with the slots.

First claim

What is claimed is:

1. A method of manufacturing an extrusion die, the method comprising:
joining a first plate comprising a first upstream surface and a first downstream surface to a second plate comprising a second upstream surface and a second downstream surface,
wherein the first plate is formed of a metal having a first elastic modulus and the first plate comprises a plurality of pins formed between a plurality of slots, the plurality of pins and the plurality of slots defining a discharge face for the extrusion die, and
wherein the second plate is formed of at least one of a ceramic material or a metal matrix composite material having a second elastic modulus greater than the first elastic modulus and wherein a plurality of feed holes of the extrusion die extend through the second plate.

2. The method of claim 1 , wherein joining the first plate to the second plate comprises a brazing method.

3. The method of claim 2 , wherein the brazing method comprises directly brazing a first upstream surface of the first plate to a second downstream surface of the second plate.

4. The method of claim 2 , wherein the brazing method comprises screen printing a brazing paste in a pattern on the second downstream surface of the second plate.

5. The method of claim 2 , wherein the second plate is formed of the metal matrix composite material, and wherein the metal is a stainless steel.

6. The method of claim 5 , wherein the metal matrix composite material comprises tungsten carbide-cobalt, and
wherein the brazing method comprises brazing the metal and the metal matrix composite material together with a first layer of brazing alloy BAg-8, a second layer of brazing alloy BAg-8 and a third layer of a copper brazing material between the first and second layers.

7. The method of claim 1 , wherein joining the first plate to the second plate comprises a mechanical fastening method.

8. The method of claim 1 , wherein the first upstream surface of the first plate is directly joined to the second downstream surface of the second plate.

9. The method of claim 1 , wherein the extrusion die is a honeycomb extrusion die.

10. The method of claim 1 , wherein the second plate is formed of the ceramic material.

11. The method of claim 10 , wherein the ceramic material comprises aluminum oxide.

12. The method of claim 1 , wherein the second plate is formed of the metal matrix composite material.

13. The method of claim 12 , wherein the metal matrix composite material comprises tungsten carbide-cobalt.

14. The method of claim 1 , wherein the extrusion die comprises an effective die modulus of 250 GPa or more.

15. The method of claim 1 , wherein the second elastic modulus is 50% or more greater than the first elastic modulus.

16. The method of claim 1 , wherein a coefficient of thermal expansion of the ceramic material or the metal matrix composite material is from 50% to 150% of a coefficient of thermal expansion of the metal.

17. The method of claim 1 , wherein the plurality of feed holes extend from the second upstream surface of the second plate through the extrusion die and into communication with the plurality of slots of the first plate.

18. The method of claim 1 , wherein the plurality of feed holes comprise first feedhole portions in the first plate and second feedhole portions in the second plate.

19. The method of claim 18 , wherein a first average diameter of the first feedhole portions is larger than a second average diameter of the second feedhole portions.

20. The method of claim 18 , wherein a first average diameter of the first feedhole portions is in a range of 5% to 15% larger than a second average diameter of the second feedhole portions.

Assignees

• Corning Inc

Inventors

• Biswas Samir
• Demirbas Memduh Volkan
• Grohsmeyer Ryan Joseph
• Humphrey Mark Lee
• Khayat Zakariya Radwan
• Miller Kenneth Richard

Classifications

• B23K3/0638

  for viscous material feeding, e.g. solder paste feeding (B23K3/0623 takes precedence) · CPC title

• B23K1/20

  Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating · CPC title

• B23K1/19

  taking account of the properties of the materials to be soldered · CPC title

• B23K1/0008

  specially adapted for particular articles or work · CPC title

• B23K2103/05

  Stainless steel · CPC title