Extrusion dies with zoned coatings, methods of fabricating such dies, and methods of manufacturing ceramic articles

Patent metadata

Field	Value
Publication number	US-12485574-B2
Application number	US-202118032085-A
Country	US
Kind code	B2
Filing date	Nov 22, 2021
Priority date	Nov 30, 2020
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

An extrusion die ( 16 ) including a plurality of pins ( 38 ) having side surfaces defining an intersecting array of slots ( 30 ) extending axially into the die ( 16 ) from a discharge face ( 34 ) of the die ( 16 ). A plurality of feedholes ( 28 ) extend axially from an inlet face ( 32 ) of the die ( 16 ) opposite to the discharge face ( 34 ). The feedholes ( 28 ) connect with the slots ( 30 ) at intersections ( 35 ) within the die ( 16 ) to create a flow path from the inlet face ( 32 ) to the discharge face ( 34 ). A first coating ( 42 ) is on at least a portion of the feedholes ( 28 ) in a first zone ( 46 ) extending over a first axial length of the flow path. A second coating ( 44 ) that is different than the first coating ( 42 ) is on at least a portion of the side surfaces ( 37 ) of the pins ( 38 ) in a second zone ( 48 ) extending over a second axial length of the flow path. Methods of fabricating an extrusion die ( 16 ) and manufacturing a ceramic article ( 100 ), such as a honeycomb body, are also disclosed.

First claim

What is claimed is:

1 . An extrusion die comprising:
a plurality of pins comprising side surfaces defining an intersecting array of slots extending axially into the die from a discharge face of the die; a plurality of feedholes extending axially into the die from an inlet face of the die opposite to the discharge face, wherein the feedholes connect with the slots at intersections within the die to create a flow path from the inlet face to the discharge face; a first coating on at least a portion of the feedholes in a first zone extending over a first axial length of the flow path; and a second coating on at least a portion of the side surfaces of the pins in a second zone extending over a second axial length of the flow path, wherein the first coating is different than the second coating, wherein the first coating is applied over the second coating or directly to a base material of the extrusion die, or both, wherein the second coating is applied over the first coating or directly to the base material of the extrusion die, or both, wherein at least one of the first coating or the second coating is applied directly to the base material of the extrusion die, and wherein the first zone transitions to the second zone at an overlap zone at which the first coating is applied over the second coating and a thickness of the first coating tapers in an axial direction toward the discharge face until only the second coating is present.

2 . The extrusion die of claim 1 , wherein the second coating has a wear-resistance that is greater than that of the first coating.

3 . The extrusion die of claim 1 , wherein the second coating has a hardness that is greater than that of the first coating.

4 . The extrusion die of claim 1 , wherein the second coating has a roughness that is greater than that of the first coating.

5 . The extrusion die of claim 1 , wherein the second coating comprises particles embedded in a matrix, and wherein the particles have a hardness that is greater than that of the first coating.

6 . The extrusion die of claim 1 , wherein the first coating comprises at least one of a nickel plating, a titanium nitride (TiN) coating, or a titanium carbonitride (TiCN) coating.

7 . The extrusion die of claim 1 , wherein the second coating comprises at least one of a particle-embedded nickel plating, a titanium carbonitride (TiCN) coating, or a boron-doped titanium carbonitride coating (B-TiCN).

8 . The extrusion die of claim 1 , wherein the first zone extends from the inlet face to cover at least a portion of the side surfaces of the pins.

9 . The extrusion die of claim 1 , wherein the second zone extends from the discharge face to cover at least a portion of the feedholes.

10 . An extrusion die comprising:
a plurality of pins comprising side surfaces defining an intersecting array of slots extending axially into the die from a discharge face of the die; a plurality of feedholes extending axially into the die from an inlet face of the die opposite to the discharge face, wherein the feedholes connect with the slots at intersections within the die to create a flow path from the inlet face to the discharge face; a first coating on at least a portion of the feedholes in a first zone extending over a first axial length of the flow path; and a second coating on at least a portion of the side surfaces of the pins in a second zone extending over a second axial length of the flow path, wherein the first coating is different than the second coating, wherein the first coating is applied over the second coating or directly to a base material of the extrusion die, or both, wherein the second coating is applied over the first coating or directly to the base material of the extrusion die, or both, wherein at least one of the first coating or the second coating is applied directly to the base material of the extrusion die, and wherein the second zone transitions to the first zone at an overlap zone at which the second coating is applied over the first coating and a thickness of the second coating tapers in an axial direction toward the inlet face until only the first coating is present.

11 . An extrusion die comprising:
a plurality of pins comprising side surfaces defining an intersecting array of slots extending axially into the die from a discharge face of the die; a plurality of feedholes extending axially into the die from an inlet face of the die opposite to the discharge face, wherein the feedholes connect with the slots at intersections within the die to create a flow path from the inlet face to the discharge face; a first coating on at least a portion of the feedholes in a first zone extending over a first axial length of the flow path; and a second coating on at least a portion of the side surfaces of the pins in a second zone extending over a second axial length of the flow path, wherein the first coating is different than the second coating, wherein the first coating is applied over the second coating or directly to a base material of the extrusion die, or both, wherein the second coating is applied over the first coating or directly to the base material of the extrusion die, or both, wherein at least one of the first coating or the second coating is applied directly to the base material of the extrusion die, and wherein the first coating is applied along an entire length of the flow path from the inlet face to the discharge face, and the second coating is applied over at least a portion of the first coating such that the second zone corresponds to the portion covered by the second coating and the first zone corresponds to a non-covered portion.

12 . An extrusion die comprising:
a plurality of pins comprising side surfaces defining an intersecting array of slots extending axially into the die from a discharge face of the die; a plurality of feedholes extending axially into the die from an inlet face of the die opposite to the discharge face, wherein the feedholes connect with the slots at intersections within the die to create a flow path from the inlet face to the discharge face; a first coating on at least a portion of the feedholes in a first zone extending over a first axial length of the flow path; and a second coating on at least a portion of the side surfaces of the pins in a second zone extending over a second axial length of the flow path, wherein the first coating is different than the second coating, wherein the first coating is applied over the second coating or directly to a base material of the extrusion die, or both, wherein the second coating is applied over the first coating or directly to the base material of the extrusion die, or both, wherein at least one of the first coating or the second coating is applied directly to the base material of the extrusion die, and wherein the second coating is applied along an entire length of the flow path from the inlet face to the discharge face, and the first coating is applied over at least a portion of the second coating such that the first zone corresponds to the portion covered by the first coating and the second zone corresponds to a non-covered portion.

13 . The extrusion die of claim 12 , wherein the die comprises a plurality of separately coated components affixed together.

14 . The extrusion die of claim 12 , wherein the die comprises an inlet plate comprising at least an inlet portion of the feedholes that is coated by the first coating and a discharge plate comprising at least a downstream portion of the slots and the pins that is coated by the second coating.

Assignees

• Corning Inc

Inventors

• Brew Thomas William
• Bubb Keith Norman
• Grohsmeyer Ryan Joseph
• Lehman Michael James
• Sariego Kenneth Charles
• Shen Min

Classifications

• B28B2003/203

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

• B29C48/3003

  Materials, coating or lining therefor · CPC title

• B29C48/11

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

• B23P15/243

  Honeycomb dies · CPC title

• B28B3/269 Primary

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