Honeycomb Die Cavity Alignment Suppresses Distortion

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Solution Overview

Problem

The existing die for forming honeycomb structures experiences distortion and reduced formability due to misalignment between the aperture and the through-hole portion, leading to uneven pressure distribution and material introduction issues during the manufacturing process.

Innovation Solution

A die design where the diameter of the cavity is distinct from the back hole, with the open end of the cavity positioned inside the open end of the back hole, and the first plate-shaped portion is made of tungsten carbide-based cemented carbide, while the second plate-shaped portion is formed from materials like iron, steel, or aluminum alloys, ensuring proper alignment and enhanced formability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the diameter of the cavity is made equal to the diameter of the back hole, then the manufacturing process is simpler, but distortion occurs in the honeycomb structure due to misalignment

Engineering Contradiction:

Improvealignment precision between cavity and back holeVSAvoidstructural complexity of die components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention applies asymmetry by making the cavity diameter different from the back hole diameter. Specifically, the cavity has a smaller diameter than the back hole, creating a deliberate asymmetric configuration that prevents misalignment and distortion in the honeycomb structure during manufacturing

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The invention uses the nesting principle by positioning the cavity inside the back hole such that the cavity is concentric with the back hole. The smaller cavity is nested within the larger back hole, ensuring proper alignment and preventing distortion of the honeycomb structure

Inventive Principle:

Principle #7Nested doll (Nesting)

2Manufacturing precision

If the slit width is made much narrower than the back hole diameter, then the honeycomb structure formability is improved, but stress concentrates on the slits causing wear and deformation

Engineering Contradiction:

Improvehoneycomb structure formabilityVSAvoidslit durability against wear and deformation

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The invention applies local quality by making the slit width much narrower than the back hole diameter at specific locations. The slits have a narrow width suitable for forming the honeycomb structure, while the back holes maintain a larger diameter to reduce stress concentration. This creates different local dimensions optimized for different functions

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention segments the die structure into distinct components with different dimensions: the back holes serve as material introduction channels with larger diameter, while the slits serve as forming channels with narrower width. This segmentation allows each component to be optimized for its specific function without compromising the other

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration effectively suppresses distortion in the honeycomb structure and improves formability by ensuring uniform material flow and pressure distribution, resulting in higher quality honeycomb structures.

Implementation Method 1

the first plate-shaped portion is formed of tungsten carbide based cemented carbide

Methodology Applied

Scientific EffectHardness:

Implementation Method 2

the first plate-shaped portion is formed of tungsten carbide based cemented carbide

Methodology Applied

Scientific EffectStrength:

Implementation Method 3

ensuring uniform material flow and pressure distribution

Methodology Applied

Scientific EffectPressure distribution:

Implementation Method 4

the open end of the cavity on the first bonded surface is arranged inside the open end of the back hole on the second bonded surface

Methodology Applied

Scientific EffectGeometric alignment:

Data Source

PatentEP2857163B1Spinneret for molding honeycomb structure and manufacturing method therefor

Publication Date: 2019.08.21 NGK INSULATORS LTD

Figure 1~2
Figure 3~4A
Figure 4B~5

AI summary

Disclosed is a die for forming a honeycomb structure 1, including: a second plate-shaped portion 3 that is formed of iron or the like and has a second bonded surface 6, where a back hole 5 for introducing a forming raw material is formed; and a first plate-shaped portion 7 that has a first bonded surface 10 and is formed of tungsten carbide based cemented carbide, where a slit 9 communicating with the back hole 5 to form a forming raw material is formed, and a cavity 11 communicating with the back hole 5 and the slit 9 is formed in the first bonded surface 10 side, wherein the first plate-shaped portion 7 is arranged on the second plate-shaped portion 3 such that the first bonded surface 10 comes into contact with the second bonded surface 6, an open end of the cavity 11 on the first bonded surface 10 has a diameter different from that of an open end of the back hole 5 on the second bonded surface 6, and the open end 11a of the cavity 11 on the first bonded surface 10 is arranged inside the open end 5a of the back hole 5 on the second bonded surface 6. It is possible to suppress a distortion in the honeycomb structure.