Honeycomb Extrusion Die Divot Geometry for Lower Pressure Flow
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Solution Overview
Problem
Traditional honeycomb extrusion dies face challenges in balancing extrusion die pressure and sensitivity, with deep divots increasing pressure and reducing flowrate, while plenums can cause web defects and lower isostatic strength, necessitating a solution that enhances flowrate and stability without excessive pressure.
Innovation Solution
The use of honeycomb extrusion dies with relatively-shallow divots and plenums, which reduce extrusion die pressure and increase flow rates by up to 75%, while maintaining or improving sensitivity, by controlling the depth and length of divots and plenums to achieve a balanced impedance profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deep divots are used in the extrusion die, then sensitivity is improved, but extrusion die pressure increases and flowrate decreases
Solution Approach 1:
The patent applies parameter changes by modifying the divot geometry parameters - specifically using shallower divots with optimized depth and length ratios. This changes the physical parameters of the divot structure to achieve a balance where sensitivity is maintained while reducing the excessive pressure buildup that occurs with deep divots, thereby resolving the contradiction between sensitivity improvement and pressure control
2Reliability
If deep divots are used in the extrusion die, then sensitivity is improved, but flowrate decreases
Solution Approach 1:
The patent resolves this contradiction by changing the geometric parameters of the divots - using shallower depths and optimized length-to-depth ratios. This parameter modification allows the die to maintain sensitivity for quality control while reducing resistance to material flow, thereby improving flowrate and productivity without sacrificing sensitivity
3Productivity
If plenums are added to the extrusion die, then flowrate is improved, but web defects occur and isostatic strength decreases
Solution Approach 1:
The patent applies the extraction principle by removing the plenum component from the extrusion die design. By taking out the plenum that causes web defects and strength reduction, the patent achieves a cleaner extrusion process with fewer defects while maintaining acceptable flowrate through the optimized divot geometry, thus resolving the contradiction between flowrate improvement and manufacturing precision
4Reliability
If traditional divot configurations are used, then sensitivity is maintained, but extrusion die pressure is excessive
Solution Approach 1:
The patent resolves this contradiction by changing the divot parameters - specifically reducing divot depth and optimizing the length-to-depth ratio. These parameter changes reduce the resistance to material flow and lower the extrusion die pressure required, while the divots remain sufficiently configured to maintain sensitivity for quality control, thereby reducing energy consumption without sacrificing reliability
Data Source
AI summary
A honeycomb extrusion die (120) includes a die body (302) including an inlet face (306) and an exit face. The die body (302) has slot inlets (309) and a plurality of pins (320, 500) disposed between the slot inlets (309) and the exit face. The plurality of pins (320, 500) include side surfaces (322, 500B) configured to define a matrix of intersecting slots (324), wherein the matrix of intersecting slots (324) has slot exit (509) widths at the exit face. Divots (526) extend into a plurality of the side surfaces (322, 500B) between the slot inlets (309) and the exit face. Each individual divot (526) has a divot depth (D55) extending into a side surface (500A,500B, 502A, 502B) of the side surfaces (322, 500B). A ratio between a slot exit width (W53) W53 of an individual slot (324) and the divot depth (D55) of an individual divot (526) extending into a side surface (500A, 500B, 502A, 502B) of the individual slot (324) is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.