Honeycomb Structure Forming Die with Segmented Dies and Reticulated Member
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Solution Overview
Problem
Existing honeycomb structure forming dies face challenges in creating high-quality honeycomb bodies with distinct central and circumferential cell structures due to limitations in design flexibility, material distribution uniformity, and susceptibility to deformation, especially when forming dies with varying cell shapes and boundary walls.
Innovation Solution
A honeycomb structure forming die comprising a first die with a convex central region and a complementary ring-shaped second die, along with a reticulated member that allows for uniform material flow between the two, enabling the formation of honeycomb bodies with different central and circumferential cell structures while maintaining die integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single die substrate with uniform slit patterns is used, then the manufacturing process is simple, but it cannot form honeycomb bodies with different cell structures in central and circumferential regions
Solution Approach 1:
The die substrate is divided into two separate dies: a first die for forming the central region and a second die for forming the circumferential region. This segmentation allows each die to have optimized slit patterns for its specific region, enabling different cell structures (e.g., different cell densities, shapes, or sizes) in the central and circumferential areas without requiring a complex single die design.
Solution Approach 2:
Each die is designed with local quality - the first die has slit patterns optimized for the central region while the second die has slit patterns optimized for the circumferential region. This allows each die to have the specific geometric properties needed for its designated area, achieving high-quality formation of region-specific cell structures.
2Adaptability or versatility
If the first die and second die have different slit shapes to achieve different cell structures, then cell structure diversity is improved, but back hole alignment becomes difficult and material flow is obstructed
Solution Approach 1:
A reticulated member is introduced as an intermediary component between the first die and second die. This reticulated member serves as a mediator that facilitates alignment and material flow, allowing the first and second dies to have different slit shapes while maintaining proper back hole alignment and ensuring unobstructed material flow during the forming process.
3Manufacturing precision
If conventional dies are used without reticulated members, then the die structure is simple, but material flow between different die regions is non-uniform causing formation defects
Solution Approach 1:
The reticulated member acts as an intermediary that mediates material flow between the central region (formed by first die) and circumferential region (formed by second die). It ensures uniform material distribution by providing a structured pathway for material to flow evenly into both regions, preventing formation defects that would occur with direct conventional die contact.
4Adaptability or versatility
If dies are designed to accommodate boundary walls between different cell structures, then cell structure differentiation is improved, but the dies become susceptible to deformation
Solution Approach 1:
By segmenting the die into separate first and second dies, each die can be optimized for its specific region without needing to accommodate boundary walls between different cell structures. This eliminates the structural weakness that would result from designing a single die to handle boundary wall formation, thereby maintaining die structural strength while still achieving cell structure differentiation.
Data Source
AI summary
The honeycomb structure forming die includes a first die in which a central region on the side of a kneaded material discharging surface has a convex region projecting toward a downstream side in an extruding direction of a kneaded material, a ring-shaped second die, and a reticulated member interposed between the first die and the second die. In the first die, first kneaded material introducing holes are formed and latticed first slits are formed on the side of the kneaded material discharging surface of the convex region, and in the second die, there are formed second kneaded material introducing holes and latticed second slits communicating with the second kneaded material introducing holes, and movement of a kneaded material is performed between the first kneaded material introducing hole and the second kneaded material introducing hole through meshes of the reticulated member.