Monolithic Extrusion Tool Geometry for Uniform Honeycomb Flow
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Solution Overview
Problem
Existing extrusion tools for producing supports with hexagonal cell cross-sections require complex, high-precision production methods due to the need for precise coordination and adjustment of pins, resulting in inefficient and costly manufacturing processes that struggle to achieve a favorable surface-to-volume ratio and uniform flow resistance.
Innovation Solution
A method for producing an extrusion tool with a one-piece body featuring inlet openings on one side and slots and recesses on the other, where the geometry of the slots, depressions, and elements define the cross-section of the extrudate, allowing for a simpler and more efficient production process that reduces the number of required elements and improves mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If pins are pressed into the base of the extrusion tool to achieve hexagonal cell cross-section, then the surface-to-volume ratio is improved, but the device complexity and manufacturing precision requirements increase significantly
Solution Approach 1:
The invention merges the base and pins into a single integrated extrusion tool body. The hexagonal cell cross-section is formed directly by slots and recesses in the monolithic body, eliminating the need for separate pins that must be precisely coordinated and pressed into the base. This integration reduces device complexity while maintaining the favorable surface-to-volume ratio achieved by hexagonal geometry.
2Manufacturing precision
If pins are precisely coordinated and pressed into the base, then manufacturing precision of cell geometry is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The base and shaping elements are merged into a single monolithic body that can be manufactured as one piece using conventional machining or additive manufacturing. This eliminates the multi-step process of manufacturing separate pins, coordinating them precisely, and pressing them into the base, thereby significantly improving ease of manufacture while maintaining geometric precision.
Solution Approach 2:
The extrusion tool body is pre-formed with the complete geometry including slots and recesses that directly define the hexagonal cell cross-section. This preliminary formation of the final geometry eliminates the need for subsequent assembly and adjustment operations, making the manufacturing process simpler and more straightforward.
3Adaptability or versatility
If multiple individual parts are used to form the extrusion tool, then adaptability to different cell geometries is improved, but the device complexity increases
Solution Approach 1:
The invention achieves adaptability to different cell geometries by modifying parameters (slot dimensions, recess dimensions, slot patterns) within a single monolithic body design. This allows the extrusion tool to be optimized for specific hexagonal cell geometries without requiring multiple separate parts, thereby maintaining versatility while reducing device complexity.
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 approach enables the production of extrusion tools with a favorable surface-to-volume ratio and uniform flow resistance distribution, significantly reducing manufacturing complexity and costs while maintaining high precision and quality, allowing for the creation of extrudates with hexagonal or round cell cross-sections using fewer elements.
Implementation Method 1
pressing plastic material into the extrusion die on a first side, after which the plastic material exits the extrusion die on a second side after deformation
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a method for producing an extrusion tool (1) suitable for forming an extrudate by pressing plastic material into the extrusion tool (1) at a first side (13), after which the plastic material exits the extrusion tool (1) at a second side (14) following a deformation, wherein inlet openings (3) are provided into the first side (13) of a body (2), and slots (4) are provided into the second side (14) of the body (2) which connect the inlet openings (3).In order to manufacture an extrusion tool (1) suitable for producing a carrier with a favorable surface area to volume ratio and uniform flow resistance in a simple and efficient manner, the invention provides that at least one recess (5) is formed in the second side (14), which is connected to the slots (4) and the inlet openings (3), and that an element is arranged in the recess (5) such that a cross-section of the extrudate formed with the extrusion tool (1) is at least partially defined by a geometry of the slots (4), a geometry of the recesses (5), and a geometry of the element. The invention further relates to an extrusion tool (1).