Segmented Honeycomb Die for Uniform Material Flow
Find Innovative SolutionsGenerate Solutions
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 potential for formation defects and deformation.
Innovation Solution
A honeycomb structure forming die comprising a first die with a convex central region and a complementary ring-shaped second die, featuring a groove region for uniform material flow and a clearance region for forming a boundary wall, allowing for the creation of honeycomb bodies with varying cell structures by adjusting the positions and shapes of introducing holes and slits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single die is used to form honeycomb structures with different cell structures in central and circumferential portions, then manufacturing complexity increases and design flexibility is restricted, but if separate dies are used for each region, then manufacturing precision and material distribution uniformity improve
Solution Approach 1:
The die is divided into a first die for forming the central portion and a second die for forming the circumferential portion. Each die has independently optimized slit patterns and introducing holes tailored to its specific region, allowing precise control of material distribution without requiring a single complex monolithic die structure.
Solution Approach 2:
The first die and second die are positioned such that the first die is located inside the second die, with the convex region of the first die fitting into the cavity region of the second die. This nested arrangement enables both dies to function simultaneously while maintaining compact overall structure and facilitating coordinated material flow control.
2Ease of manufacture
If the die structure is simplified for ease of manufacture, then device complexity reduces, but manufacturing precision and ability to form complex cell structures deteriorates
Solution Approach 1:
By segmenting the die into two separate components (first die and second die), each can be manufactured using standard fabrication techniques without requiring complex integrated tooling. The modular design allows each die to be produced independently with appropriate precision, then assembled together to achieve the overall complex cell structure formation capability.
3Manufacturing precision
If introducing holes and slits are positioned to optimize material flow, then manufacturing precision improves, but device complexity and design constraints increase
Solution Approach 1:
The introducing holes and slits are independently positioned in each die according to the specific requirements of that region. The first die has introducing holes and slits optimized for central portion extrusion, while the second die has introducing holes and slits optimized for circumferential portion extrusion. This independent optimization provides design freedom for each region while achieving overall extrusion uniformity.
4Manufacturing precision
If boundary wall formation is emphasized to prevent defects, then manufacturing precision improves, but the risk of deformation in surrounding areas increases
Solution Approach 1:
The groove region is formed in advance on the abutment surface of one die, and the convex region is formed in advance on the other die. These pre-formed features ensure proper material flow distribution before extrusion begins, allowing the boundary wall to form with adequate material supply while preventing excessive stress concentration that could cause deformation in surrounding areas.
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, and a ring-shaped 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 the honeycomb structure forming die has a groove region where movement of the kneaded material is performed between the first kneaded material introducing hole and the second kneaded material introducing hole, in abutment surfaces of the first die and the second die.