Die for extruding ultrafine honeycomb structures

Abstract

A die for forming honeycomb structures has an arrangement that facilitates fabrication and the support of channel forming pins across the surface of the die by the use of multiple die sections. The die is used for forming multi-channeled honeycomb structures from extrudable materials. The die has a first die body that has an inlet face and outlet face and integrally formed channel forming pins that extend past the outlet face of the die. A set of integrally formed links interconnect the channeled pins and support the channeled pins from the die body. Together the channel forming pins and links define a set of cavity for passing extrudable material through the die body. The die includes at least one additional die body, which is at least partially superimposed above the inlet face of the first die body. The additional die body has an inlet face, an outlet face, and an integrally formed set of channel forming pins that extend through the cavities in the first die body and past the outlet face of the first die body. Another set of integral links interconnect the channel forming pins of the additional die body. The extension of the pins from the first die body and any additional die body together define a discharge zone which completes the formation of a multi-channeled honeycomb structure as the extrudable material passes through the die. Each set of pins in the die bodies have a minimum pitch between all adjacent pins that exceeds the minimum pitch between all the adjacent pins in the discharge zone. The die is particularly useful in the formation of ultrafine honeycomb structures having a channel density of 600 channels per square inch or more.