Die body apparatus and methods

A method of assembling a die body apparatus comprising a base member including a first face, a second face, a plurality of feed holes intersecting the first face, and a first set of elongated feed channels that each include an elongated length extending along the second face, a width extending transverse to the length, a first depth from the second face, and an elongated opening intersecting the second face and extending along the length of the feed channel, wherein each of the elongated feed channels of the first set of elongated feed channels is in fluid communication with a corresponding set of the plurality of feed holes that are intersected by the elongated feed channel;

• and at least one discharge member including a first face, a second face, a second set of elongated feed channels that each include an elongated length extending along the first face of the at least one discharge member, a width extending transverse to the corresponding elongated length, a second depth into the at least one discharge member from the first face of the at least one discharge member, and an elongated opening intersecting the first face of the at least one discharge member and extending along the corresponding length of the feed channel, the at least one discharge member further including an array of pins that are spaced apart to define a honeycomb network of discharge slots intersecting the second face of the at least one discharge member, wherein the second set of elongated feed channels are in fluid communication with the honeycomb network of discharge slots, the method comprising the steps of:
• (I) forming the discharge slots to have a third depth into the at least one discharge member from the second face of the at least one discharge member, such that a sum of the second depth of the feed channels and the third depth of the discharge slots is greater than a height of the at least one discharge member;
• and
• (II) bonding a selected discharge member of the at least one discharge member with respect to the base member with each elongated opening of a plurality of the elongated feed channels of the first set of elongated feed channels being aligned with a corresponding elongated opening of the elongated feed channels of the second set of elongated feed channels to provide a plurality of elongated feed passages placing a plurality of the feed holes in fluid communication with the honeycomb network of discharge slots.

A method of extruding batch material into a honeycomb body with a die body apparatus comprising a base member including a first face, a second face, a plurality of feed holes intersecting the first face, and a first set of elongated feed channels that each include an elongated length extending along the second face, a width extending transverse to the length, a first depth from the second face, and an elongated opening intersecting the second face and extending along the length of the feed channel, wherein each of the elongated feed channels of the first set of elongated feed channels is in fluid communication with a corresponding set of the plurality of feed holes that are intersected by the elongated feed channel;

• and at least one discharge member including a first face, a second face, a second set of elongated feed channels that each include an elongated length extending along the first face of the at least one discharge member, a width extending transverse to the corresponding elongated length, a second depth into the first discharge member from the first face of the at least one discharge member, and an elongated opening intersecting the first face of the at least one discharge member and extending along the corresponding length of the feed channel, the at least one discharge member further including an array of pins that are spaced apart to define a honeycomb network of discharge slots intersecting the second face of the at least one discharge member, wherein the second set of elongated feed channels are in fluid communication with the honeycomb network of discharge slots, the method comprising the steps of:
• (I) forming the discharge slots to have a third depth into the first discharge member from the second face of the at least one discharge member, such that a sum of the second depth of the feed channels and the third depth of the discharge slots is greater than a height of the at least one discharge member;
• (II) bonding a selected discharge member of the at least one discharge member with respect to the base member with each elongated opening of a plurality of the elongated feed channels of the first set of elongated feed channels being aligned with a corresponding elongated opening of the elongated feed channels of the second set of elongated feed channels to provide a plurality of elongated feed passages placing a plurality of the feed holes in fluid communication with the honeycomb network of discharge slots;
• and
• (III) extruding a quantity of ceramic or ceramic-forming batch material through the die body apparatus into an extruded honeycomb body with a honeycomb network of channels.