# US 12,109,727 B2 · Honeycomb extrusion dies and forming methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,109,727 B2 - Document ID: US12109727B2 - Status: Granted - Kind: B2 - Application number: 17/608,765 - Filed: 2020-05-13 - Published: 2022-10-06 - Granted: 2024-10-08 - Earliest claimed: 2019-05-17 - Assignees: Corning Incorporated - Applicants: Corning Incorporated - Inventors: Thomas William Brew; Thomas Mark Dubots; Kenneth Charles Sariego; Min Shen - Web page: https://patentgrep.com/patent/US12109727B2 ## CPC - B28B 3/269: {For multi-channeled structures, e.g. honeycomb structures} - B29C 48/11: comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped - B29C 48/30: Extrusion nozzles or dies (extrusion characterised by the shape or cross-section of the extruded article B29C48/03) - B29C 48/345: Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising - B29C 48/40: using two or more parallel screws {or at least two parallel non-intermeshing screws}, e.g. twin screw extruders - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract A honeycomb extrusion die (120) includes a die body (342) including an inlet face (315) and an outlet face (341). A plurality of pins (330) extend from the die body (342), wherein the pins (330) are arranged to define primary (312P) and secondary slots (312S). Primary slots (312P) include primary slot inlets (320P) and primary slot outlets (3120) and the secondary slots (312S) include secondary slot inlets (312SI) and secondary slot outlets (312SO). Feedholes (317) extend within the die body (342), the feedholes (317) including feedhole outlets (319), wherein the feedhole outlets (319) intersect only with the primary slot inlets (320P). First surface indentation features (345) extend into side surfaces (332) of the plurality of pins (330) defining the primary slots (312P). The first surface indentation features (345) are spaced from the primary slot outlets (3120). The secondary slots (312S) are devoid of surface indentation features. Other die bodies, extruders, and methods are disclosed. ## Claims ### Claim 1 A honeycomb extrusion die, comprising: a die body comprising an inlet face and an outlet face; a plurality of pins extending from the die body, wherein the pins are arranged to define primary slots and secondary slots, the primary slots comprising primary slot inlets and primary slot outlets, the secondary slots comprising secondary slot inlets and secondary slot outlets; a plurality of feedholes extending within the die body from the inlet face, the feedholes comprising feedhole outlets, wherein the feedhole outlets intersect the primary slot inlets; first surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the first surface indentation features spaced from the primary slot outlets; second surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the second surface indentation features extending from the primary slot inlets toward the outlet face; and wherein the secondary slots are devoid of surface indentation features. ### Claim 2 (depends on 1) The honeycomb extrusion die of claim 1, wherein the secondary slot inlets do not intersect with the feedhole outlets such that only the primary slot inlets intersect with the feedhole outlets. ### Claim 3 (depends on 1) The honeycomb extrusion die of claim 1, wherein the primary slots extend a first depth from the outlet face, wherein the secondary slots extend a second depth from the outlet face, and wherein the first depth is greater than the second depth. ### Claim 4 (depends on 1) The honeycomb extrusion die of claim 1, wherein the second surface indentation features comprise first ends located proximate the primary slot inlets and second ends located opposite the first ends and wherein the secondary slots extend from the outlet face to a depth defined by the second ends. ### Claim 5 (depends on 1) The honeycomb extrusion die of claim 1, wherein the second surface indentation features extend into side surfaces of the plurality of pins defining the primary slots to a depth in a range from 0.15 mm to 0.23 mm. ### Claim 6 (depends on 1) The honeycomb extrusion die of claim 1, wherein the second surface indentation features extend along portions of the plurality of pins defining the primary slots at a length in a range from 0.9 mm to 2.3 mm. ### Claim 7 (depends on 1) The honeycomb extrusion die of claim 1, wherein: some of the primary slots and some of the secondary slots extend in a first direction; some of the primary slots and some of the secondary slots extend in a second direction transverse with respect to the first direction; the secondary slots extending in the first direction intersect with the second surface indentation features of the primary slots extending in the second direction, and the secondary slots extending in the second direction intersect with the second surface indentation features of the primary slots extending in the first direction. ### Claim 8 (depends on 1) The honeycomb extrusion die of claim 1, wherein the pins have a pin density in a range from 15.5 and 124.0 pins per cm2. ### Claim 9 (depends on 1) The honeycomb extrusion die of claim 1, wherein the pins have a pin density in a range from 58.9 pins per cm2 to 96.1 pins per cm2. ### Claim 10 (depends on 1) The honeycomb extrusion die claim 1, wherein: some of the primary slots and some of the secondary slots extend in a first direction, some of the primary slots and some of the secondary slots extend in a second direction transverse with respect to the first direction, primary slots extending in the first direction intersect primary slots extending in the second direction at primary intersections, and the feedhole outlets are located at locations defined by at least some of the primary intersections. ### Claim 11 (depends on 10) The honeycomb extrusion die of claim 10, wherein the first direction is orthogonal to the second direction. ### Claim 12 (depends on 10) The honeycomb extrusion die of claim 10, wherein the feedhole outlets are located at all the primary intersections. ### Claim 13 (depends on 10) The honeycomb extrusion die of claim 10, wherein the feedhole outlets are located at alternating ones of the primary intersections in the first direction and the second direction. ### Claim 14 (depends on 10) The honeycomb extrusion die of claim 10, wherein secondary slots extending in the first direction intersect secondary slots extending in the second direction at secondary intersections, and wherein the secondary intersections are devoid of feedhole outlets. ### Claim 15 (depends on 1) The honeycomb extrusion die of claim 1, wherein the primary slots and the secondary slots alternate. ### Claim 16 (depends on 1) The honeycomb extrusion die of claim 1, wherein the primary slots and the secondary slots have widths in a range from 0.051 mm to 0.30 mm. ### Claim 17 (depends on 1) A system comprising an extruder and the honeycomb extrusion die of claim 1, wherein the honeycomb extrusion die is coupled to the extruder. ### Claim 18 A method of manufacturing a honeycomb structure, comprising: coupling an extrusion die to an extruder, the extrusion die comprising: an inlet face and an outlet face; a plurality of pins, wherein the pins are arranged to define primary slots and secondary slots, the primary slots comprising primary slot inlets and primary slot outlets, the secondary slots comprising secondary slot inlets and secondary slot outlets; a plurality of feedholes extending from the inlet face, the feedholes comprising feedhole outlets, wherein the feedhole outlets intersect with the primary slot inlets; first surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the first surface indentation features spaced from the primary slot outlets; and second surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the second surface indentation features extending from the primary slot inlets toward the outlet face, wherein the secondary slots are devoid of surface indentation features; and extruding a batch mixture through the extrusion die. ### Claim 19 A method of manufacturing a honeycomb extrusion die, comprising: forming a plurality of pins in a die body comprising an inlet face and an outlet face, wherein the pins are arranged to define primary slots and secondary slots, the primary slots comprising primary slot inlets and primary slot outlets, the secondary slots comprising secondary slot inlets and secondary slot outlets; forming a plurality of feedholes extending within the die body from the inlet face, the feedholes comprising feedhole outlets, wherein the feedhole outlets intersected with the primary slot inlets; forming first surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the first surface indentation features spaced from the primary slot outlets; and forming second surface indentation features extending into side surfaces of the plurality of pins defining the primary slots, the second surface indentation features extending from the primary slot inlets toward the outlet face, wherein the secondary slots are devoid of surface indentation features.