Metal honeycomb substrates for chemical and thermal applications
First Claim
1. A method for making an extruded metal honeycomb article comprising the steps of:
- heating a metal feed stock to a temperature effective to provide a softened bulk metal feed charge, wherein the metal feed stock does not comprise a metal powder;
forcing the feed charge into and through an array of feedholes provided in a body plate of a honeycomb extrusion die;
thereafter forcing the feed from the feedholes through an intersecting array of discharge slots connecting with the feedholes in a discharge section of the honeycomb extrusion die, thereby to shape the charge into a metal extrudate comprising an interconnected wall structure forming channels and channel walls for a metal honeycomb; and
cooling the extrudate to a temperature below the softening temperature of the metal feed stock.
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Accused Products
Abstract
Extruded metal honeycombs are produced by the direct extrusion of a softened bulk metal feedstock through a honey-comb extrusion die comprising a feedhole array for delivering softened metal through a supporting die baseplate to a honeycomb die discharge section, the discharge section comprising an array of intersecting discharge slots that form the walls of an extruded metal honeycomb structure. This process can be optimized by employing a proper pressure gradient for a particular extrudate flow rate, extrudate composition, and wall-drag condition arising from the particular composition of the feedhole wall, as illustrated graphically in FIG. 4.
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Citations
13 Claims
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1. A method for making an extruded metal honeycomb article comprising the steps of:
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heating a metal feed stock to a temperature effective to provide a softened bulk metal feed charge, wherein the metal feed stock does not comprise a metal powder; forcing the feed charge into and through an array of feedholes provided in a body plate of a honeycomb extrusion die; thereafter forcing the feed from the feedholes through an intersecting array of discharge slots connecting with the feedholes in a discharge section of the honeycomb extrusion die, thereby to shape the charge into a metal extrudate comprising an interconnected wall structure forming channels and channel walls for a metal honeycomb; and cooling the extrudate to a temperature below the softening temperature of the metal feed stock. - View Dependent Claims (2, 3, 4, 5)
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6. An extruded metal honeycomb article comprising:
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a channeled metal body of unitary structure incorporating a two-dimensional array of parallel channels extending in a third dimension from a first end face to a second end face of the body, the channels being spaced to provide a honeycomb cell density of from 10 to 40 cells per square inch of honeycomb cross-section as measured transverse to the direction of the channels in the array; and interconnecting channel walls defining the channels, the channel walls being of a thickness in the range of about 0.001-0.1 inches from the first end face to the second end face of the body, being formed of a bulk metal having a porosity below 5% by volume, and being substantially free of channel wall discontinuities in directions transverse to the direction of honeycomb channel orientation in the article. - View Dependent Claims (7, 8, 9, 10, 11, 12)
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13. A method for making an extruded metal honeycomb article comprising the steps of:
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heating a metal feed stock to a temperature effective to provide a softened bulk metal feed charge, wherein the metal feed stock is selected from bar stock, tubing stock, ingots, and billets; forcing the feed charge into and through an array of feedholes provided in a body plate of a honeycomb extrusion die; thereafter forcing the feed from the feedholes through an intersecting array of discharge slots connecting with the feedholes in a discharge section of the honeycomb extrusion die, thereby to shape the charge into a metal extrudate comprising an interconnected wall structure forming channels and channel walls for a metal honeycomb; and cooling the extrudate to a temperature below the softening temperature of the metal feed stock.
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Specification