Abstract 1. THE METHOD OF MAKING AN EXTRUSION DIE FOR EXTRUSION FORMING OF A MATERIAL INTO A CELLULAR MEMBER OR BODY TO BE SUBSEQUENTLY USED AS A CORE MEMBER FOR A CATALYTIC CONVERTER OR THE LIKE, SUCH METHOD COMPRISING; (A) PROVING A MULTIPLICITY OF RELATIVELY THIN PLATES OR DISKS OF A SELECTED SIZE AND OF A GLASSY MATERIAL, EACH SUCH PLATE HAVING PLANAR OPPOSITE SURFACES; (B) SELECTIVELY ECHING ALMOST THROUGH ONE OF SAID PLATES IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF AND FROM ONE OF SUCH SURFACES TOWARDS THE OTHER WHILE LEAVING ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE A CONTINUOUS SUBSTANTIALLY THIN AND PLANAR SUPPORT LAYER OF THE PLATE MATERIAL AND THEREBY PROVIDING, IN SUCH PLATE AND EXTENDING IN PLANES PARALLEL WITH SAID PLANAR SURFACES, A RELATIVELY NARROW CURVED CHANNEL PREFERABLY CONCENTRIC AND PARALLEL WITH THE OUTER PERIMETER OF THE PLATE AND SPACED THEREFROM A SELECTED DISTANCE AND A REPETITIVE PATTER OF RELATIVELY NARROW AND SHORT STRAIGHT-LINE INTERCONNECTING AND NON-LINEARLY CONTINUOUS OR COEXTENSIVE CHANNELS, SOME OF WHICH CONNECT WITH SAID CURVED CHANNEL AND GROUPS OF SIX OF WHICH CHANNELS INTERSECT EACH OTHER AT SUBSTANTIALLY EQUAL ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES AND PROVIDE A COMMON CENTER AXIS OF INTERSECTION OF THE CENTER LINES OF THE SIX CHANNELS OF EACH SAID GROUP OF SIX CHANNELS WITH EACH SUCH CENTER AXIS BEING SPACED SUBSTANTIALLY THE SAME DISTANCE FROM THE CORRESPONDING CENTER AXIS OF EACH OF THE SIMILAR ADJOINING GROUPS OF SIX CHANNELS, THE WALLS OF SAID PATTERN OF CHANNELS BEING DEFINED BY THE SIDEWALLS OF A MULTITUDE OF CLOSELY AND CORRESPONDINGLY SPACED-APART COLUMNS HAVING, WHERE POSSIBLE, CORRESPONDING PLANAR CROSS-SECTIONAL GEOMETRIC CONFIGURATIONS GENERALLY THOSE OF RHOMBUSES WITH ACUTE OBLIQUE ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES; (C) SELECTIVELY ETCHING COMPLETELY THROUGH EACH OF A SUCCESSION OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF RADIATE PASSAGES HAVING PLANAR GEOMETRICALLY SIMILAR RADIATE CONFIGURATIONS SEPARATED FROM EACH OTHER AND EACH HAVING HAVING SIX RADICALS WITH THE CENTER AXES OF SUCH PASSAGES IN EACH OF SUCH SUCCESSION OF PLATES BEING EQUALLY SPACED FROM THE CENTER AXES OF EACH OF LTHE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING GROUPS OF SIX CHANNELS IN SAID ONE ETCHED PLATE, AND WITH SAID RADIATE PASSAGES IN EACH SUCCEDING ONE OF SAID SUCCESSION OF PLATES BEING GEOMETRICALLY SIMILAR TO SUCH PASSAGES IN ANY IMMEDIATELY PRECEDING ONE OF SUCH SUCCESSION OF PLATES BUT HAVING SMALLER DIMENSIONS IN THE DIRECTION OF THE PLANES OF SAID PLANAR SURFACES OF THE PLATES; (D) SELECTIVELY ETCHING COMPLETELY THROUGH A PLURALITY OF REMAINING ONES OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF CIRCULAR PASSAGES EACH HAVING A DIAMETER SUBSTANTIALLY CORRESPONDING TO THE DISTANCE BETWEEN THE ENDS A PAIR OF OPPOSITE ONES OF THE RADICALS OF THE LARGEST ONES OF SAID RAIDATE PASSAGES ETCHED THROUGH SAID SUCCESSION OF PLATES AND WITH THE CENTER AXES OF THE CIRCULAR PASSAGES THROUGH EACH OF SUCH PLURALITY OF PLATES EQUALLY SPACED FROM THE CENTER AXIS OF EACH OF THE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING RADIATE PASSAGES ETCHED IN SAID SUCCESSION OF PLATES; (E) MAKING A STACK OF SAID ETCHED PLATES WITH THE PLANAR SURFACES THEREOF ABUTTING AND WITH SAID CENTER AXES OF THE PASSAGES AND CHANNELS ETCHED THEREIN GENERALLY ACIALLY ALIGNED WITH EACH OTHER, SUCH STACK COMPRISING: (I) SAID SUCCESSION OF PLATES IN ITS SUCCESSIVE ORDER WITH THE PLATE HAVING THE LARGEST DIMENSIONAL PASSAGES THERETHROUGH AT A FIRST END OF SUCH SUCCESSION AND THE PLATE HAVING THE SMALLEST DIMENSIONAL PASSAGES THERETHROUGH AT THE SECOND END OF THE SUCCESSION; (II) SAID PLURALITY OF PLATES WITH THE PLANAR SURFACE OF ONE OF THE END PLATES OF SUCH PLURALITY REMAINING EXPOSED AND THE PLANAR SURFACE OF THE OTHER END PLATE OF SUCH PLURALITY ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT SAID FIRST END OF SAID SUCCESSION OF PLATES, AND (III) SAID ONE PLATE WITH SAID ONE ETCHED PLANAR SURFACE THEREOF ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT THE SECOND END OF SAID SUCCESSION OF PLATES AND SAID OTHER PLANAR SURFACE OF SUCH ONE PLATE REMAINING EXPOSED; (F) HEATING SAID STACK OF PLATES TO FUSE ALL OF THE PLATES OF SUCH STACK INTO A HOMOGENEOUS UNITARY BODY AND THEN PERMITTING SUCH BODY TO COOL; AND (G) GRINDING OR ABRAIDING SAID OTHER PLANAR SURFACE OF SAID ONE PLATE AND THROUGH SAID CONTINUOUS PLANAR SUPPORT LAYER ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE TO REMOVE SUCH LAYER AND EXPOSE SAID ETCHED CHANNELS PROVIDED IN SUCH ONE PLATE AND THEREBY COMPLETE THE MAKING OF SAID EXTRUSION DIE.
THE METHOD OF MAKING AN EXTRUSION DIE FOR EXTRUSION FORMING OF A MATERIAL INTO A CELLULAR MEMBER OR BODY TO BE SUBSEQUENTLY USED AS A CORE MEMBER FOR A CATALYTIC CONVERTER OR THE LIKE, SUCH METHOD COMPRISING; (A) PROVING A MULTIPLICITY OF RELATIVELY THIN PLATES OR DISKS OF A SELECTED SIZE AND OF A GLASSY MATERIAL, EACH SUCH PLATE HAVING PLANAR OPPOSITE SURFACES; (B) SELECTIVELY ECHING ALMOST THROUGH ONE OF SAID PLATES IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF AND FROM ONE OF SUCH SURFACES TOWARDS THE OTHER WHILE LEAVING ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE A CONTINUOUS SUBSTANTIALLY THIN AND PLANAR SUPPORT LAYER OF THE PLATE MATERIAL AND THEREBY PROVIDING, IN SUCH PLATE AND EXTENDING IN PLANES PARALLEL WITH SAID PLANAR SURFACES, A RELATIVELY NARROW CURVED CHANNEL PREFERABLY CONCENTRIC AND PARALLEL WITH THE OUTER PERIMETER OF THE PLATE AND SPACED THEREFROM A SELECTED DISTANCE AND A REPETITIVE PATTER OF RELATIVELY NARROW AND SHORT STRAIGHT-LINE INTERCONNECTING AND NON-LINEARLY CONTINUOUS OR COEXTENSIVE CHANNELS, SOME OF WHICH CONNECT WITH SAID CURVED CHANNEL AND GROUPS OF SIX OF WHICH CHANNELS INTERSECT EACH OTHER AT SUBSTANTIALLY EQUAL ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES AND PROVIDE A COMMON CENTER AXIS OF INTERSECTION OF THE CENTER LINES OF THE SIX CHANNELS OF EACH SAID GROUP OF SIX CHANNELS WITH EACH SUCH CENTER AXIS BEING SPACED SUBSTANTIALLY THE SAME DISTANCE FROM THE CORRESPONDING CENTER AXIS OF EACH OF THE SIMILAR ADJOINING GROUPS OF SIX CHANNELS, THE WALLS OF SAID PATTERN OF CHANNELS BEING DEFINED BY THE SIDEWALLS OF A MULTITUDE OF CLOSELY AND CORRESPONDINGLY SPACED-APART COLUMNS HAVING, WHERE POSSIBLE, CORRESPONDING PLANAR CROSS-SECTIONAL GEOMETRIC CONFIGURATIONS GENERALLY THOSE OF RHOMBUSES WITH ACUTE OBLIQUE ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES; (C) SELECTIVELY ETCHING COMPLETELY THROUGH EACH OF A SUCCESSION OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF RADIATE PASSAGES HAVING PLANAR GEOMETRICALLY SIMILAR RADIATE CONFIGURATIONS SEPARATED FROM EACH OTHER AND EACH HAVING HAVING SIX RADICALS WITH THE CENTER AXES OF SUCH PASSAGES IN EACH OF SUCH SUCCESSION OF PLATES BEING EQUALLY SPACED FROM THE CENTER AXES OF EACH OF LTHE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING GROUPS OF SIX CHANNELS IN SAID ONE ETCHED PLATE, AND WITH SAID RADIATE PASSAGES IN EACH SUCCEDING ONE OF SAID SUCCESSION OF PLATES BEING GEOMETRICALLY SIMILAR TO SUCH PASSAGES IN ANY IMMEDIATELY PRECEDING ONE OF SUCH SUCCESSION OF PLATES BUT HAVING SMALLER DIMENSIONS IN THE DIRECTION OF THE PLANES OF SAID PLANAR SURFACES OF THE PLATES; (D) SELECTIVELY ETCHING COMPLETELY THROUGH A PLURALITY OF REMAINING ONES OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF CIRCULAR PASSAGES EACH HAVING A DIAMETER SUBSTANTIALLY CORRESPONDING TO THE DISTANCE BETWEEN THE ENDS A PAIR OF OPPOSITE ONES OF THE RADICALS OF THE LARGEST ONES OF SAID RAIDATE PASSAGES ETCHED THROUGH SAID SUCCESSION OF PLATES AND WITH THE CENTER AXES OF THE CIRCULAR PASSAGES THROUGH EACH OF SUCH PLURALITY OF PLATES EQUALLY SPACED FROM THE CENTER AXIS OF EACH OF THE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING RADIATE PASSAGES ETCHED IN SAID SUCCESSION OF PLATES; (E) MAKING A STACK OF SAID ETCHED PLATES WITH THE PLANAR SURFACES THEREOF ABUTTING AND WITH SAID CENTER AXES OF THE PASSAGES AND CHANNELS ETCHED THEREIN GENERALLY ACIALLY ALIGNED WITH EACH OTHER, SUCH STACK COMPRISING: (I) SAID SUCCESSION OF PLATES IN ITS SUCCESSIVE ORDER WITH THE PLATE HAVING THE LARGEST DIMENSIONAL PASSAGES THERETHROUGH AT A FIRST END OF SUCH SUCCESSION AND THE PLATE HAVING THE SMALLEST DIMENSIONAL PASSAGES THERETHROUGH AT THE SECOND END OF THE SUCCESSION; (II) SAID PLURALITY OF PLATES WITH THE PLANAR SURFACE OF ONE OF THE END PLATES OF SUCH PLURALITY REMAINING EXPOSED AND THE PLANAR SURFACE OF THE OTHER END PLATE OF SUCH PLURALITY ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT SAID FIRST END OF SAID SUCCESSION OF PLATES, AND (III) SAID ONE PLATE WITH SAID ONE ETCHED PLANAR SURFACE THEREOF ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT THE SECOND END OF SAID SUCCESSION OF PLATES AND SAID OTHER PLANAR SURFACE OF SUCH ONE PLATE REMAINING EXPOSED; (F) HEATING SAID STACK OF PLATES TO FUSE ALL OF THE PLATES OF SUCH STACK INTO A HOMOGENEOUS UNITARY BODY AND THEN PERMITTING SUCH BODY TO COOL; AND (G) GRINDING OR ABRAIDING SAID OTHER PLANAR SURFACE OF SAID ONE PLATE AND THROUGH SAID CONTINUOUS PLANAR SUPPORT LAYER ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE TO REMOVE SUCH LAYER AND EXPOSE SAID ETCHED CHANNELS PROVIDED IN SUCH ONE PLATE AND THEREBY COMPLETE THE MAKING OF SAID EXTRUSION DIE.
Claim 2
Independent Claim
791 words
THE METHOD OF MAKING AN EXTRUSION DIE FOR EXTRUSION FORMING OF A MATERIAL INTO A CELLULAR MEMBER OR BODY TO BE SUBSEQUENTLY USED AS A CORE MEMBER FOR A CATALYTIC CONVERTER OR THE LIKE, SUCH METHOD COMPRISING; (A) PROVING A MULTIPLICITY OF RELATIVELY THIN PLATES OR DISKS OF A SELECTED SIZE AND OF A GLASSY MATERIAL, EACH SUCH PLATE HAVING PLANAR OPPOSITE SURFACES; (B) SELECTIVELY ECHING ALMOST THROUGH ONE OF SAID PLATES IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF AND FROM ONE OF SUCH SURFACES TOWARDS THE OTHER WHILE LEAVING ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE A CONTINUOUS SUBSTANTIALLY THIN AND PLANAR SUPPORT LAYER OF THE PLATE MATERIAL AND THEREBY PROVIDING, IN SUCH PLATE AND EXTENDING IN PLANES PARALLEL WITH SAID PLANAR SURFACES, A RELATIVELY NARROW CURVED CHANNEL PREFERABLY CONCENTRIC AND PARALLEL WITH THE OUTER PERIMETER OF THE PLATE AND SPACED THEREFROM A SELECTED DISTANCE AND A REPETITIVE PATTER OF RELATIVELY NARROW AND SHORT STRAIGHT-LINE INTERCONNECTING AND NON-LINEARLY CONTINUOUS OR COEXTENSIVE CHANNELS, SOME OF WHICH CONNECT WITH SAID CURVED CHANNEL AND GROUPS OF SIX OF WHICH CHANNELS INTERSECT EACH OTHER AT SUBSTANTIALLY EQUAL ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES AND PROVIDE A COMMON CENTER AXIS OF INTERSECTION OF THE CENTER LINES OF THE SIX CHANNELS OF EACH SAID GROUP OF SIX CHANNELS WITH EACH SUCH CENTER AXIS BEING SPACED SUBSTANTIALLY THE SAME DISTANCE FROM THE CORRESPONDING CENTER AXIS OF EACH OF THE SIMILAR ADJOINING GROUPS OF SIX CHANNELS, THE WALLS OF SAID PATTERN OF CHANNELS BEING DEFINED BY THE SIDEWALLS OF A MULTITUDE OF CLOSELY AND CORRESPONDINGLY SPACED-APART COLUMNS HAVING, WHERE POSSIBLE, CORRESPONDING PLANAR CROSS-SECTIONAL GEOMETRIC CONFIGURATIONS GENERALLY THOSE OF RHOMBUSES WITH ACUTE OBLIQUE ANGLES ON THE ORDER OF ABOUT SIXTY DEGREES; (C) SELECTIVELY ETCHING COMPLETELY THROUGH EACH OF A SUCCESSION OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF RADIATE PASSAGES HAVING PLANAR GEOMETRICALLY SIMILAR RADIATE CONFIGURATIONS SEPARATED FROM EACH OTHER AND EACH HAVING HAVING SIX RADICALS WITH THE CENTER AXES OF SUCH PASSAGES IN EACH OF SUCH SUCCESSION OF PLATES BEING EQUALLY SPACED FROM THE CENTER AXES OF EACH OF LTHE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING GROUPS OF SIX CHANNELS IN SAID ONE ETCHED PLATE, AND WITH SAID RADIATE PASSAGES IN EACH SUCCEDING ONE OF SAID SUCCESSION OF PLATES BEING GEOMETRICALLY SIMILAR TO SUCH PASSAGES IN ANY IMMEDIATELY PRECEDING ONE OF SUCH SUCCESSION OF PLATES BUT HAVING SMALLER DIMENSIONS IN THE DIRECTION OF THE PLANES OF SAID PLANAR SURFACES OF THE PLATES; (D) SELECTIVELY ETCHING COMPLETELY THROUGH A PLURALITY OF REMAINING ONES OF SAID MULTIPLICITY OF PLATES AND IN THE DIRECTION NORMAL TO SAID PLANAR SURFACES THEREOF A MULTIPLICITY OF CIRCULAR PASSAGES EACH HAVING A DIAMETER SUBSTANTIALLY CORRESPONDING TO THE DISTANCE BETWEEN THE ENDS A PAIR OF OPPOSITE ONES OF THE RADICALS OF THE LARGEST ONES OF SAID RAIDATE PASSAGES ETCHED THROUGH SAID SUCCESSION OF PLATES AND WITH THE CENTER AXES OF THE CIRCULAR PASSAGES THROUGH EACH OF SUCH PLURALITY OF PLATES EQUALLY SPACED FROM THE CENTER AXIS OF EACH OF THE ADJOINING PASSAGES IN SUCH PLATE A DISTANCE CORRESPONDING TO THE DISTANCE BETWEEN SAID CENTER AXES OF SAID ADJOINING RADIATE PASSAGES ETCHED IN SAID SUCCESSION OF PLATES; (E) MAKING A STACK OF SAID ETCHED PLATES WITH THE PLANAR SURFACES THEREOF ABUTTING AND WITH SAID CENTER AXES OF THE PASSAGES AND CHANNELS ETCHED THEREIN GENERALLY ACIALLY ALIGNED WITH EACH OTHER, SUCH STACK COMPRISING: (I) SAID SUCCESSION OF PLATES IN ITS SUCCESSIVE ORDER WITH THE PLATE HAVING THE LARGEST DIMENSIONAL PASSAGES THERETHROUGH AT A FIRST END OF SUCH SUCCESSION AND THE PLATE HAVING THE SMALLEST DIMENSIONAL PASSAGES THERETHROUGH AT THE SECOND END OF THE SUCCESSION; (II) SAID PLURALITY OF PLATES WITH THE PLANAR SURFACE OF ONE OF THE END PLATES OF SUCH PLURALITY REMAINING EXPOSED AND THE PLANAR SURFACE OF THE OTHER END PLATE OF SUCH PLURALITY ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT SAID FIRST END OF SAID SUCCESSION OF PLATES, AND (III) SAID ONE PLATE WITH SAID ONE ETCHED PLANAR SURFACE THEREOF ABUTTING AGAINST THE PLANAR SURFACE OF SAID PLATE AT THE SECOND END OF SAID SUCCESSION OF PLATES AND SAID OTHER PLANAR SURFACE OF SUCH ONE PLATE REMAINING EXPOSED; (F) HEATING SAID STACK OF PLATES TO FUSE ALL OF THE PLATES OF SUCH STACK INTO A HOMOGENEOUS UNITARY BODY AND THEN PERMITTING SUCH BODY TO COOL; AND (G) GRINDING OR ABRAIDING SAID OTHER PLANAR SURFACE OF SAID ONE PLATE AND THROUGH SAID CONTINUOUS PLANAR SUPPORT LAYER ADJACENT TO AND BENEATH SUCH OTHER PLANAR SURFACE TO REMOVE SUCH LAYER AND EXPOSE SAID ETCHED CHANNELS PROVIDED IN SUCH ONE PLATE AND THEREBY COMPLETE THE MAKING OF SAID EXTRUSION DIE.