Bow Deflector Device for Honeycomb Extrudate Straightening
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Solution Overview
Problem
The production of straight ceramic honeycombs for exhaust treatment applications is hindered by 'bowing' in the honeycomb extrudate due to uneven flow resistance across the extrusion die, which is difficult to correct despite careful die fabrication and machining.
Innovation Solution
A bow deflector device positioned upstream of the extrusion die, featuring a base with a constant aperture and a movably mounted bow plate with a smaller opening, adjusts to superimpose a unique flow velocity on the plastic batch material, correcting bow in any direction to 'true zero' magnitude.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion die fabrication and machining are used, then die manufacturing is simplified, but bowing in the extrudate occurs due to uneven flow resistance
Solution Approach 1:
The bow deflector device is positioned upstream of the extrusion die to preemptively correct flow non-uniformities before the material enters the die. By adjusting the bow plate position in advance, the system compensates for uneven flow resistance that would otherwise cause bowing, allowing conventional die fabrication methods to be used without sacrificing extrudate straightness
Solution Approach 2:
The bow deflector device acts as an intermediary component between the material feed and the extrusion die. The adjustable bow plate creates a controllable flow resistance that counterbalances the uneven flow resistance in the die, serving as a mediator to achieve uniform material flow and eliminate bowing while keeping the die structure simple
2Productivity
If the opening area of the bow plate is increased to allow more material flow, then productivity improves, but bow correction capability is reduced
Solution Approach 1:
The bow plate is designed with movable positioning capability, allowing the opening area to be dynamically adjusted based on the specific bowing conditions and production requirements. This dynamic adjustment enables the system to optimize between flow rate and bow correction capability, achieving both high productivity and precise bow control depending on the operational needs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bow deflector device effectively corrects bowing in honeycomb extrudate, ensuring straight and parallel sides, reducing preferential flow and hardware costs, and increasing product output by minimizing bow-related failures.
Implementation Method 1
By passing through the bow deflector device a unique flow velocity is superimposed on the feed stream of plastic batch material, as determined by the diameter of the opening, and the position of the opening
Data Source
AI summary
Disclosed apparatus and method to extrude a honeycomb, providing correction in bowing of the extruded honeycomb structure, employs a deflector device having a base plate including an opening aligned in a direction parallel to the extrusion axis through which the plastic material is conveyed to the die. The deflector device includes a bow plate movably mounted to the downstream or upstream side of the base plate. The bow plate includes a constant area aperture. The deflector device positioned upstream of extrusion die imparts a degree of bow reduction by the position of the constant area aperture over the opening imparting a pressure drop gradient on the flow stream entering the die.