Infrared Drying and Vapor Removal for Ceramic Extrudate Stability
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Solution Overview
Problem
High-speed extrusion processes produce soft ceramic honeycomb bodies that are prone to deformation due to the addition of liquid vehicles, which need to be quickly dried and hardened to maintain structural integrity during and after extrusion.
Innovation Solution
A system comprising an extruder, a radiative heat assembly with infrared light sources arranged in rings around the extrudate, a differential pressure assembly for vapor removal, and an air bearing for support, along with a controller to adjust the heating based on skin temperature, ensuring efficient drying and hardening of the extrudate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid vehicle is added to reduce pressure and die-wear during extrusion, then extrusion speed and ease of manufacture are improved, but the extrudate becomes soft and prone to deformation
Solution Approach 1:
The patent applies preliminary action by immediately drying the extrudate in the die outlet region before it exits the extrusion die. The drying assembly with heated air or gas flow removes moisture from the extrudate surface and interior quickly, preventing deformation while maintaining the benefits of liquid vehicle addition during extrusion.
Solution Approach 2:
The patent uses an intermediary drying assembly positioned between the extrusion die outlet and the extrudate. This intermediary device (drying assembly with heated air flow) acts as a mediator to rapidly remove moisture from the extrudate, resolving the contradiction between ease of extrusion and extrudate strength.
2Productivity
If high extrusion speed is used to increase productivity, then output is improved, but the extrudate remains soft and deforms during handling
Solution Approach 1:
The patent applies preliminary action by immediately drying the extrudate in the die outlet region before it exits the extrusion die. The drying assembly with heated air or gas flow removes moisture from the extrudate surface and interior quickly, preventing deformation while maintaining the benefits of liquid vehicle addition during extrusion.
Solution Approach 2:
The patent implements continuity of useful action by maintaining continuous moisture removal from the extrudate as it exits the die. The drying assembly provides continuous heated air flow throughout the critical transition zone, ensuring the extrudate rapidly achieves structural stability without interruption.
3Strength
If rapid drying is applied to prevent deformation, then extrudate strength is improved, but energy consumption increases
Solution Approach 1:
The patent applies local quality by concentrating the drying action specifically in the die outlet region where moisture removal is most critical. The drying assembly is positioned locally at this critical zone rather than drying the entire extrudate uniformly, reducing overall energy consumption while maintaining effectiveness.
Solution Approach 2:
The patent uses the skipping principle by rapidly removing moisture from the extrudate through the die outlet region in a quick, intensive drying action. This rushed through approach prevents deformation by not allowing the extrudate to remain in a soft state for extended periods, reducing total energy exposure time.
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 system effectively prevents deformation by rapidly drying and hardening the extrudate, enhancing its strength and stability during processing, allowing for high-speed extrusion without structural compromise.
Implementation Method 1
The radiative heat assembly is configured to heat the extrudate. According to an example, the radiative heat assembly comprises one or more infrared (IR) light sources.
Implementation Method 2
The differential pressure assembly is configured to remove at least a portion of water vapor from around the extrudate. The differential pressure assembly can direct an air flow out of the chamber via a gap between the housing and the extrudate.
Implementation Method 3
The system further comprises an air bearing configured to support at least a portion of the extrudate after the extrudate is formed by the extruder.
Data Source
AI summary
A system (100) for manufacturing an extrudate (10), such as a honeycomb body, is provided. The system comprises an extruder (102). The extruder is configured to form an extrudate from a wet mixture, such as a ceramic forming mixture. The system further comprises a radiative heat assembly (104). The radiative heat assembly is configured to heat the extrudate. The radiative heat assembly comprises one or more IR light sources (112). The one or more IR light sources are arranged as one or more rings around the extrudate. The system further comprises a differential pressure assembly (108). The differential pressure assembly is configured to remove at least a portion of water vapor from around the extrudate. The differential pressure assembly can direct an air flow out of a chamber (136) formed by a housing (132) surrounding the radiative heat assembly. Alternatively, the differential pressure assembly can direct an air flow into the chamber.