Wet Ceramic Extrudate Stiffening via Fluid Heating
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Solution Overview
Problem
Conventional extrusion processes often result in skin grooves due to the collapse of peripheral cells during cutting, leading to visual defects and reduced structural integrity in honeycomb structures, as existing methods for stiffening the extrudate are non-uniform and ineffective.
Innovation Solution
An extrusion system that includes a controller, fluid supply, and applicator apparatus to uniformly heat and stiffen the outer layer of the extrudate by increasing the temperature of the binder material to its gelation point, preventing cell collapse during cutting, using a temperature unit and fluid supply to control the extrusion process and ensure uniform heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If microwave energy is used to stiffen the wet extruded ceramic body, then the structural integrity is improved, but non-uniform heating patterns occur particularly at or near the outer layers of the extrudate
Solution Approach 1:
The patent replaces microwave heating with a fluid-based heating system. A fluid is circulated through a heating jacket or channels in contact with the extrudate, providing uniform thermal energy transfer through conduction and convection, thereby eliminating the non-uniform heating patterns caused by microwave energy while still achieving the desired stiffening effect.
Solution Approach 2:
The patent introduces a fluid as an intermediary heat transfer medium between the heat source and the extrudate. The fluid circulates through heating elements in contact with the extrudate surface, evenly distributing thermal energy and preventing the localized overheating and non-uniform heating patterns associated with direct microwave energy application.
2Object-generated harmful factors
If the batch water percentage is reduced to stiffen the batch material, then the skin groove formation is reduced, but the extrusion process becomes more difficult due to increased viscosity
Solution Approach 1:
The patent changes the physical state of the binder material by controlling its temperature and moisture content during and after extrusion. By heating the extrudate to a specific temperature range or controlling the evaporation rate, the binder transitions to a stiffer state that prevents skin groove formation, while the extrusion process itself maintains adequate moisture for proper flow and forming.
Solution Approach 2:
The patent applies a preliminary heating or surface treatment to the extrudate immediately after formation but before cutting. This preliminary action stiffens the outer layer or skin of the extrudate, preventing skin groove formation during subsequent handling and cutting operations, while the internal moisture content remains sufficient for maintaining structural integrity during extrusion.
3Strength
If the outer layer of the extrudate is stiffened to prevent cell collapse, then the structural integrity is improved, but non-uniform heating results in defective stiffening at the periphery
Solution Approach 1:
The patent replaces microwave heating with a fluid-based heating system that provides uniform thermal energy transfer. The fluid circulates through heating elements in contact with the extrudate surface, ensuring even heat distribution across the entire surface including peripheral areas, thereby achieving uniform stiffening without the non-uniform heating patterns caused by microwave energy.
Solution Approach 2:
The patent uses a hydraulic or pneumatic fluid circulation system to transfer heat uniformly to the extrudate. The fluid flows through channels or jackets in contact with the extrudate surface, providing consistent thermal energy distribution across the entire surface, including difficult-to-reach peripheral areas, ensuring uniform stiffening throughout.
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 increases the stiffness of the extrudate's outer layer, reducing or eliminating skin grooves and enhancing structural integrity by uniformly applying heat to the binder component, thereby preventing cell collapse and improving the extrudate's handling and cutting precision.
Implementation Method 1
increase the temperature of a binder material of the extrudate to its gelation point and stiffening at least the outer layer of the extrudate
Data Source
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AI summary
The present disclosure provides a method of stiffening an outer layer of a wet extrudate (426), where the extrudate (426) has a honeycomb cellular structure. The method includes extruding the extrudate (426) through an extrusion apparatus (402) and directing a substantially uniform flow of fluid onto the outer layer of the extrudate (426). The method also includes increasing the temperature of a binder material of the extrudate (426) to its gelation point and stiffening at least the outer layer of the extrudate (426).