Ceramic Honeycomb Filter Plug Formation Rotation Method
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Solution Overview
Problem
Existing methods for forming ceramic honeycomb filters result in uneven plug lengths due to plugging material slurry being pulled back when the ceramic honeycomb structure is lifted, leading to unstable particulate-capturing and pressure loss performance, and often result in defective filters.
Innovation Solution
A method and apparatus that involve inflating an elastic member to seal the ceramic honeycomb structure, introducing a plugging material slurry, rotating the structure to fluidize the slurry, and then lifting it, ensuring air enters and preventing the plugs from being pulled back, thereby reducing length unevenness and enabling continuous, efficient plug formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ceramic honeycomb structure is lifted from the plugging material slurry, then the plug formation process is completed, but the plugging material slurry falls from the end portions resulting in large unevenness in plug length
Solution Approach 1:
The patent applies preliminary action by rotating the ceramic honeycomb structure before lifting it from the slurry. This rotation pre-fluidizes the plugging material slurry between the structure and the bottom surface, preventing slurry from being pulled back during lifting. The rotation is performed as a preparatory step that ensures uniform plug lengths are maintained when the structure is subsequently lifted.
Solution Approach 2:
The patent uses mechanical vibration in the form of rotation to fluidize the plugging material slurry. By rotating the ceramic honeycomb structure, shear forces are applied to the slurry, transforming it from a static to a fluidized state. This mechanical action prevents the slurry from adhering to the structure during lifting, thereby maintaining plug length uniformity.
2Manufacturing precision
If the ceramic honeycomb structure is slid horizontally when taken out of the vessel, then plug length unevenness is suppressed, but the process requires additional vessel modifications and cannot conduct plug formation continuously
Solution Approach 1:
The patent inverts the conventional approach by rotating the ceramic honeycomb structure vertically instead of sliding it horizontally. This inversion allows the structure to be rotated in place within the vessel, fluidizing the slurry through rotation rather than requiring horizontal movement. The structure is then lifted vertically for continuous processing, eliminating the need for detachable vertical walls.
Solution Approach 2:
The patent enables continuous production by allowing the ceramic honeycomb structure to be rotated and lifted without requiring vessel modifications. The rotation and lifting process can be continuously repeated for multiple structures, eliminating the need to stop and modify the vessel between operations. This maintains continuous useful action in the plug formation process.
3Ease of manufacture
If the plugging material slurry is introduced under pressure into the cells, then plugs are formed in the end portions, but the slurry is pulled back when the structure is lifted causing defective filters
Solution Approach 1:
The patent applies preliminary action by rotating the ceramic honeycomb structure before lifting it from the slurry. This rotation pre-fluidizes the plugging material slurry between the structure and the bottom surface, preventing slurry from being pulled back during lifting. The rotation is performed as a preparatory step that ensures uniform plug lengths are maintained when the structure is subsequently lifted.
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 method effectively reduces plug length unevenness both within individual ceramic honeycomb structures and across multiple structures, ensuring consistent filter performance and reducing the number of defective filters by maintaining plug integrity during the formation process.
Implementation Method 1
a holding member (30) for holding the ceramic honeycomb structure (10), having an elastic member (33) on an inner peripheral side, the elastic member being inflatable to come into close contact with an outer peripheral surface of the ceramic honeycomb structure (10)
Implementation Method 2
rotating the ceramic honeycomb structure (10), thereby sufficiently fluidizing the plugging material slurry (40) between the lower end surface of the ceramic honeycomb structure (10) and the upper surface of the porous plate (24), and easily allowing air to enter from the surroundings
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(b)
Figure 2(c)~2(d)
AI summary
A method for producing a ceramic honeycomb filter having a ceramic honeycomb structure having plugs in predetermined cells: comprising using an apparatus having a reservoir having an inlet for a plugging material slurry and an upper opening, a porous plate with pluralities of openings covering the upper opening of the reservoir, and a holding member fixed to an upper end of the reservoir; keeping a lower surface of the sealing film attached to a lower end surface of the ceramic honeycomb structure apart from an upper surface of the porous plate by a distance D of more than 0 mm and 2.0 mm or less; supplying a predetermined volume of the plugging material slurry into the reservoir to introduce it into the predetermined cells of the ceramic honeycomb structure; rotating the ceramic honeycomb structure after sealing of the ceramic honeycomb structure is released; and lifting the ceramic honeycomb structure after the rotation starts.