Ceramic Honeycomb Pore Volume Control via Microcapsule Density

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Solution Overview

Problem

Conventional methods for producing ceramic honeycomb structures struggle to achieve stable pore volumes quickly and cost-effectively, especially when microcapsule production lots change, requiring lengthy testing and high costs.

Innovation Solution

Adjusting the amount of microcapsules based on their packed bulk density to control the pore volume of the honeycomb structure, allowing for rapid adjustment and minimizing variations among production lots.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If microcapsules are stored for long periods or production lots are changed, then pore volume stability deteriorates, but conventional testing methods require lengthy storage testing (4 weeks at 40°C) and high costs

Engineering Contradiction:

Improvepore volume stabilityVSAvoidtesting time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The invention changes the parameter used for microcapsule characterization from gas content to packed bulk density. This parameter change enables rapid assessment of microcapsule properties without lengthy storage testing, while still allowing accurate prediction of pore volume in the sintered honeycomb structure. The packed bulk density can be measured immediately upon receipt of microcapsules, eliminating the need for 4-week storage testing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the thermal storage testing system (40°C for 4 weeks) with a mechanical measurement system (packed bulk density measurement). This substitution allows for immediate assessment of microcapsule properties through simple density measurement, eliminating the need for time-consuming thermal storage tests while maintaining the ability to predict pore volume stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If conventional testing methods are used to determine proper microcapsule amounts, then pore volume stability improves, but production cost increases due to extensive testing requirements

Engineering Contradiction:

Improvepore volume stabilityVSAvoidproduction cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The invention changes the measurement parameter from gas content (requiring storage testing) to packed bulk density (measurable immediately). This parameter change eliminates the need for expensive and time-consuming storage tests, thereby reducing production costs while maintaining the ability to achieve stable pore volume in the final product.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If the amount of pore-forming material is adjusted to increase pore volume, then pressure loss decreases, but the strength of the honeycomb filter is reduced

Engineering Contradiction:

Improvepressure lossVSAvoidhoneycomb filter strength

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The invention changes the parameter for controlling pore volume from total pore volume to packed bulk density of microcapsules. By using packed bulk density as the control parameter, the invention enables precise adjustment of pore volume while maintaining structural integrity. The packed bulk density accounts for both the volume and distribution of microcapsules, allowing optimization of the balance between pressure loss and strength.

Inventive Principle:

Principle #35Parameter changes

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

This method enables the production of ceramic honeycomb structures with stable and consistent pore volumes, reducing production time and costs by determining the proper amount of microcapsules in a short period without extensive testing.

Implementation Method 1

a pore-forming material composed of microcapsules... the amount of the microcapsules added being adjusted depending on the packed bulk density of the microcapsules

Methodology Applied

Scientific EffectPore formation: Porosity

Data Source

PatentUS8309012B2Method for producing ceramic honeycomb structure

Publication Date: 2012.11.13 MIRAI CASTING AMERICA INC

AI summary

A method for producing a ceramic honeycomb structure comprising the steps of mixing and blending at least a ceramic material and a pore-forming material to form a moldable material, extrusion-molding the moldable material, and drying and sintering the resultant molded honeycomb article, the amount of the pore-forming material added being adjusted depending on the packed bulk density of the pore-forming material.