Customizable Cover for Ceramic Honeycomb Log Drying
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Solution Overview
Problem
Ceramic honeycomb logs often exhibit shape imperfections due to differences between desired and actual extrudate shapes, leading to increased production costs and defects in final ceramic articles, such as automotive filters, as it is difficult to control and correct these shape issues post-extrusion.
Innovation Solution
A customizable cover system for microwave drying of ceramic honeycomb logs, which includes a wrap or rigid structure that can control moisture and drying differentials to alter the log's shape, allowing for selective control of shape components like slump and slide, and can be used in combination with tray moisturizing methods to achieve desired shape specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a standardized drying process is used, then production efficiency is maintained, but shape defects occur due to drying differentials
Solution Approach 1:
The patent applies local quality by using customizable covers with varying degrees of microwave transparency at different locations on the log surface. The cover can be made more transparent in regions prone to excessive drying (like the leading edge) and less transparent in regions needing moisture retention, thereby achieving uniform drying across the entire log surface while maintaining high production efficiency.
2Manufacturing precision
If the extrudate shape is corrected after extrusion, then shape specifications can be met, but it is difficult to control and correct the shape
Solution Approach 1:
The patent applies preliminary action by implementing shape control during the drying process itself rather than attempting correction after extrusion. The customizable cover is designed beforehand to compensate for expected drying differentials, allowing the log to achieve the desired shape naturally during drying without difficult post-extrusion corrections.
3Manufacturing precision
If the log shape is altered during drying, then shape defects are reduced, but additional process complexity is introduced
Solution Approach 1:
The patent applies parameter changes by modifying the microwave transparency parameter of the drying environment through the customizable cover. Rather than introducing complex mechanical shape adjustment mechanisms, the solution changes the electromagnetic parameter (microwave transparency) of the cover material to control moisture distribution and achieve shape correction, thereby reducing overall process complexity.
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 customizable cover system effectively reduces shape defects and improves the quality of ceramic articles by controlling moisture and drying differentials during microwave drying, enabling the logs to meet shape specifications and reducing production costs.
Implementation Method 1
microwave drying of extruded ceramic honeycomb logs
Implementation Method 2
The leading edge of the log dries before the trailing edge, and this drying differential can give rise to deformities in the log shape
Implementation Method 3
The vapor space that the cover creates immediately adjacent the log surface allows that portion of the log surface to remain wetter than the portions of the log surface that remain uncovered
Implementation Method 4
The lip serves to substantially trap the moisture adjacent the leading edge of the log
Data Source
AI summary
Microwave drying of ceramic honeycomb logs using a customizable cover that can take the form of a flexible wrap or a rigid cover is disclosed. The cover can be in the form of a wrap disposed directly in contact with the leading edge of the log surface. The cover can also be a rigid cover disposed adjacent but not in contact with the leading edge of the log surface. At least a portion of the trailing edge of the log can remain uncovered either by having windows in the wrap or by the rigid cover only covering the leading edge of the log surface. The customizable cover can be configured to compensate for log shape deformities as well as or in addition to the adverse effect on log shape cause by the drying differential created by passing a log through a microwave drying station leading-edge first.