Conical Tip Closing Jig for Honeycomb Through-Holes
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Solution Overview
Problem
Existing methods for closing green honeycomb molded bodies face inefficiencies due to difficulties in inserting closing jigs into through-holes with positional deviations, leading to reduced closing efficiency.
Innovation Solution
A closing jig with conical tip end portions and truncated pyramidal base portions, designed to easily insert into and weld partition walls of through-holes, even with slight positional deviations, using ultrasonic vibration to liquefy and press the walls for efficient closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight needle closing jig is used, then the closing structure is simple, but insertion into through-holes with positional deviation is difficult
Solution Approach 1:
The closing protrusion features a conical tip end portion with a curved surface instead of a straight needle shape. This conical configuration allows the tip to easily enter through-holes even when positional deviation occurs, while the truncated pyramidal base portion provides sufficient pressing area for effective closing. The curvature of the conical surface enables automatic alignment and insertion without requiring precise positioning.
2Ease of operation
If a conical tip closing protrusion is used, then insertion ease is improved, but partition wall cutting may occur
Solution Approach 1:
The conical tip end portion has a gradually tapering curved surface that distributes insertion force over an area rather than concentrating it at a single point. This gradual tapering allows the partition wall material to be progressively displaced and softened (especially when heated) rather than abruptly cut, preventing harmful cutting effects while maintaining easy insertion capability.
Solution Approach 2:
The closing protrusion incorporates a truncated pyramidal base portion with a larger apex angle than the conical tip. This geometric parameter change provides a broader pressing area at the base that distributes the closing force, preventing excessive stress concentration that could cause partition wall cutting while maintaining the conical tip's insertion advantage.
3Productivity
If heating is applied to soften partition walls, then closing efficiency is improved, but energy consumption increases
Solution Approach 1:
The closing process applies heating to soften the partition wall material before the pressing action occurs. This preliminary thermal softening reduces the force required for closing and improves material flow, enhancing closing efficiency. The heating is applied only to the localized area around the through-holes rather than the entire honeycomb structure, minimizing overall energy consumption.
Solution Approach 2:
Heating is applied locally to the partition wall regions surrounding the through-holes that need closing, rather than heating the entire honeycomb structure. This localized heating approach softens only the necessary areas for closing operations, improving closing efficiency while minimizing energy consumption by avoiding unnecessary heating of other parts of the structure.
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 solution enables easy insertion and efficient closure of through-holes, preventing partition wall cutting and ensuring smooth ends, reducing turbulence and pressure drop when used in diesel particulate filters.
Implementation Method 1
Each of the closing protrusions includes a conical tip end portion which is located at a tip end portion of the closing protrusion and has a conical shape
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
A closing jig for a green honeycomb molded body includes closing protrusions which are arranged at positions corresponding to regular hexagonal cells and are inserted into the regular hexagonal cells to weld partition walls to each other for closing. Each of the closing protrusions includes a conical tip end portion that has a conical shape, and a triangular pyramidal base portion with a truncated triangular pyramidal shape having an apex angle larger than an apex angle of the conical tip end portion. The conical tip end portion has the conical shape with an acute apex angle, and thus even when positional deviation occurs in the regular hexagonal cells, it is easy to insert the conical tip end portion into each of the regular hexagonal cells. The triangular pyramidal base portion has the truncated triangular pyramidal shape having the large apex angle, and thus it is easier to weld the partition walls to each other by pressing and expanding the partition walls.