Flow Speed Control Plate for Monolithic Substrate Extrusion
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Solution Overview
Problem
Existing die systems for forming monolithic substrates with varying cell densities face challenges in maintaining uniform clay flow speed, leading to formation defects such as collapsed cells, imperfect cell walls, and warping due to positional misalignment and machining accuracy issues between the flow speed control plate and the die.
Innovation Solution
A flow speed control plate with a base plate, clay flow holes, and a positioning mechanism is used to equalize clay flow speed by ensuring coaxial alignment and reducing the diameter of clay flow holes to prevent interference, thereby maintaining uniform flow and reducing the risk of formation defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the diameter of clay flow holes in the flow speed control plate is reduced to prevent interference with the die, then the flow speed uniformity is improved, but the clay flow resistance increases
Solution Approach 1:
The patent applies parameter changes by optimizing the diameter of clay flow holes to a specific range (0.5-2.0mm) that balances two competing requirements: small enough to prevent interference with the die and ensure flow speed uniformity, but large enough to maintain adequate clay flow and reduce resistance. This precise parameter selection resolves the contradiction between flow uniformity and flow resistance.
2Manufacturing precision
If a positioning mechanism is added to ensure coaxial alignment between clay flow holes and clay inflow holes, then the positional accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent implements preliminary action by providing a positioning mechanism that pre-establishes coaxial alignment between the clay flow holes in the flow speed control plate and the clay inflow holes in the die before clay extrusion begins. This preliminary positioning prevents positional misalignment during the forming process, ensuring that clay flows smoothly without interference despite the added device complexity.
3Manufacturing precision
If the flow speed control plate is used to suppress clay flow speed in low-cell-density regions, then the flow speed uniformity is improved, but the risk of positional misalignment and interference with the die increases
Solution Approach 1:
The patent applies parameter changes by specifying that the diameter of clay flow holes should be in the range of 0.5-2.0mm, which is small enough to prevent interference with the die while still effectively controlling flow speed. Additionally, the positioning mechanism parameters are optimized to ensure stable coaxial alignment, resolving the reliability issue caused by the flow speed control plate's presence.
Data Source
AI summary
A flow speed control plate is provided for use in combination with a die for forming a monolith. The flow speed control plate includes: a base plate having both a clay supply surface and a clay outflow surface that is to be superposed on a clay inflow surface of the die; clay flow holes which each penetrate the base plate and through which the clay flows from the clay supply surface to the clay outflow surface; and a positioning mechanism provided to position the flow speed control plate with respect to the die so that each of the clay flow holes of the flow speed control plate has its central axis arranged coaxially with a central axis of a corresponding one of clay inflow holes of the die. Moreover, a diameter of the clay flow holes is set to be smaller than a diameter of the corresponding clay inflow holes.