Hermetic Slurry Flow Path for Uniform Porous Body Production

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Solution Overview

Problem

Existing methods for producing sheet-like porous bodies, such as filters and heat radiation members, face issues with uneven air bubble distribution due to large air bubbles forming when the expandable slurry is continuously shaped over time, leading to variations in the porous body's structure.

Innovation Solution

An apparatus and method that hermetically seals the flow path of the expandable slurry from the mixer to the discharge opening, using a die-coater and a carrier sheet with a controlled gas incorporation system to prevent air bubbles from growing, ensuring consistent air bubble distribution by deaerating the powdered slurry and incorporating a controlled amount of gas before forming the sheet.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the expandable slurry is continuously shaped for a long period of time using an opened chamber, then productivity is improved, but manufacturing precision deteriorates due to uneven air bubble distribution

Engineering Contradiction:
Improvecontinuous production capabilityVSAvoidair bubble distribution uniformity
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies the inert atmosphere principle by hermetically sealing the flow path of expandable slurry from the mixer to the discharge opening, creating an isolated environment that prevents air bubbles from entering the slurry during continuous production. This sealed flow path maintains a controlled atmosphere, preventing the accumulation and coalescence of air bubbles that would otherwise occur in an open chamber system, thereby maintaining uniform air bubble distribution even during long-term continuous operation.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent segments the flow path into distinct sealed sections (mixer to discharge opening) that are isolated from the external atmosphere. By dividing the continuous production process into hermetically sealed segments, the system prevents air bubble contamination while maintaining continuous operation, thus resolving the contradiction between productivity and manufacturing precision.

Inventive Principle:
Principle #1Segmentation

2Ease of operation

If air bubbles are allowed to accumulate in the opened chamber, then ease of operation is improved, but manufacturing precision deteriorates due to large air bubbles passing between carrier sheet and doctor blade

Engineering Contradiction:
Improvecontinuous slurry supplyVSAvoidair bubble size control
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The hermetically sealed flow path creates an inert environment that prevents air bubbles from accumulating in the slurry during continuous supply operations. This sealed system maintains ease of operation by enabling continuous slurry supply while simultaneously preventing the formation of large air bubbles that would compromise manufacturing precision.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent extracts the harmful air bubbles from the system by hermetically sealing the flow path, preventing their entry and accumulation. This extraction of the problematic element (air bubbles) allows the system to maintain both ease of operation and manufacturing precision simultaneously.

Inventive Principle:
Principle #2Taking out (Extraction)

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 approach allows for continuous, long-term production of porous bodies with evenly distributed air bubbles, enabling precise control over porosity and preventing air bubble variations, thus maintaining consistent quality in the final product.

Implementation Method 1

a flow path of the expandable slurry from inside the mixer to the discharge opening of the die-coater is hermetically sealed from the outside

Methodology Applied
Scientific EffectHermetic sealing: Physical Containment

Implementation Method 2

a die-coater used for shaping, that has a discharge opening which discharges the expandable slurry provided from the mixer to an external thereof so as to shape the expandable slurry into a sheet

Methodology Applied
Scientific EffectDie-coating: Extrusion

Implementation Method 3

a carrier sheet arranged so as to face the discharge opening of the die-coater with a gap interposed therebetween, and feeding the expandable slurry discharged from the discharge opening

Methodology Applied
Scientific EffectConveyor transport: Friction

Implementation Method 4

an expandable slurry including an inorganic powder, a foaming agent, an organic binder, a liquid solvent

Methodology Applied
Scientific EffectFoaming: Foam

Data Source

PatentUS8747710B2Method for producing porous body
Publication Date: 2014.06.10 MITSUBISHI MATERIALS CORP
  • US8747710B2 patent drawing
  • US8747710B2 patent drawing
  • US8747710B2 patent drawing

AI summary

An apparatus for producing a porous body that forms an expandable slurry containing at least inorganic powder, a foaming agent, and a binder into a sheet, causes the expandable slurry sheet to be foamed and baked, and thereby produces the porous body, the apparatus includes: a mixer preparing the expandable slurry by containing inorganic powder, a foaming agent, and a binder; a die-coater that has a discharge opening which discharges the expandable slurry provided from the mixer to an external thereof so as to shape the expandable slurry into a sheet; and a carrier sheet arranged so as to face the discharge opening of the die-coater with a gap interposed therebetween, and feeding the expandable slurry discharged from the discharge opening, wherein a flow path of the expandable slurry from inside the mixer to the discharge opening of the die-coater is hermetically sealed from an outside.