Honeycomb Cell Structure Dry Mass Machining
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Solution Overview
Problem
The existing methods for manufacturing catalyst carriers with honeycomb-shaped ceramic structures face challenges in achieving uniform catalyst component distribution due to variations in partition wall thickness and pore properties, leading to inconsistent catalyst loading and increased production costs from excessive use of rare noble metals.
Innovation Solution
The method involves measuring the dry mass of honeycomb-shaped cell structure precursors and machining one end face to achieve uniform dry mass, using techniques like cutting, grinding, electro-discharge machining, or beam machining, ensuring consistent catalyst loading and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wash-coat conditions are set up based on partition wall thickness and pore properties of an arbitrarily selected cell structure, then the manufacturing process is simple and efficient, but the amount of catalyst component carried varies among cell structures due to differences in partition wall thickness and pore properties
Solution Approach 1:
The patent applies preliminary action by measuring the dry mass of each cell structure before wash-coating and pre-adjusting the catalyst slurry volume or wash-coat conditions based on these measurements. This allows the catalyst component amount to be controlled uniformly across all cell structures while maintaining manufacturing efficiency, as the adjustments are made before the actual wash-coating process begins.
2Reliability
If the amount of catalyst component is increased to ensure sufficient exhaust gas purification performance, then purification performance and durability are improved, but production costs increase due to excessive use of expensive noble metals
Solution Approach 1:
The patent applies feedback by measuring the dry mass of each cell structure and using this information to adjust the catalyst slurry application. This feedback mechanism ensures that each cell structure receives the appropriate amount of catalyst component needed for sufficient purification performance, preventing both under-loading and over-loading, thereby optimizing noble metal usage and reducing waste.
3Manufacturing precision
If partition wall thickness is made uniform across all cell structures to avoid variance in catalyst component amount, then manufacturing precision is improved, but the extrusion molding die wears down more quickly and productivity decreases
Solution Approach 1:
The patent applies parameter changes by shifting the control parameter from partition wall thickness (which is difficult to control uniformly due to die wear) to dry mass (which can be easily measured and adjusted). By controlling the catalyst slurry application based on dry mass measurements, the patent achieves uniform catalyst component amount without requiring uniform partition wall thickness, thus maintaining high extrusion molding speed and productivity.
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 results in cell structures with a uniform amount of catalyst component, reducing production costs by minimizing excessive catalyst use and ensuring consistent exhaust gas purification performance.
Implementation Method 1
water in the catalyst slurry is absorbed by the pores of the partition walls, and the catalyst component, which is a solid component in the catalyst slurry, adheres to a surface of the partition walls and the inside of the pores opening on a surface of the partition walls by the water-absorbing power
Data Source
AI summary
There is provided a method for manufacturing cell structures having a plurality of cells divided by porous partition walls and extending from one end face to the other end face to function as fluid passages. Dry mass of each of a plurality of honeycomb-shaped cell structure precursors is measured, and at least one end face of each of the cell structure precursors is subjected to machining according to the dry mass measured to obtain a plurality of cell structures having a uniform dry mass. The method can suppress excessive use of a catalyst component to reduce production costs and uniformalize the amount of a catalyst component carried on the structures.