Honeycomb Body Coating With Real-Time Filtration Feedback
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Solution Overview
Problem
The existing process for depositing inorganic particles on honeycomb bodies is semi-closed loop, leading to inconsistent filtration efficiency and high rejection rates due to over- or under-coating, lacking real-time feedback for optimal coating application.
Innovation Solution
An apparatus and method that includes a duct system with sampling ports and a particle counter to monitor and adjust the application of inorganic particles, calculating filtration efficiency in real-time using the formula (n_u - n_d) / n_u, allowing precise control of particle deposition on honeycomb bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the same process set points are used for all parts in the deposition process, then the manufacturing process is simple and consistent, but the filtration efficiency becomes inconsistent and rejection rates increase due to over- or under-coating
Solution Approach 1:
The patent implements a closed-loop feedback control system where a particle counter continuously monitors the concentration of inorganic particles in the exhaust stream both upstream and downstream of the honeycomb body. This real-time feedback enables dynamic adjustment of deposition parameters (such as spray time and suspension weight) to maintain target filtration efficiency, resolving the contradiction between manufacturing precision and process simplicity by automating the control process.
Solution Approach 2:
The system enables self-regulating deposition control where the process automatically adjusts based on real-time particle count measurements. The control system autonomously modifies deposition parameters without manual intervention, allowing the process to self-correct deviations in filtration efficiency and eliminate the need for complex manual monitoring and adjustment procedures.
2Manufacturing precision
If real-time measurement and control of filtration efficiency is implemented, then manufacturing precision and consistency improve, but device complexity and measurement requirements increase
Solution Approach 1:
The patent replaces complex manual measurement and testing procedures with an automated optical particle counting system. The particle counter uses light scattering or electrical sensing methods to automatically detect and count inorganic particles in real-time, substituting manual mechanical testing with automated optical/electrical measurement that provides continuous feedback without requiring complex intervention.
Solution Approach 2:
The system introduces inorganic particles as tracer particles that serve as intermediaries to indirectly measure filtration efficiency. By monitoring the concentration of these tracer particles upstream and downstream of the honeycomb body, the system indirectly quantifies filtration performance without requiring direct measurement of exhaust gas composition or complex analytical procedures.
3Productivity
If semi-closed loop feedback process is used with post-deposition testing, then measurement equipment is simpler, but productivity decreases due to rejection and re-work of undercoated parts
Solution Approach 1:
The patent implements preliminary real-time monitoring and control during the deposition process itself, allowing deviations from target filtration efficiency to be detected and corrected before the deposition is complete. This prevents undercoating or overcoating from occurring in the first place, eliminating the need for post-deposition rejection and re-work, thereby simultaneously improving productivity and reliability.
Solution Approach 2:
The closed-loop feedback system continuously monitors particle concentration during deposition and automatically adjusts process parameters to maintain target filtration efficiency. This real-time quality control ensures consistent filtration performance without requiring post-deposition testing and rejection, improving both productivity by eliminating re-work and reliability by ensuring quality during production.
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
Enhances filtration efficiency by ensuring optimal particle coating, reducing rejection rates and improving the consistency of filtration performance.
Implementation Method 1
a particle counter in fluid communication with the first sampling port and the second sampling port configured to count a selected portion of the inorganic particles
Implementation Method 2
configured to deliver a mixture of the inorganic particles, the liquid and the binder to an atomizing nozzle and to the deposition zone
Data Source
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AI summary
An apparatus (400) and a method are disclosed which apply inorganic particles (407) to a plugged honeycomb body (415) comprising porous walls, an inlet end and an outlet end. The apparatus (400) comprises a particle counter (408) and the method comprises counting a selected portion of the inorganic particles (407) from a first sampling port (410) upstream from the plugged honeycomb body (415) and a second sampling port (412) downstream from the plugged honeycomb body (415). The selected portion of the inorganic particles are in a preselected inorganic particle size range. Filtration efficiency can be determined while inorganic particles are being deposited, for example to increase filtration efficiency.